To make handmade cigars, the bales of cigar tobacco are brought into the rolling factory and placed in a temperature and humidity controlled area.
Tobacco for cigars is unpacked on an as needed basis and classified once again by the color, size and texture of the fully fermented and aged leaf. After carefully selecting the cured leaves, they are transferred and organized in the blending room based on the cigars to be made and their blend. The handmade cigars process requires precision.
The Master Cuban Cigar blender prepares the tobacco leaves for the cigar Roller and Master Roller teams. The teams work together as a pair to hand make the cigars. The Blender normally mixes enough tobacco for the daily production of the handmade premium cigars by the Roller and Master Roller pair.
The Rollers are highly trained and only reach the Master level after many years of on-the-job training.
First the Roller “bunches” the tobacco leaves and forms the cigars. It is done by taking a measured handful of leaves for the filler and then forming it into the desired shape. Then they wrap a binder leaf around the filler tobaccos to hold them together. The partially finished cigars are pressed in a wooden mold. The press is turned by hand until the Roller feels that there is enough pressure on the tobacco leaves to properly form the cigars into perfect, predetermined shapes. After the press is released, each cigar is removed from the mold by hand and passed on to the Master Roller.
The Master Roller, who is the most experienced member of the pair, carefully finishes the forming of the cigar and delicately puts on the wrapper leaf. Both hands are used in this process, a chaveta (hand cutter for tobacco leaves), and an all natural tree sap glue.
The Master Roller puts on the head of the cigar and looks it over for any possible flaw or imperfection. After adding the finishing touches and details, it is now ready for the aging process, which requires patience and time.
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