Manufacture

First of all the binder, which holds the filler, is prepared. The leaves of the medium part of the tobacco plant are used for the binder, because they are more flexible and resistent. The filler is formed with a cylindrical shade. In this process, the filler leaves are pleated so that they form horizontal air-channels along the cigar. This is made for a better drawing and for a constant and full flavour in each of the draws.

Forming of the filler

The filler, the heart of a cigar, contains three different types of tobacco: ligero (light), seco (dry) and volado. The light tobacco (ligero) is harvested from the upper part of the tobacco plant and gives the cigar his taste and body. The dry tobacco (seco) comes from the middle of the plant and contributes to the aroma of a cigar. The volado proceeds from the lower parts of the tobacco plant and gives the cigar good burning qualities. The blend of these cigars, which is called ligada, is the secret recipe of each master cigar-roller.

Closing of the binder

One of the most delicate processes is the combination of filler and binder, because it will give the cigar its consistence and shape.
Then the binder is rolled over the filler and the wrapper leaf is cut to the requiered size. To cut the wrapper leaf in an exact way, the length of the cigar must been known and calculated. The combination of binder and filler forms the bruncho (bunch).

The moulding

The objective of the mouldingis to give the cigar a stronger body and to hold the different leaves before the wrapper is rolled over the bunch. This is the most difficult process in the whole cigar production.
The bunch (bruncho) is put into a woodden mould for pressing. It stays there for a short period of time until the final look is given.

Wrapping of the bunch

The wrapper leaf is prepared and rolled over the bunch. The wrapper leaves are specially choosen, because they represent the final look of the cigar and must have a perfect colour, texture and brightness.
Until the next stage, the cutting, the wrapper leaf has to be polished.

Then the wrapper is cut with a curved knife, called chaveta (roller's knife). The type of the cut is very important for a good finishing and depends on the size of the cigar, that has to be produced. Only the middle part of the tobacco leaves are used for the wrapper so they do not show the veins.
Once the wrapper is prepared, it must be located perfectly, in a way that it becomes as tighted and stretched as possible. The thin end of the leaf must be located at the foot and the base at the head of the cigar. In this way, the cigar is smoother at the first draws.

Cutting the wrapper

Se utiliza sólo el centro de la hoja, para que no ofrezca las venas del exterior.
Una vez preparada la hoja de la capa, esta hoja debe ser colocada perfectamente, de forma que quede lo más sujeta y estirada posible. La punta de la hoja debe quedar en el pie y la base de la hoja en la cabeza; así, el tabaco es más suave en las primeras caladas.

Producing the cap

The final stage is the production of the cap (perilla). Again the chaveta (roller's knife) is used to cut the wrapper leaf to form the cap. Then the cap is pasted with a vegetable gum.
Finally the cigar is stretched so it gets a smooth texture. Then the cigars are cut to the length of the desired cigar-size. After a final check of the shape and size, the cigars are tied together with a smooth band in bundles of 50 cigars each. Those bundles are then put into a vacuum fumigation chamber to immunize them against possible plagues.