How A cigar is Made

From Seed to Smoke

Great cigars are more than just fire and tobacco. Only a true artist, who loves his craft as much as he respects it, can achieve the distinction and flavor of a premium cigar. Utilizing the finest tobaccos in the world, and an unyielding drive for excellence, Rocky Patel has redefined the industry.

Please join us as we walk through the steps of how a cigar is made!

Chapter 1. The Nursery

Chapter 2. Tobacco Fields

Chapter 3. Curing Barns

Chapter 4. Sorting & Fermentation

Chapter 5. Rolling Room

Chapter 6. Quality Control

Chapter 7. Aging Room

Chapter 8. Quality Control “Aesthetics”

Chapter 9. Boxed Pressed

Chapter 10. Banding & Boxing

THE TIMELINE

Chapter 1
The Nursery

NURSERY

THINK BIG. START SMALL.
All great ideas start out small. Each one of our premium cigars begins life under close observation.
Upon arrival to our Nurseries, our two varieties of tobacco seeds – Habano and Criollo – are separated into thousands of individual pods and carefully placed underneath a layer of cheesecloth...
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Chapter 2
Tobacco Fields

Tobacco Fields

SUN & SHADE GROWN TOBACCO
Tobacco plants can be either Sun Grown or Shade Grown. Sun grown tobacco will only reach 5 ½ feet in height and its leaves will be used for the wrapper, binder, and filler...
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Chapter 3
Curing Barns

Curing Barns

HUNG TO DRY
After 100 days of toiling in the hot sun, how do we treat our plants? We hang them.
The harvested tobacco is brought from the fields to the curing barns. At the curing barn, plants are subjected to a drastic increase in humidity and...
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ENTERING
THE FACTORY

THE FACTORY

WELCOME TO THE ROCKY PATEL FACTORY
From the coveted fields to our signature curing barns and facilities, to our bustling factories, our tobacco moves from one premium establishment to another – because everything we do is premium. Anything less wouldn't be worthy of the label.
Chapter 4
Sorting & Fermentation

Sorting & Fermentation

REHYDRATED. REVITALIZED. INFORMATION
Our cigars are premium inside and out. But it’s not just the quality that makes it premium; it’s the delicate nature in which each individual tobacco leaf is sorted. After curing and prior to fermentation, every single leaf must be classified as either: wrapper, binder, or filler...
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Chapter 5
Rolling Room

The Rolling Room

ROLLING THE CIGAR
Once the tobacco is up to our standards it’s finally time to start rolling. Rolling a cigar is the process of constructing the filler, binder, and wrapper into a single form...
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Chapter 6
Quality Control Room

Quality Control Room

METICULOUSLY JUDGED
Once rolled, each cigar goes through a series of quality control steps. Every cigar is carefully examined to guarantee that only excellence gets our stamp of approval...
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Chapter 7
Aging Room

Aging Room

LETTING SIT
After quality control, the cigars are sent to an aging room for a minimum of 90 days. This final aging period allows for the different layers of tobacco within the cigar to fuse together...
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Chapter 8
Judging Aesthetics

Quality Control on Aesthetics

"AESTHETICS"
After the aging room, each cigar goes through yet another round of quality control. We sacrifice nothing when it comes to flavor. We don’t cut corners and we don’t compromise. We make every effort, no matter how tedious, to clean up any and all rough edges...
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Chapter 9
Boxed Pressed

Boxed Pressed

SHAPING UP
After the second quality control, a cigar may journey down a number of different roads. The first choice of which is if the cigar is box-pressed or not. Box-pressed cigars are a specialty that...
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Chapter 10
Banding & Boxing

Banding & Boxing

A SIGNATURE LOOK
Whether box-pressed or left round, our cigars are then branded with our label. Carefully, decisively and proudly we band each of our cigars. The band is not just a label to queue what tastes will be revealed within the cigar, it is a testament to the labor and craftsmanship that went into every individual leaf...
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PARTING WORDS

We put a lot of love into our cigars. When we brand and box them with the Rocky Patel logo, it’s not just for the purpose of sale. It’s an opportunity to pay homage to a living legend. And it’s our chance to say, “goodbye, good luck, and make us proud.”