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Making of a cigar

Part 1:

In The Fields

- How a cigar is made -

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.

NURSERY

THINK BIG. START SMALL.

All great ideas start out small. Each one of our premium cigars begins life under close observation.

Upon arrival, our two varieties of tobacco seeds – Habano and Criollo – are separated into thousands of individual pods and carefully placed underneath a layer of cheesecloth for over a week. After being consistently monitored and watered for 7-10 days, only the absolute healthiest plants are transported to the main nursery.

At our main nursery, plants spend another 45 days under the watchful eye of our seasoned growers. At the end of this time the plant will be nearly six inches tall with a healthy root system in place.

ONLY THE BEST. NO EXCEPTIONS.

Before leaving the main nursery, a lawnmower goes over each bed and precisely severs the tips of each plant. By severing the tips, the plants develop a need for survival causing them to be stronger, yielding unprecedented growth.

Since we expect great things from our tobacco we must maintain the highest standards for quality even before the first leaf has sprouted.

PARTS OF A CIGAR

WRAPPER, BINDER, & FILLER

Tobacco plants are grown to provide the building blocks of every cigar. Once harvested, each leaf will be classified as a wrapper, binder or filler. These classifications pertain to the different layers that create a cigar. Filler tobacco is located in the center of the cigar and is responsible for the cigar’s taste. Binder tobacco wraps around the filler tobacco, holding the cigar together. A wrapper leaf is the outer most layer of a cigar, giving the cigar its color and feel.

FIELDS

FROM THE GROUND UP.

Prior to each growing season, before our precious new plants take root, the soil is tested for five key elements. Sufficient levels of Boron, Magnesium, Nitrogen, Potassium and Phosphate are measured and mixed into the soil. The trademark of such highly nutritious soil is a beautifully dark, almost black color. Once the field is properly assessed, each tobacco plant is transplanted individually to ensure maximum quality.

SUN GROWN

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.

SHADE Grown

Shade grown tobacco will be grown under cheesecloth, blocking out up to 65% of the sun’s UV rays. These plants will grow up to 9 feet, and unlike Sun Grown, Shade Grown leaves will generally be used only for the wrapper.

REAPING THE BENEFITS

After 100 days, the plants are harvested from bottom to top in sections. These sections are classified as Seco the bottom of the plant, Viso the middle, and Ligero the top of the plant. These three sections are further subdivided by layer into smaller groups called primings. Each leaf of the plant can supply a slightly different flavor. By dividing the plant further into primings, Rocky Patel has greater control in pinpointing the exact flavor he wants from each of his plants.

CURING BARN

TURNING UP THE HEAT

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 moisture. Sections of the plant are partitioned and hung in their primings to guarantee the finest quality flavor.

TURNING OVER A NEW LEAF

After forty days of curing, plants will transition from green to yellow to brown, shrinking significantly. The vein that divides the leaf known as the “midrib” is particularly shrunken during the process. Once an even color of brown is achieved the tobacco is brought to the factory for sorting.

End of part 1: In the fields

Part 2

The Cigar Factory