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3/4.
From workbench to the box |
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 Preparation
of the Tobacco
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On
arrival from la Vuelta, the containers or “Tercios” are dismantled. Each of the 5 types of leaves is treated differently before being
passed to the “Galera”
or
the cigar workshop.
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Outer
Layer Leaves
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Their
very delicate nature requires that their suppleness and smoothness is
returned before they are classified and sorted for the last time. The
wetting or “Moja” is carried out exclusively during the cooler hours
of the early morning. The leaves
are then shaken to remove any excess water and are then hung overnight
to ensure a uniform humidity.
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The next day, the affectionate and expert hands of the “Despalilladoras”,
or gromder,
eliminate the central section and so divide the leaf in two.
Following this the “Rezagadoras”, or sorters, place the
leaves in piles depending on their size, colour or texture before the
leaves go to the “Galera”.
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Core
of the cigar and Undercoat
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These
leaves must not be wet. The drying time for each of the four types of
leaf is different. The
“Ligeros” must be allowed to mature for a minimum of two years,
whereas the "Volados” or “Capotes”, about 12 months.
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The head mixer keeps a watch on the development of each of the leaf
varieties. Once perfection is reached, the leaves are admitted to the
“Liga” or mixing room. It is
in this room that the mixing recipes for each mark of Habano cigar are
enviously kept.
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Making
the Cigar
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The
heart of the creation of the cigar is “La Galera”. It is here that the
craftsmen, “Torcedores”, create the different
brands and formats. Their only tools : a
wooden table, a sharp knife (Chaveta), a guillotine, a jar of vegetable resin
and… their fingers. Each
craftsman rolls about 120 cigars a day.
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Quality
Control
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The
team in charge of quality control, regularly collects a sample of 50
cigars from each craftsman. The
length, shape, diameter, appearance and weight is controlled.
The craftsman is paid for each cigar finished to the required
quality standard.
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The
Packaging Room
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The
cigars leave the workbenches and are taken to the “Escarpate” or
Packaging Room. It is a protected room in which draw cupboards made of
cedar are lined up.
The cigars rest here for a minimum of three weeks or several
months, in ideal conditions; temperature of 16 to 18 degres and humidity
of 65% to 70%.
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Sorting
by Colour
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The
presentation of “Habanos” must be perfect : The “Escogedor” or
colour sorter starts by sorting in no less than 65 different shades. A second “Escogedor” sorts the cigars in a provisional box,
in such a way that they are placed in order of dark to light and he
selects the finest side of the cigar, the side that is seen when the box
is open.
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Ring
Tagging
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“L’Anillador”,
or tagger, removes the cigars from the provisional box in order to put
on the ring tag. In no case
can she modify the order established by the “Escogedor” or choose a
different side.
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Labelling
and Finish
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The
partially decorated boxes are returned from the “Anillado” for final
packaging including the Governmental Stamp of Guarantee. The boxes, made of cedar wood allow the cigars to breathe and
continue to mature.
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