From tobacco to cigar - By: Dotrhey

First steps becomes cigar tobacco were called “Magic Six. A fermentation of the total tobacco practiced Cigar called Nunez said: “You take six weeks to germinate seeds, six weeks to grow the plants for six weeks before harvest, six weeks to dry and cure, and for six weeks to ferment for the first time. We call it the magic six. ” cigar tobacco is grown in many regions today. The most important of these is the Caribbean and Central America. The outer surface of these areas, large cigar tobacco countries include America, Venezuela, Ecuador, Mexico, Brazil, Indonesia, Philippines and South Africa.The Caribbean countries are Cuba, Dominican Republic, Jamaica and Puerto Rico. The rich, red soil Vuelta Abajo in Cuba is recognized as the most beautiful region in the world, Tobacco, and is one of Cuba in the five core areas of tobacco.

Dominican Republic tobacco is mainly grown in the Cibao River Valley, and is the main rival in Cuba attracts the best for growing tobacco.In of Central America, the prime tobacco states of Honduras and Nicaragua, who also believe that tobacco is as good as any produced by Cuba. America to produce the best package of tobacco products in the world, at least, outside of Cuba, which is all grown up in Connecticut. Connecticut-shade tobacco product packaging is in constant demand and receive premium prices. In tobacco wrappers, Ecuador, Indonesia and Cameroon, the African nation, have become serious contenders for trade.Firstly increasingly important as growing cigar tobaccos, and the manufacture of cigars are the people of Mexico, Indonesia and Brazil. You will find a lot of premium cigars now use tobacco products from those countries in their fillers, binders and wrappers.

Cigars start as a tiny seed tobacco grown in nurseries for 45 days, then hand set in very straight rows. Shade tobacco is additionally charged as a tent on the gauze or mesh. It took another 45 days to six weeks for the plants mature. The leaves are collected on their own, and at different times to ensure the best quality. The plant usually has a sixteen to eighteen leaves. The leaves of tobacco plant with a mild taste of the progress at the bottom to the top at the top. The various leaves are divided into three groups. “Valdo,” is the soft leaves from the bottom of the plant. In the middle section of the leaves is called “SECO”. Despite the fact that the top layered, strong taste of the leaves is called “ligero.” After collection, leaves are tied together in pairs and hung on poles or in the set, as a rule, in accordance with the texture and size, and in barns or sheds to be dried to treat, where the colors change from green to various shades of brown. They are still here, you go from up to eight weeks.After the first treat, then the leaves are sorted and evaluated for size, texture, and color now. At the leaves are sorted and stacked in bundles of twenty leaves, called “hands” and start their first fermentation. The hands and then placed in groups of three to six feet high and ready to fermentation.During fermentation in the stacked leaves begin to rise in temperature. Moisture, SAP, nicotine, and ammonia are released during the process. Monitoring temperature is a continuous process. When the temperature reaches the desired point in the hand restacked, changing its position in the group that all fermented evenly. This recovery of these groups can be done more than tenfold over the period up to three months, with leaves, such as Maduro take as long as six months.After of the fermented tobacco leaves are dry and brittle. They are easily applied with water and steamed. The leaves then re-graded and divided into the filler, binder and wrapper leaves. Usually, the leaves will be the second or third fermentation process.After fermented tobacco before the age of three years, and in some cases even longer. Only tobacco is ready to be in cigars.

The making cigars:

A cigar is composed of three parts: filler, binder and filler wrapper.The is the heart of the cigar, its center, surrounded by a wrapper and binder covers. In premium cigars, only long filler tobacco is used, long-leaf tobacco, which goes along the entire length of the cigar. Two or three and sometimes four different tobaccos are combined together to make the filling. This combination or “recipe” of these mixtures with different binders and wrappers, that the distinction between different brands of cigars, giving them a distinctive flavor. Short-leaf, or cut tobacco, used mainly for production machines cigars.The binder is what holds the filler together. The binder affects the taste, burn, and the aroma of cigars and is an integral part of the brand in the “recipe”.

In premium cigars, specializing binder leaves, while the mass-market car manufacturing cigars use a homogenized binder tobacco parts.The wrapper is the outer layer of the cigar. They not only judged by their appearance and texture, but to taste is added to the cigar they provide, which may account for up to 60% of the cigars taste. Hand-rolled cigar wrapper around the cigar requires the most skilled masters cigar factory, called the roll, and takes years to become a master roller.Cigars can be manual, mechanical and hand-rolled or bunched machine – made. Cigars Handmade just that, handmade from beginning to end. Simulated-bunched cigar shaped by machines, but the wrapper is applied hand. Machine manufacturing cigars have all stages of their design done in machine.Handmade cigars start with a “buncher,” who mixes and form filler in a cylindrical shape by crimping them together like an amateur, the creation of horizontal air spaces to do good and to ensure that each of flaky cigar fuse together all the tobacco in the mixture.

Liquid binder and then rolled in a sheet and is known as a “bunch”. A Buncher takes bunches and place them in forms that are stacked in a heap of press, which applies enough pressure to compress the beam in the form of cigars, which takes about forty-five minutes, during which the individual bunches are rotated to create a good shape.The cylindrical beams then taken to the rollers, the most skilled craftsmen in the factory, which is used in the package. The video cuts off the package the size sheet and surrounded by a cigar, with its outer layer. The video then cuts a small piece of wrapper leaf for the upper mounting it on the head with a sticky, tasteless swab from a natural tree gum. The finished cigars then cut to the desired length. A master roller called “Torcedor.” Nevertheless, the ‘Finish’ cigar is not really complete. Tobacco moistened for the first time in their production. Now, cigars should be dry, and did so in a temperature contolled room cedar. This drying time is also designed to allow different mixtures inside a cigar to meld together. This process may take several weeks, months or, in special cases, even years. Cigars are then evaluated at the last moment, the color range, boxed and shipped out.

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