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Tobacco conditioning.
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Each and every step in the elaboration of an Habano requires first
class abilities, nowhere else is this demand as strong as on the
table of the Tabaquero or Torcedor (the cigar-maker).

A cigar-maker
can wrap up to 120 Habanos a day, each one perfectly calibrated.
We should mention that all specifications concerning the size and
length of a cigar are strictly predetermined and subject to very
little tolerance of any variations..

Thanks to the
agility and sensibility of their fingers..
The pursuit of
perfection can not be detained. The hands of experts will place
the
in their respective boxes which will then be decorated.
.
To some people
this may seem a waste of time on something that will eventually
vanish in a cloud of smoke. For cigar lovers, however, the Habanos
can be compared to works of art. .
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Tripas y capotes
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On their arrival in Vuelta
Abajo, the .
Each one of the five leaves is processed in a different way before
it is taken to the Galeras or cigar-making workshops.
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These leaves do not need humectación
. The ageing of each one of the four types of leaves needs different
periods of time. In the case of the Ligero (the light ones), which
are the leaves with the greatest endurance, their ageing takes two
years or more, whereas the Volado and the Capote are considered
to be ready within just 12 months.

The Liga, or department of mixing, is known
as the Barajita (small pack of cards), since the procedure is very
similar to the action of shuffling playing cards.
The master cigar-maker monitors
the progress of each type of leaf. Only when they reach perfection
are they admitted in the department of . Very strict security measures
are taken to protect that place because that is where all the secret
recipes of all the different cigar brands in Cuba are kept. Once
they are mixed, the leaves are delivered to the tobacco wrappers,
in quantities necessary to make no more than fifty cigars each time.
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The own delicacy of the leaves
requires extreme caution in order to restore their flexibility and
silkiness before they are put through the whole process of selection
and classification. This is achieved by a special Moja (spraying
with water) that always takes place during the small hours of the
day. The water excess is shaken off the leaves and these are left
hanging during a whole day, so that all humidity evaporates. The
next day, the skillful hands of the despalilladoras take out the
main vain in the centre of the leaf, this way dividing the leaf
into two. Then, it is time for the rezagadoras or classifiers to
select the leaves and group them according to their colour, size
and texture, before they are transported to the workshops. .

A rezagadora, a woman classifier, selecting
the leaves on her lap; a process that is probably responsible for
the popular myth that wants Cuban cigar to be made on the thighs
of beautiful Cuban girls.
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