Tobacco conditioning.


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. .

 

Tripas y capotes
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.

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.

Layers

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.