THE JOURNEY OF OUR CIGARS
"Highlighting dedication and skill that goes into creating each cigar"
Embark on a Journey of Taste and Tradition.
PLANTING & HARVESTING
Tiny, coated seeds are planted into a sterilized growing medium where they germinate. The seeds are monitored closely and grown under strict humidity and controlled temperature.
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Seedlings are planted in the field – either by hand or by machine. After six weeks in the field, the plants are ready for harvesting. Tobacco leaves mature from the bottom of the plant upward.
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The quality of a tobacco is mainly determined by the composition
of the soil, climatic conditions, and the amount of sun hours. Therefore the most tobaccos come from countries where there is plenty of warmth and sun such as Dominican Republic, Nicaragua, and Ecuador.
CURING
After Harvesting the leaves have to be gently cured.
So it is hung in a wooden sheds for approximately 30 days.
As the leaves turn from green to yellow to brown,
they are slowly dried to reduce their moisture content and release their natural sugars.
FERMENTING
After being removed from the sheds, the tobacco undergoes a complex fermentation process, which develops its flavors, aroma and color. The leaves are stacked and the weight and humidity cause the middle leaves to start fermenting.
Once the desired temperature is
reached, the pile is rearranged and the process starts all over again. This expert fermentation takes months.
SORTING AND GRADING
Moisture is applied to the leaves. The moisture makes the leaves easier to handle and reduces the risk of broken leaves. The leaves are ready to be sorted according to their color, quality and size.
The central vein of the tobacco is removed completely with wrapper tobacco and binder, and partially removed for filter tobacco. Stripping can be done either by hand or machine.
ROLLING
The bulk of the cigar, a blend of leaves called the filler, is held in place by a binder that is wrapped around the filler.
The filler and binder together are called a bunch.
Once the bunch is made, the very important wrapper is wrapped around it.
Cigars are rolled in teams of two: a buncher and a roller.
INSPECTION & AGING
Every cigar is meticulously inspected. Cigars with imperfections are rejected. Cigars that pass inspection are stored in cedar-lined aging rooms
for at least three weeks. Here, they lose 3-4% of their moisture.
The aging process allows the different aromas and
flavors of the selected tobaccos in the cigar to form an exquisite balance. When the cigars are done with the aging process,
they are ready to be packed.
PACKAGING
The cigars are sorted according to color shading, ensuring a homogenous assortment in each box of cigars. Placing bands on each cigar.
STORAGE
Storage needs to take place in optimal humidity
(between 72 and 75%). If the cigar is too humid, it burns unevenly.
If it is too dry, the combustion is too quick and the taste will be unpleasant.
TRANSPORTATION
Our cigars are shipped to destinations all over the world. Mainly they are sold in Belgium, France, Germany, Italy and Vietnam, Myanmar and Thailand.