Leaves are picked by hand in several stages, starting with the upper “volado” leaves, followed by the “seco” and finally the thicker “ligero” leaves found at the top of the plant.
The process begins with the careful selection of seeds, which are sown in seedbeds under controlled conditions to protect young plants from adverse weather and pests. After approximately two months, the seedlings are transplanted into well-prepared fields, spaced to optimize growth and leaf development. Throughout the growing season, which lasts about six months, farmers apply organic fertilizers and employ traditional pest control methods to maintain the health of the crops. The quality of soil and climatic factors such as humidity, temperature, and rainfall are critically monitored, as they directly influence the tobacco’s texture and aroma.
When the tobacco plants reach maturity, typically indicated by the yellowing of lower leaves, the harvesting process commences. Leaves are picked by hand in several stages, starting with the upper “volado” leaves, followed by the “seco” and finally the thicker “ligero” leaves found at the top of the plant. This selective harvesting ensures that each leaf is gathered at optimal ripeness. Once harvested, the leaves undergo an initial curing phase known as barn curing or air curing. They are hung in well-ventilated curing barns, where temperature and humidity are carefully regulated over a period of four to eight weeks. This method facilitates the gradual drying of leaves, reducing chlorophyll content and developing the characteristic color and scent essential for premium tobacco.
Following curing, the leaves are sorted and classified based on size, texture, and color. The fermentation process then begins, a vital step in which leaves are bundled and stored in humid conditions to encourage microbial activity that further refines flavor profiles and removes undesirable harshness. Fermentation may last from weeks to several months, depending on the desired characteristics.
Finally, the prepared tobacco leaves are aged, often for several years, allowing complex chemical changes to enhance their aroma and smoking qualities. Only after this extensive preparation are the leaves handed over to skilled torcedores (cigar rollers), who expertly craft them into cigars. This intricate sequence of cultivation, harvesting, curing, fermentation, and aging underscores the dedication and tradition behind every cigar, contributing to its esteemed reputation as a luxury product enjoyed worldwide.