How cigars are made in a cube. How real Cuban cigars are made
Time has done its work and the leaf is finally ready to play its part in the Habano making process. The following describes this extraordinary art, which has changed little over the past 200 years. The heart of any factory where cigars are made by hand is the la galera workshop. Since 1865, spinners have been reading newspapers and books while working. Varying in the production method, except for a small number, Habanos are made entirely by hand “Totalmente a mano”, with the filling made from whole, uncrushed leaves. These are classic cigars in the style of Habanos Totalmente a Mano Tripa Larga (“Abanos Totalmente a Mano Tripa Larga”). Totalmente a Mano - entirely by hand. Tripa Larga – long filling.
Some other cigars are also made entirely by hand, but their filling consists of small particles of leaf. These are Habanos Totalmente a Mano Tripa Corta (“Abanos totalmente a mano tripa corta”) - Habanos made entirely by hand, with a “short” filling.
Finally, there are also machine-made cigars. However, no matter how the cigars are made, they have one general feature- origin of tobacco.
Preparation of the Intercession
After aging, the leaves are ready for final sorting and classification. At this moment they must be freed from the central vein. Moistening – “moha” – brings the leaf into the optimal condition necessary for removing the midrib, sorting and, finally, wrapping the cigar with a wrapper.
Bunches – “gavilhas” – of 40-50 leaves each (depending on their classification) are irrigated with clean water. Excess drops are shaken off to avoid the formation of any stains, after which the leaves are hung on racks so that moisture is absorbed evenly.
Then soft hands highly skilled workers undergo the removal of the midrib (“despalillo”) and the final classification -rezagado (“resagado”). With a precise movement, they completely remove the midrib of the leaf, dividing it into two halves, ready to be classified according to about 20 finely differentiated sizes and shades.
These women take leaves from a pile that they hold on their laps, hence the myth that Habanos are rolled on girls' thighs.
Preparing the sheet for filling
In turn, the leaves intended for stuffing and binding are carefully removed from the bales for careful inspection.
If necessary, they are ventilated to remove excess moisture. The leaves are then placed in wooden barrels where they are stored until they are deemed ready for use.
Preparation of tobacco mixture - “ligadas” (ligada)
Selecting each brand's mix to its specific recipe begins long before the bales arrive at the factory.
Once the factory layout for brands and sizes is known, the blender - ligador (“ligador”) – prepares a list of all the leaves that are needed to make these cigars.
The selection is carried out in a central warehouse, where a huge number of bales of leaves of all types are stored, each of which is classified according to its “tempo” (lijero, seco, volado and capote), size, age and, most importantly, region and site, where it was grown.
The great thing about Cuban tobacco is that the Vegas Finas de Primera plantations, which are so small in size, can produce such a huge variety of flavors - even in neighboring areas. Indeed, the tobacco that grows in the Vuelta Abajo on one side of the highway may taste completely different than the tobacco that grows on the other side of the road.
There is a strong connection between the factory and the areas that supply the leaves for the brands it produces. However, it is the responsibility of the blender, the “ligador,” to taste the tobacco every day. He keeps the recipes for each brand and each size in his head and ensures the mixture is consistent.
A mixture of leaves of each type in a proportion determined by the blender - the “ligador”, is prepared in the mixture department - in the quantity necessary for the daily production of cigars.
The mixture department is called La Barajita (“La Barajita”), literally translated - “ card deck” because selecting leaves for the mixture is like shuffling cards.
And finally, three years (or more) after the first leaf is harvested, the moment comes for the tobacco leaves to become Habano.
Anatomy of Habano
Filler
Three types of leaves are mixed to form the cigar filler, or tripa. It is this source of rich taste and aroma that immediately distinguishes Cuban cigars from the rest.
Volado: light-strength leaves that provide a hump-like body to the cigar; also known as Fortaleza 1.
Seco: medium-strong tobacco leaves, most important for the aroma of the future cigar - Fortaleza 2.
Ligero: strong and juicy leaves that burn slowly and provide strength to the cigar - Fortaleza 3.
Binder
The binder leaf, also called capote, is a special sheet used to wrap around the filler leaves, defining the shape of the cigar and holding the filling together.
Wrapper
The cover or capa is an exquisite thin and soft sheet that forms outer surface cigars.
The cover does little to contribute to the Habano's flavor, but it is the ultimate symbol of the cigar's perfection.
Stamps Cuban cigars
Although cigars traditionally called "Havana" have had a good reputation for their exceptional taste and quality for quite some time, recent popularity polls have confirmed that interest in them has grown significantly over the past decade. This is not surprising. “Havana” is a symbol of luxury and elegance. And even if you are not a real fan or lover of a good “smoke,” then this information will undoubtedly help you understand the vast world of Havana cigars.
Someone from wise people wrote that “Havana” is something more than a cigar. It's a world in itself. Cuban cigars are a style element associated with good location and a friendly atmosphere and deserve to be appreciated and treasured.
Have you noticed that the expression used is not “to smoke a cigar”, but “to enjoy a cigar”? This expression hides much more than a simple actual replacement of one verb with another. It reflects, above all, the incredible progress that has occurred in the thinking of novice and experienced cigar lovers in recent years. In the same way that we learn to drink a certain wine with a certain dish, we should treat smoking Havana cigars. The brand and type must be chosen based on the mood, the occasion in which we want to smoke, and at the same time taking into account the environment and society in which we will indulge our passion.
The choice of cigar is, in fact, an overture to a future truly gourmet experience. Let's enjoy this moment: let's look at the shape and quality, appreciate the skill of the packer, and then check the strength of the knitting and the tenderness of the cover sheet by touch. Already when lighting, you can appreciate the fruity or spicy aroma.
There has been a dramatic development in smokers' expectations for the taste of cigars over the course of this century: Today's Havana cigar connoisseurs tend to appreciate different aromas and flavors than previous smokers. Whether someone is a fan of a strong, pungent taste that leaves a heavy smell, we wish him so, but today the trend is somewhat different. It is no coincidence that the flavors are popular, although they are quite strong, but delicate, soft with a touch of a blooming woody smell. And this is exactly what “Havana” offers.
BOLIVAR
Most connoisseurs agree that the cigars of this brand do not look very good in appearance, but in reality they are excellent. During its existence, the Bolivar company has wisely expanded the selection of tastes and smells, which we can find on a wide scale - from too delicate to very strong. If you know exactly what you want from a cigar, you will undoubtedly choose from the Bolivar offer and we guarantee you that you will not be disappointed. Most of all, lovers appreciate the taste of dry earth with a pinch of spice, which, however, is characteristic of this brand. The best species are Petit Coronas, Royal Corona and the massive Coronas Gigantes (Churchill type).
COHIBA
Originally, this was the old Indian name for the tobacco plant, which stuck and is today used to designate one of the most famous and beloved brands of Cuban tobacco products. These cigars are still famous not only for their old name, whose resurrection took place in the late sixties. Cohiba offers an incredible range of full flavors with which all connoisseurs are certainly familiar, and in recent years has expanded the range of products to Linea 1492 and the Siglo I – V range. You will recognize the cigars of this brand at first sight - due to their typical orange, black and white ring. We recommend Esplenditos, Robusto and Siglo V.
LA FLOR DE CANO
This is a relatively young brand that achieved its reputation only during the eighties of our century by offering the world perfectly formed cigars made from tobacco of the highest quality. La Flor de Cano is distinctive for its sweet, uncomplicated flavors and is a big hit among Havana's youth. The brand offers a small selection of species, has a small number of products, and therefore, sadly, it is slowly but surely heading towards extinction.
LA GLORIA CUBANA
This brand is “special” in that it offers a standard selection of sizes. She attracted big circle devotees who prefer non-aggressive tastes. La Gloria Cubana, of course, also offers full-flavored cigars, distinctive and easily distinguishable from, for example, the famous spicy Partagas. Try Tainos (Churchill) or Medaille d'Or N 1 and 2.
HOYO DE MONTERREY
A true nobility among Havana cigars. Expensive, but popular, with rich history and a promising future. When pronouncing this brand, most connoisseurs will remember the classic “factory”, where the secret instructions of the original smell and taste are carefully guarded by skilled packers. Each Hoyo de Monterrey cigar is specific with its sweetish taste, which is skillfully combined from different floral aromas. Most smokers start out with cigars from this brand because it offers “easy” cigars that have a fresh taste and burn evenly. The current series began production in the sixties, and the most famous include Gran Corona Le Hoyo des Dieux, Corona Le Hoyo du Roi and Petit Corona Hoyo du Prince.
H.UPMANN
Although the H. Upmann brand seems to disappear from time to time on the market, our review of Cuban cigars would be incomplete without it. It was founded by an English family back in the last century, and since then it has been an important example of Cuban products and, in fact, led to the production of the first Montecristo. Today, H. Upmann is characterized by a strong, “scratchy” and very earthy taste, reminiscent of the brand's earlier products. Although connoisseurs call this “harsh privilege” a “noble scratch,” the truth is that because of it the brand has lost many adherents. There are still many experienced lovers with a refined taste who remain loyal. The best are two types of Churchill cigars: the majestic Sir Winston and Monarchs. It is also worth noting the lightweight Robusto Connoisseur N 1.
JUAN LOPEZ
This Havana manufacturer offers only five types of cigars self made, which, however, are a guarantee of consistently high quality. They are light, made from very sweet mixtures, smell pleasant and can be recommended for beginners.
MONTECRISTO
This world famous brand, which has achieved the recognition of all smokers, appeared to the world in 1935 and later became the property of H. Upmann. This explains why Montecristo was not so well known until now. After the change of ownership, the brand gained a first-class reputation and since then has been one of the richest in taste and “most intelligent” on the market. We recommend that connoisseurs try Special Montecristo and anything from series N 1-5.
PARTAGAS
One of the richest in taste and widest choice of brands. It earned its reputation mainly due to two things: large selection species from the smallest to the largest Coron and a wide range of specific tastes. The spicy, strong flavor of the cigars, clearly present from the start of smoking until the very end, retains its woody base, which is sometimes very sharp, sometimes creamy. The Partagas brand is also appropriate for meals with heavy dishes. A cigar from the Connoisseur series is suitable for any time of day; you can try Shorts as an aperitif. Londles goes well with seafood dishes.
PUNCH
P (perfecciones) - perfect, U (unicales) - unique, N (nobles) - aristocratic, C () - valued, H (havanas) - Havana. The name of the brand can be explained by these anagrams, which “capture” its exceptional qualities. This big family cigars are known, on the one hand, due to the high requirements for production, on the other, due to the special claims made by the manufacturer in relation to the breadth of the assortment. Lovers of a good “smoke” have the opportunity to choose cigars from long Specials to small Petit Coronas. All of them are characterized by a strong aroma, mostly fruity or woody. We recommend Double Coronas – Super Selection N 1 and 2 and Royal Selection N 12, which are truly excellent Havanas.
QUAI D'ORSAY
This French brand was founded in the seventies of our century, and since then has acquired a very solid reputation. Quai d'Orsay cigars are intended for experienced smokers who enjoy woody, slightly dry or earthy flavors. The manufacturer does not focus on strength, but rather on aroma. Try Churchill Imperiales.
RAFAEL GONZALEZ
It is an excellent representative of “improved products” and the greenish color of the wrapper leaf of this brand of cigars (called Clarisimos in Spanish) deviates from the generally accepted standard. Rafael Gonzales is revered by everyone who loves rich and honeyed flavors with a slight aroma of ginger. Lately, the brand has found many followers, and if you try the very elegant Lonsdale, Coronas Extra or Petit Lonsdales, maybe you will be one of them too.
RAMON ALLONES
This is a very old Cuban brand, typical for its strong and “straightforward” taste. Although all classic sizes are produced, it is primarily known for its Double Corona, Robusto and Corona types. Connoisseurs of this brand of cigars value them primarily because of their excellent structure and exceptional taste, and Ramon Allones is always present on the holiday table. The brand has a rich tradition and one can only regret that the best cigar - Private Stock - is no longer produced. We recommend: Gigantes, an earthy and slightly spicy 8-9-8 Cabinet Selection Varnishid and Small Club - a gentle and “easy” cigar.
EL REY DEL MUNDO
The main advantage of the brand is its sweetish taste, which is sometimes dry, sometimes creamy. This attribute, together with freshness and lightness, places El Rey del Mundo among the best that “Havana” has to offer. And experienced connoisseurs who rather like strong cigars cannot resist the sophistication of this brand. If you want to experiment, Tainos (Churchill), Grandes de Espana and Robusto Choix Supreme will certainly not let you down.
ROMEO Y JULIETA
Over the course of its existence, this brand has acquired an excellent reputation among lovers who prefer rich-tasting and strong Havanas. While Romeo y Julieta has become famous for offering the slightly dry, bitter-tasting cigars favored by the British, its latest sweeter, fuller or fruitier flavors have also had great market success. The success was primarily due to the type of Fabulosos and Robusto Exhibicion N 4. The development of the brand can be divided into several stages that it went through: in the sixties Cazadores, very spicy, even aggressive Gran Coronas, in the seventies and eighties Churchills, with rich, woody and strong taste, and later, in the nineties, the Exhibicion series, which is characterized by very aromatic and floral flavors. Romeo y Julieta is undoubtedly one of the best and most famous Cuban brands, as evidenced by its growing number of fans.
SAINT LUIS REY
This ancient Cuban brand again found its place in the sun in the late eighties. The typical selection is very rich and well designed. Cigars are defined by earthy and spicy flavors, and are sought after not only by connoisseurs, but also by novice smokers, for whom smoking them is a good experience. The best and most famous are Double Coronas Prominente. We recommend Series A, of which Gran Coronas and Robusto Regios are representatives.
SANCHO PANZA
Also a very old Cuban brand, which invariably has a good reputation not only among its loyal fans. It offers a carefully selected selection of cigars, including Churchill Coronas Gigantes, Lonsdale Molinos and Special Belicosos. The success of Sancho Panza lies, of course, in the elegant and delicate style of sweet and aromatic blends that provoke consumers to try other cigars of this brand.
Hand rolled cigar
A hand-rolled cigar consists of several elements: filling, binder and wrapper. The cigar filling is a mixture of three types of leaves. The volado leaf (translated from Spanish as “volatile”) has the lowest strength and is primarily responsible for burning the cigar. The seco (“dry”) leaf has a medium strength and provides flavor. The strongest of the leaves included in the filling, ligero (“light”), provides flavor and character. The proportion in which they are mixed various types leaves in the filling this is a cigar recipe. Strong cigars have a high percentage of ligero leaves in their filling. In soft aromatic cigars, on the contrary, seco leaves predominate. The initial proportion changes almost every year, because depending on the harvest, the properties of the same tobaccos vary greatly, while the manufacturer needs to keep the taste of their cigars unchanged. The bag master is responsible for creating the recipe and maintaining the consistency of taste. From the tobacco brought to the factory every year, he selects the best types suitable for this particular brand of cigars, and, mixing them, repeats the taste of previous years.
Until the early 1980s, Cohiba cigars could not be purchased at any price. Only high-ranking guests of Cuba could receive them as a gift. The villa where they are made belongs to Fidel Castro himself, entry is by special permission. What's going on inside?
(Total 18 photos)
Post sponsor: Vocal lessons: In the vocal studio, group acting classes are held, the task of which is to develop the vocalist’s acting abilities, his organic and relaxed existence on stage, and the ability to perform this or that work at a professional level.
Source: venividi.ru
1. Cohiba is one of the youngest brands of Cuban cigars, but quite expensive short term its products have managed to acquire cult status and become desirable in the collection of every self-respecting smoker. The history of the brand dates back to 1969.
2. For Cuba, this was a transitional period: the revolution died down relatively recently, loud political slogans were slowly but surely put into practice by Fidel Castro and his loyal henchmen. Under these conditions, the production of elite cigars opens at the Villa El Laguito, owned by Fidel. It was headed by Eduardro Riviera, who had previously worked at another factory - La Corona.
3. It is not known what reached Castro faster - rumors about the tobacco maker’s extraordinary skill or the aroma of his surprisingly strong cigars, but the fact of Riviera’s presence at the new factory clearly speaks in his favor.
4. The success of the Cohiba brand is largely predetermined by the use of the highest quality tobacco from the plantations of Pinar del Rio, where, unlike the factory itself, excursions are regularly organized. By the way, if you still really want to visit cigar production in person, the Tabacalera De Garcia factory in the Dominican Republic is open for tourist excursions. Let us note that the tobacco used in the production process of real Cuban cigars does not contain any foreign chemical impurities or pesticides. For the Cohiba brand, the rarest and thinnest leaves are used.
5. The mandatory first stage of cigar production is fermentation. The fermentation process is particularly complex and takes place in several stages. Its ultimate goal is to improve the taste of tobacco and reduce the content of nicotine, various tars and ammonium in it. First, the collected leaves are dried in strictly sealed bags. Repeated fermentation introduces specific flavors into the dried leaves, while the tobacco is stored in a dark, closed room. The final, third, stage of fermentation is designed to clean the leaves used for filling cigars as much as possible. Compliance with all stages of this complex biochemical process provides each real Cuban cigar with a persistent, unforgettable aroma and excellent quality worthy of the ambitions of the declared premium brand.
6. After the tobacco is brought to light after a long fermentation process, it goes on an equally lengthy journey through the workshops of tobacco factories. The movement of tobacco between workshops is controlled by tobacco workers, each of whom performs their own range of work. Such workers are called tabaquero, and among them, by the way, there are many women.
7. Tobacco is cleaned of deformed leaves and insects, sorted by color, thickness and quality, large leaves are removed, and then sent to the next production line - blending. At this stage, prepared tobacco leaves are selected according to varietal characteristics, and then they are mixed. The main thing is to determine the aroma of essential oils and create a varietal mixture based on them. This is perhaps the most important stage of production, which is why only professionals are involved in it. There are no random people in these positions - it is easier to pass the selection process at Google than to get the corresponding job at Cohiba.
8. The next stage of production logically follows from all the previous ones: tobacco workers who are responsible for the shape of cigars come into play. To give the final product correct form, you need to be good at chaveta - this is a special knife that is used to cut the stem and trim the edges of each leaf. If the cigar is based on a solid tobacco leaf, then there are no barriers to the air passing through the cigar. The smoker thus gets the opportunity to fully enjoy the subtlest shades of aroma.
9. The future aroma is determined by the nature of the filling - the central part of the cigar. Locals call it tripa. It is based on several whole tobacco leaves, the most fragrant and coarse, folded like an accordion. As a rule, tripa consists of three leaves, and if the first leaf is the most aromatic, then the other two serve a completely different purpose - they provide a mild taste and good combustion.
10. In order for the filling to be firmly held in place and not fall apart, it is wrapped in a capote - a strong thin sheet that is pre-pressed into a given shape.
11. The appearance of a cigar is determined by the burl - this is the part of it that is made from the most expensive tobacco leaves, soaked in the best essential oils.
12. When sorting cigars into boxes, consider thickness and color. This knowledge is available only to a few - they control this stage produced only by the most experienced Cuban craftsmen with big names.
13. Slowly but surely we have approached the final stage of production of elite Cuban cigars - labeling. The nimble hands of factory workers confidently maneuver between boxes full of cigars and stick on the tags required by the documentation. Let us note that there is no talk of any automation here: all tags are glued manually, and each of them is strictly accounted for.
16. Cigars are stored in rooms where there are no temperature changes, because when the temperature level increases, there is a risk of tobacco bugs appearing. Ideally, cigars should be stored in special boxes made of wood. noble breeds, - humidors. In such favorable conditions, each cigar has a good chance of celebrating even its tenth anniversary. Unless, of course, it is smoked first.
17. In 2009, the Cohiba factory celebrated its 40th anniversary. On this occasion, the company released the most expensive cigar in the world - Cohiba Behike. Be careful: it has been noticed that when looking at this miracle, the desire to smoke it arises even among those who have never even thought about tobacco.
18. P.S. Once Sigmund Freud, in response to the laughter of students who saw him with a cigar in his mouth during a lecture, declared: “Sometimes a cigar is just a cigar.” Arguing with Freud is the same as being offended by God, but let us note that the very process of smoking cigars has long outgrown the status of a habit and has taken shape into a fully-fledged cultural phenomenon.
Totalmente a mano
Those made in this way are considered the most expensive and noble, since they are made entirely by hand. These cigars are famous for their elite quality tobacco, which goes into the filling. The filling, in turn, is rolled from whole leaves of high-quality tobacco, the leaves of which are longer than ordinary tobacco crops. The finished filling is placed in a binding sheet and finally rolled into a cover sheet.
Professionals claim that there are no two cigars identical in size in the world, since by nature there are no two identical tobacco leaves. It is also believed that its appearance and proper circulation of smoke when smoking depend on the accuracy of the work performed and, of course, on the experience of the twister.
Hecho a mano
These cigars also, but the filling is placed into the binding sheet using a convenient cigar rolling machine, and the rest of the work is completed by the hands of the roller. With the help of this device, the filler in cigars becomes denser. All over the world, this cigar making technique is often used in many industries.
The name speaks for itself - such cigars are entirely produced by machine twisting. These cigars are mainly sold on the shelves; they can be purchased both in Cuban stores and in Moscow tobacco shops. With the help of such machine production, cigars can be produced not only with a filling from a whole tobacco leaf, but also with a filling from crushed tobacco. Such cigars, of course, are significantly inferior in quality to hand rolled cigars, so manufacturers came up with a little trick and, with the help of various flavors and attractive appearance, raise customer demand. And so that it is coated with a light solution of tobacco powder, but still, such cigars differ significantly from handmade ones.
They say that before cigar rolling was done directly by men, and women helped in preparing tobacco leaves. All production began with drying tobacco leaves. There are two ways to dry tobacco: 
one - natural, in the sun, and the second - with the help of fire, which significantly worsens the quality of tobacco products. Tobacco leaves dried in the sun have a brighter smell, higher quality and softer leaves. Also, the color scheme of the leaf depends on the drying method; in the sun, tobacco acquires a beautiful brown-red color, and from fire, the tobacco leaf will simply be pale yellow. After drying, depending on the color, the leaves are sorted into varieties. The first two varieties are yellow-orange and red leaves, the fourth variety is black leaves, and the third variety is all other colors. After selection, a process called twisting begins.
Before rolling, tobacco leaves must “rest” for some time in production so that the leaves gain the necessary moisture for rolling, after which the veins and stems will be removed from all leaves. Now the twister starts working, it would be more correct to call it - torsedoros. Depending on the size of the cigar, torsedoros takes 4-5 leaves of tobacco for 
fillings and lays them out lengthwise, then folds them in half or twists them into a spiral. This requires attention, because the filling is not rolled too tightly, but not too loosely, it depends on traction and. After this, the filling is wrapped in binding leaves and the cigar blanks are placed in a special container to give the desired shape. At the end, future cigars will be weighed and checked for draft. Now they just pull out the blanks and begin to wrap them in a wrapper sheet; they begin to wrap from the beginning of the cigar to the end, where the tip of the sheet is secured with cigar glue. The finished cigar is cut to the required length and placed in a special cabinet to dry for about two weeks. Dried cigars are sorted by color, emblems are attached and placed in boxes. All, cigar making process finished.
Many manufacturers of cigars such as Gohiba, Montecristo, Partagas achieved varied and interesting tastes by mixing different types of tobacco, the secrets of which are kept secret to this day.
El Laguito is the most famous cigar factory. It was she who gave rise to the Cohiba brand, a brand under which cigars are produced exclusively for the needs of the Government of Cuba and personally for Fidel Castro and his brother Raul.
In an interview with Cigars Aficionado magazine, the great Comandante told how this factory and famous brand came into being.
In the 1960s, Benvenido Perez, nicknamed “Chicho,” worked for Fidel as a driver-bodyguard. One day, when Fidel was returning home, he smelled the fragrant smell of a cigar in his driver’s car. He inquired about the brand and manufacturer, to which the driver said that the cigars were made by his friend, 20-year-old Eduardro Riviera, who works at the La Corona factory in the suburbs of Havana. Then there was no question of any brand.
The Comandante asked for some cigars for himself and liked them. As a result, he asked to find Eduardo. A contract was signed with him and the El Laguito factory was founded in 1966. Subsequently, Eduardo became the country's main torseodor.
Eduardo explained what blend of tobacco he used and from which plantations. A group was selected in Cuba
cigar manufacturers, supplied them with everything they needed. This is how a new brand was founded. Since Cohiba came out, Castro smoked only these cigars, they were so smooth and pleasant for him that they were easy for him to smoke.
Initially, the factory's products were not intended for sale, but were used exclusively as gifts for foreign guests and diplomats. The key was “quality and once again quality.” The best tobacco was used, which went through not two (as usual), but three stages of fermentation, which gave the cigars extraordinary softness. In just a few years, the brand’s fame spread all over the world, and to this day it is a cult brand in diplomatic, financial, and cinematic circles. The enterprise switched to a commercial basis only in 1982, but approximately a quarter of the production is still used exclusively for expensive gifts.
The Cohiba trademark was registered in Cuba in 1966. Much time has passed since then. Now Cohiba is known all over the world. But the factory is famous not only for Cohiba cigars. It became the parent of another brand, Trinidad, and at the end of 2009 they launched the production of Cohiba Behike cigars, the most expensive cigars in the world.
Today, the Cohiba cigar factory is a state-owned Cuban enterprise with strategic status. There are no excursions here and no tourists are allowed. An exception is made only for officials arriving by special invitation.
But enough history, let's take a look at the factory from the inside. The photographs of Desmond Boylan, a Reuters photojournalist who visited the workshops and captured how the most famous Cuban cigars are made, will help us with this.
In the production of El Laguito cigars, the most expensive, highest quality tobacco is used, grown in the Vuelta Abajo region of the Pinar del Rio province. Cuban tobacco is 100% natural; the use of chemical additives or pesticides is prohibited when growing it. The first stage of production is fermentation. The longer tobacco is fermented, the less nicotine and ammonium it contains. Fermentation takes place in a dark, closed room. After its third stage, the tobacco leaves are taken out into the light and sent for sorting.
Tobacco goes through several different workshops. Each tobacconist (tabaquero) is trained for each individual production line. The leaves are carefully inspected for damage and the presence of insect pests. In addition, the sheet is tested for tensile and elasticity. All work is done manually.
Each sheet is valuable and unique. They are disassembled and sorted by quality, color, then counted and placed in separate piles. Cigar tobacco should not contain large stems; they should be carefully removed so as not to damage the integrity of the leaf. The tobacco sorted in this way is sent to the next stage - to the blending workshop. Here the tobacco will go through several stages of mixing, after which it will be classified as one or another type of cigar.
Determining the aroma of essential oils and creating a varietal mixture is the most delicate and important stage of production; real art, accessible to only a few. Tobacco selected for thickness, color and aroma goes into the hands of the master responsible for the form.
First, the craftsman cuts out the stem and trims the edges of the leaf. For this purpose, a “chaveta” knife is used - a traditional tobacconist’s knife. All expensive cigars are made from a single leaf of tobacco. Air should flow through the cigar effortlessly and the aroma should be easy to inhale. In addition, the shape of the ash cap is important: a smooth, neat cap on the tip of the cigar is a sign of high quality.
Relatively speaking, a cigar consists of three parts: tripa, capote and capa. The “tripa” filling is the most central part of the cigar. It consists of several solid sheets, but always without veins, stems and veins. Leaves are selected according to the same thickness. If one sheet of filling is thicker than the other, the burning rate will be uneven. The filling is made from the coarsest leaf, of a certain fermentation and aging, but at the same time the most fragrant, responsible for the aroma and taste. In this case, appearance and color do not matter. It is the filling that creates the “bouquet” and the main taste characteristics of a particular variety.
The filling includes three types of leaves: the first (ligero) is the leaf growing on top of the tobacco bush. The darkest, full of aroma and taste, containing greatest number essential oils. The second type (seco) is a leaf coming from the middle of the tobacco bush. These leaves are much lighter and milder in taste. Typically fermented for about 18 months. The last component (volado) is a leaf growing at the very base of the plant. They are the least aromatic, but burn very well. The combination of three leaves in different proportions makes up a unique bouquet of each variety. The filling is folded like an accordion (and this can only be folded by hand). This accordion burns well and allows air to pass through easily.
“Capote” is the wrapper, what holds the filling inside the cigar. This sheet is slightly thinner than the inner one, but at the same time the most durable, responsible for its shape. The material is pressed into special forms so that the workpiece does not fall apart.
"Kapa" is the most expensive, most elastic leaf, the best tobacco leaf, responsible for general view. A cigar is wrapped in it. In expensive varieties, the outer leaf literally shines with essential oils. Masters say that it is much more difficult to grow and prepare tobacco than to roll it into a cigar. In this regard, the cover leaf is the most capricious and requires special care when growing. This is usually a very thin, pleasant-smelling sheet that is protected from external damage, such as rain. In the sun, any drop, like a lens, burns through a leaf, leaving spots on it, which is why the leaves grow under a canopy.
After the cigar is ready, the quality control department checks the cigars for stretching. If the test is passed, the cigar is sent for color sorting. In addition to monitoring thickness and color, compliance with the “bouquet” will be checked - a skill passed down from generation to generation. All cigars must not only have the perfect shape, but also be the same color in each box. The master can distinguish more than ninety shades of tobacco leaves by eye.
Cigars do not like changes in temperature and humidity, and their lifespan depends on where they are stored. Optimal conditions– temperature range 16-21 °C and relative humidity about 70%. If the temperature increases, the tobacco bug will appear in the tobacco. If the humidity increases, mold will grow. At low humidity, tobacco dries out, and while water can be restored, essential oils cannot be restored. To store cigars, “humidors” are used - cigar boxes of noble wood. Ideally, Spanish red cedar, which perfectly maintains humidity. If all conditions are met, the cigar will live for up to ten years.
After sorting, the cigars go to the labeling workshop. Each tag is under the strictest accounting and is handed over to the replacements against signature. Workers also glue the tags by hand.
The price range for cigars varies depending on the type, size, and quality. There are about twenty species of Cohiba. For example, a box (25 cigars) of Cohiba Esplendido sells in Cuba for about $380 dollars per box. In Canada, on free sale and after paying all taxes, their cost already increases to $800-900. In Europe, the price of the box exceeds 1000 euros. Cuban cigars are not officially sold in the states, but unofficially, in connoisseur circles, the price of one Cohiba Esplendido reaches up to $100 per cigar. There are collectible varieties that cost up to $1,000 per cigar. This is not even an element of luxury, it is already a cult.
Some varieties are not sold in Cuba at all, but are only exported. It must be remembered that initially Cohiba are the most expensive cigars, manufactured as an element of prestige. After 1982, when the factory entered the market, each new collection released goes first to gifts, to the government and to auctions. The second echelon goes to expensive foreign stores, and only lastly does the collection go on sale in Cuba.
The best Cuban tobacco grows in the Pinar del Rio Valley. Here, the land allocated for tobacco is allowed to be cultivated only with a plow drawn by oxen. Tobacco bushes grow in the open air, thus producing various aromatic substances in the leaves. Leaf collection begins 50 days after pollination. It's hard work—each leaf has to be torn off by hand to avoid damaging it.
The strongest aroma is possessed by young leaves from the top of the bush - they are called ligero. They are mixed with leaves that grow lower - seco and volado, and volado leaves grow at the very base of the bush. Between them are capote leaves, which are used when rolling cigars. To ensure that only large leaves grow, all young shoots are removed as soon as the plant reaches the ideal height. The combination of these leaves, in accordance with secret proprietary recipes, allows you to create high-quality cigars.
The space covered in white in the middle of tobacco fields is an unusual sight. This thin sheet protects the bushes that produce the leaves used on the outside of the cigars. Their importance in cigar making process means they must be well protected.
The leaves are further processed in a tobacco casa, not far from the plantation. The leaves are dried to concentrate the aroma and taste. They are hung on special poles for several weeks. Changes in humidity are carefully monitored - if necessary, workers sprinkle the floor with water or light small fires to maintain the necessary balance. In such mild conditions, the leaves do not dry out or rot. With each new collection of leaves, the poles move higher until they finally reach the ceiling, marking the completion of the drying process.
The “heart of production” is tobacco leaves, collected several years ago. The leaves are rolled in a special way for each variety. The workbench is simple, as are the tools - blades for cutting leaves, gelatin for giving them the desired shape, vegetable resin for sealing the tip and, finally, a mold. Each worker can roll up to 100 cigars per day. They are paid according to the number of finished cigars. The mixture of different types of leaves is determined by the type of cigar. Ligero provides flavor, volado provides combustion, and seco provides subtle aroma. Each worker makes one specific type of cigar, but does it with great precision, observing all dimensions.
After rolling, the cigars are collected into bundles of 50 and placed in cedar boxes to remove moisture absorbed during the manufacturing process. Over the course of several weeks, the aromas of different tobaccos are mixed, resulting in traditional Havana cigars.
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Finally, the moment comes when the cigars reach their final readiness. They are removed from the boxes and handed over to specialists who evaluate the color of the cigar. At this stage, color is given great attention— more than 60 color nuances are taken into account.
The boxing is done by another specialist who sorts the cigars depending on quality. Cigars are stacked from left to right - from darkest to lightest.
According to legend, stickers on cigars were needed to prevent aristocrats from getting their white gloves dirty while smoking. But, most likely, in this way the manufacturers protected the goods from counterfeits.
Cigar tasters are the smallest group involved in the long process of cigar production.
Partagas is one of the most famous varieties of cigars. They are produced in the capital, at a factory founded in 1845.
Another famous factory – H. Upmann. There are still a lot of people working here. A significant portion of the city of Havana's population makes their living from the cigar industry.
