Knowledge

In order to create a Premium Cigar, there is a specific process that must be followed, from the selection of the seed to the final work of art of the Cigar Master.

Before entering into detail, it must be mentioned that one of the most important qualities during this process is the fact that the manufacturer is located in the same production zone. This is essential in order to supervise constantly and personally the crop and all subsequent processes of the transformation into a Premium Cigar. This is the only way to guarantee 100% the pureness and quality of a Vitola (Traditional name for a Fine Premium Cigar).

There is great importance in the knowledge of the variety of seed and the conditions in which it must be grown. We produce two kinds of tobacco for Premium Cigars “Olor Dominicano” is from the Dominican seed and “Habanensi” is from the Cuban seed. In one hectare of land we plant 35,000 plants from the “Habanensi” seed, while only 18,500 plants from the “Olor Dominicano” seed will be planted. The reason for this is that the “Olor Dominicano” plants are 50% more robust than the “Habanensi” and require the additional space to produce the best leaves.

The Cuban Seed (“Habanensi”) grows better in loose soils and high pluviometry or irrigation. “Olor Dominicano” (Dominican Seed) can withstand heavier soils and less pluviometry or irrigation.

Unless otherwise instructed by the laboratory, in general, we apply 2 to 4 fertilizations in the first month of the crop.

Fertilization is necessary to supplement the naturally occurring essential mineral elements in the soil and thus maintain the level for optimum growth and health of the plants. Daily soil analysis combined with knowledgeable observation of the plants progress are keys for a successful harvest.

In the beginning of February the solar radiation is at its peak and the plants absorb more energy. The solar rays stimulate the plants to photosynthesize at higher levels and produce more Alkaloids; a naturally occurring reserve. These reserves are what we enjoy when we smoke a cigar. In order to retain these reserves and inhibit flower production, the top bud is removed just before the plant blossoms. This causes an explosion of growth in side shoots which must be removed in order to protect these coveted reserves. Careful daily attention must be paid to every plant in the crop to make sure this process is done correctly. Only selected plants will be chosen to bloom to later collect the seeds for next year’s production. One of the key points in a crop is controlling weeds and diseases without damaging the environment. This is especially important to us because we live here with our families.

In average a tobacco plant lives about 70 to 100 days. Around 52 days after planting out, the harvest of the Cuban Seed starts (the Dominican Seed starts at 65 days). A time consuming process takes place here because only a few leaves can be taken at a time. Leaves are picked at weekly intervals from the bottom of the plant. The leaves located at the bottom have less nicotine since they receive less solar light.

The leaves collected are classified according to size and characteristics. They are then tied in bunches around a stick 6-feet long called “Cuje” in Spanish. These sticks are arranged horizontally in the Curing House with a minimum space between them of 6 inches to facilitate proper ventilation.

The third step is the fermentation or aging, also called “añejamiento” in Spanish, which is essential to the smoking quality of the Premium Cigar. It is here where the tobacco we get from the field is transformed from a raw material into The Premium Cigar with the characteristic unique flavor, color and aroma.

Fermentation starts by piling and moisturizing properly the cured leaves. This triggers the natural reaction of the Alkaloids and starts the fermentation process. We achieve this when we increase the temperature of the pile of cured leaves. Once we have reached the desired level, another pile is created with this same tobacco to reduce its temperature and ventilate the leaves by changing their place in the new pile. This process is repeated as much often as needed. By properly fermenting the cured leaves we smooth its flavor as the tobacco sweats out its impurities, reducing acidity, tar and nicotine. Controlling temperature level at this step is crucial and must be preformed exclusively by experts. This is due to the fact that the temperature levels vary according to the characteristics of the leaves. If the heat is too high, the leaves will be spoiled. On the other hand, if the temperature does not reach the correct level, the desired reaction will not occur.

There is a famous Dominican saying “You can make anything but aged tobacco”. If we want to store our cigars for any amount of time, appropriate levels of temperature and humidity must be kept. Measures to protect our cigars against insects also must be taken. A good example is “Lasioderma Serricorne”, which is the biggest threat to the finished product. This insect drills through the cigar completely destroying it. The process of gradually reducing the temperature of the cigar insures that this plague is eliminated completely in all forms including larvae and eggs. To guarantee a great cigar you must have optimum selection of seed, ideal climate, delicate harvest, patient curing and specialized fermentation.

A Premium Cigar is a balanced blend of aroma and flavor with ideal combustion; combined with the old art of hand rolling with love for the raw material. All of this with the delicate process of packaging and preservation completes the perfect cigar.