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During harvesting, leaves are picked beginning at the bottom. Valdo,
the bottom leaf has the mildest taste. Seco, in the middle, has a
medium flavor. Ligero, at the top, has the strongest taste.
Curing is the next step. The chosen leaves are bundled according to
size and texture and are hung to dry in curing barns for six to eight
weeks.
Tobacco must ferment, "sweat" properly in order to smoke with good
taste and aroma. Fermentation removes ammonia and other chemical components.
Improperly fermented tobacco causes harshness or bitterness, and will
not stay lit.
The filler, the binder, and the wrapper are the three parts that make
up a cigar. In premium cigars, each has to go through meticulous preparation,
including sorting and stripping.
After this preparation, the master blender is now ready to create
the "recipe." He pre-blends the filler, selecting the special combination
of tobacco leaves. Depending on the ring gauge and type of cigar,
a cigar will contain a blend of two to four different tobaccos.
Expert hands make the difference in a fine cigar. The "buncher" forms
the filler into a cylindrical shape. This is rolled into a binder
leaf and placed in a mold to coax it into a cigar shape. The "roller"
then skillfully applies the outer wrapper tobacco leaf.
After rolling, cigars are placed in the "marrying room" for a minimum
of three weeks. This is a temperature and humidity-controlled Cedar
room. This gives the selected tobaccos time to meld their tastes and
for the moisture to equilibrate.
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