The tobacco that is rolled into cigars is usually grown in the tropical regions of the world. The Canary Island, Cuba, Dominican Republic, Ecuador Nicaragua and Sumatra are world famous in growing quality tobacco. Tobacco is planted in late September and generally take about two months to reach maturity. Harvesting begins before the plant flowers and can take several months as the leaves are harvested in different phases.
Once the tobacco is harvested the leaves are sent to tobacco barns where the tobacco is dried. leaves tied in pairs and hung for the curing process. the tobacco barn. The tobacco barn faces from west so that the sun hits one side in the morning and the other side at night. The doors at either side can be opened or closed to keep the temperature consistent. The tobacco is kept in the barn for approximately 2 months while the leaves change color from green to yellow brown.
After the leaves have dried, they are carefully laid into large piles for fermentation, where they are kept for several months. The piles are moistened and covered in cloth and are watched closely as the temperature can rise and harm the tobacco. The fermentation reduces natural resins, ammonia and nicotine present in the tobacco leaves.
The fermented tobacco is taken to warehouses, stored in large bales and allowed to slowly mature. The aging process can last from several months to many years depending on the quality desired.
Once the aged tobacco reaches the factory, the leaves are graded according to size, color and quality. Leaves that a torn or have holes are set aside and used primarily as filler. Finally the leaves are de-veined by removing the center vein from the leaf.
A cigar consists of three kinds of tobacco leaves, the outer wrapper leaf, the binder leaf, and the filler leaves (which can be long, short or mixed).
