Fermentation
The tobacco leaves are packed into long piles where they are subjected to the first fermentation process which takes about 30 days. If the temperature exceeds 35 Degrees C the piles are broken up and allowed to cool before the piles are rebuilt. The process results in a more uniform colouring of the leaves. When completed, the leaves undergo a moisturising process. The leaves are then classified by size, colour, texture and type. This process takes up to 60 days and results in a reduction in the amount of impurities and makes the leaves more palatable. The leaves are then laid out on airing racks and made into solid packages where they are then stored. Once the ageing process is complete, they are transported to the various cigar factories.

Manufacture
The production process is carried out by a torcedor(a) – cigar-roller - using a crescent shaped blade called a ‘chaveta’. The cigar will be made up from three types of leaves - filler, binder and wrapper.
Filler
The filler provides the bulk of the cigar and by careful blending, the desired flavour is reached. The least flavoured tobacco comes from the bottom leaves of the plant and is called ‘Volado’, the light-flavoured, ‘Seco’ comes from the middle with the strong flavoured ‘Ligero’ coming from the top of the plant. The preferred flavour is achieved by blending these three types of leaves.
Fillers are either long or short – the long filler comprises complete leaves and a high quality cigar whereas the short filler which is comprised of chopped leaves and stems, produces a much lower quality product.
Binder (Capote)
The binder simply holds the bunches of filler together before the wrapper is added. (The binder leaves are often wrapper rejects).
Wrapper (capa)
This is the most important part of the cigar and the leaves are specially grown under shade which reduces the size of the veins. Leaves grown under these conditions are very pale and result in the claro end of the scale. The opposite applies when the leaves are subjected to full sunlight resulting in the dark maduro wrapper.
The leave selected for the wrapper is layed face down and rolled from the base of the cigar to the foot. Finally a small cap is place around the base end and secured with a vegetable glue to prevent the wrapper unravelling.
Once the cigars have been made, they are then scrutinised for their size and colour before being accepted and subsequently boxed.

Ring Gauge

The diameter of cigars is called the Ring Gauge and measured in increments 0f 1/64th’s of an inch

The Main Shapes

Parejo

Piramide

Figurado

The most popular sizes of cigars are:

Churchill - 175mm 48 Gauge
Lonsdale - 165mm 42 Gauge
Robusto - 127mm 50 Gauge
Corona - 142mm 42 Gauge
Petit Corona - 127mm 42 Gauge
Tres Petit Corona - 116mm 40 Gauge
Panatela - 116mm 30 Gauge

Cigar Accessories

Punch	Cutters There four main types of cutter and it is purely a matter of choice as to which one is used. It should be noted that the punch cutter is only suited to larger ring gauge cigars and for cigars without pointed ends. Great care must be taken when cutting the cigar as if too much is cut off, the wrapper will start to unravel, just remove sufficient cap to allow a wide enough aperture to allow for an unobstructed draw.
Guillotine	Where to Cut Your Cigar"
Double Cut
Scissors
Lighters There are numerous types of cigar lighter but it is very important that the lighter produces an odourless flame, therefore a petrol lighter or candle should not be used – only use a lighter fuelled by butane, a long match but make sure the sulphur has burned away first or a spill.