FROM BENCH TO BOX

From seed to barn | From barn to bench | From bench to box
Each torcedor, or roller, specializes in one particular size and only the most experienced torcedor is permitted to roll the larger sized cigars.

To begin, there are three leaves integral to the composition of a Habanos.

The calculated blend of these three filler leaves depends entirely on the varying House flavors. Ligero - Full-flavored leaves from the top of the plan Seco - Medium flavored leaves from the centre of the plant Volado - Milder flavors from the bottom of the plant

This leaf encases the filler leaves to form a 'bunch', which is then placed into a wooden mould to further set their shape

This leaf always remains a little moist to ensure a perfect stretch around the filler and binder leaves.

The cap is cut separately and wound around the head of the cigar to close off the open end and secure the wrapper.

Finally, using vegetable gum, a small disc of tobacco is secured to the head of the cigar, which is then guillotined to length.

Each batch of cigars is labelled with the torcedor’s number, the type of cigar and the date of manufacture to facilitate a strict quality control. Cigars are tested for combustion, color, rolling quality, dimensions and the finish of the cap. Torcedors are paid per cigar.

Color Classifications_Cigar wrappers naturally display around 12 different colors and up to 72 different shades. Ensuring that each box is consistent in color is a great task accomplished in by the Escojedores (choosers) who work in pairs to color-match the wrappers.