SEEDBED
The roots of the plants are very delicate and require soil free of weeds, only then can they welcome the seeds that will become strong and promising plants.
PLANTATION
Once these little plants have reached a height of between 15 and 20 cm, they are planted in separate rows with enough space between them to allow them to grow. A hectare will accommodate approximately 25 thousand plants.
DRYING
The plant grows and develops by slowly absorbing the best nutrients from the soil, until it reaches maturity. Once the plant reaches maturity, the harvest begins. Later, the tobacco is taken to the tobacco barns, where skilled hands tie the leaves with cords and hang them from bamboo poles that are placed at different heights to dry
1ST FERMENTATION
Once the leaves are cured and the tobacco has lost a significant amount of its water content, the leaves are bundled into groups called “matules” and taken to the warehouse. There, they are arranged in piles called “trojes,” where the temperature is carefully monitored throughout the fermentation process.
2ND FERMENTATION
After the first fermentation, the leaves are classified according to their size, color, and texture. They are then grouped into new bundles called “gavillas” and placed again in piles called “trojes,” where they undergo further fermentation at the intensity required for their quality. During this process, the tobacco develops and refines its aroma and flavor.
AGING
Once the fermentation is complete, the tobacco is packed into bales, known as “tercios,” and stored in the warehouse. There, the tobacco is aged, allowing its aroma and flavor to develop and become richer. Once the desired level of aging has been reached, the tobacco is ready to be delivered to the “tabaqueros,” who will use it to make the cigars.
BUNCHING
To begin making a cigar, the tabaquero selects leaves known as “filler” and uses them to form the inner part of the cigar, leaving air channels through which the smoke can pass. The filler is then wrapped with another leaf known as the “binder,” forming what is called a “bunch.” The bunch is then placed in molds, which are pressed to give the cigar its characteristic round shape.
ROLLING
After approximately 20 minutes, the pressed bunchos are removed from the molds to begin the “rolling” process, which involves using a leaf called the “wrapper” to cover the buncho and give the cigar its final appearance.
CIGAR HEAD
Using the same leaf that wraps the cigar, the head is formed at one end. The Santa Clara tabaqueros create the “natural head” from the same wrapper without ever cutting it separately from the cigar. Among experts, this is considered a hallmark of a master cigar maker.
LABELING
The cigar undergoes several quality control checks before the cigar band is carefully placed, marking the completion of an exceptional process.
QUALITY
Each cigar is carefully inspected for construction, appearance, draw, and overall quality, ensuring that every cigar meets Santa Clara’s high standards.
PASSION IN EVERY CIGAR
From seed to finished cigar, every step reflects dedication, tradition, and pride. This is the art of cigar making. This is Santa Clara
