{"id":1768,"date":"2026-09-07T17:52:08","date_gmt":"2026-09-07T17:52:08","guid":{"rendered":"https:\/\/santaclarapuros.com\/saclasa\/?page_id=1768"},"modified":"2026-09-18T16:04:48","modified_gmt":"2026-09-18T16:04:48","slug":"the-santa-clara-process","status":"publish","type":"page","link":"https:\/\/santaclarapuros.com\/saclasa\/the-santa-clara-process\/","title":{"rendered":"The Santa Clara Process"},"content":{"rendered":"\t\t
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\n\t\t\t\t\tSEEDBED\t\t\t<\/h3>\n
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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. <\/p>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n<\/div>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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\n\t\t\t\t\tPLANTATION\t\t\t<\/h3>\n
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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.<\/p>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n<\/div>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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\n\t\t\t\t\tDRYING\t\t\t<\/h3>\n
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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<\/p>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n<\/div>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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\n\t\t\t\t\t1ST FERMENTATION\t\t\t<\/h3>\n
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Once the leaves are cured and the tobacco has lost a significant amount of its water content, the leaves are bundled into groups called \u201cmatules\u201d and taken to the warehouse. There, they are arranged in piles called \u201ctrojes,\u201d where the temperature is carefully monitored throughout the fermentation process.\n<\/p>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n<\/div>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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\n\t\t\t\t\t2ND FERMENTATION \t\t\t<\/h3>\n
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After the first fermentation, the leaves are classified according to their size, color, and texture. They are then grouped into new bundles called \u201cgavillas\u201d and placed again in piles called \u201ctrojes,\u201d where they undergo further fermentation at the intensity required for their quality. During this process, the tobacco develops and refines its aroma and flavor.\n<\/p>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n<\/div>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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\n\t\t\t\t\tAGING\t\t\t<\/h3>\n
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Once the fermentation is complete, the tobacco is packed into bales, known as \u201ctercios,\u201d 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 \u201ctabaqueros,\u201d who will use it to make the cigars.\n<\/p>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n<\/div>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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\n\t\t\t\t\tBUNCHING\t\t\t<\/h3>\n
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To begin making a cigar, the tabaquero selects leaves known as \u201cfiller\u201d 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 \u201cbinder,\u201d forming what is called a \u201cbunch.\u201d The bunch is then placed in molds, which are pressed to give the cigar its characteristic round shape.\n<\/p>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n<\/div>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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\n\t\t\t\t\tROLLING\t\t\t<\/h3>\n
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After approximately 20 minutes, the pressed bunchos are removed from the molds to begin the \u201crolling\u201d process, which involves using a leaf called the \u201cwrapper\u201d to cover the buncho and give the cigar its final appearance.\n<\/p>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n<\/div>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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\n\t\t\t\t\tCIGAR HEAD\t\t\t<\/h3>\n
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Using the same leaf that wraps the cigar, the head is formed at one end. The Santa Clara tabaqueros create the \u201cnatural head\u201d from the same wrapper without ever cutting it separately from the cigar. Among experts, this is considered a hallmark of a master cigar maker.\n<\/p>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n<\/div>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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\n\t\t\t\t\tLABELING\t\t\t<\/h3>\n
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The cigar undergoes several quality control checks before the cigar band is carefully placed, marking the completion of an exceptional process.\n<\/p>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n<\/div>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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\n\t\t\t\t\tQUALITY\t\t\t<\/h3>\n
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Each cigar is carefully inspected for construction, appearance, draw, and overall quality, ensuring that every cigar meets Santa Clara\u2019s high standards.\n\n<\/p>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n<\/div>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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\n\t\t\t\t\tPASSION IN EVERY CIGAR\t\t\t<\/h3>\n
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From seed to finished cigar, every step reflects dedication, tradition, and pride. This is the art of cigar making. This is Santa Clara<\/p>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n<\/div>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"

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 […]<\/p>\n","protected":false},"author":1,"featured_media":0,"parent":0,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"page-full-width.php","meta":{"footnotes":""},"class_list":["post-1768","page","type-page","status-publish","hentry"],"_links":{"self":[{"href":"https:\/\/santaclarapuros.com\/saclasa\/wp-json\/wp\/v2\/pages\/1768","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/santaclarapuros.com\/saclasa\/wp-json\/wp\/v2\/pages"}],"about":[{"href":"https:\/\/santaclarapuros.com\/saclasa\/wp-json\/wp\/v2\/types\/page"}],"author":[{"embeddable":true,"href":"https:\/\/santaclarapuros.com\/saclasa\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/santaclarapuros.com\/saclasa\/wp-json\/wp\/v2\/comments?post=1768"}],"version-history":[{"count":52,"href":"https:\/\/santaclarapuros.com\/saclasa\/wp-json\/wp\/v2\/pages\/1768\/revisions"}],"predecessor-version":[{"id":3095,"href":"https:\/\/santaclarapuros.com\/saclasa\/wp-json\/wp\/v2\/pages\/1768\/revisions\/3095"}],"wp:attachment":[{"href":"https:\/\/santaclarapuros.com\/saclasa\/wp-json\/wp\/v2\/media?parent=1768"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}