Cuba and Cigars | Factory of Pure Cigars |
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The raw material
arrives to warehouse of the factory in bales of yagua and sackcloth where
they are stored and then they are open according to the demand of rolling.
Tobacco for wrappers comes in bales of yagua and tobacco for binders and
fillers in those of sackcloth. |
The packs
sent to the factory are opened by the workers, and in the case of binder
and the different grades of fillers the leaves are weighed in proportions
called tareas (day's work).
After weighed
they go directly to the drawers for the use of the cigar rollers, and
if the leaves have lost the required humidity because of the storage,
they are moistened the same as with the wrapper, aired and continue their
process.
With the
sheaves of leaves for wrappers the leaves are separated one by one because
they have lost humidity during the whole process and they have become
fragile. For that reason, it is necessary to carry out moistening, operation
dedicated to restore humidity in order to facilitate their manipulation,
and they remain resting in tanks approximately one hour to match humidity.
Moistening
finishes in the airing room, where the sheaves are hung during some two
hours, in an environment with 95% of humidity.
When
finishing the airing process the sheaves are deposited later in barrels
that will maintain a uniform humidity, later the aired leaves for wrappers
pass to the female tobacco strippers in plastic bags.
In
the stripping house the wrappers are ironed first and later they are stripped.
The
rezagadora should select between eighteen and twenty grades of
leaves of tobacco according to their size, color and texture dedicated
to the beautiful wrapper that wraps the Habano.
Later on,
the man who counts the wrappers gathers groups of twenty-five half leaves
also called sheaves, used for the production of different vitolas.
Then
the groups of leaves are kept in a box with divisions respecting the classification,
where the temperature of the wrappers is conserved, maintaining them separated
according to their size. From the stripping house the leaves go toward
the rolling room where the wrappers stay and the whole raw material.
The cigar
rollers early in the morning pick up their day's work or norm that consists
on the necessary raw material (wrapper, binder and three types of filler),
to produce around 100 or 125 pure cigars.
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