How a Habano is made

Time has done its work, and the leaf is ready at last to play its part in the making of a Habano. Here we describe the extraordinary craft that has changed little in almost 200 years.

VARIATIONS IN THE METHOD OF MAKING

All but a small number of Habanos are made totally by hand with a filler composed of complete leaves. These are the classic Totalmente a Mano Tripa Larga (long filler) Habanos.

Some others are made totally by hand, but the filler is partly composed of shorter sections of leaf. These are the Totalmente a Mano Tripa Corta (short filler) Habanos.

Some others again are made with the help of machines, but one element is the same for all – the origin of the tobacco.

PREPARING THE WRAPPER LEAVES

The wrapper leaves are now aged and it is time for their final sorting and classification. They must also be stripped of their stems.

A moistening, or moja, brings them to the supple condition required for stripping and sorting, and their final purpose of wrapping a cigar.

The gavillas or bunches of up to 40 to 50 leaves are held under a fine spray of fine water. Excess droplets are then shaken off with practised flourishes to avoid any staining, and the leaves are hung on racks so the moisture is absorbed evenly.

Next the tender hands of highly skilled women perform the despalillo (stripping) and rezagado (grading). One movement deftly removes the entire central vein of the leaf leaving its two halves ready to be graded in to some 20 finely distinguished sizes and shades.

These women work from piles of leaves on their laps, lending weight perhaps to the popular myth that Habanos are rolled on maidens’ thighs!

PREPARING THE FILLER LEAVES

Filler .....

To read the rest of this article you can buy this issue or subscribe to Cigar Buyer to have every issue delivered direct to your door.

By Dominic Roskrow

Section : Cigar Production

Page number : 21

Published in Cigar Buyer Issue 3 on 01/05/2005.

This article is 88 months old and some information provided may be time sensitive. Please check all details of events, tours, opening times and other information before travelling or making arrangements.



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	How a Habano is made Time has done its work, and the leaf is ready at last to play its part in the making of a Habano. Here we describe the extraordinary craft that has changed little in almost 200 years. VARIATIONS IN THE METHOD OF MAKING All but a small number of Habanos are made totally by hand with a filler composed of complete leaves. These are the classic Totalmente a Mano Tripa Larga (long filler) Habanos. Some others are made totally by hand, but the filler is partly composed of shorter sections of leaf. These are the Totalmente a Mano Tripa Corta (short filler) Habanos. Some others again are made with the help of machines, but one element is the same for all – the origin of the tobacco. PREPARING THE WRAPPER LEAVES The wrapper leaves are now aged and it is time for their final sorting and classification. They must also be stripped of their stems. A moistening, or moja, brings them to the supple condition required for stripping and sorting, and their final purpose of wrapping a cigar. The gavillas or bunches of up to 40 to 50 leaves are held under a fine spray of fine water. Excess droplets are then shaken off with practised flourishes to avoid any staining, and the leaves are hung on racks so the moisture is absorbed evenly. Next the tender hands of highly skilled women perform the despalillo (stripping) and rezagado (grading). One movement deftly removes the entire central vein of the leaf leaving its two halves ready to be graded in to some 20 finely distinguished sizes and shades. These women work from piles of leaves on their laps, lending weight perhaps to the popular myth that Habanos are rolled on maidens’ thighs! PREPARING THE FILLER LEAVES Filler ..... To read the rest of this article you can buy this issue or subscribe to Cigar Buyer to have every issue delivered direct to your door. By Dominic Roskrow Section : Cigar Production Page number : 21 Published in Cigar Buyer Issue 3 on 01/05/2005. Subscribe Buy this issue More from this issue Preview other issues This article is 88 months old and some information provided may be time sensitive. Please check all details of events, tours, opening times and other information before travelling or making arrangements. Copyright Cigar Buyer © 1999-2012. All rights reserved. To use or reproduce part or all of this article please contact us for details of how you can do so legally.