To produce a cigar with the Habanero signature, you need a total of six different types of tobacco leaves. Each type of tobacco leaf is grown individually, and each type of tobacco leaf is used for a different purpose. Filler tobacco leaves are generally composed of two, three or four different types of tobacco leaves. This mixture creates an excellent taste and unique flavor source. Every tobacco leaf has its destiny and function.
Cuban tobacco leaves are grown through two different cultivation methods. One is the shade leaf, also called the cover leaf. The tobacco field is covered with a large piece of thin and breathable fabric to block the sun and avoid too much sunlight. This kind of tobacco leaf is generally thin. There are also those that grow in open fields where they are directly exposed to the sun and fully receive the Cuban sun. This kind of tobacco leaves generally grow thicker.
Volado tobacco leaves, or leaf leaves, are collected from the bottom of the plant. The veins are more obvious and the leaves are thicker. They are very flammable and suitable for use as filler.
Scotch tobacco leaves are taken from the middle part of the plant. They are lighter in color, dry in texture, and moderately flammable. This kind of tobacco leaves has a lighter taste.
Ligro tobacco leaves, although the literal translation is light, on the contrary, it is a dark-colored tobacco leaf with a rich flavor. Ligro tobacco leaves are refined from the fastest growing, strongest part of the plant. Burns more slowly. A lot of Ligro tobacco leaves are used as the wrapper.
Medeo Timber tobacco leaves are taken from the two thickest tobacco leaves at the top of the plant. They have a particularly rich flavor and the yield is extremely rare. This tobacco leaf is used to produce Cohiba's finest BHK series of cigars.
Binder leaf, the leaf that holds the filler leaf in place and gives the cigar its shape and structure. The filler tobacco blends the aroma of each cigar very well and is crucial to the quality of the cigar.
The wrapper leaf is a delicate, delicate and elastic tobacco leaf that wraps around the outermost part of the tobacco body, forming the outer surface of the cigar. The wrapper does not have a great impact on the taste of the cigar, but its velvety glossy surface perfectly reflects the beauty of the cigar.
Since the 16th century, tobacco grown naturally in Cuba has gained an unparalleled reputation around the world. As botany enters a new era, scientists are making purposeful improvements by studying tobacco plant seeds. Botanists ensure the tobacco leaves retain their unique Cuban flavor while improving their defenses against pests and diseases.
In 1973, the first research institute in the cigar industry was established in San Juan Martinez, specializing in the research of cigar tobacco leaves. Four years later, Corojo seeds, developed from Criollo seeds, were used as the basis for all tobacco seeds used to grow Havana's unique tobacco leaves. Corojo's name comes from a well-known plantation that specifically tested it.
Tobacco leaf cultivation is a very hard work. Based on the experience of the growers, each top plantation has its own special cultivation method. An experienced farm worker can take care of more than 1 million plants. During the production season, he must continuously monitor and observe more than 150 times. Every tobacco leaf of the plant is important.
Generally speaking, tobacco planting starts in June and July every year, which are very hot months, and the planting time lasts for 9 months without interruption. In order to reasonably distribute the workload during the tobacco growing period, different fields must be planted continuously at different times to allow the tobacco leaves to grow at different times.
For tobacco plants that are grown in the shade and need to be covered with cloth to cover the sun (mostly used for wrappers), the sowing and harvesting time is approximately 17 weeks. The tobacco leaves used for filler and binder are sown and harvested in approximately 16 weeks.
Tobacco plant seedlings are grown in special areas and protected by straw mulching. After 45 days, the seedlings reach a height of 13-15 cm and can be transplanted to tobacco fields. 18-20 days after transplanting and transplanting, build a circle of soil around the roots of the plants to promote root development. After the plant reaches the desired height, pinch off the buds at the top so that the plant can concentrate on growing the leaves on the sides. In order to promote accelerated plant growth, farmers must constantly control each plant and remove these side branches.
Planting wrapper tobacco leaves is more troublesome. Within 10 to 20 days after transplanting to the farmland, the field must be covered with a mesh of special fabric to fix the tobacco plants to vertical vertical supports. Irrigation is very important, and plants need to be given a certain amount of water at the right time.
Tobacco grown in the sun has a special flavor and aroma, thanks to Cuba's year-round bright sunshine. These leaves are ultimately used for binders and fillers.
It takes about 40 days after transplanting to start harvesting. Each farm worker can only pick two or three tobacco leaves at a time. This work is very hard, and several days are needed before each harvesting step. It takes about 30 days to completely harvest the tobacco leaves of a plant.
When harvesting, generally start from the lower part of the plant and work your way up. After each few tobacco leaves are picked, a few days are left for the remaining leaves to continue to grow. Shade leaves (shade leaves) growing under mesh generally grow taller and have more leaves, which require multiple pickings during harvesting. The blades are too small and will not meet the requirements for producing Havana-labeled cigars. In fact, only half of the tobacco harvested each year meets this requirement.
The picked tobacco leaves will be stacked on the oxcart, and the oxcart will take them to the drying shed for drying. For the tobacco leaves, this is a necessary stop and the beginning of a long journey. After drying, they are also sent to warehouses for aging. It can sometimes take several years from harvest to the time when Havana cigars are ready to be rolled.
Tobacco leaves from different parts of the plant ferment and mature at different times, which is why different varieties of tobacco are needed to roll Havana cigars.
