Tobacco leaves are harvested and aged using a process that combines use of heat and shade to reduce sugar and water content without causing the large leaves to rot. This first part of the process, called curing, takes between 25 and 45 days and varies substantially based upon climatic conditions as well as the construction of sheds or barns used to store harvested tobacco. The curing process is manipulated based upon the type of tobacco, and the desired color of the leaf. The second part of the process, called fermentation, is carried out under conditions designed to help the leaf die slowly. Temperature and humidity are controlled to ensure that the leaf continues to ferment, without rotting or disintegrating. This is where the flavor, burning, and aroma characteristics are primarily brought out in the leaf.
Once the leaves have aged properly, they are sorted for use as filler or wrapper based upon their appearance and overall quality. During this process, the leaves are continually moistened and handled carefully to ensure each leaf is best used according to its individual qualities. The leaf will continue to be baled, inspected, unbaled, reinspected, and baled again repeatedly as it continues its aging cycle. When the leaf has matured according to the manufacturer's specifications, it will be used in the production of a cigar.
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