Handmade Habanos

Appreciation of a fine handmade Cuban cigar starts with understanding what goes into making them

By Ian Gordon

Cigars share many characteristics with vintage wine. The climate, the soil, the heritage and ageing all contribute to the unique character, which any handmade premium cigar embodies — and Cuban premium, handmade cigars, commonly known as 'Habanos', are widely regarded as the benchmark of quality by cigar aficionados.

Tobacco has been cultivated in Cuba since the 16th Century. The unique combination of microclimate, soil and heritage provide tobacco-leaf from the elite Vegas Fincas de Primera with a character that sets Cuban cigars apart from all others.

It takes two to three years and up to five different types of tobacco leaf to create an unforgettable, premium, handmade, cigar. Initially, the harvested tobacco leaf is sorted based on its quality and is air-cured in thatched roof barns, near the tobacco field for approximately 50 days. The leaf is then tied in bundles, known as gavillas, and placed in cloth-covered piles where they undergo an entirely natural process of fermentation. This first fermentation takes approximately 30 days.

The leaf then goes through a further selection process based on size, colour and texture before moving on to the stripping house (despalillo), where the leaves are prepared for a second fermentation. This fermentation lasts between 45 and 90 days, depending on the quality and purpose of the leaf.

Upon completion of the second fermentation the tobacco leaf is aired on racks for a few days prior to being packed and transported to the warehouse for a final ageing, which varies from nine months to two years. Tobacco leaf that has been cured for a longer period of time is used to manufacture only the very best cigars.

The final stage in the production of a 'Habano' is the selection of the different types, sizes and textures of leaf, which combine to give a specific type of cigar its unique characteristics of appearance, size, aroma and flavour. Three types of leaf are used to create the filler, or tripa; one for combustibility, volado; one for aroma, seco; and one for strength and slow burning, ligero. The binder or, capote, is a special leaf, which wraps the filler and provides the cigar with its structure and shape.

The entire process is not only an art but also a craft. The tobacco leaf, grown, cured and rolled in Cuba is a totally handmade product — hecho totalmente de mano! Consequently, premium hand-made cigars brands such as Cohiba, Montecristo and Trinidad tend to have a price that reflects their heritage.

Understandably, a cigar aficionado, like any connoisseur of fine wine, will savour every nuance of character in a premium, handmade cigar.

Ian Gordon is president of Cuarenta Bucaneros, 25 Church Street, Hamilton. Tel: 295-4523 or 336-2446. Fax: 292-5116. cigarbox.bm