The Process

The Process

As most people know, cigar tobacco comes predominantly from Indonesia. The islands Sumatra and Java are the major suppliers for the cigar tobacco industry.

Growing and processing tobacco is a very delicate and complex profession. After harvesting, the tobacco is placed in large warehouses where the tobacco leaves loose 80% of their moisture. This first process, also referred to as curing, is being followed by fermentation, the most important crucial element for obtaining an excellent, tasteful and combustible tobacco. The tobacco is bundled and piled on huge stacks. During the brewing process, the broiling heat can reach up to 60 Celsius. This is where the flavour, burning and aroma characteristics are brought out in the tobacco leaf.

The leaves are than sorted on colouring, length and quality and packed in bales of 80 up to 100 kilo's. Accordingly, the bales are shipped to the Tobacco Exchange in Bremen (Germany) where a bi-annual Sumatra-auction takes place. After purchasing, the Tobacco is transported to the manufacturer.

After this, the production process commences.

  • Upon receipt, the bales are opened and tobacco bundles are detached;
  • The tobacco is moistened (Dry tobacco leaves cannot be handled);
  • Accordingly, the vein of the leaves are pulled from the leaves (strip-leaf);
  • By this, two piles of half tobacco leaves remain (left and right);
  • Blending different types of tobacco together according to own recipe (character of cigar);
  • The cigar-maker grabs a little tobacco and rolls around the Java binder that holds the tobacco together in the body of the cigar;
  • The body is placed in a cigar-mould to give the cigar its shape; * After 24 hours the cigars are turned as to avoid any moulding remarks on the cigar;
  • Accordingly, the cigar-maker carves the Deli-wrapper in the right shape;
  • The Java binder is then wrapped with the Deli tobacco, the wrapper giving the cigar appearance and aroma;
  • Accordingly, the cigars are sorted by colour;
  • The cigars are packed and conditioned up to 60% humidity;
  • Minimal 6 weeks after production, the cigars are ready for sale.