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 bigger 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 dry 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, un-baled, re-inspected, and baled again repeatedly as it continues the aging cycle. When the leaf has matured according to the manufacturer’s specifications, it will be used in the production of a cigar.
Quality cigars are still handmade. An experienced cigar-roller can produce hundreds of very good, nearly identical, cigars per day. The rollers keep the tobacco moist — especially the wrapper — and use specially designed crescent-shaped knives, called chavetas, to form the filler and wrapper leaves quickly and accurately. Once rolled, the cigars are stored in wooden forms as they dry, in which their uncapped ends are cut to a uniform size. From this stage, the cigar is a complete product that can be “laid down” and aged for decades if kept as close to 21 °C (70 °F), and 70% relative humidity, as the environment will allow. Once cigars have been purchased, proper storage is usually accomplished by keeping the cigars in a specialized wooden box, or humidor, where conditions can be carefully controlled for long periods of time. Even if a cigar becomes dry, it can be successfully re-humidified so long as it has not been handled carelessly and done so gradually. The loss of original tobacco oils, however, will greatly affect the taste.