After the leaves are stripped from the tobacco plant, they are dried out in a barn, made to hold the tobacco. The ribs of the leaf are removed at this point; they make the tobacco too hard to handle while rolling cigars, taste bad, and also look bad. After this step, the cigars are sold immediately, or allowed to age for a few years before being released to the general public. In order to prevent the leaves from breaking down and turning into dirt, the piles are deconstructed and reconstructed every day. Once removed from the pile, the leaves are sorted according to how they look. These skilled rollers are assigned a bunch of each type of leaf, one bunch of filler, binder, and wrapper. Workers carefully process the tobacco leaves. It is mostly used to mellow out the taste of the tobacco. Anything without holes in it becomes wrapper leaf, while everything else becomes binder and filler.
The leaves will dry and begin to change color. The skilled workers are able to remove the midrib with ease. Hot Stamping Adhesive In order to get the cigar tobacco to turn brown, a process called fermentation is used. After it dries out a little bit, the worker that rolled it wraps it with the wrapper tobacco that was pre-sorted for them.Cigars are not green, but the leaves they come from are. After a few weeks of fermenting, the tobacco leaves are removed from the pile. After the tobacco leaves have been processed and had their mid ribs removed, they are sent to another factory, where many skilled cigar rollers are kept. .
The fermentation process begins when workers take the tobacco leaves down from their drying hooks, and stack the leaves into fermentation piles. Fermentation isn't just for turning greens brown, however. The bottom line is that green cigars would be unsmokable, so we ferment the leaf. Carefully, the cigar roller glues a cap on the end of the cigar, and then places it in a box. This process is a long one, and it requires many hours of work from all parties involved. The leaves sit in this tobacco barn for about six weeks. It would be acceptable to celebrate their successes by lighting up your favorite cigar.
Now you know how tobacco is fermented, and how the tobacco that has been fermented is used to create a cigar. Once the leaves have begun changing color, they are ready to be fermented. The skilled rollers take their time picking out the correct pieces of filler for the flavor they've been asked to blend, and then wrap the filler with binder leaves. Fermentation also removes some of the nicotine that was in the cigar leaf. A machine that destroys the product is worthless, and this is why the factory workers are such a great asset to the cigar companies. The leaves begin to heat up due to the numerous chemicals being released (sort of like a compost pile), and thus fermentation has started. This is almost always done by hand, because a machine would tear the delicate tobacco leaves apart. This simple chunk of tobacco is then placed into a mold, and let to dry for about a day.