Producing cigars is an art in its own right – a craft that takes years of experience and dedication to master. A group of VILLIGER employees from Germany and Switzerland took a 10-day trip to the Dominican Republic to get a first-hand look at this fascinating process. The training trip introduced them to all aspects of tobacco processing and offered a deep insight into the tradition and perfection of cigar making. This trip provided more than just training – it delved into the soul of cigar making, and the group returned with a new understanding and an even greater passion for cigars.
A glimpse into the world of tobacco
After arriving in Havana and spending Sunday recovering from jet lag, the training began on Monday with a visit to ABAM Cigars. Here, the group was introduced to the different tobacco varieties: Ligero for strength, Seco for flavor, and Nicaraguan Viso for lighter cigars. They learned that wrappers are stored at 25 percent humidity, while fillers and binders require only 15 to 18 percent. After the theory came the practical part: Everyone got the chance to apply the knowledge they had acquired that morning by assembling and rolling their own cigars. The result was a range of exciting blends. The afternoon was spent learning about wrapper processing and box production. This first day provided the foundation for understanding the complex world of tobacco and cigar production.
Tuesday was all about blending. This process involves sorting the tobacco by color, texture, and size – too many white spots, for example, tend to make the blend too bitter. White spots on tobacco leaves indicate they had dew on them when they were harvested. After the pre-sorting, the leaves are left to dry on special racks. One particular highlight for everyone was the opportunity to roll their own DOMINICO cigar, which was then analyzed by an expert. This helped give the participants a better understanding of the burning properties of the different tobaccos. This day highlighted how important it is to get the blending and drying of the tobacco right to achieve optimal results – a perfect cigar. Every step in this process requires precision and experience.
The art of rolling cigars
On Wednesday, the group visited the “Galera”, the area where the torcedoras and torcedores create their masterpieces. They got to see the skill and precision of the professionals at work and also had a go at rolling a cigar themselves – with varying degrees of success. After that, they were introduced to the quality control process. The day concluded with a sampling of DOMINICO and VILLIGER 1492 cigars to demonstrate the differences in flavor. This sampling session provided a perfect finish to the day.
Thursday was a special day: Siegfrid Maruschke, the owner of José Méndez & Co., S.R.L., gave the group a tour of his tobacco fields, which are tucked away in the world-famous Cibao Valley near Santiago de los Caballeros. Unlike many other producers, who grow their plants in greenhouses until they are large enough, Maruschke plants his seedlings directly in the field because “only those that survive outside will become good plants.” Next, the group visited the curing barn located directly on the tobacco field. Here, the green tobacco leaves develop their characteristic brown color over a period of 30 days. The leaves are then taken to the Méndez factory, where they undergo the first fermentation, sorting, and stripping. After the second fermentation, the leaves are stored in 60-kilogram jute sacks for one year before being further processed. The day provided a complete overview of the process from harvest to fermentation and made it clear how much care and patience go into making a cigar.
The final touches and conclusion
Friday was dedicated to the final steps: putting bands on the cigars and wrapping them in cellophane. What looked easy turned out to be quite the challenge. This last day marked the culmination of a journey packed with valuable information and inspiring passion, celebrated with a farewell dinner. After a jam-packed week, the group can proudly claim to have learned how to judge cigars by their foot – the part that is lit.
This excursion offered more than just a learning experience – it delved into the very soul of cigar-making. Everyone got involved in every step, from harvesting the tobacco to rolling the finished cigar. The team returned home with a deeper appreciation and understanding of the art of cigar-making, and a newfound respect for the work of the torcedoras and torcedores – and they can’t wait to share their knowledge and passion with others. Given the trip’s positive impact, we are planning to offer more employees the opportunity to go on such trips.
We want to express our heartfelt thanks to the entire team at ABAM S.A. and Siegfried Maruschke of José Méndez & Co., S.R.L. for giving the team the opportunity to learn so much more about what we all love and cherish – cigars!
