From the Table to the World: Quality, Control, and a Touch of Steel

The journey of a cigar does not end on the torcedor's table. What follows is an equally important process that ensures only perfect examples find their way to the aficionado. It is a path marked by trained eyes, strict controls, and finally, the protective embrace of cedarwood. At the same time, another world exists in parallel – a world where steel and precision complement or replace manual labor.

The Master's Eye: Quality Control

Every single hand-rolled cigar moves from the roller's table directly to quality control. Here, an experienced supervisor with an incorruptible eye and trained hands inspects each cigar thoroughly:

• Weight and Dimensions: Is the weight correct? Do the length and ring gauge exactly match the format's specifications?
• Appearance: Is the wrapper flawless? Is the color uniform? Is the head perfectly shaped?
• Feel: Is the cigar rolled evenly? Are there soft spots (too loose) or hard knots (too tight)?
• Draw Resistance: Cigars are randomly tested for their draw resistance using a special machine.

Cigars that do not pass this strict inspection are sorted out. They do not make it into the boxes for export. This guarantees the high and consistent quality for which premium brands are known.

Media Ruedas: The Wheel of Order

The inspected and approved cigars are now prepared for an initial rest phase and for counting. They are bundled into groups of 50 and tied with a simple cotton ribbon. These bundles are called Media Ruedas, Spanish for "half wheels."

This method facilitates easy handling, transport within the manufactory, and accurate counting of the daily production. After resting for a while in the Media Ruedas, the cigars move to the final step: color sorting and packaging. An Escogedor (sorter) arranges the cigars in a box according to the finest color nuances, from darkest on the left to lightest on the right, so that the opened box presents a perfect, harmonious picture.

The Language of the Box: Seals and Codes

An original box of Cuban Habanos is marked with several features that prove its authenticity:

• The Warranty Seal: A green, numbered seal with a hologram and coat of arms.
• Habanos Seal: A sticker confirming the protected designation of origin.
• Brand Stamp on the Bottom: "Habanos S.A.", "Hecho en Cuba," and the crucial note "Totalmente a mano."
• Date and Factory Code: An ink stamp that reveals in which factory and in which month/year the cigars were packed.

These codes are your cigar's birth certificate and an important tool for collectors and connoisseurs.

A Touch of Steel: The Mechanical World

Besides traditional craftsmanship, there is the world of machine-made cigars. Here, the focus is not on uniqueness and supreme complexity, but on efficiency, accessibility, and absolutely consistent quality.

• Shortfiller: Instead of whole leaves, a filler of cut or torn tobacco (Picadura) is used here.
• Homogenized Tobacco Leaf (HTL): Often, a so-called homogenized tobacco leaf or HTL is used as a binder. This is an industrially produced sheet made from tobacco dust, water, and cellulose. It guarantees a perfect, straight burn and a consistent taste, but lacks the aromatic depth of a real tobacco leaf.
• The Process: Machines form the filler, wrap it with HTL into an endless strand, mechanically apply a wrapper, and cut the cigars to the correct length.

A manufacturing defect that only occurs in machine production is the so-called Goldschnitt (golden cut). Here, the wrapper is not completely wrapped around the binder, leading to air leaks and significant draw problems. Such specimens are, of course, sorted out during inspection.

Machine-made cigars and traditional masterpieces are two different worlds for different occasions and budgets. One offers reliable enjoyment for everyday life, the other a deep, cultural experience for the special moments in life.