R. Paxtián Cigar Factory/Cigars Cycle


Cigars Cycle

01. Tobacco Seed

It is characterized by its small size and almost spherical shape. Dark brown to clear, depending on the variety, it only takes 5 g. of them to get more than 20 thousand seedlings tobacco.
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02. Greenhouse

This is the place where the tobacco seeds germinate and start receiving their first cares as a plant. The seed germination lasts a period of 6 to 8 days; after germinated they stay in the greenhouse for another 25 days so it can grow stronger and finally they are transplanted to the field to continue to grow.
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03. SowingTobacco

It is the period in which our tobacco plants are planted manually in open field, in an orderly and symmetrical way, for their total development.
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04. Tobacco Growing

In this period, only 55 days are needed for the total development of the plants. There are so many tasks, care and knowledge applied to this stage of life of tobacco, that we assure that no other crop in the world is as fascinating, complex and extraordinary as the cultivating Tobacco for Cigars.
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05. Tobacco harvest

The titanic labor during the harvest are to cut strictly careful and by hand each leaf of each plant, with a specific order and defined periods of time. Subsequently the leaves are carefully placed in tobacco barns to dry and be cure.
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06. Tobacco brainding

It is in the drying galleys, where the green leaves are tied in ropes, in amounts of 55 to 60 leaves, and these in turn are hung symmetrically inside the barn for their early dehydration.
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07. Tobacco drying

Once the tobacco leaves are braided, they are hung for a period of 35 days on average, inside a barn, to apply slow and homogeneous heat for their complete dehydration.
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08. Go down tobacco

Process when the leaves be go down from the tobacco barns, gathered in piles of 55 to 60 leaves. A necessary condition to unhang tobacco leaves have a relative humidity, which has to be around 65 to 70 to have the most optimal condition to follow the next step, fermentation.
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09. Tobacco Fermentation

Fermentation is achieved in a period of 45 to 50 days; It consists of grouping the bundles of tobacco in pylons, in an orderly, proportional and symmetrical way, so that the leaves, through the pressure exerted on them, and by the moisture that it contains, begins to raise its temperature and become dehydrated , containing a cooking between them, and therefore, exudation and elimination of excess resin, nitrogen and nicotine; At the end of the process the aromas are refined and the color of the leaves is homogenized, giving character, quality and exclusivity to the tobacco. This process is repeated four or six times as necessary.
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10. Tobacco Classification

The leaves are selected one by one according to their variety, texture, size, color, appearance and harvest, by artisans who are dedicated to the classification of leaves. Then, they are pressed according to their class, to be packed by means of some cloth or organic fiber, for later aging.
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Añejamiento del Tabaco
11. Tobacco Aging

In cellars with special temperature and humidity, the pressed tobacco bales can rest from one to the years that the company considers necessary, since this is where the tobacco acquires its unique flavor and character, allowing the leaves to lose their youthful defects and gain body and complexity. The more years it remains stored, it acquires a better quality, aroma and class.
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12. Tobacco preparation

Once the tobacco is aged, it is unpacked to moisten it and to maneuver it. Each class of tobacco has a different function inside the cigar, so each class is maneuvered and processed differently according to its use, either totally or partially detaching its central vein, ironing or flattening them, drying them, moistening them or semi-moistened.
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Elaboración de Cigars
13. Cigar Manufacture

To make a cigar, not only tobacco workers with many years of experience are required, but also tobaccos that have been meticulously worked for years. It is here where art, time and perfection reach their maximum expression, manifesting in the heart, in the mind and hands of the extraordinary craftsman, who in an almost indescribable way, with all skill, dexterity, patience and sensitivity, makes a perfect cigars.
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Cigars Aging
14. Aging cigars

Once the cigars are made, they are subjected to a process of resting and aging, at controlled temperature and humidity, in order to acquire their flavor and character that identifies them as a brand of "Tabacalera R. Paxtián".
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Control de Calidad
15. Quality control

This is one of the most significant and important processes in the life of cigars, because they are evaluated by experienced quality inspectors, the main aspects that are considered for their acceptance or rejection are: weight, length, color, texture, aroma, draw, moisture, appearance and consistency.
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16. Labeling cigars

This process consists of placing the ring or the label for each cigar, to identify it as a brand. It is the way in which the name and recognition to a product is given.

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17. Cigar packaging

This procceses consist labeling and packaging each cigar individually with stablished temperature and humidity in fine cedar boxes and so each and every of our tobaccos will give life, presence and prestige to a Cigar from “Tabacalera R. Paxtian”.
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Producto Terminado
18. Finished product

By letting them rest again for a period of at least four months, the cigars will be destined for final consumption.
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19. Cryogenics

And as if it were a cold farewell, the cigar, as finished product, undergoes a process of sanitization, which consists of introducing it in a freezing chamber, for a period of 5 to 7 days, at temperatures of -24 ° C, this to guarantee the total quality of our products.
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