|
|
|
|
|
| |
|
|
| |
|
|
| |
OUR FACTORY
|
|
| |
The tradition of our tobacco
originated in the high mountains of Costa Rica's Central Valley
... the "paradisiacal land of the Huetar Indians." |
|
| |
|
|
| |
|
|
|
|
|
|
|
| |
We at
Tabacos de la Cordillera have the experience and expertise
to transform that tobacco into the highest quality cigars. |
|
| |
|
|
| |
|
|
| |
|
|
| |
| Behind every cigar is a long history that
begins in a greenhouse, where the seeds undergo a rigorous
selection process. We select our seed from a proprietary
bank of legendary tobacco strains obtained from
ancestral Cuban seed, bearing long forgotten names like
Rezago 11, Partido and Cola de Gallo (Rooster Tail). |
Seedlings in hothouse trays approach
transplanting time
from hothouse to farm plot |
|
|
| |
|
|
| |
It is a fallacy to say that what matters in
creating the Cuban flavor and bouquet, is that the tobacco be
grown in Cuban soil. By skillful agronomical "engineering,"
Cuban seeds with the proper genetic blueprint can duplicate the
performance of the same seed grown on the island. Not every seed
strain is suited to every growing area ... not even in Cuba,
where the best wrapper tobacco is grown in the Vuelta Abajo,
while filler and binder leaf is found growing in other
provinces. What is crucial is the matching of seed strains to
the soil (and, of course, to the climate). This is as important
as the seed itself, in order to optimize flavor, aroma, burning
properties, crop productivity, good leaf size and shape, pest-
and disease-resistance, and more. Many think the abundance of
nutrients in the soil determines plant success. This is only
partially true ...what matters is a specific strain's ability to
utilize those nutrients. Different strains require different
nutrients, and in different proportions. Only by laboratory
comparison of the nutrients "taken up" by the plant into the
leaves, expressed as a percentage of the nutrients available in
the soil, can one determine whether a particular strain is
ideally matched to the soil. |
|
| |
|
|
| |
| Under careful management ,the plants are
sown in greenhouses and transplanted into the field after 35
days. They then continue their growth in soil that is
properly fertilized to receive the vibrant,
disease-resistant transplants.
We grow tobacco naturally, minimizing the use of
chemical fertilizers and pesticides. When the plant is ready
to harvest, we make sure that the leaf is ripe and ready for
the curing process, maintaining its elasticity, color and
aroma. |
Leaves well into the curing cycle
hang in curing barn
|
|
|
| |
|
|
| |
|
|
| |
Next, we skillfully and carefully subject them
to a fermentation process for a period of six months. This
eliminates the tobacco's natural acidity, and requires precise
control over temperature and humidity conditions. Two
fermentation periods are necessary to obtain the best possible
product for its subsequent aging. Following fermentation, the
tobacco rests peacefully for months, with its flavors and aromas
melding and softening. |
|
| |
|
|
| |
In the factory, inspectors scrutinize the leaves
for any impurities or defects. Sharp-eyed specialists, able to
discern the subtlest differences in color shading, separate the
leaves by color and size, binding them together into "hands" of
about 25 leaves. |
|
| |
|
|
| |
| Next, we begin preparing the leaves for the
cigar manufacturing phase. The ladies in our leaf
preparation department deftly and patiently strip the
central stem vein from each cured leaf. This is called "frog
stripping," due to the frog-like shape of de-veined leaves
... if you have imagination. |
 |
|
|
| |
|
|
| |
Our shift inspector then decides how each leaf
will be used in the construction of the cigars, with some used
as wrapper, others as binder or filler. Appearance, uniformity
of color, lack of spots or discoloration, inconspicious veins,
vein spacing, a silky feel and elasticity are factors in
choosing what leaf will become the outer skin that the cigar is
judged by, in the hand of the smoker. The selected leaves are
the components that determine the flavor, aroma and burn. Mixing
tobacco leaves is a result of gaining knowledge that requires
years to master, to obtain the finest final product. |
|
| |
|
|
| |
After having been selected, and according to the
blend, the leaves are bunched and rolled, activity that requires
unique craftsmanship and strict supervision. |
|
| |
|
Assembled filler blend is wrapped
with binder leaf |
Bound filler is placed in mold-half for
pressing, prior to wrapping |
|
|
| |
|
|
| |
|
|
| |
| The finished cigars are aged one more month
before they are packed in the different presentations, to
satisfy all the varied and demanding tastes of our
customers. |
Finished cigars being packaged |
|
|
| |
|
|
| |
|
|
| |
Our
cigars come in all sizes: Churchill, Corona, Petit Corona,
Torpedo, Pyramid, Robusto, Mini Cigars, and Mini Torpedoes ...
truly flavor giants in midget's bodies. Our cigars are produced
in families: |
|
| |
|
|
| |
Cumbres
de Puriscal™, a premium cigar in Gold, Silver, and
Emerald. We roll
these cigars in light and dark wrappers that complement the
different flavors, from medium to strong. |
|
| |
|
|
| |
Purisco™,
in blue and red presentations, are of excellent quality, strong
bouquet, light and dark wrappers. |
|
| |
|
|
| |
Colinas™
is our short filler cigar, with surprisingly high quality
and reasonable price. They come in light and dark wrappers, and
their secret mixture of tobaccos have a light flavor and intense
personality . |
|
| |
|
|
| |
 |
|
| |
|
|
| |
Finally, Mini Cigars and
Picos™
mini-torpedoes are designed for the pleasure of cigar
aficionados, and for ladies that know and appreciate good
tobacco. |
|
| |
|
|
| |
All our cigars are hand made by highly
experienced craftsmen who work under meticulous supervision. |
|
| |
|
|
| |
Our product is environmentally friendly, since
we maximize the use of organic fertilizers and pesticides to
attain desired growth and pest control. Also, we buy the wood
for our boxes only from ecologically aware companies that
practice reforestation and land management policies. |
|
| |
|
|
| |
We are also proud to manufacture our product in
Costa Rica, the oldest and most stable democracy in Central and
South America. |
|
| |
|
|
| |
Each of our cigars is a result of a meticulous
process that includes scientific genetic improvement, scrupulous
leaf selection, attention to detail and rigorous inspection. |
|
| |
|
|
| |
We invite you to try the premium cigars of
Tabacos de la Cordillera. You can be sure our cigars are made
with the best tobacco that you, the connoisseur can find. |
|
| |
|
|
| |
|
|
| |
|
|
| |
|
|
| |
|
|
| |
|
|
|
|
|
Director John Vogel selects seeds for
next crop of tobacco
Workers scale the curing barn’s
rafters to hang freshly-harvested leaves
Workers rearrange “hands” of tobacco
leaves after first fermentation, in
preparation for second fermentation
This leaf shows the elasticity a wrapper
needs for proper application on the
bunched filler
Worker selects and folds leaves
into filler blend
Finished cigars rest in the aging
racks, prior to packaging |
|
|
| |
|
|
|
|
|
|
|
