pre castro cuban cigars tabacos de puriscal tobacco cigar cigars cigarillos curchill cuban tobacco tobacco cigars
cuban tobacco cigars
cuban tobacco cigars cuban tobacco cigars
cuban tobacco cigars
cuban tobacco cigars
cuban tobacco cigars
cuban tobacco cigars
cuban tobacco cigars
cuban tobacco cigars
cuban tobacco cigars cuban tobacco cigars cuban tobacco cigars
   
 
     
     
 

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

 
       

 



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