The process of making a premium cigar, starting with planting a seed, can take anywhere from two to five years. If it is a cigar like our ULTRA BLACK it can take considerably longer since the Tobacco is aged for much much longer than a normal Escobar Cigar.
First, the tobacco seeds are planted in nurseries where they are grown for about two months before being transplanted to the fields. The tobacco plants are then grown for about four to six months until they reach maturity.
Once the tobacco leaves are fully grown, they are harvested by hand. After the leaves are harvested, they are then hung to dry in a process called curing. This can take anywhere from several weeks to several months, depending on the type of tobacco being used and the desired flavor profile.
After curing, the tobacco leaves are sorted and graded according to color and quality. The leaves are then fermented, a process that can take several months. Fermentation helps to bring out the natural flavors of the tobacco and reduce its harshness.
Once the fermentation process is completed, the leaves are then ready to be rolled into cigars. This process is typically done by hand by skilled cigar rollers, who carefully construct the cigars to ensure an even burn and a smooth draw.
Finally, the cigars are aged for several months or even years to allow the flavors to meld together. After aging, the cigars are inspected, sorted and packaged for distribution.
In total, from planting the seed to having a ready to smoke cigar, it can take 2-4 years. However, this time frame can vary depending on the tobacco used, the desired flavor profile, and the specific production methods employed by the cigar maker.