Cigar Safari: How The Joya de Nicaragua Cabinetta Serie is Rolled
While on the Cigar Safari with Drew Estate, we had the fortune of spending some valuable time at the Joya De Nicaragua fabrica. In this video, Mario Perez walks us through the process of rolling the Cabinetta Serie, a unique cigar with two wrappers of different lengths and flavors.
In the Joya de Nicaragua factory, the rollers take on two positions by also behaving as a part of quality control. Each cigar is measured to be certain the proper diameter is met throughout the length of the cigar and is then hand checked for texture and feel. This keeps consistency within the cigars size, and also prevents from letting cigars that are rolled too tight with too much tobacco from getting through.
This experience trains them to detect the right texture of an evenly rolled cigar. This translates into an even smoking experience for the cigar smoker.
The team work of quality control between the bunchero (person bunching the tobacco together with filler and binder) and the torcedor/roller (person rolling the wrapper for the final product) helps maintain overall consistency in the highest quality of product. At the end of the day, their cigars are sent through another quality control. If the cigars do not meet up to standards, then the buncher and roller both miss out on their days production. By working together first hand they can correct any problems on the spot, eliminate creating bad habits, and be more productive in their day. Because they are paid by the number of good cigars they produce, this means more pay for them and a better quality of cigar for the factory.
Watch in the video how the cigar is rolled with the wrapper starting from the foot and ending at the head. Mario explains the technique being used, and enlightens us on the two sides of the tobacco wrapper leaf (the front and the back and why which is which). In order to maintain a smooth beautiful wrapper on the exterior of the cigar, the side of the leaf with the veins are kept to the interior.
*note: stems and veins aren’t bad- this is a plant and that is where all the nutrients go and the intensity of the flavor. An artful blender understands how to use the stems and veins properly for a balanced and rich cigar.
Everyone at the Joya de Nicaragua fabrica works with patience, focusing on quality and respect for the cigar. The best worker is not the one that makes the most product, but the one who does it properly. It’s important that the proper attention and technique is given to each cigar (as each cigar will give an individual experience to the smoker). This is especially true when handling such a unique cigar as the Cabinetta Serie which has an upper cap with a clean line. It is art meeting functionality.
For more videos and lessons from the Cigar Safari: Nicaragua, Click Here.