The El Laguito factory in Havana, known for producing the prestigious Cohiba cigars, meticulously crafts each cigar through a detailed process in a historic villa, showcasing the rich tradition and exceptional skill of Cuban cigar-making.
Nestled in a fancy neighbourhood of Havana, the El Laguito factory stands as a jewel of Cuban cigar craftsmanship. This is where the legendary Cohiba cigars were born, also Trinidad. Fidel chose El Laguito to become the factory it is today and it was all housed within a luxurious villa—a necessity, perhaps, because a regular villa simply wouldn't have enough rooms for all the stages of creating a fine cigar, right?
El Laguito is situated in a grand mansion, a relic from Cuba's colonial past, surrounded by lush gardens and stately palm trees. The building's architecture is a harmonious blend of neoclassical and colonial styles, featuring majestic columns, delicate ironwork, and large windows that flood the interior with natural light. Originally a private residence, this elegant structure was repurposed into a cigar factory, retaining an air of timeless elegance. High ceilings and spacious rooms provide the perfect setting for the various stages of cigar production.
Our journey begins in the sorting room, where the tobacco leaves, harvested from the renowned Vuelta Abajo region, are carefully examined. Here, skilled workers sort the leaves based on size, color, and quality, ensuring that only the best are selected for the production process. This meticulous sorting is crucial as it determines the consistency and quality of the final cigars. The air is filled with the rich aroma of tobacco, offering a sensory preview of the delights to come. If I could only fill a bottle with that scent …
After sorting, the selected leaves are taken to the moistening chamber. In this climate-controlled room, the leaves are gently rehydrated to regain their natural pliability, which is essential for the subsequent stages of processing. The humidity and temperature are carefully regulated, creating the perfect conditions to maintain the leaves' integrity. This step is vital to ensure the leaves can be rolled without cracking or tearing, preserving their quality and appearance.
Once adequately moistened, the leaves move to the classification room. Here, they are classified into different grades based on their characteristics. The finest, most uniform leaves are set aside for use as wrappers, while others are designated for fillers or binders. This careful classification allows for the creation of cigars with consistent flavors and strengths. The room buzzes with activity as workers, with practiced eyes, swiftly sort through the leaves, ensuring each one is placed in its appropriate category.
The rolling room, known as "la galera," is the heart of El Laguito. Here, master torcedores craft the cigars with extraordinary skill. Each torcedor has their own workstation, equipped with a chaveta (cutting tool), a tabla (wooden board), and a special glue made from natural plant extracts. The torcedores carefully roll the cigars by hand, blending different types of tobacco to achieve the desired flavor and strength. The atmosphere in la galera is almost reverent, a tribute to the artistry and tradition of Cuban cigar making.
After rolling, the cigars undergo a crucial quality control process in a dedicated room. Here, they are subjected to a draw test using a specialized machine. This test measures the airflow through the cigar, ensuring that it provides the perfect draw when smoked. A cigar that is too tight or too loose can ruin the smoking experience, so this step is vital to maintain the high standards for which Cuban cigars are known.
Next, the cigars are taken to the color classification room. In this brightly lit area, cigars are meticulously sorted based on the shade of their wrappers. This sorting ensures that each box of cigars has a uniform appearance, a detail that is particularly important for premium cigars like Cohiba. The workers, trained to discern even the slightest variations in color, arrange the cigars into groups, preparing them for the next stage.
Once sorted by color, the cigars are moved to the boxing room. Here, they are carefully placed into wooden boxes, each one a work of art in its own right. The boxes are designed not only to protect the cigars but also to enhance their presentation. The workers in this room handle each cigar with great care, ensuring they are perfectly aligned and securely packed. This meticulous packing process shows the pride taken in Cuban cigar production.
The final stop on our tour is the quality check and box stamping room. Before the boxes are sealed, they undergo one last inspection to ensure that the cigars meet all quality standards. This includes a visual check and, occasionally, a taste test by seasoned experts. Once approved, the boxes are stamped with the factory's mark and other necessary information. This final stamp is a guarantee of authenticity and quality, a seal of approval from one of Cuba's most prestigious cigar factories.
El Laguito is a sanctuary of Cuban culture and craftsmanship. The luxurious villa, with its many rooms dedicated to different stages of production, embodies the meticulous care that goes into every cigar. From the careful sorting of leaves to the final quality check, each step is carefully done 100% by hand.
Beyond the beautiful architecture and lush surroundings, it is the meticulous attention to detail and dedication at every stage that sets this factory apart. From the careful sorting and classification to the skillful rolling and rigorous quality checks, each cigar is a masterpiece, crafted with a legacy of excellence. For visitors, El Laguito offers a journey into the heart of Cuban culture, where every cigar tells a story of artistry and passion.