30/01/2013
Cultivation, Leave preparations
The cultivation of s***f is grown in the Cibao Valley, north of Santiago. The seeds are placed in the soil and cultured for about 5 feet 6 to 8 weeks. For Premium Ci**rs are 12 different to***cos grown in the Dominican Republic.
Pick only the upper leaves are good enough for premium ci**rs. All leaves of other plants are used for lower quality ci******es. Woody cores are carefully removed. DON VIRGINIO used as Connecticut Shade wrappers famous / line sheets covering Broad Leaf Wrapper soft and spicy midline and strong.
Drying All selected sheets are dryed in open huts in the fields for six weeks.
Fermentation During fermentation processing dryed leaves are layered and watered enough. These layers of heat themselves and ni****ne, protein, ammonia, chlorine, sugar and basic exhaust s***f. Depending on the number of layer-changings during the time of three months, s***f outcoming be mild, medium or strong. Through fermentation of s***f puts the final taste.
Storage lightly pressed to bales containing 120 pounds, s***f premium must be stored for at least 2 years before use. DON VIRGINIO prealtered s***f only pure high quality with an age of 4-6 years is used.
roduction
1. Preparation On each day before you leave the processing, binding and wrapping must be moistered with water. It takes half a day and 10 to 12 Step work. Wet hands often stretch the leaves down to its original size. Wrappers are classified in two sizes (for small and large ci**rs). Folders and envelopes should be kept moist until processing ci**rs.
2. Combining two Cuban varieties (grown in the Dominican Republic) and a premium Dominican to***cos as filler combined. This is done by hand using master rollers only whole leaves (long cigarette filler). In virginio using a special technique of rolling, with which is obtained through many channels of rotation of the ci******es. In large plants of this technique is not possible due to lack of time.
3. Pressing premium ci**rs (clusters) are pressed 45 min. woody special molds inside. In the meantime they have to be reopened and every cigar gets a quarter turn.
4. Wrap raw wrapper ci**rs are removed from the molds and wrap special teachers are finishing wraps on very fine quality. Each cigar requires half of a wrapping sheet.
5. Maturation of ci**rs After a first selection of ci**rs are bundled to 50 units. and three weeks storage. During this time, ci**rs reduce slightly, as the moisture released. All to***co used now melt together the unique flavor of a cigar Don Virginio.
6. Final Control In the fourth week after finishing a cigarette, final inspection is performed. The owner and one of his master cigar to***co ckeck each hand only.
7. Finally Attachments black and white ring Don Virginio is connected and each cigar has its own individually cellophane helmet.
8. Conclusion Ci**rs Don Virginio property is a small factory, Dominican / high qualified teachers in the Dominican Republic. Quality is our top priority. For a premium cigar virginio are over 50 steps. A to***co produces only 100 ci**rs per day, compared with at least 150 to 200 in the mass production factories.
