Trust the cigars from Cigar Conexion, as we are the official importers in India for Multi-branded Premium Handmade Cigars. Visit our exclusive cigar shop and lounge in Bangalore and Delhi or buy cigars online. Our cigars are stored in well maintained humidors with automated accurate hygrometers.

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How a Cigar is Made - Rocky Patel Premium Cigars

From Seed to Smoke - Rocky Patel Premium Cigars

Great cigars are more than just fire and tobacco. Only a true artist, who loves his craft as much as he respects it, can achieve the distinction and flavor of a premium cigar. Utilizing the finest tobaccos in the world, and an unyielding drive for excellence, Rocky Patel has redefined the industry.

Chapter 1 - The Nursery

Upon arrival, our two varieties of tobacco seeds – Habano and Criollo – are separated into thousands of individual pods and carefully placed underneath a layer of cheesecloth for over a week. After being consistently monitored and watered for 7-10 days, only the absolute healthiest plants are transported to the main nursery.
At our main nursery, plants spend another 45 days under the watchful eye of our seasoned growers. At the end of this time, the plant will be nearly six inches tall with a healthy root system in place.

Chapter 2 - Tobacco Fields

Prior to each growing season, before our precious new plants take root, the soil is tested for five key elements. Sufficient levels of Boron, Magnesium, Nitrogen, Potassium and Phosphate are measured and mixed into the soil. The trademark of such highly nutritious soil is a beautifully dark, almost black color. Once the field is properly assessed, each tobacco plant is transplanted individually to ensure maximum quality.
Tobacco plants are grown to provide the building blocks of every cigar. Once harvested, each leaf will be classified as a wrapper, binder or filler. These classifications pertain to the different layers that create a cigar. Filler tobacco is located in the center of the cigar and is responsible for the cigar’s taste. Binder tobacco wraps around the filler tobacco, holding the cigar together. A wrapper leaf is the outermost layer of a cigar, giving the cigar its color and feel.

Chapter 3 - Curing Barns

After 100 days of toiling in the hot sun, how do we treat our plants? We hang them.
The harvested tobacco is brought from the fields to the curing barns. At the curing barn, plants are subjected to a drastic increase in humidity and moisture. Sections of the plant are partitioned and hung in their primings to guarantee the finest quality flavor.
After forty days of curing, plants will transition from green to yellow to brown, shrinking significantly. The vein that divides the leaf known as the “midrib” is particularly shrunken during the process. Once an even color of brown is achieved the tobacco is brought to the factory for sorting.

Chapter 4 - Sorting and Fermentation

Our cigars are premium inside and out. But it’s not just the quality that makes it premium; it’s the delicate nature in which each individual tobacco leaf is sorted. After curing and prior to fermentation, every single leaf must be classified as either: wrapper, binder, or filler.

Chapter 5 - The Rolling Room

Once the tobacco is up to our standards it’s finally time to start rolling. Rolling a cigar is the process of constructing the filler, binder, and wrapper into a single form.
This process is broken up into two steps: bunching and rolling. Bunchers and rollers sit side by side in teams of two during the construction of each cigar.

Chapter 6 - Quality Control

Once rolled, each cigar goes through a series of quality control steps. Every cigar is carefully examined to guarantee that only excellence gets our stamp of approval.
Each cigar is meticulously judged on its color consistency, veins, soft spots, and ring gauge. Any cigar that falls short of perfection is classified as a "Factory Select" or a "Second".

Chapter 7 - Aging Room

After quality control, the cigars are sent to an aging room for a minimum of 90 days. This final aging period allows for the different layers of tobacco within the cigar to fuse together.

Chapter 8 - Quality Control 'Aesthetics'

After the aging room, each cigar goes through yet another round of quality control. We sacrifice nothing when it comes to flavor. We don’t cut corners and we don’t compromise.
We make every effort, no matter how tedious, to clean up any and all rough edges. The result: the smoothest tasting cigars known to man.

Chapter 9 - Box Pressed

After the second quality control, a cigar may journey down a number of different roads. The first choice of which is if the cigar is box-pressed or not. Box-pressed cigars are a specialty that we take much pride in. The cigars are laid out on trays and are separated by individual slabs of wood.
After they are laid out and separated, the trays are stacked and then compressed - the pressure from which causes the cigar to press out against the wood slabs surrounding it, forming the cigar into a box shape. Once released from the tray, the cigar is no longer round but instead boxed.

Chapter 10 - Banding and Boxing

Whether box-pressed or left round, our cigars are then branded with our label. Carefully, decisively and proudly we band each of our cigars. The band is not just a label to queue what tastes will be revealed within the cigar, it is a testament to the labor and craftsmanship that went into every individual leaf. Each exhale is worth a thousand tired breaths in another part of the world. Because quality isn’t just a sacrifice, it’s a gift.
The creation of a cigar is finished once it is placed next to its brother in a Rocky Patel box. It took our tobacco at least 5 years to get to this point. It took 300 hands almost 2000 days to make it this far.
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