A cigar is only as good as the tobacco that goes into the blend. That’s why we use only the finest hand-picked tobacco from Kentucky and Tennessee. And to achieve the perfect blend, we use tobacco from at least three different crop years in every cigar we make.
When Avanti crops are harvested, the tobacco leaves are hung to dry inside special barns. During this critical period, the leaves are smoked using select Hickory logs, a process known as fire curing. The leaves go through a fermentation process to develop their full, hearty and robust flavors. This curing removes 85% of the moisture, allowing the leaves to burn evenly when lit.
At our plant, special rolling machines combine the wrapper and fill tobacco to form the cigar.
We use two types of tobacco: a master blend
that is used to “fill” the cigar, and special
leaves used as wrappers. No binder is required
because the wrapper encases the cut master tobacco twice. Each end is then hand-clipped. The wet cigars are carefully placed into long wooden trays inside drying rooms.
The aging process takes four to five weeks. DeNobili, Parodi and Petri lines are hand-packaged immediately for shipping. Other
cigars are infused with various flavors, such
as anisette for the Avanti line, Café Mocha for the Estilo brand, bourbon for the rugged Ramrod line, and cherry-vanilla for select Parodis. These brands require one extra day to let the flavoring dry, then are immediately packaged and shipped.
After the cigars are rolled, they are inspected.
The perfect ones rest in our drying rooms for six weeks so that the flavors of the tobacco are permanently retained. As they dry, the cigars
take a slight curve.