Cigar Quality Control

From Cigar Wiki

q.v. Cigar Manufacturing

There are strict quality control tests at all stages of hand making. Cigars that fail will never become Habanos.

Everyday the Workshop Manager (El Jefe de Galera) supervises the work of the cigar rollers. At the same time supervisors, who are themselves top grade Torcedores, oversee each brigade of 30 to 40 workers watching their technique and checking the dimensions of the cigars they are making.

Source: 5THAVENUE Products Trading GmbH

Finished cigars are tied in bundles of 50, known as media ruedas - literally half-wheels, which are labelled with the Torcedor’s number, the type of the cigar and the date of manufacture.

Source: 5THAVENUE Products Trading GmbH

On the following day the bundles go to the quality control department where technicians check the cigar for weight, length, girth, consistency, construction and appearance, particularly examining the tightness of the wrapper and the finish of the cap.

Samples of each Torcedor’s work are regularly taken apart to verify their internal construction and blend. When problems are found the cigars are deducted from the daily quota - a serious matter for the Torcedors who are paid by piecework.

The very latest quality control technique is a machine that checks the draw of the bunch by suction. The test takes place after the bunch has been pressed in the mould and before the wrapper is added. It was first introduced at the end of 2001 and is now widely used.

Source: 5THAVENUE Products Trading GmbH

There are more quality inspections when the cigars go for colour grading and finally before the box is sealed.

Source: 5THAVENUE Products Trading GmbH

Every factory has its team of cigar tasters - the Catadores - who meet every day to test cigars and score them according to a six-point quality checklist for draw, burn, aroma, flavour, strength and overall quality. 3-5 different cigars are tested at each sitting. If any deviation from the normal character of any brand and size is detected, they recommend adjustments to the blend. The Catadors are the front line of the National Commission for Tasting, which is ultimately responsible for the blends of all Habanos.