Agio Cigars

Cigar strength: mild

Cigar Production – From Leaf to Finished Craft

The preparation of tobacco for cigar making is a labour-intensive process, beginning at the subsidiary in Sri Lanka. Here, the binder and wrapper leaves are carefully cut into the desired shapes. First, the tobacco is gently moistened to achieve the supple texture needed for rolling. Each leaf is then carefully selected according to size and colour, before being machine-cut to match the specifications of the cigar model. These pre-cut leaves are rolled into ‘bobbins’—semi-manufactured goods ready for the next stage of production.

At the factory in Geel, these semi-finished bobbins from Westerlo are transformed into finished cigars. On specialised complete machines, the bunch is formed with binder and filler tobaccos, before the wrapper is added to complete the product. The wrapper is not only crucial for the cigar’s appearance, but also plays a significant role in defining its flavour and character.

This detailed process allows for the production of a wide variety of shapes and styles of cigars, each crafted with precision and consistency. From leaf selection to final rolling, every step is essential to ensuring the quality, taste, and presentation of the finished cigar.