At ACC we age and ferment the tobacco for years, a rare practice even among the most well-known brands. We then roll the cigars in our own factory and age them again. This process takes many years and is very difficult for producers that mass-produce well known brands. As every cigar aficionado knows, age is a cigar’s best friend! Our tobacco vintages range from 3 - 12 years and more.
Nursery: The development of new agricultural and industrial processes begins with the total sterilization and fertilization of the soil. The seeds are carefully chosen for the nursery, where a genetic selection is made from the reproducer plants. Before planting the seeds, samples are tested for germination and the growing process is carefully monitored for its optimum development.
Transplanting: After a new analysis of the soil and the fertilization process the best plants from the nursery are selected and transplanted to the furrows. Before and during the process, strict botanical and sanitary controls are carried out, and advanced controlled irrigation systems are applied, besides the regular agricultural controls.
Harvest: This operation is carefully carried out through different cuts and sub-cuts in the different plots, according to the planting stage. Processing and Drying: This is done by separating the different cuts that come from the fields. After this, a permanent control of temperature and humidity is maintained to guarantee a perfect processing (curing), which will result in an optimum quality of the leaves.
Fermentation: All ACC tobaccos complete a 6-9 month fermentation process naturally without heating chambers or force heating, which can be seen in the beautiful white ash color of all ACC branded cigars.
According to the harvesting schedules, the leaves are arranged in fermentation piles that are exposed to a controlled temperature and relative humidity conditions, until the shades of the leaves in the clusters become uniform.
Selection: The next step is to select the leaves based on strict categorization norms which consist in selecting the leaves according to the characteristics of each fermentation pile. The leaves are classified as WRAPPERS, BINDERS AND FILLERS respectively and are organized by size according to a normative scale, to then go through the process of partially extracting the vein.
At the same time, the WRAPPER is separated and is taken through a meticulous selection where quality, texture, color, tone and size are determined. Aging and De-veining: Once the tobacco has been selected, it is exposed to an aging process that allows the leaves to reach a maximum level of maturation and the next step is ready to follow: The vein is carefully removed from the leaf prior to the beginning of the cigar manufacturing, which is the start of the construction process.