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Fermentation is the process used to get the ideal physical and chemical structures of tobacco leaves prepared to be used for the production of premium cigars. In this process, tobaccos are fermented to get the desired exotic aroma, unique taste, and interesting texture. In Indonesia, fermentation is done in large barns that are temperature and humidity controlled.

The fermentation process is done in four stages based on the parts of the leaves that are separated during the harvesting and after the air curing of the leaves has been accomplished.

Stage One
In this first stage of the fermentation process 2.5 tons of tobacco are formed into a large cube measuring 2m x 4m x 3m (7' x 13' x 10'). The temperature and humidity of the tobacco cube is closely monitored. Once the temperature reaches 35 degrees Celsius or 95 degrees Fahrenheit, the cubes have to be rearranged by rotating the tobacco over a three week period so that the outer tobaccos are rotated to the inside, so that the every leaf is subjected to the fermentation process.

Stage Two
In this stage, larger cubes are formed to continue the fermentation process by combining cubes from stage one. This combination is made by bundling the upper side of one cube with the underneath side of the second cube, so the arrangement of tobaccos is smooth. This stage lasts another three weeks at 35 degrees Celsius or 95 degrees Fahrenheit.
 
Stage Three
The process continues further by again combining the cubes formed in stage two of fermenting tobaccos which at this point measure is 8 m x 4 m x 3 m (26' x 13' x 10') with the weight of each cube now at 9-10 tons each! If one of the outer leaves is broken in the process, we remove it so that it won't affect the other leaves in this stage of the fermentation process, which takes 3-4 weeks.

Stage Four
In this step, the two cubes of stage three are bundled together with the same arrangement and rotation as in the previous stages. The measure of one cube in this final stage of fermentation is 10m x 4m x 3m (33' x 13' x 10'), with physical and chemical characteristics that are now very different from the leaves in stage one or two. After what has now been twelve weeks of fermentation the texture of the leaves is thinner and more mature, with almost same color, and a strong, pungent aroma.