Once the aging process is complete and the bales are transported from the warehouse to rolling facility, the bales must be unwrapped with care because of the pressure exerted in the fermentation and aging processes.
Again, as we did between fermentation and sorting we give the leaves fresh air until it is time for the rolling, which usually takes about 24 hours.
After being carefully separated and "refreshed" from storage in their bales, the tobacco leaves are separated from their bales by wrapper, filler, and binder. The wrapper leaves are cut into two parts, so the main vein of the leaves that is not smooth can be thrown away and the smooth part of the leaf is kept to eventually wrap the cigar with perfection and beauty.
Meanwhile, the filler and the binder tobaccos are taken to the scale room where the Wismilak Master Blender determines the exact proportion and combination of Java and Brazil tobaccos to be used as filler and binder in order to get the desired taste.
