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Some of the most famous tobacco in the world is grown in southern Honduras, all of it from tobacco seeds originally brought from Cuba. Sorting tobacco at the Plasencia Cigar Factory in Honduras. We pulled into the Plasencia Cigar Factory, which was started by Cuban immigrant Nestor Plasencia, and within moments a man named Hector, who appeared to be the head of the entire operations, emerged from his office, popped a cigar into his mouth and lead us to the factory. Hector enthusiastically showed us around the whole facility explaining the process from seed to cigar. Picked tobacco leaves arrive at the Plasencia factory and are sorted into various quality categories. Sorted leaves are then tied into small, neat bundles. Bundled tobacco at the Plasenca Cigar Factory in Honduras. Women sorting tobacco into different grades. The tied bundles of sorted tobacco leaves are tightly stacked in vast warehouses and allowed to naturally ferment for up to a year. Fermentation enhances and polishes the taste and aroma of the tobacco, but the process produces an overwhelming amount of ammonia inside the warehouses where ventilation and even face masks are important safety measures. At times it really was hard to breathe. Stacked tobacco begins the fermentation process at Plasencia Cigar Factory in Honduras. Tobacco grading at Plasencia Cigar Factory in Honduras. Once the tobacco leaves have fermented women expertly strip out the central vein so the tobacco burns evenly. After fermenting, the central vein of each leaf of tobacco must be removed by hand. A finished cigar is made up of three different types of tobacco leaves which are rolled together in three different stages. The main part of the cigar is called the filler. This is bundled together and placed inside a tobacco leaf called a binder because it holds all of the filler together. These rough tubes of tobacco are placed into wooden cigar-shaped molds which press them together, forcing the tubes to hold their shape. Part of the complicated cigar rolling process. The pressed and molded tobacco tubes are then neatly rolled into a tobacco leaf called a wrapper. The outermost tobacco layer of a cigar is called a wrapper and is rolled last. The Plasencia factory can produce tens of thousands of cigars per day in all shapes, sizes, strengths, flavors, and brands. The Plasencia factory makes cigars on contract for more than 30 different brands their only in-house brand is called Flor de Honduras. Every finished cigar must be labeled by hand. Being a cigar lover I am truly jealous. Of all my travels I have yet to make it to a cigar factory. Dominicans, Nicaraguans and Hondurans are as good if not better than most of the Cuban cigars I have smoked. The factory you went to puts out some fine sticks and I have tried more than a few from there. Great story on the making of some fine cigars and what goes into it. Great photos also. Great photos as always, guys! Coffee mills and candy factories in Hawaii, rum distilleries in Barbados… seeing how this stuff is put together is fascinating to me. This was such an interesting post! I love doing these sorts of tours. Did you try any of the cigars they made? This was really fascinating to see how it is produced. I had no idea it took 2 years!! No wonder it hurts your lung and head so much. Never been a smoker myself but can appreciate why some people love them considering the effort that goes into making them. Very cool — I would have loved to be on that tour! Did you get an opportunity to smoke a freshly rolled one? Can you get a nicotine buzz touring the factory? Nice photos! I guess it makes sense why cigars are so expensive. Sounds like a really interesting tour! Excellent overview and images guys! If you were on a mission to get me smoking a cigar this weekend, you succeeded. I never knew such work went into crafting cigars! Amazing, the manufacturers have my utmost respect. Wow what a process! Did you buy any cigars? One of the great things about taking a cigar factory tour is that you usually get a finished product at the end! Outstanding photography and very interesting statistics. I had always dreamed of going to a cigar factory. I keep waiting to see how I can order some of these cigars. I bought some in Mahogany Bay. I only wish I had got more. If anyone can help would be appreciated. Smoking a Flor De Honduras right now. Overlooking a beautiful redwood forest. Dense slow burning mild with rich smooth flavor. Nice tangy tobacco taste on the tongue. Coupled with a local IPA. Life is good! Green tobacco being hung to dry. Getting ready to roll. Nearly finished cigars. Cigars ready to be boxed and stored. Cigars in all shapes and sizes. Sorting finished cigars. These rectangular cigars seemed odd to us. Freshly labeled cigars. Rocky Patel cigars elegantly packaged. Share What You Love. Share via. Previous Next. Related Posts. March 14, 0 Comments. June 27, 3 Comments. October 13, 4 Comments. June 7, 7 Comments. June 1, 10 Comments. May 21, 7 Comments. May 16, 5 Comments. May 11, 6 Comments. May 9, 9 Comments. May 3, 1 Comment. May 1, 5 Comments. April 28, 4 Comments. April 19, 5 Comments. April 16, 20 Comments. The Travel Fool May 29, at pm - Reply. Bret May 29, at am - Reply. Lindsey May 29, at pm - Reply. Caz Makepeace May 29, at pm - Reply. Cole May 31, at am - Reply. Wandering Educators May 31, at pm - Reply. Don Faust May 31, at pm - Reply. Sandra Foyt May 31, at pm - Reply. Ava Apollo May 31, at pm - Reply. Angela June 1, at am - Reply. Very fascinating production process. It shows a natural angle on cigars! Ali June 1, at am - Reply. Matthew Karsten June 2, at pm - Reply. Raymond June 3, at am - Reply. I never realized how much work went into making something that stinks so badly. Jade Johnston - OurOyster. Brooke vs. Very interesting! Love getting to see how those things are made — very hands on! Jonathan Bentz August 3, at am - Reply. Marina K. Villatoro June 19, at am - Reply. When we arrived to Cuba, the week we were there, all the factories were closed! Arlesmaradiaga June 15, at am - Reply. Orville Couch March 28, at pm - Reply. Robert Jacobson July 18, at pm - Reply. Leave A Comment Cancel reply Comment. Help Us Keep Inspiring Travel. Since , we've been publishing inspiring and informative posts about travel in the Americas. If you can, please support our travel reporting on Patreon to keep our site ad-free. Learn more. Become A Patron Now! Thank you. Send this to a friend. Send Cancel.

Producing Puros – Plasencia Cigar Factory, Danlí, Honduras

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