The galera on the top floor of the Partagás factory on Calle Industria in Havana is still quiet. Daylight is just bleeding through the high windows. Javier, a torcedor of the highest category, Segundo Chaveta, does not yet approach his rolling bench. His first task is at the selection table, under the watchful eye of the rezagadora, the head of leaf selection.

For the D4—a Robusto (50 ring gauge, 4.9 inches / 124mm)—the recipe is precise. Javier’s practiced fingers riffle through piles of cured, fermented leaves. He is choosing by texture, aroma, and instinct honed over 22 years.

• The Fillers (Tripa): He selects three leaves. One Ligero from the top of the plant, dark and oily, for strength and peppery power. One Seco from the middle, for body and foundational aroma. One Volado from the bottom, for its exceptional combustibility, ensuring an even draw. Each leaf is mentally assessed for elasticity, vein structure, and fragrance. A single stiff vein in the Ligero could ruin the draw.

• The Binder (Capote): A single, sturdy but elastic leaf. It must be strong enough to hold the bundle but supple enough to mold.

• The Wrapper (Capa): This is the crown jewel. For a D4, it is a Colorado capa, a medium-brown wrapper with a subtle reddish hue. Javier examines half a dozen before choosing one. It must be flawless—no prominent veins, no tears, a perfect, oily sheen. Its aroma is sweet, almost like cedar and dried fruit. This leaf alone costs more than the other four combined.

Time Elapsed: 15 minutes. The performance has not yet begun, but the instruments are chosen.

6:00 AM - The "Bonche" – Heart of the Draw

Javier settles at his tabaquero bench, a worn wooden surface bearing the scars of thousands of chaveta cuts. He takes the three filler leaves and, in a sequence known only to him and the Partagás recipe, stacks them. This is not a random bunching. He arranges them so their stems and veins do not align, creating a natural, unobstructed channel for smoke.

With a fluid motion, he rolls them lightly in his palms—the "pre-bunch." He then takes the binder leaf, lays it flat, and places the filler bundle upon it. In a series of quick, firm tucks and rolls, he encases the filler, creating the crude, cylindrical "bonche." He tests it briefly for give and uniformity. It already feels promising.

Tools Used: Hands, intuition.
Time Elapsed: 25 minutes. The cigar has a heartbeat.

6:25 AM - The First Press – The Mold's Embrace

The raw bonche is not yet the perfect 50-ring gauge cylinder. Javier places it into one half of a two-part cedar mold. The molds are labeled with the vitola code: "D4." He pairs it with its mate, clamps the mold shut, and places it in a stack with others from his morning's work.

For the next 45 minutes, the cigar will rest under pressure. The heat and moisture from the leaves, combined with the pressure of the wood, will meld the binder and filler into one cohesive unit, solidifying the draw and perfecting the shape. This is where the Robusto gets its signature firm, round form.

During this wait, Javier will roll more bonches, a rhythmic dance of productivity. But his mind is on the one in the mold.

Time Elapsed: 30 minutes (Active). The form is being imposed.

7:10 AM - The "Beautiful Wrap" – Dressing the Icon

This is the moment of truth. Javier retrieves the molded bonche. It is now firm, perfectly cylindrical. He takes his precious wrapper leaf and lays it on the dampened leather of the bench, smooth side down. He places the bonche on one edge.

With a surgeon's precision, he makes three critical cuts with his chaveta—the curved, razor-sharp knife that is an extension of his hand.

1. The first cut creates the "flag"—a small piece of wrapper used later for the cap.

2. The next two trim the wrapper to its exact, efficient shape.

Now, the ballet. He rolls the bonche onto the wrapper, initiating the spiral. He applies even, supreme tension, stretching the delicate wrapper just enough to lie smooth, but not enough to tear. A single pucker or tear means starting over with a new, costly wrapper. The leaf adheres to itself with its own natural gum. He completes the spiral, and the D4 is now cloaked in its iconic Colorado robe.

Time Elapsed: 55 minutes. The cigar has its skin.

7:25 AM - The Head & The Cap – Sealing the Craft

The open end—the head—must be sealed. Javier takes the small "flag" of leftover wrapper and, using a dab of odorless, flavorless vegetable gum, begins the intricate process of forming the cap. He creates a series of small, tight folds—the "trenza" (braid). For the D4, this typically results in a distinctive "pigtail" or a perfectly rounded triple cap.

This requires the finest motor skills. The cap must be seamless, secure, and aesthetically perfect. He trims the excess with a final, definitive snip of the chaveta.

Time Elapsed: 70 minutes. The vessel is sealed.

7:35 AM - The Final Cut & The Weight of Expectation

Javier picks up his "casquillo"—a small, sharp guillotine. He places the foot of the cigar into the hole and makes a single, clean cut, opening the smoking end to exactly the right diameter. He gives it a final, critical inspection: a perfect cylinder, a seamless wrapper, a flawless cap, a clean cut.

He holds it. For a moment, it is just his. Then, he places it in the "galera" cedar tray to his left, alongside the others from this session. It will later be sorted by color for box consistency, banded, and aged.