In was in Estelí, Nicaragua remote working for a week and, as it is the cigar production centre of Nicaragua, I had reached out (with the help of a Spanish speaking colleague) to some factories to arrange tours to Las Villas, Rocky Patel, and Plasencia. This led to one of the more unique and personal experiences I have had, combining two of my passions: travel and cigars.
The first of the factories that I visited in Estelí was Las Villas. This wasn’t a factory or brand that I was familiar with, but they were the first to extend an invitation so happily accepted.
I walked there from my hotel. It took a little less than half an hour but the heat made it feel longer. Along the walk I passed other buildings that had cigar logos on the outside. These were not ones that I was familiar with and appeared to be small operations. Occasionally I walked past a building that had no signage outside whatsoever but I could hear voices and smell tobacco through the cracks in the windows. I don’t mean that I could smell smoke from tobacco I meant that I could smell raw tobacco, and it was apparent to me that these were also small rolling operations. There are entire streets in Estelí that smell like tobacco, or like heaven depending on your perspective.
I walked down some unpaved back roads in a residential neighbourhood and passed a couple of donkeys when I found my destination. Behind the security gate was a small, new-looking building containing the cigar factory.
I was met by a fellow who gave me a tour of the factory, I think because his English was the best of the people on staff. And I feel like a jerk because I wrote down the names of the people that I met but I lost the paper and so I don’t remember his name, but this was him and me in the picture enjoying a cigar.
He took me through the Las Villas where people were fermenting tobacco, rolling cigars, bundling and aging them. This glimpse into cigar production was truly fascinating. I had visited factories previously in Miami and Cuba, but it was still thrilling to see. Something about cigars that not many people realize unless you know cigars is how many steps it takes to make a cigar from when you plant the seed to when you box them up. They go through a long and intricate process of growing, harvesting, aging, fermenting, sorting, rolling, testing, aging some more, banding, and boxing. It is said that a cigar passes through 200 hands on its way to being ready to smoke. It’s one of those rare items that still, today, is made entirely by hand. I find it kind of moving to see all of these people handcrafting this thing that I enjoy so much. I don’t think I take it for granted, but it is very special to see first hand all of the effort that goes into a cigar.
My guide showed me around the factory and took me into the rooms where they were aging tobacco. He gave me a cigar to sample which was excellent (and thankfully it was excellent, because I had never had these cigars before and it would have been an awkward experience if the cigars were bad).
The little oily pigtail ones on the end are a custom roll for a buyer.
After the tour I was taken into the office of the owner of the company and his brother. Guillermo Pena Jr. Is the owner of Las Villas and of course I forget his brother’s name because I lost the little piece of paper where I wrote it down. The brother didn’t speak English, but Guillermo did. He told me the story of how he and his brother grew up in Cuba and worked as cigar rollers there before escaping to Miami in the early 2000s. They started working initially at cigar factories in Miami before going out on their own to create their own cigars. They eventually created a factory in Estelí, Nicaragua and started rolling cigars for other brands as well as creating their own. They started with eight rollers and today they have over 200. While I was there, I tried a Las Villas cigar called By The Book, which came in a cigar box that looked like a book. It was excellent. Full bodied, leathery, earthy, with a hint of natural sweetness, and a perfect construction in an oily wrapper. It was a truly amazing experience to be sitting in this office on the leather sofa in the middle of a cigar factory in the middle of Nicaragua talking about cigars with these men. bonded over our mutual passion.
I left feeling elated. It was such a unique experience – but it was only the first of three.
The next day I would visit Rocky Patel and tour both the farm and factory.
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