How a Cigar is Made

TheHumidor.com has introduced what goes into a cigar, but how are they made? This meticulous procedure is taken step-by-step with different professionals dedicated to their own roles. In a recent video, Chief Certified Tobacconist, Chris Gwaltney, breaks down each part of the process that goes into rolling the perfect cigar.

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How is a Cigar Made?

To make a cigar, you first must have tobacco, and this tobacco must be prepared for the process. The three components to be prepared are the wrapper leaf, binder leaf, and filler tobacco. In a cigar factory, there are individuals dedicated to prepping each of these cigar components. There are usually two main roles in charge of this part of cigar creation: the buncher and the roller.

The breakdown of a cigar – wrapper leaf, binder leaf and filler tobacco

The buncher will take the job of gathering the filler tobacco and the binder leaf. Depending on the size of the cigar, the filler tobacco can contain between three to five leaves which is known as the ring gauge. The buncher takes that tobacco and carefully places those leaves in a specific order that will allow the cigar to burn properly. The darker, higher priming leaves will be placed in the center, while the drier leaves that provide more combustion will be on the outer edge of the cigar. If the leaves are placed improperly, the cigar may tunnel. A properly constructed cigar should look like a pencil when ashed prematurely because the center tobacco will burn a bit slower than the dryer leaves around it.

Sorting through tobacco

“I call this the scientific part of the process,” says Gwaltney. “[The buncher] is going to take the bunch, making sure he gets the right tobaccos in the right place, and then lay that bunch on a binder leaf and roll it out.”

Some bunchers will roll the leaves on a table, others will use a machine called a Lieberman. This machine is a leather matt with a handle on it that allows for a faster rolling process. Once the leaves are rolled, they are trimmed and put into a cigar mold. After the mold has been filled, it is placed in a cigar press and from there, the cigar roller will apply the wrapper leaf.

Tobacco rolling station

What is the Purpose of the Wrapper Leaf?

“The wrapper leaf is the money leaf,” says Gwaltney. “This is the artisan part of the job.”

A cigar with blemishes can deter buyers from purchasing a cigar, the wrapper leaf is what adds eye appeal for consumers. The first thing a roller must do is examine the leaves to make sure they meet a certain standard. The roller then takes the bunch and rolls it into a cigar with the wrapper leaf. The cigar gets trimmed and placed back for a final inspection. It will be checked for loose-fill, rolling quality, and soft spots. After it passes the inspection process, the cigar is taken to a room to age, also known as marrying. The length of time it ages is dependent on the tobacco within the cigar.

Cigars wrapped and let to age

What is the Most Important Part of the Process?

There is not a singular most important part of the cigar rolling process. From an aesthetic standpoint, the roller applying the wrapper must ensure the cigar is presentable for the consumer and holds up to quality standards. While the buncher must make sure the filler tobacco is constructed correctly. If the buncher messes up on the filler tobacco, the cigar may look beautiful, but will not provide a good smoking experience. This puts both the rollers and bunchers in equally important positions.

Looking to learn more about cigars? Browse our articles on TheHumidor.com.