How a Cigar is made

A Peak Into The Beginning of a Cigar

A quality cigar starts with the finest tobacco leaves. Without this important component, the final product is at best, an ordinary cigar. To understand what makes a good tasting, smooth burning cigar, it helps to know how a cigar is made.  For a good intro to cigars, be sure to familiarize yourself with my Cigar’s 101 guide!

The Cigar Essentials

There are essentially three components to a cigar, the filler, the binder, and the wrapper. The filler is made by using three to six tobacco leaves and bunching them together. A person known as a buncher wraps the leaves tightly together, making sure the leaves are formed evenly in width and length. The buncher also checks for overly dry or extremely wet portions of the leaves, and removes them accordingly. The bunching process ensures the inner core of the cigar is tight, so it burns hotter than the other parts.

Cigar Bindingcigarrolling

The next step in cigar making is the binding process. In the binding process, one sturdy, thick tobacco leaf is used to wrap around the core. The single leaf is rolled uniformly, until the end of the leaf is rolled around the core completely. At this point, the cigar must be shaped, to ensure all cigars in a box look uniform in length and width, to satisfy the end consumer. The ends are cut off, to give the cigar a better shape.

The next step is putting the cigar in a press. Usually, 10 cigars go into a mold. They are then placed in a press for about 30 minutes, to ensure it stays tightly packed. When the cigar is done in the press, it is ready for the wrapping process.

The Final Touch – The Wrapper

Wrapping a cigar requires using on the best leaves. A leaf must be smooth, stretchy, and evenly colored, to use as a wrapper. The person wrapping the cigar with begin at one end and roll at an angle. When the wrapping is done, one end of the cigar is capped with a pectin adhesive. The other end is cut to size. Each cigar is inspected, then aged for at least a month, to remove any excess moisture before packaging.

Do you have a favorite wrapper? My personal favorite is Connecticut Shade. It’s mild, yet bold at the same time and burns evenly.  Read more about Connecticut Shade here.

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