The creation of a premium cigar is a testament to skilled craftsmanship, demanding precision and an intimate understanding of tobacco. For both seasoned aficionados and curious enthusiasts, appreciating the intricate process of how cigars are rolled enhances the enjoyment of the final product. This guide details the stages involved in crafting a handmade cigar, from the initial leaf preparation to the final inspection.
The art of rolling cigars is a profoundly gifted undertaking. While few are qualified to roll a cigar to professional standards, understanding the meticulous steps involved fosters a deeper appreciation for the craftsmanship. Many precise techniques and quality control measures contribute to a top-notch, handcrafted cigar.
The Cigar Rolling Process
The Buncher (Bonchero) and The Roller (Torcedor)
The meticulous process of cigar rolling typically involves two primary artisans: the buncher (bonchero) and the roller (torcedor). While some highly skilled individuals perform both roles, particularly for smaller production runs or bespoke cigars, the division of labour is common in larger factories.
The buncher is responsible for assembling the cigar’s core: the filler and the binder. This involves carefully selecting and arranging the long filler leaves – typically three to four different types – ensuring they are folded, bunched, or cut to the precise length required for the specific cigar vitola. The critical skill of the buncher lies in creating a consistent internal structure that allows for an optimal draw and even burn. Once the filler is bundled, it is secured with the binder leaf, forming a cylindrical ‘bunch’. These bunches are then placed into wooden moulds, or presses, for approximately 30-60 minutes, often rotated halfway through, to achieve a uniform shape and density.
The roller, or torcedor, takes the perfectly formed bunch from the press and applies the delicate wrapper leaf. This is the final, most visible stage of the cigar’s construction, requiring exceptional dexterity and an artistic eye.
Testing the Draw of the Cigar
Following the bunching process, many modern factories employ a ‘Drawmaster’ machine to test the airflow, or ‘draw’, of the unbound cigar bunches. This device simulates the action of a smoker, measuring the resistance and ensuring a consistent draw within specified parameters. This quality control step helps identify and rectify any issues with the bunch’s construction before the wrapper is applied, though factories with highly experienced bunchers may rely more on their artisans’ tactile assessment.
Applying the Wrapper Leaf
The wrapper leaf, chosen for its flawless appearance, uniform colour, fine texture, and elasticity, is the final component applied. Prior to rolling, these delicate wrapper leaves are carefully humidified to maintain pliability. The torcedor uses a specialised, crescent-shaped blade called a chaveta to trim the wrapper leaf, removing any prominent veins and shaping it precisely for the cigar’s dimensions. The wrapper is then expertly applied in a spiral motion, starting from the foot and working towards the head, with the roller gently stretching and smoothing the leaf to ensure a seamless finish. A minimal amount of flavourless, plant-based gum (often tragacanth) is used to secure the wrapper’s edge.
Adding the Cap
The final, intricate step in the rolling process is the application of the cap, which secures the wrapper at the head of the cigar. The most esteemed method, particularly prevalent in Habanos and other premium New World cigars, is the ‘triple cap’ or ‘mounted head’. This involves three distinct pieces of wrapper leaf:
1. A small, circular piece is applied to the very top of the cigar’s head.
2. A slightly larger, circular piece is then placed over the first, secured with a plant-based adhesive.
3. Finally, a thin strip of wrapper, known as the ‘flag’, is meticulously wound around the cigar’s shoulder and over the previous two caps, creating a robust and aesthetically pleasing finish. This triple cap not only provides structural integrity but also allows for a clean cut when preparing the cigar for smoking. Simpler caps, often a single or double layer, are also used depending on the cigar’s origin and size.
Inspecting the Finished Cigars
Upon completion, each cigar undergoes a rigorous inspection. Quality control specialists meticulously examine the wrapper leaf for any imperfections, such as discolouration, spots, tears, or inconsistencies in texture. Crucially, cigars are sorted by colour (colour-matched) to ensure that all cigars within a single box present a uniform appearance, reflecting the high standards of premium cigar production.
Aging the Cigars
After rolling, cigars are transferred to a dedicated aging room, where they rest under controlled temperature and humidity for a minimum of 21 days, often much longer. This crucial period allows the various tobaccos – filler, binder, and wrapper – to ‘marry’ or ‘coalesce’, enabling their distinct flavours and aromas to harmonise and develop a more complex, balanced profile. Many premium cigars are aged for several months, or even years, before being released to the market, further enhancing their smoking characteristics.
Packaging the Cigars
Following the maturation period, cigars undergo a final inspection for colour consistency and any last-minute defects. They are then carefully banded and arranged into boxes, typically lined with Spanish cedar, which imparts a subtle aroma and helps regulate humidity. This final presentation ensures that only the finest, perfectly crafted cigars reach the discerning consumer.
