The Cigar Manufactoring Process
There are two ways that the cigars you see today are made. You have the hand made cigars and the machine processed cigars.
At Cigar Experience the majority of the cigars you see here will be handmade cigars, though in some instances we will carry machine rolled cigars. These cigars will be clearly marked as such.
Hand Made Cigars
The best cigars are always made by hand. Why? Because of the absolute skill and attention to detail of the professional cigar roller. When you smoke a hand made cigar you are experiencing a unique work of art, and the cigar roller is the artist.
A handmade cigar consists of three parts. The first is the filler. There are two kind of filler, long filler, which is a whole leaf expertly cared for and aged to perfection, the masterfully rolled into the cigar. The second type is the short filler, which is made up of the clippings from making the long filler.
The second part is the binder, which consists of several layers of leaf to hold the filler together.
The last part is the wrapper. The wrapper leaves have to be specially grown to make sure that they have very few veins and are of a very high quality, so that the cigar is perfect, in function and in presentation.
The first step in making the cigar is bunching the tobacco leaves to form the cigar. This is done by taking a measured amount of filler leaves and forming it into the correct shape.
Once the cigar
roller has the filler bunched he must then wrap the binder
leaves around it, so it will hold it's shape. Then this is put
into a wooden mold that is hand tightened by feel until the roller
feels th pressure is perfect.
Once the cigar is released
from the press it is carefully formed to perfection and the wrapper
is gently rolled on and secured with an all natural tree sap glue.
Now that the cigar is rolled the cap must be added to the end. This is a small piece of tobacco that is used to keep the cigar from unrolling.
