“A good cigar is like tasting a good wine: you smell it, you taste it, you look at it, you feel it – you can even hear it. It satisfies all the senses.” – Anonymous
A cigar is basically tobacco leaf wrapped around a tobacco leaf filling. Bigger and better than a cigarette, a cigar is often considered the finest way to enjoy tobacco, especially be veteran smokers.
Let us take a quick look how cigars are made.
This process includes obtaining the best wrappers, fillers, and binders; after which they are sorted according to color, texture, strength, resiliency, and size.
After processing the tobacco, a blend is prepared for each cigar roller which is a specific combination of leaves used to make certain brands of fine cigars, like Macanudo cigars that boasts that its every cigar is rolled by hands in the Dominican Republic to give it a distinct savory flavor.
After blend is prepared, it is given the shape of a rough cylinder of tobacco referred to as ‘bunch.’ This process needs great care to ensure that leaves are laid in a bunch uniformly and straight.
After creating a bunch, it is tightly wrapped in a coarse layer called a binder. It gives shape, and structure to cigar to maintain its moisture content.
Mold contains a minimum ten unfinished cigars put into a screw-type press where cigars are further mold into the desired shape. The mold has two parts – top and bottom. A compression can be noticed in the mold where upper and lower halves meet.
After cigars are pressed and turned, they are rolled with the skilled hands. The craft workers use silky, elastic wrapper tobacco to stretch around the molded cigar body.
Finished cigars are weighted and inspected to make sure that the roller is making rightly tight cigars.
Cigars are stored in cedar bins, drawers or shelves with ideal temperature and humidity conditions so that they can be stored for three weeks to a year. The longer they remain in the seasoning room, the better their quality will be.
Tobacco absorbs oils and aromas of anything around, so the longer they remain in a room, the better they absorb each other’s oils and aroma. Them they taste and smell alike.
This is how a fine quality cigar is made through a series of steps.