How Are Cigars Made: An In-depth Look At Rigorous Manufacturing Process

by Evelyn Brown | Published On

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What is a cigar? Made from leaves – a cigar is a roll of dried tobacco leaf or paper that contains tobacco for smoking. They are considered luxurious and are loved by many people.

Cigars are of different shapes, colors, flavors, and sizes so you can choose as per your preference. The round-headed cigar with parallel sides is the most common shape.

Cigar Manufacturing

Why do people enjoy and love cigars? Cigars allow people to cherish essential occasions. Many folks can unwind by smoking cigars. At the same time, others would like to pair cigars and drinks together. The rich scent and distinct flavor of a cigar can have a relaxing effect, removing stress and assisting you in being joyful.

Now, let’s take a closer look at the cigar manufacturing process.

Cigar Design


  • Cap: A little, rounded piece of cigar wrapper leaf connected to the cigar’s head. The cap’s purpose is to keep the wrapper secure.
  • Band Of Cigar: It is the covering that wraps around a cigar’s head.
  • Head Of Cigar: The closed end of any cigar is called the head of the cigar, which needs to be cut roughly 2 millimeters before lighting the foot of the cigar.
  • Foot: A cigar’s foot is the end that is lit, usually pre-cut.

Cigar Making Materials

Cigars comprise three types of tobacco leaves: wrapper, filler, and binder. These differences influence smoking and flavor characteristics.

  • 3 Types Of Fillers: Since the tobacco plant is so huge, the tobacco priming used—top, middle, or bottom—will determine the cigar’s flavor.
  • Volado Priming: is found in the root of the tobacco plant and is noted for its great burn quality, hence almost all cigars have Volado in their blend. Otherwise, Volado is almost flavorless.
  • Middle priming Or Seco: are oily leaves with a moderate flavor and a deep olfactory appeal.
  • Ligero: This thick, sun-drenched top leaf priming is strong in flavor but lacking in combustibility and scent, therefore it is frequently coupled with Volado.

The Manufacturing Process Of Cigars

  1. Cultivation Of Tobacco

    Tobacco cultivation can be done in limited areas only. Ideal soil and seeds play a crucial role in good cultivation. The plants are harvested 70-120 days after transplanting.

  2. Curring The Tobacco

    Curing barns are designed to allow farmers to control the biochemical transformation by adjusting the inside climate of the barn. Most of the time, this will consist of doors and shutters that can be opened and closed as needed. In a nutshell, the curing barn is a massive humidor.

    A steady temperature of 80°F to 90°F (27°C to 32°C) and a humidity of 80% to 85% are required for optimum curing. During the dry season, the doors and shutters are closed to keep the natural heat and moisture in. Tobacco leaves are hung back-to-back along laths, which are commonly constructed of bamboo. There is just enough space between the leaves to allow air to flow and prevent rotting.

    The center vein or “midrib,” which signifies that the tobacco leaf is ready for fermentation, will be the last component to cure. Because tobacco cannot be over-cured, a single batch will be kept in the barn until the very last leaf is properly cured.

  3. Fermentation

    After curing, the leaves are separated by color and size. The leaves are bundled into bundles and kept in boxes for 6 months to 5 years. During this stage, the leaves undergo chemical changes known as fermentation. The aroma and flavor of the tobacco leaf develop during fermentation.

  4. Manual And Mechanical Preparation

    The filler leaves must need to have their main vein removed, otherwise, it will be difficult to burn the cigar evenly or else it will not at all burn. So, this could be done by hand manually or with the help of a machine. Also, right before the leaves are ready to be made into cigars, they must be steamed to recover the lost humidity and sorted once more.

  5. Rolling By Hand

    Depending on the format, two to four tobacco leaves are hand folded around each other in a conical shape. This method creates air tunnels inside the cigar, ensuring an equal draw. The filler is then folded into one half of the binder; bigger forms require two halves. The resulting cluster is then pressed into a wooden frame.

    The cigar maker now takes one of the soaked wrappers and unfolds it on his cutting board before stretching and cutting it to size. The bunch is now carefully arranged on the wrapper in an angled fashion and wrapped. Then, using natural glue, a spherical piece is cut out of the remaining wrapper leaf and fitted onto the head of the cigar. Some cigars form the head by twisting the wrapper ends together.

    The cigar maker then strokes his blade over the wrapper before rolling the cigar on his table to polish it. The final step is to trim the cigar to the proper length.

  6. Machine Rolled

    The majority of cigars are manufactured with the help of machines. One of the workers feeds tobacco leaves to adjust the desired length of the cigar. The filler is formed by the machine bunching the leaves. The second worker applies a binder leaf to the binder die effectively. The suction holds the leaf in place, and the machine cuts it to size.

    After that, the filler is put onto the binder die. The machine then starts to roll the binder around the filling. The wrapper leaf (or HTL) is subsequently placed on a wrapper die by a third worker. The machine rolls the wrapper around the cigar after the cigars are ready. A fourth employee inspects the finished cigars before placing them in trays.

Are Cigars Better For You Than Cigarettes?

Switching from cigarette smoking to cigar smoking might be extremely deadly since you may inhale cigar smoke in the same way you did cigarette smoke. Since it is said that the effect of smoking a cigar is minimal, it would be good if it is not being smoked at all. Instead of deciding between cigarette and cigar smoking, try quitting tobacco totally as both of them contain tobacco.

Tobacco is present in both products. Cigars are often unfiltered, although most cigarettes have filtered ends. The amount of nicotine is also different. Cigars can contain up to 100-200 milligrams of nicotine, while cigarettes have an average of eight milligrams. That means that smoking one cigar can provide the same amount of nicotine as smoking a pack of unfiltered cigarettes.

How Can I Cut A Cigar Without Ruining It?

Variety is essential in the cigar culture. Aside from having a plethora of fantastic cigar brands to pick from, cigar fans may also choose the best cigar cutter that suits their taste and needs. There are numerous ways to cut a cigar, making the overall experience more unique for everyone.

Having said that, knowing about the tools to be used in cutting the cigars could also prove to be really handy. Hence, if you are wondering what to use to cut a cigar then we have mentioned some of the names of the tools that one could use.

  • Punch-Cutters
  • V-Cutter
  • Cigar Scissors
  • Straight Cutter or Guillotine Cutter
  • Finding the Cigar Cap

How To Cut A Cigar

  • What is the best place to cut a cigar? The cap is the final piece, and you should concentrate your cut on it. It’s usually bonded together a little to help the wrapper hold the cigar together. You should only cut off the cap region because any wider incision will harm the wrapper and your smoking experience.
  • Identifying the cap is frequently simple. It’s the leaf’s rounded tip. Make a shallower cut and leave a small amount of the cap on to help keep the wrapper and cigar together.
  • Some professionals, however, wet the cap with their tongues before cutting. It isn’t a necessary maneuver, but it can help you make a somewhat smoother cut when the leaf is excessively dry. Even with the best cigar cutter on the market, too-dry leaves can hinder you from making a clean cut.
  • Now that you know where to cut a cigar, it’s time to do so. It may appear simple on paper, but it does necessitate some talent. The truth is that every time you slice a cigar, you are one move away from the perfect cut.
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Evelyn Brown

Evelyn Brown is a housewife and spends most of the time at home taking care of her infant son. The time that she has left after cleaning the house and taking care of the son and the daddy is dedicated to making her mark on the internet. She loves to write about the kitchen appliances that she uses in her daily life. She also likes to spend quality time with her husband and drink aged wine and scotch.

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