a Cigar Is Made
how a cigar is made from start to finish?
This infographic explains it all in an easy to understand format.
The Infographic information is also displayed in text form below:
Cigars are made carefully through the following process: Before
we explain the specifics, we first want to familiarize you with
the structure and composition of a cigar. The Structure of Cigar
- Cap - A small, round piece of tobacco wrapper leaf attached
to the head of a cigar. The purpose of the cap is to lock in
the wrapper and finish the head. Head - This is the part of
the cigar that one draws or smokes from. The head is always
the closed end of the cigar and must be cut about about 3 millimeters
before the foot is lit. Cigar Band - The label that surrounds
the head of the cigar. Foot - The foot of a cigar is normally
pre-cut and is the part of the cigar that is lit. Composition
of Cigar - Cigars are made up of of 3 types of tobacco leaves:
the wrapper, filler and binder. Variations of these will determine
the flavor characteristics of the cigar. Wrappers - The leaves
on the outer or widest part of the tobacco plant. The wrapper
has a large influence on a cigar's overall character and flavor.
The wrapper color is often used to describe the cigar in general.
Fillers - The large majority of a cigar is comprised of filler.
Filler is bunches of tobacco leaves grouped together inside
the wrapper. Binders - Leaves that have an elastic character
that are used to secure the filler of a cigar together. Binders
are for the most part wrappers that were rejected linked to
blemishes, holes, discoloration or excessive veins, etc. The
3 types of Tobacco Filler -Filler is generally made up of strong
ligero leaf in the middle, the lighter seco leaf surrounds the
ligero and the volado wraps around both the ligero and seco.
Ligero - Is harvested from the top of the tobacco plant, which
is normally exposed to the highest level of direct sunlight.
It is normally the darkest and the most flavor rich filler of
the three. Seco (Dry) - Is pulled from the central portion of
the plant. These tobacco leaves are generally lighter than Ligero
in both flavor and color. Volado - is extracted from the lowest
portion of the plant. Volado is mostly utilized for its burning
properties to help keep a consistent burn. Volado leaves have
very little influence on the flavor of a cigar.
The Manufacturing Process - Cigars are made in 2 ways. By hand
or machine. Cultivation of Tobacco - Tobacco plants are planted
and cared for indoors and transplanted into fields once they
have aged 6 to 10 weeks. The plants then take several months
to grow and mature in the tobacco fields before they are harvested.
Curing - Once the plants are harvested, the tobacco leaves are
then cured once they become yellow or dried brown in color.
The curing process is begun when the harvested tobacco plants
are secured and strung to laths (thin strips of wood). The laths
are then hung in a curing barn that is well-ventilated. Fermenting
- After the leaves are cured, they are grouped together and
are tied into bundles by size and color. They are then stored
away months to years. During this time, the tobacco leaves undergo
chemical composition changes (fermentation). During the fermentation
process, the tobacco's flavor and aroma intensifies. Stripping
- The filler leaves are cleaned up and main vein and stems are
removed. This is essential to insure the cigar burns evenly.
The stripped tobacco leaves are wrapped in bales and stored
away so that fermentation can progress further. Once the leaves
are just about ready to be used, they are physically steamed
to rejuvenate lost humidity. Wrapping - Wrapping is the most
difficult step that can make or break the cigar. The worker
takes the partially completed cigar and sets it on the wrapper
tobacco leaf. With a unique tool called a chaveta (essentially
a rounded knife), the worker trims away any abnormalities from
the filler. The hand roller spirals the wrapper leaf around
the binder and filler several times, and then finished it off
by securing the end of the wrapper with a vegetable paste. The
cigar is finished! Hand rolling - Premium cigars are made by
hand. The filler of hand rolled cigars always must be packed
carefully and evenly so the cigar always burns smoothly. The
wrapper is rolled in an even spiral around the cigar. Machine
rolling - The vast majority of cigars are manufactured by machine.
Inspecting - Completed cigars are inspected in a variety of
ways and vary from factory to factory. The cigars are grouped
together from the rollers in bundles and are labeled and or
stamped with the following details: "Vitola" or size
number. The name of the "tabaquero," or cigar factory.
And finally the Production Date.
Phone & Online Orders Accepted
With Major Credit Cards
We also accept Checks or Money
(Toll Free order line)
(888) 396-6838 (Quantum
(Order by Fax)
511 East Sample Road
Pompano Beach, FL 33064
396-6838 (Quantum Inc.)
Web site: www.cigarhumidors-online.com
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