Oxman
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Making Cigars
I have been lucky enough to do this a couple of times, here is a brief guide:
Cigars are made from 3 main ingredients –
1. The Filler which gives the cigar its structure, body and determines the draw and burn quality. The filler is usually a blend of tobacco from various sources and will be in 2 different forms:
Long Filler – These are whole leaf pieces used in Premium cigars
Short Filler – Scrap pieces used in lower grade or machine made cigars
Long filler ready for production – note the 3 grades which create the blend.
IMG-20130616-00573 by oxmanonline, on Flickr
The filler is collected in your hand and then rolled into the binder (This is already laid in the rolling machine.
IMG-20120919-01528 by oxmanonline, on Flickr
2. The Binder is the layer that holds the cigar together. This is normally a second grade wrapper style which may have blemishes or small holes, it normally adds 10% of the flavour.
Once the cigar has been rolled into a binder, it will go into a mould and be pressed for several hours to maintain its shape:
IMG-20120919-01535 by oxmanonline, on Flickr
IMG-20130616-00577 by oxmanonline, on Flickr
3. The Wrapper is the outside layer that you see and is the most important part of the cigar. It has to be blemish free and will provide up to 40% of the final flavour to the cigar.
The wrapper is cut to shape:
IMG-20120919-01583 by oxmanonline, on Flickr
And then rolled onto the cigar with a bit of tension:
IMG-20120919-01578 by oxmanonline, on Flickr
The final thing is to cut the scrag end off for a completed cigar:
IMG-20120919-01589 by oxmanonline, on Flickr
Professionals will roll hundreds in a day:
hand rolled cigars by oxmanonline, on Flickr
Cigars ready for packing!
cigars ready for packaging by oxmanonline, on Flickr
Fermenting wrapper
IMG-20130920-00079 by oxmanonline, on Flickr
I have been lucky enough to do this a couple of times, here is a brief guide:
Cigars are made from 3 main ingredients –
1. The Filler which gives the cigar its structure, body and determines the draw and burn quality. The filler is usually a blend of tobacco from various sources and will be in 2 different forms:
Long Filler – These are whole leaf pieces used in Premium cigars
Short Filler – Scrap pieces used in lower grade or machine made cigars
Long filler ready for production – note the 3 grades which create the blend.
IMG-20130616-00573 by oxmanonline, on Flickr
The filler is collected in your hand and then rolled into the binder (This is already laid in the rolling machine.
IMG-20120919-01528 by oxmanonline, on Flickr
2. The Binder is the layer that holds the cigar together. This is normally a second grade wrapper style which may have blemishes or small holes, it normally adds 10% of the flavour.
Once the cigar has been rolled into a binder, it will go into a mould and be pressed for several hours to maintain its shape:
IMG-20120919-01535 by oxmanonline, on Flickr
IMG-20130616-00577 by oxmanonline, on Flickr
3. The Wrapper is the outside layer that you see and is the most important part of the cigar. It has to be blemish free and will provide up to 40% of the final flavour to the cigar.
The wrapper is cut to shape:
IMG-20120919-01583 by oxmanonline, on Flickr
And then rolled onto the cigar with a bit of tension:
IMG-20120919-01578 by oxmanonline, on Flickr
The final thing is to cut the scrag end off for a completed cigar:
IMG-20120919-01589 by oxmanonline, on Flickr
Professionals will roll hundreds in a day:
hand rolled cigars by oxmanonline, on Flickr
Cigars ready for packing!
cigars ready for packaging by oxmanonline, on Flickr
Fermenting wrapper
IMG-20130920-00079 by oxmanonline, on Flickr