The Construction of a Cigar

The construction of a fine cigar is as important as the tobacco that goes into it. No good cigar was ever made in haste. Premium cigars are made by hand, lovingly, one at a time, as they have been for hundreds of years. While the Dominican Republic, Cuba, Nicaragua, and Honduras are the leading manufacturing countries for premium handrolled cigars, the tobaccos used to make these cigars come from those same countries as well as Costa Rica, Brazil, Ecuador, Africa, Mexico, and the United States.
 
From tobacco grown throughout the Caribbean Basin, Connecticut, Mexico, Central and South America, and Cameroon, great cigars are blends of different tobaccos, masterfully combined to create an experience that carefully balances the strength, flavor, aroma, and combustion. Blends can be made of tobaccos from one country or different countries and often use varying types of tobacco, leaf position, and harvest year. Much like champagne, the majority of cigars are made in a "non-vintage" style, meaning that the blend represents a particular experience that must be maintained year after year. All handmade cigars share the same basic components: filler tobaccos, one binder leaf, and one wrapper leaf. It is the marriage of these tobaccos - properly aged and equilibrated - through which cigar makers achieve tobacco's highest potential.
 
Tobaccos used for premium cigars are harvested leaf by leaf, beginning from the bottom of the plant and working toward the top. Each priming (leaf position) has unique characteristics due to its location on the plant. As a general rule, the lower on the plant the leaf is the larger and thinner it is. It will burn faster and be milder in flavor. The higher on the plant, the smaller and thicker the leaves become. These leaves burn more slowly and offer a stronger, heavier flavor.
 
In order to use the tobaccos accurately, they are sorted and classified based on their leaf position. The plant is divided into four "regions," beginning with volado on the very bottom, seco right above, viso above that, and finally ligero at the top.
position) has unique characteristics due to its location on the plant. As a general rule, the lower on the plant the leaf is the larger and thinner it is. It will burn faster and be milder in flavor. The higher on the plant, the smaller and thicker the leaves become. These leaves burn more slowly and offer a stronger, heavier flavor.
In order to use the tobaccos accurately, they are sorted and classified based on their leaf position. The plant is divided into four "regions," beginning with volado on the very bottom, seco right above, viso above that, and finally ligero at the top.
 

The Filler:
Filler tobaccos are the innermost leaves of the cigar. When you look at the open end of the cigar (the foot), you are looking at the ends of the tobacco filler leaves. These leaves make up most of the volume of the cigar. Filler leaves are generally intact as "full leaves."
A portion of the center vein is removed (about one third from the tip toward the center). When the filler leaves are combined in the hand, they're combined in a particular order to ensure proper combustion. Leaves from the lower portion of the plant are positioned further to the outside, while the higher leaves are placed in the center, ensuring an even burn.
 
The Binder:
The binder leaf is one-half of a full leaf. Generally, "ligeros" are not used as a binder, since they are too thick to encourage combustion of the whole cigar. The binder leaf is rolled around the filler leaves to hold them together in what's called "the bunch." The bunch is then placed into a mold, pressed, and rotated four times to ensure even distribution of the filler tobaccos. This creates a sound and even form over which to apply the wrapper.

The Wrapper:
The wrapper is like the expensive gift wrapping paper with which you would wrap an important gift. Although a wrapper leaf is but one of many in a cigar, it is the one by which the cigar is judged and must therefore be flawless. The wrapper is cut into a crescent shape using a chaveta and, beginning at the foot, the wrapper leaf is stretched with one hand while the bunch is rolled into the leaf with the other. The cap is applied using the same wrapper leaf in order to fasten the leaf. Cigars are ultimately classified by their wrapper shade. The lightest is Double Claro, increasing in browns through Claro, Colorado, Maduro, and finally Oscuro.

Although a wrapper leaf is but one of many in a cigar, it is the one by which the cigar is judged and must therefore be flawless. The wrapper is cut into a crescent shape using a chaveta and, beginning at the foot, the wrapper leaf is stretched with one hand while the bunch is rolled into the leaf with the other. The cap is applied using the same wrapper leaf in order to fasten the leaf. Cigars are ultimately classified by their wrapper shade. The lightest is Double Claro, increasing in browns through Claro, Colorado, Maduro, and finally Oscuro.

Double Claro/Candella, American Market Selection:
A very green in color, light-tasting wrapper.

Claro:
Usually referring to shade-grown, light green to tan in color. Natural, English Market Selection or Café:    This light brown, almost almond-colored wrapper is common for Connecticut shade-grown tobacco. Colorado Claro:    Mid-brown or tawny.

Colorado:
Medium to dark brown

Maduro:
Very dark brown to brown-black

Oscuro:
Brown-black to black

Note: the term Maduro also refers to a specific fermentation process, using higher heat for a longer time, creating more sugars within the leaf and resulting in a slightly sweeter, richer taste. This intense process can be tolerated only by certain types of tobacco, most commonly Connecticut broadleaf, Brazilian Mata Fina and Arapiraca and other thick, dense tobaccos.

Double Claro/Candella, American Market Selection:
A very green in color, light-tasting wrapper.

Claro:
Usually referring to shade-grown, light green to tan in color.

Natural, English Market Selection or Café:    
This light brown, almost almond-colored wrapper is common for Connecticut shade-grown tobacco.

Colorado Claro:
Mid-brown or tawny

Colorado:
Medium to dark brown

Maduro:
Very dark brown to brown-black

Oscuro:
Brown-black to black

Note: the term Maduro also refers to a specific fermentation process, using higher heat for a longer time, creating more sugars within the leaf and resulting in a slightly sweeter, richer taste. This intense process can be tolerated only by certain types of tobacco, most commonly Connecticut broadleaf, Brazilian Mata Fina and Arapiraca and other thick, dense tobaccos.
 
Aging:
Once a cigar has been rolled, it is important to allow the cigar to rest. This process allows the different tobaccos to marry with each other, creating a "rounder," more balanced experience of flavor rather than the unique characteristics of each tobacco coming across singularly. The more a cigar ages, the more it continues to mellow and marry as a blend.
 
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    -Last updated on July 28th, 2015