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Written by Puff Staff

Monday, 30 December 2013

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Once the leaves arrive at the rolling factory, the Master Blender gets the tobacco ready for the rolling team. The rolling team consists of a roller and a Master roller. The roller takes the leaves, and bunches them, forming the basic shape. Next, they bind and encase the bunched filler in a binder before pressing them in wooden molds (giving them the shapes and formats we all love).

Next, the Master Roller wraps the cigar in its wrapper and applies the head. After careful inspection, the cigars are stacked and ready for (yet another) aging.

From here, the cigars are bundled in groups of 50 and placed in the aging room. The length of time is determined by the company, but can range anywhere from three months to several more years.

The final step is to pack the cigars into boxes, which are then sent on to tobacco stores. Each cigar gets hand labeled by a labeler and placed into a plastic wrapper. These cellophane wrapped cigars are then placed in cigar boxes, which are then placed in even bigger boxes before being shipped out to stores and distribution centers.

So, as you can see, a lot of work goes into each and every cigar. And not for nothing, but this is the abridged version of the process. It does not begin to really touch upon the massive effort it takes to produce a single cigar. How we don't have to pay a hundred dollar a stick is beyond me!

So next time you sit down, smoke a cigar, and frown at a little give in the construction or get irritated that you have to touch it up a time or two, think back to all the work it took to get that cigar into your hands. It might make you appreciate - and enjoy - the experience all the more.

 






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