How is a cicar constructed?

Almost all handmade cigars have 4 elements:

Filler: The filler is the tobacco in the center of the cigar.

 The following is the types of fillers:

1. Long filler: is a tobacco leaf that runs the length of the cigar. 

2. Mid Filler: Long leaf rolled with short leaf spread over the long prior to rolling.

3. Short Filler: The left over clippings from the of long filler cigars during production.

4. When a cigar is finished it shoul have no large stems and an even one way directed leaf.

A high quality filler will be naturally age with time and only time no additives. The very best fillers come directly from Cuba second would be the Domincan republic and so on down the line. There should be no large stems in a high quality cigar.

When the filler is matched and rolled correctly with little to no stems you get a consistant draw with a long burn time from your cigar.

Binder: The binder is made from a heavier larger leaf and is used to wrap the filler to hold the shape of the cigar.

Wrapper: The highest quality tobacco leaf is used for the wrappers. Generally very smooth and silky and is wrapped around the binder to give the cigar one of its major flavor components.

Cap: The cap is the end of the cigar with aglued on or small stran of tobacco leaf from the wrapper to hold the finished end together.
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The cigar roller will take tobacco leaves fold them over to make a basic shape of the cigar. This is called bunching. He will  take leaves from different tobacco types ( in our case time aged Cuban seed and Domincan long filler) to adjust the of flavor the cigar. Then he will take a binder leaf to wrap filler. They are then cut to lenth. After that the cigars are placed in a wooden (wooden is what we use) or the new plastic mold and pressed together for at least 30 minutes. This compresses the cigar for a consistent shape.