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Construction of Cigars

Date Published: 22nd August 2009
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Cigar blending is a finest art, so the taste and flavor of cigar depends upon the interplay of the various types of tobacco and the quality of the leaves from different regions. Cigars have three basic components; the binder, wrapper and the filler. Each of these parts has a different function when the cigar is actually smoked.



Wrappers

the outer most part of the cigar is called wrapper which is made from the widest part of the plant. Much of the taste and flavor comes from the wrapper part of the cigar. The wrapper also describes the color of cigar, to indicate the strength of the cigar. It is perhaps the most important layer among the three providing it not only exterior appearance but also contributing the overall flavor and aroma of the cigar. Although only comprising 10% of the cigar by weight the wrapper contributes as much as 70% to the value of the cigar. If the wrapper fails to attract the customer by its smooth silky touch, oily consistency and inviting aroma, the sale will be lost. It must be strong yet elastic to be stretched over the filler and binder and must be without visible coarse veins. Quality wrappers come from Honduras, Costa Rica, Nicaragua, Mexico and Cuba. Some of the more sought-after wrappers come from Sumatra, Connecticut or Cameroun.


Distinction among cigars on the basis of wrapper color (lightest to darkest)

Double Claro- It is very light in color and slightly greenish. These leaves are picked before maturing and dried quickly; they are often grown in Connecticut.

Claro – They are light tan with yellowish appearance and are grown under shade.

Natural – They are light brown or brown; generally sun-grown.

Colorado Claro – It is mid-brown, generally grown in Cuba.

Colorado – It is reddish-brown (also called Rosado)

Colorado Maduro – The color of this type of tobacco is dark brown; particularly grown in Honduras or Cuba.

Maduro - dark brown to very dark brown

Oscuro – They are also refered as Double Maduro. It is black in color with an oily appearance; tend to be grown in Cuba, Nicaragua, Brazil, Mexico, or Connecticut.





Filler

The filler consists of the larger amount of tobacco and it is main part of the cigar. It contains a blend of whole leaves running through the length of the cigar. The assembly and composition of the filler determine the cigars overall character and taste. In hand-crafted cigars, the filler is in the form of strips of tobacco leaf cut to the length of the cigar. But in machine made ones smaller tobacco shreds or pieces (short leaf) are used. There are three styles of leaf used in the filler; Ligero, Seco and Volado. The art of blending one leaf with another, gives uniqueness to each cigar and to each brand of cigar as well.

Ligero leaves are the ones cultivated in rainfall seasons and left to mature for two to three years, which gives it an oily appearance with a fine tobacco flavor. These leaves burn slowly, therefore must be placed in the center of the cigar to make it burn evenly.

Seco tobacco is lighter in color having less oily appearance. These leaves are typically matured for 18 months. These leaves are used to give subtlety to the cigar.

Volado leaves are even more subtle with the least amount of oil and with little flavor.



Binder

The function of the binder is to keep he cigar properly structured. It holds together the leaves of the filler and gives a proper shape and size to the cigar. It does not play an important role in the smoking quality. Still care is usually taken to ensure that it imparts a complementary flavor to the filler and wrapper. The binder is usually constructed from a tougher leaf than is used for the wrapper although the same leaf is often used as a wrapper on non-export cigars.



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