We believe that the artistic genius of our cigars lies in the touch of our rollers’ hands. So, how do they get the perfect cigar? Here’s an exclusive look at our process:
Depending on the size of the cigar and the blend, two to four filler leaves are folded together lengthways in an accordion fashion known as a “concertina." This forms tiny passages in the cigar so that air and smoke can be drawn.
The filler is then rolled into the binder leaves to form a bunch. It is essential that the filler is distributed evenly. If it’s rolled too loosely, the cigar will burn too fast and taste harsh. Too tight, and the smoke would be more work than enjoyment. All of our OBT cigars are hand-rolled for a light, easy draw.
The unfinished bunches are then placed in a cigar mold. The trough determines the shape of the cigar, keeping it round and uniform. Once 10 molds (100 cigars) are ready, the surplus filler is trimmed from the ends and the molds are placed under a press for an hour to help shape the cigars.
After the bunches have taken shape, they’re removed from the molds and given to a roller, who applies the wrapper leaf. An oval-shaped steel cutter, known as a chaveta is used to trim the wrapper leaf to the right size.
Normally, the top of the wrapper leaf is placed at the foot (or lighting end) of the cigar, and the base of the wrapper is at the mouth. This provides a milder flavor during the first few puffs. We have also been known to “reverse wrap” and do the opposite. With the reverse, the taste remains the same with a mild flavor consistently throughout the smoke.
Lastly, a cap is attached with a vegetable-based glue. A “pigtail” finish is another traditional option you’ll see as well, where the tobacco is twisted into a little pigtail at the ends.
Now you're ready for packaging!