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Masters and apprentices
Three basic leaves are used to roll cigars: the filler, binder and wrapper. A master roller can create an infinite variety of cigars from these components. There is a huge difference between the cigars produced by a master and by an apprentice. In Cuba, there are seven classes of cigar rolling. Even in Communist Cuba, a category-seven roller earns more than a category-five roller. As a result, Pyramid, Bellicoso and Double Corona cigars are more expensive than other cigars.
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Cigar leaves
Before rolling begins, the master blender lays out the tobacco in front of the roller.Filler: The heart of the cigar. Long-leaf is used in premium cigars and short-leaf is used in machine-made cigars. Three different tobaccos are blended together. Dark, aromatic Ligero leaves from the top of the plant are used in the middle of the cigar and provide the bulk of the flavour. Seco leaves from the middle of the plant and velado leaves from the bottom of the plant are also used to determine the strength and the flavour of the cigar. Two to four varieties of leaves can be used in the filler.
Binder: This holds the cigar together and gives its shape and dimension. It should be flexible and strong and complement the recipe of the cigar.
Wrapper: This accounts for 70% of the monetary value and 10% of the weight of the cigar. It should be smooth, silky and shiny and attract smokers with its aroma and appearance. If the wrapper is not attractive, the cigar is a failure. Therefore, the function of the torcedor is paramount to producing a quality cigar.
Let's get rolling
1. The filler that has been selected by the blender is formed into a cylinder by crimping the leaves together like a fan, creating horizontal air spaces for a good draw.
2. The filler is then rolled into a binder. In essence, this is a cigar without its wrapper. These bunches are placed into wooden presses that will give them their shape and left for 15-20 minutes.
3. The torcedor only now enters the equation. He selects a wrapper and places it face down on the board before him. The wrapper is then trimmed using a special blade called a chaveta. The torcedor tightly rolls the wrapper from the bottom up. A flavourless vegetable gum is added to hold it all together. A round piece is cut from the excess wrapper to form the cap of the cigar--this is the mouth end.
4. After the cap has been made, the open end of the cigar is guillotined by hand to create the desired length of cigar. It takes years of training plus natural talent and know-how to become a torcedor. In their reliable hands, a cigar is born that can provide anything from 15 minutes to 3 hours of pleasant smoking.
