Cigar Making - Bunching

Bunching is a crucial step in cigar making, involving the assembly of the filler leaves before they are encased in the binder and wrapper. The method used for bunching can significantly affect the draw, burn, and overall smoking experience of the cigar. Here are the primary methods of bunching cigars:

Entubado Method

Process: In the entubado method, each filler leaf is rolled into a small tube or scroll. These tubes are then gathered and rolled together.

Advantages: This technique creates air channels throughout the length of the cigar, facilitating an excellent draw and even burn.

Skill Level: It is a more time-consuming and skill-intensive method, typically used in high-quality, premium cigars.

Accordion or Book Method

Process: Here, the filler leaves are folded back and forth in an accordion-like fashion. The folded leaves are then gathered together side by side.

Advantages: The accordion method is quicker than entubado and still provides a good draw and even burn, though perhaps not as optimal as entubado.

Common Use: This method is widely used due to its balance of efficiency and quality.

Lieberman Machine Bunching

Process: A Lieberman machine assists in the bunching process. The filler leaves are placed on a canvas strap on the machine, which then rolls them into a bunch when the strap is pulled.

Advantages: This method increases consistency and efficiency in production.

Skill Level: While it requires less manual dexterity than hand-rolling methods, operating the machine effectively still demands skill and experience.

Tubular Method

Process: Similar to entubado, the tubular method involves rolling each leaf into a tube. However, in this method, the tubes are not rolled together but instead laid parallel to each other.

Advantages: Like entubado, it offers excellent air flow for a smooth draw and even burn.

Skill Level: This method is also skill-intensive and more time-consuming, typically reserved for higher-end cigars.

Freehand Bunching

Process: In freehand bunching, the cigar maker gathers and rolls the filler leaves without any specific technique or mechanical aid.

Advantages: This method allows for a lot of flexibility and individual expression from the cigar maker.

Variability: The quality of the draw and burn can vary significantly, depending on the skill of the roller.

The Scrunch Method

Process: The filler leaves are literally scrunched or bunched up together in the roller’s hands before being enclosed in the binder.

Use: This method is less common and generally considered to be less refined, but it can be effective in the hands of an experienced roller.

Conclusion

Each bunching method has its own set of advantages and influences the final smoking experience of the cigar. Higher-end, premium cigars often use more labor-intensive methods like entubado or tubular, which are celebrated for their superior draw and even burn. More efficient methods like the accordion or Lieberman machine are commonly used for mass production while still maintaining good quality. The choice of bunching method is a crucial aspect of the cigar maker's craft, reflecting their style, skill, and the quality level of the cigar being produced.