Cigar Making: Bunching Methods Explained
Bunching is the assembly of filler leaves (and often the binder) before the wrapper is applied. It shapes a cigar’s draw, burn, combustion rate, and even its flavor clarity. Different techniques trade speed for precision—here’s how they compare and when they shine.
Quick take
Airflow is everything. Methods that create long, continuous channels (e.g., entubado) tend to deliver the most reliable draw and even burns; faster methods boost consistency and output when trained teams and QC are in place.
Why Bunching Matters
- Draw: Channel geometry and density determine resistance—too tight and you struggle; too loose and it burns hot/thin.
- Burn line: Even distribution of leaf thickness prevents canoeing, tunneling, or coning.
- Flavor delivery: Stable airflow preserves temperature and releases oils predictably for clearer flavors.
- Consistency: Repeatable technique = repeatable experience box-to-box.
Method Overview (At a Glance)
| Method | How it works | Draw / Burn | Speed / Skill | Typical use |
|---|---|---|---|---|
| Entubado | Each filler leaf is rolled into a small tube; tubes are aligned, then wrapped with binder | Outstanding airflow; very even combustion | Slow; highly skilled | Artisanal, premium lines |
| Tubular | Leaves formed into parallel tubes and laid side-by-side | Excellent airflow; clean burn | Slow; skilled | High-end SKUs; select factories |
| Accordion / Book | Leaves folded back-and-forth (accordion) or stacked like pages (book) and wrapped | Very good draw; even burn when executed well | Faster than entubado; moderate skill | Many premium and volume lines |
| Lieberman-assisted | Canvas strap machine helps roll filler into a uniform bunch before hand-binding | Consistent when operators are trained | High efficiency; lower manual load | Scaled production; consistency focus |
| Freehand | Roller gathers and shapes filler without a strict pattern | Can be excellent—or variable—by roller | Flexible; skill-dependent | Small workshops; limited editions |
| Scrunch | Leaves are loosely “scrunched” into shape before binding | Inconsistent channels; risk of hot spots | Fast; not refined | Budget or niche uses |
Myth check
Entubado isn’t automatically “better” if density, leaf placement, or binder tension are off. Any method can shine with great leaf sorting and QC.
Inside the Bunch: What the Torcedor Controls
- Leaf order: Volado (combustion) supports ignition; seco provides aroma; ligero adds strength/body. Their placement balances burn and flavor.
- Orientation: Aligning veins and cutting tips controls thickness along the length.
- Density: Firm enough to hold shape, open enough for steady airflow (often checked by feel and draw-testing).
- Binder tension: The binder sets the “chassis.” Too tight suffocates, too loose collapses channels.
- Head & foot geometry: Tapers, parejos, and figurados need tailored channeling so the draw stays consistent as ring gauge changes.
Quality Checks & Common Issues
| Symptom | Likely cause | Fix / Prevention |
|---|---|---|
| Tight draw / hard spots | Over-dense bunch; binder over-tensioned; misaligned ligero | Rebalance density; re-place heavier leaves; monitor press time |
| Hot, fast burn | Under-packed channels; too much volado; wrapper too loose | Add body; adjust binder tension; verify moisture before rolling |
| Canoeing / tunneling | Uneven density; wet pockets; mixed moisture levels | Normalize leaf moisture; fold/entube evenly; rest cigars post-roll |
Practical caution
Great tobacco can be ruined by poor bunching—and average leaf can be elevated by precise airflow management. Technique + QC are non-negotiable.
Bottom Line
Entubado and tubular maximize airflow and burn at the cost of speed; accordion/book balance performance and efficiency; Lieberman-assisted boosts consistency for scale. Whatever the method, the best cigars share the same secret: correct density, clean channels, and a well-set binder.