Bunching is the cigar’s internal architecture. It defines the airways you draw through, the way oils heat and vaporize, and how evenly a blend burns. The method—entubado, accordion, book, or machine‑assisted—determines how stable and repeatable that experience is.
What the bunch actually does (airflow, heat, and moisture)
Airflow. Filler geometry creates a network of paths. Too few or pinched paths → hard draw and coning; too many wide paths → hot, fast burn with washed‑out aroma. The aim is a gentle, continuous resistance across the length of the cigar.
Heat distribution. Even path density spreads combustion heat; clumps or flats concentrate it, causing tunneling or canoeing. A good bunch keeps the coal round and centered.
Moisture dynamics. Leaves absorb and release moisture at different rates. Uniform folding/tubing helps the cigar equilibrate quickly after rolling and after every opening of the humidor.
| Method | Airflow geometry | Strengths | Risks if rushed | Best use |
|---|---|---|---|---|
| Entubado | Parallel micro‑tubes, ligero centered | Very consistent draw; protects against plugs; excellent for aging | Collapsed tubes if rolled too tight; time‑intensive | Premium long‑filler, heavier ligero blends, figurados |
| Accordion (fan) | Z‑fold “springs” across the binder | Good uniformity; faster than entubado; forgiving | Edge choking if folds stack; uneven at the foot if misaligned | Broad daily production; robusto–toro ring gauges |
| Book (booking) | Leaves stacked and folded like a book | Efficient; repeatable in experienced hands | Flat planes → hot lanes; draw inconsistency if binder tension varies | Value lines, mixed‑filler or lighter blends |
| Lieberman‑assisted | Filler arranged, binder applied with machine apron | Throughput and repeatability; consistent binder tension | Over‑compression if settings are off; less craft “tuning” per stick | High‑volume SKUs; some long‑filler lines use it well |
Entubado (entubar): method and checkpoints
- Arrange the blend. Ligero toward the core for axial strength, viso/seco to complete the cylinder.
- Tube each filler leaf. Roll into loose, even straws; align ends at the foot for a clean light.
- Bind with uniform tension. Binder should compress the tubes just enough to stay coherent without collapse.
- Balance the head. Avoid a dense knot under the cap; keep path density continuous into the head.
Why it works: Discrete tubes resist lateral collapse and preserve parallel channels. The cigar draws the same today and six months from now—with proper storage.
Accordion (abanico): method and checkpoints
- Fan the leaves. Fold each leaf into a gentle Z, rib aligned for spring.
- Stagger the folds. Avoid stacking the same fold edge in one line.
- Binder, then roll. Wrap with consistent pressure; feel for any “flat bar” along the length.
Why it works: The Z‑fold creates repeating channels across the cross‑section. It’s faster than entubado but still highly uniform when disciplined.
Book (booking): method and checkpoints
- Stack by role. Place ligero where support is needed; sandwich with viso and seco.
- Fold like a book. Keep layers thin; avoid thick “spines.”
- Binder discipline. Slightly higher care on tension to avoid choking flat planes.
Why it works (and fails): The simplicity is the virtue—and the risk. Done well, it’s clean and efficient. Rushed, it creates hot lanes and draw variability.
Lieberman‑assisted: when to use, what to watch
- Consistency at scale. The apron sets binder tension; operators stage filler for even density.
- Watch compression. Settings that are too tight produce hard draws; too loose, airy burns.
- Long‑filler use. Many factories run long‑filler on Lieberman with strong QC; it isn’t limited to short‑filler.
Method × blend × ring gauge (selection guide)
- Heavy‑ligero, large ring (52–56): Favor entubado or entubado‑core hybrid; keeps the core breathing.
- Balanced blends, mainstream rings (48–52): Accordion excels—speed with uniformity.
- Delicate, aromatic blends: Accordion or careful entubado to avoid over‑compression of fragile seco.
- Figurados/torpedoes: Entubado or hybrid is safer near the taper; channels can otherwise pinch at the head.
Quality control that actually predicts performance
- Weight & density spread. Tight ranges indicate consistent bunching; outliers often smoke “off.”
- Foot read. Clean, even exposure at the foot suggests aligned paths; messy or lopsided feet correlate with uneven lights.
- Draw testing. Many factories use a draw‑test machine (measures pressure drop in inches of water). Targets vary by size; the point is consistency—too high = tight, too low = airy.
- Cap structure. A bunched knot under the cap often smokes tight even when the body is perfect.
Troubleshooting (symptom → likely cause → fix at the bench)
| Symptom in smoking | Likely bunching cause | Manufacturing fix |
|---|---|---|
| Hard draw from first light | Collapsed tubes; over‑tight binder; head knot | Loosen binder tension; re‑tube core; refine head shaping |
| Airy, hot burn | Too many open channels; uneven packing | Add filler mass; redistribute folds; adjust binder |
| Canoeing on one side | Flat plane in book fold; packed corner | Break up the plane; re‑fold; center density |
| Tunneling | Dense core, loose wrapper side | Move ligero inward; even radial density |
| Relights, sooty aroma | Over‑humidified filler at rolling or storage | Dryer staging leaf; post‑roll rest; storage at 65–67% RH |
From joinery to air paths, our method removes volatility so the cigars—not the conditions—do the talking.
Storage synergy: why a steady humidor matters to any method
Even the best bunch loses elegance in a volatile box. Keep ~65–67% RH and ~65–70°F, distribute humidification, and leave air paths around boxes and trays. Premium humidors simply make those conditions easier to hold—day after day.
Quick, high‑signal answers for collectors.
Is entubado always “better”?
Can I tell the method by looking at the foot?
Do machine‑assisted cigars draw worse?
Which method ages best?
What ring gauge benefits most from entubado?
Bottom Line
Method shapes the draw; discipline shapes the result. Choose the bunching approach that suits the blend and size, verify with sensible QC, and store in a calm environment. Do that, and the cigar speaks with clarity—today and a year from now.