BUNCHING
Bunching is the process of combining the filler leaves (tripa) of tobacco (usually 3 to 5 varieties) and covering them with a binder leaf (capote). Cigar rollers, or torcedores as they are known, "bunch" the tobacco leaves just before the cigar is placed in the cigar mold and pressed. Because cigar wrappers are basically applied in the same manner (left to right/right to left, with vein side facing inward), the bunching method is what defines (or differentiates) the type of cigar rolling technique being used: entubado, accordion, book, and Lieberman (machine) are the major techniques, in descending order of complexity.
Entubado Bunch (Entubar): This is the bunching technique which rolls each filler leaf into itself, almost like a small scroll. Each individually "scrolled" leaf is then placed together to form the bunch. This skillful rolling technique creates a more firmly packed cigar which allows air to travel between all of the leaves, carrying more aromatics/flavors to the palate. Entubado rolling is the most difficult and complex bunching method and is therefore rarely employed in large scale manufacturing.
A similar bunching method is called estrujado, a.k.a. "Lazy Entubado", as nicknamed by the cigar makers at Drew Estate.
Click here and visit our YouTube channel to see a video of estrujado bunching.
Accordion Bunch: This bunching technique involves folding the outer sides of the filler leaves inward, one at a time, and placing the leaves on top of each other until the bunch is complete: then the leaves are rolled together with a binder leaf. The "folds" created by this technique allow excellent air passage through the cigar. If you dissect an accordion rolled cigar, the leaves will separate much like an accordion moves in and out. Accordion rolling takes more skill and time to execute than book rolling, but is not quite as technically sophisticated as entubado rolling.
Book Bunch: An alternative to entubado or accordion rolling, booking involves laying filler leaves flatly on top of one another and then folding them up, like a book or taco, to complete the bunch. This technique is simpler than entubado and accordion rolling and creates a less aerated cigar structure: placing the leaves directly on top of each other does not allow as much air to pass through each individual leaf in the cigar. The advantage of book rolling is that it is quicker and more efficient from a manufacturing perspective. This is probably the most popular technique for making premium cigars today.
Lieberman Bunch (Machine Bunching Technique): This bunching technique involves laying the binder and filler leaves on a canvas which is rolls them up mechanically. While the Lieberman machine/rolling technique uses a mechanical aid, they are hand assisted and cigars bunched by it are still considered premium products.
Figurado / Hybrid Bunch: Shaped cigars such as torpedos and perfectos typically use a hybrid bunching technique. The tapering or bulging of the cigar requires extra skill and care when bunching occurs: a single misplaced leaf can easily plug a shaped cigar.
Certified R&D Tobacconists: United States |
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