What ia a cigar is made up of fermented tobacco leaves which are bunched and rolled into a cylindrical shape. To fully visualize the cigar, we will start with the tobacco seed. Tobacco seeds are planted generally in a tropical environment for ideal growing conditions. Some of the most prominent farming regions include Cuba, the Dominican Republic, Honduras, Nicaragua, Mexico, the USA (Connecticut and Pennsylvania), Central African Republic (Cameroon), and Indonesia. The tobacco growing season takes 18 weeks. From seed to cigar, it takes between 2 - 3 years.ction into wrapper, binder, and filler. The center stems of the leaves selected for wrappers are removed and those leaves are once again sorted for consistency in color and size. The specific filler, binder, and wrapper leaves are piled together to complete a particular cigar brand’s composition and stored until they’re needed by the cigar production team, which consists of a buncher, or bunchero, and roller, or rollera.Buncheros combine three to five of the filler leaves and wrap them inside the binder. The individual bunches are then placed in a cigar mold. Once the mold is filled, it’s placed in a press to create pressure to give the bunch its shape. The bunches are rotated several times under pressure to avoid creating seams in the cigar.After being in the press for several hours, the cigar bunches are removed from the mold and are prepared for their wrapper application. A rollera uses a curved cutting device, called a chaveta, to trim away excess tobacco from the wrapper leaf. She then deftly stretches the wrapper leaf and rolls it onto the bunch. Depending on the cigar’s shape, she uses a variety of techniques to finish the head and applies a bit of natural vegetable gum to fix the cap onto the top of the cigar. When a cigar factory needs the tobacco for rolling into a cigar, the bales are moved from the warehouse and unpacked. A day before it’s rolled into a cigar, the tobacco is re-humidified to make it pliant and reduce the chance for damage to the leaves. It is then sorted once again by size, color, and condition for selection into wrapper, binder, and filler. The center stems of the leaves selected for wrappers are removed and those leaves are once again sorted for consistency in color and size. The specific filler, binder, and wrapper leaves are piled together to complete a particular cigar brand’s composition and stored until they’re needed by the cigar production team, which consists of a buncher, or bunchero, and roller, or rollera.Buncheros combine three to five of the filler leaves and wrap them inside the binder. The individual bunches are then placed in a cigar mold. Once the mold is filled, it’s placed in a press to create pressure to give the bunch its shape. The bunches are rotated several times under pressure to avoid creating seams in the cigar.After being in the press for several hours, the cigar bunches are removed from the mold and are prepared for their wrapper application. A rollera uses a curved cutting device, called a chaveta, to trim away excess tobacco from the wrapper leaf. She then deftly stretches the wrapper leaf and rolls it onto the bunch. Depending on the cigar’s shape, she uses a variety of techniques to finish the head and applies a bit of natural vegetable gum to fix the cap onto the top of the cigar.