When discussing cigars, one of the key distinctions comes down to the type of filler used. Handmade cigars typically contain long filler—whole, carefully selected tobacco leaves rolled together to form a consistent structure. Machine-made cigars, on the other hand, often utilize short filler composed of chopped tobacco bits and even stems. But what does this mean for the smoking experience? Let’s break it down, starting with a little historical context.
A Brief History
Cigar-rolling machines date back to the late 19th century, with a patent filed between 1883 and 1888 by Oscar Hammerstein of New York. By the 1920s, these machines were increasingly used in American cigar production. Hammerstein later enhanced his design to process tobacco stems, claiming that it would make them more enjoyable to smoke and reduce waste, as reported by The New York Times in 1913.
The affordability of machine-made cigars eventually led to their adoption by Cuban manufacturer Por Larrañaga in 1925. Seeking to cut costs and boost production, the company introduced rolling and wrapping machines from the United States. The result? A 25% cost reduction and the ability to train operators in just two weeks—far quicker than the years required to master hand-rolling. However, resistance from cigar rollers led to strikes and boycotts, ultimately forcing Por Larrañaga to abandon the machines.
Key Differences Between Handmade and Machine-Made Cigars
Burn Quality and Smoke Experience
Handmade cigars, when properly crafted, offer a slow, controlled burn, producing a cooler and more enjoyable smoke. In contrast, machine-made cigars tend to burn faster and hotter due to their composition, often leading to an uneven smoking experience.
The Role of the Wrapper
A handmade cigar’s wrapper consists of a whole, natural tobacco leaf, retaining essential oils that contribute to an even and steady burn. Even if ignited unevenly, a high-quality handmade cigar often corrects itself during smoking. In contrast, machine-made wrappers frequently incorporate non-tobacco elements to increase durability, making them less supple and more prone to burning inconsistencies.
Differences in Filler Composition
Long-filler tobacco, found in handmade cigars, promotes a slow and consistent burn. Machine-made cigars, however, often contain short filler—small tobacco fragments held together with adhesives. Some even use homogenized tobacco leaf (HTL), a processed sheet of reconstituted tobacco scraps mixed with cellulose. These materials combust more rapidly and may include additives to standardize the burn rate and flavor.
Interestingly, some cigars classified as "handmade" are partially machine-bunched, with only the wrapper applied by hand. This hybrid method is still common in Cuba, though the filler in these cigars is often short rather than long.
The Art of Blending
Premium handmade cigars undergo meticulous blending processes, where master blenders curate specific tobacco leaves to achieve a distinct and balanced flavor. Since tobacco is an agricultural product, its characteristics can vary due to environmental factors. Skilled blenders adjust their selections to maintain flavor consistency from year to year. In contrast, machine-made cigars rely more on uniformity and may include additives to stabilize taste.
Premium Cigars
The cigar world presents a vast selection to match various preferences and budgets. Whether you’re looking for a budget-friendly option, a well-balanced blend, or the ultimate in fine cigar craftsmanship—like the ultra-premium Zaven by G.P.Grant—every cigar offers its own distinct experience.
Conclusion
The choice between premium handmade and machine-made cigars ultimately depends on personal preference. Fine handmade cigars offer superior craftsmanship, slower burn rates, and richer flavors, making them the preferred choice among connoisseurs. Meanwhile, machine-made cigars provide affordability and accessibility, albeit often at the cost of quality. Whether you prioritize tradition or convenience, understanding these distinctions can help you choose the best cigar for your taste.
