Although a machine-rolled process allows the industry to manufacture at a considerably higher rate than traditional rolling by hand, there are inherent complexities of processing products made with natural tobacco. In this regard, the vast majority of machine-made cigars are done with a natural filler, bunched with a homogenised tobacco leaf before being wrapped in a natural tobacco leaf.
Not surprisingly, also the mechanised processes employed in cigar and cigarillo manufacturing are significantly more complex, much different and slower than those used in the mass volume manufacturing of cigarettes. Automated cigar and cigarillo manufacturing requires specific machines for bobbinising, bunch making, over-rolling, cutting, packaging, and box finishing at much smaller numbers.
Despite using mechanised processes, several operators are necessary to manage the production of machine-rolled cigars. Once approved, the cigars will be passed on for mechanised binding, wrapping and final packaging either as individually sold, exclusive cigars or in one of many different, particular packages.
As packaging also has to communicate regulatory obligations, a final step applies labelling on country-specific elements such as public health or taxation information, often through the use of stickers.