The Art of Craftsmanship: How Cigar Boxes Are Made

Table of Contents

Introduction

Cigar boxes are more than just packaging; they are an integral part of the cigar experience.

The presentation of cigars, from their bands to their boxes, plays a crucial role in attracting customers and enhancing the overall smoking experience. This article delves into the intricate process of how cigar boxes are made, highlighting the craftsmanship and attention to detail that goes into creating these beautiful containers.

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The Importance of Presentation

The significance of a well-crafted cigar box cannot be overstated. Carlito Fuente, a renowned name in the cigar industry, emphasizes the importance of presentation in the overall cigar experience. A beautifully designed box not only protects the cigars but also enhances their appeal, making the smoker feel special and valued.

Crafting the Perfect Box

The Fuente Example

To meet the high standards of presentation, the Fuente company built a 50,000-square foot factory in Santiago, Dominican Republic, dedicated to making cigar boxes. This factory produces over 40,000 boxes weekly, totaling more than two million boxes annually. The meticulous attention to detail in each box mirrors the craftsmanship of the cigars themselves. Fuente boxes, such as the Opus X and Ashton Symmetry, are known for their vibrant colors, ornate clasps, and rounded corners, indicating the premium quality of the cigars inside.

In-House Manufacturing

Many cigar companies, following Fuente’s example, have started making their own cigar boxes to ensure quality and consistency. General Cigar Corp. has several factories, including one in the Dominican Republic, to manufacture the most intricate boxes. Nestor Plasencia also produces boxes for his cigars and other companies in Danlí, Honduras. While Davidoff does not make its own boxes, it collaborates with a nearby company with over a century of experience in crafting cigar boxes.

Types of Cigar Boxes

Cigar boxes generally fall into two categories: dress boxes and cabinet boxes.

Dress Boxes

Dress boxes are typically made from cedar plywood and are often hand-made. These boxes are covered with artwork and are stapled at the edges. They provide a visually appealing and protective enclosure for the cigars.

Cabinet Boxes

Cabinet boxes, made from solid cedar or mahogany, are considered more premium. These boxes usually hold cigars in rows and are designed to allow better air circulation, which aids in the aging process. The classic cabinet-style box holds 50 cigars tied with a ribbon, without cigar bands, maximizing space and airflow.

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The Manufacturing Process

Sustainable Sourcing

The process of making a cigar box begins with sourcing high-quality timber. For example, Perdomo Cigars purchases Spanish cedar from a sustainable supplier on the Atlantic coast of Nicaragua. For every tree harvested, three more are planted, ensuring a sustainable practice.

Preparing the Wood

Once the timber arrives at the factory, the bark is stripped, and the wood is cut into rectangular blocks. The moisture content of the wood is measured to ensure optimal levels for cutting and shaping.

Precision Craftsmanship

State-of-the-art machinery and lasers are used to cut and sand the kiln-dried wood with precision. The direction of the wood grain is carefully matched to ensure consistency among the panels.

Fine Finishing

Nick Perdomo describes their boxes as pieces of fine furniture. The wood is sanded multiple times to achieve a smooth finish. The first coat of lacquer is applied, followed by hand-staining. After drying, the box is sanded again and receives a second coat of lacquer. This meticulous process ensures that the boxes are uniformly finished and visually appealing.

Adding the Final Touches

Lacquering and Drying

The final coat of lacquer is applied in a controlled environment with air filters to ensure a dust-free finish. Some manufacturers use artificial lights to aid the drying process, although natural drying is often preferred for a more even finish.

Artistic Decoration

The final step in the process involves adding artwork and any additional decorations. This can include branding, intricate designs, and other embellishments that make the cigar box stand out.

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Conclusion

The craftsmanship and attention to detail that go into making cigar boxes are a testament to the artistry involved in the cigar industry. From sourcing the finest materials to precision crafting and finishing, every step is carefully executed to produce boxes that not only protect the cigars but also enhance their presentation. Whether you prefer the elegance of a dress box or the premium feel of a cabinet box, the quality of the box reflects the quality of the cigars inside. The next time you enjoy a fine cigar, take a moment to appreciate the craftsmanship of the box that held it.

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