Drew Estates Flying Pig rolling photos

T.G · 01-19-2011, 05:41 PM

Over in Stephen's (zappaFREAK) review thread of the Flying Pig, Dave (Dave128) and I ended up talking about some things regarding the rolling of these cigars, and I told Dave I would post some pictures of the procedure, but I wanted to take the discussion over to it's own thread as not to completely jack Steve's thread, so, here we go...

First off, I'd like to apologize for the quality of some of the photos - there were a number of us crammed into a very tiny walkway between benches and each of us was trying to simultaneously listen to Jonathan, smoke a cigar, not burn the BOTL next to you with your cigar, watch what was going on and take some photos.

Here is the cigar being bunched and the capote (binder) being applied. As you can see, it's really not that different from any other cigar, EXCEPT for the final step before it goes into the mold. As seen in the fourth photo, the bunchero uses a loop hook, something resembling a very thin crochet hook or loop. He will stick the loop about 1/4" into the filler and then yank it back out, which removes a bit of the tobacco leaf. He'll do this in a circular pattern just in from the edge a bit and then a few stabs in the center. He then flips the cigar over and does the head. This allows the cigar to fit into the mold and be pressed with the rounded ends.

T.G · 01-19-2011, 05:42 PM

The application of the capa (wrapper) isn't really that different from any other figurado except for the extra wraps at the foot and the tail, which the rollera can be seen creating here.

loki · 01-19-2011, 05:42 PM

nice pics, just wish i enjoyed the cigars more

Pat1075 · 01-19-2011, 05:44 PM

very interesting stuff there. thank you for the pictures

longknocker · 01-19-2011, 05:48 PM

Nice Pics & Story, Adam!

Thanks!

Zeuceone · 01-19-2011, 05:50 PM

Nicely done.

jesseboston81 · 01-19-2011, 05:51 PM

Excellent pictures! I really enjoy seeing gifted rollers performing their craft.

jitzy · 01-19-2011, 05:52 PM

Very cool pics thanks for posting

Kreth · 01-19-2011, 05:56 PM

Cool pics. Thanks for posting them.

Posted via Mobile Device

muhren · 01-19-2011, 06:02 PM

Love the thread and pics! very informative.

I'm curious...Has DE ever posted a video of it being done?

M

muhren · 01-19-2011, 06:06 PM

Another question!

I read through the other thread and noticed you said all buncheros were male, all rollers female. Is there a rationale behind the gender bias?

M

T.G · 01-19-2011, 06:27 PM

Quote:

Originally Posted by muhren

Love the thread and pics! very informative.

I'm curious...Has DE ever posted a video of it being done?

M

I don't think they have. I'll shoot Johnny Brooke an email and ask though.

Quote:

Originally Posted by muhren

Another question!

I read through the other thread and noticed you said all buncheros were male, all rollers female. Is there a rationale behind the gender bias?

M

Their hands.

Typically speaking, men have larger hands and much greater strength in their hands. Besides being able to hold the entire filler bunch of tobacco for a cigar while simultaneously folding the leaves, there's a lot of compressing of the tobacco that has to happen while rolling it into the capote (binder). They can also easier hold the bunch under compression mid-roll if they need to adjust the capote.

There's really no requirement for hand strength for applying the capa (wrapper) but a delicate touch, good manual dexterity and small fingers to right up to the edge of the cigar and smooth out the capa as it's applied is.

thebayratt · 01-19-2011, 06:07 PM

Cool pics!!

You should have yelled "ROLL FASTER!!!" hahaaaa
We need more piggies!!

kelmac07 · 01-19-2011, 06:29 PM

Cool stuff...thanks for sharing.

cigarlvr · 01-19-2011, 07:00 PM

Great photos thanks

wayner123 · 01-19-2011, 08:56 PM

Are those plastic molds?

T.G · 01-19-2011, 09:38 PM

Quote:

Originally Posted by wayner123

Are those plastic molds?

Yes. Plastic or a polycarbonate of some sort.

In fact, all of the cigar factories I saw that had very special, difficult, unique shapes used plastic/polycarbonate molds like that for them. DE Eggs, DE Flying Pigs and the the Padron 80th, immediately come to mind.

Most of the other stuff used wooden molds. I think it's simply a matter of what's easier or more cost effective to produce. A shape like the FP mold would be difficult to replicate exactly by hand in a wood mold, especially for as many molds as they would need, yet a standard parejo shape would be easy and inexpensive to manufacture in wood, plus, no set up costs, unlike a poly mold. In fact, the box shop at the factory could easily turn out as many wooden parejo molds as they needed on demand.

hscmit · 01-19-2011, 09:01 PM

great info

EricF · 01-19-2011, 09:22 PM

Great Pics! Thanks for sharing them!

bscottskangum · 01-19-2011, 09:25 PM

Great pics, thanks for sharing!

01-19-2011, 05:41 PM	#1
T.G Grrrrrr Join Date: Mar 2009 First Name: The Other Adam Posts: 15,557 Trading: (37)	Drew Estates Flying Pig rolling photos Over in Stephen's (zappaFREAK) review thread of the Flying Pig, Dave (Dave128) and I ended up talking about some things regarding the rolling of these cigars, and I told Dave I would post some pictures of the procedure, but I wanted to take the discussion over to it's own thread as not to completely jack Steve's thread, so, here we go... First off, I'd like to apologize for the quality of some of the photos - there were a number of us crammed into a very tiny walkway between benches and each of us was trying to simultaneously listen to Jonathan, smoke a cigar, not burn the BOTL next to you with your cigar, watch what was going on and take some photos. Here is the cigar being bunched and the capote (binder) being applied. As you can see, it's really not that different from any other cigar, EXCEPT for the final step before it goes into the mold. As seen in the fourth photo, the bunchero uses a loop hook, something resembling a very thin crochet hook or loop. He will stick the loop about 1/4" into the filler and then yank it back out, which removes a bit of the tobacco leaf. He'll do this in a circular pattern just in from the edge a bit and then a few stabs in the center. He then flips the cigar over and does the head. This allows the cigar to fit into the mold and be pressed with the rounded ends.

01-19-2011, 05:42 PM	#2
T.G Grrrrrr Join Date: Mar 2009 First Name: The Other Adam Posts: 15,557 Trading: (37)	Re: Drew Estates Flying Pig rolling photos The application of the capa (wrapper) isn't really that different from any other figurado except for the extra wraps at the foot and the tail, which the rollera can be seen creating here.

01-19-2011, 05:42 PM	#3
loki H.A.T.E Join Date: Oct 2008 Location: Pittsburgh pa Posts: 1,484 Trading: (7)	Re: Drew Estates Flying Pig rolling photos nice pics, just wish i enjoyed the cigars more

01-19-2011, 05:44 PM	#4
Pat1075 Feeling at Home Join Date: Nov 2008 First Name: Patrick Location: Lakewood, OH Posts: 755 Trading: (11)	Re: Drew Estates Flying Pig rolling photos very interesting stuff there. thank you for the pictures

01-19-2011, 05:48 PM	#5
longknocker Postwhore Join Date: Oct 2008 First Name: Greg Location: Mobile, Alabama Posts: 11,174 Trading: (82)	Re: Drew Estates Flying Pig rolling photos Nice Pics & Story, Adam! Thanks!

01-19-2011, 05:50 PM	#6
Zeuceone You're next Join Date: Dec 2010 First Name: G Location: SoCal Posts: 1,737 Trading: (16)	Re: Drew Estates Flying Pig rolling photos Nicely done.

01-19-2011, 05:51 PM	#7
jesseboston81 CC Simple PIF Promoter Join Date: Dec 2010 First Name: Jesse Location: Londonderry, NH Posts: 2,231 Trading: (41)	Re: Drew Estates Flying Pig rolling photos Excellent pictures! I really enjoy seeing gifted rollers performing their craft. __________________ Come play in the CC Simple PIF!

01-19-2011, 05:52 PM	#8
jitzy Illusione Whore Join Date: Oct 2008 Location: Windermere Fl Posts: 306 Trading: (17)	Re: Drew Estates Flying Pig rolling photos Very cool pics thanks for posting __________________

01-19-2011, 05:56 PM	#9
Kreth Ronin smoker Join Date: Jan 2009 First Name: Jeff Location: Oneonta, NY Posts: 3,620 Trading: (14)	Re: Drew Estates Flying Pig rolling photos Cool pics. Thanks for posting them. Posted via Mobile Device

01-19-2011, 06:02 PM	#10
muhren The Cigar Artist Join Date: Sep 2009 First Name: Mike Location: Ohio Posts: 1,268 Trading: (43)	Re: Drew Estates Flying Pig rolling photos Love the thread and pics! very informative. I'm curious...Has DE ever posted a video of it being done? M __________________ Cigar Art available for sale: www.mikeuhren.com

01-19-2011, 06:06 PM	#11
muhren The Cigar Artist Join Date: Sep 2009 First Name: Mike Location: Ohio Posts: 1,268 Trading: (43)	Re: Drew Estates Flying Pig rolling photos Another question! I read through the other thread and noticed you said all buncheros were male, all rollers female. Is there a rationale behind the gender bias? M __________________ Cigar Art available for sale: www.mikeuhren.com

01-19-2011, 06:07 PM	#13
thebayratt Still Watching My Ash Join Date: Jan 2010 First Name: Shawn Location: Mississippi Posts: 1,326 Trading: (11)	Re: Drew Estates Flying Pig rolling photos Cool pics!! You should have yelled "ROLL FASTER!!!" hahaaaa We need more piggies!!

01-19-2011, 06:29 PM	#14
kelmac07 Resident Maduro Whore!! Join Date: Apr 2009 First Name: Mac Location: Newport News, VA Posts: 27,322 Trading: (218)	Re: Drew Estates Flying Pig rolling photos Cool stuff...thanks for sharing. __________________ Dom in the MLB thread "I could probably get you to wear a Yankee hat for a Maduro!"

01-19-2011, 07:00 PM	#15
cigarlvr Adjusting to the Life Join Date: Dec 2008 Location: NYC Posts: 289 Trading: (11)	Re: Drew Estates Flying Pig rolling photos Great photos thanks

01-19-2011, 08:56 PM	#16
wayner123 Country Gentleman Join Date: Oct 2008 Location: Deltona, FL Posts: 2,351 Trading: (159)	Re: Drew Estates Flying Pig rolling photos Are those plastic molds? __________________ 'It is an honor for a man to keep aloof from strife; But every fool will be quarrelling.'

01-19-2011, 09:01 PM	#18
hscmit Have My Own Room Join Date: Sep 2010 First Name: James Location: no where Posts: 2,200 Trading: (4)	Re: Drew Estates Flying Pig rolling photos great info

01-19-2011, 09:22 PM	#19
EricF Ain't Never Gonna Leave Join Date: Oct 2010 First Name: Eric Location: Miramar, FL Posts: 7,004 Trading: (116)	Re: Drew Estates Flying Pig rolling photos Great Pics! Thanks for sharing them! __________________ It might taste crummy, but at least it's huge.

01-19-2011, 09:25 PM	#20
bscottskangum Oh yeah, I'm awesome! Join Date: Jan 2010 First Name: Barry Location: Hampton, VA Posts: 681 Trading: (11)	Re: Drew Estates Flying Pig rolling photos Great pics, thanks for sharing!