I agree, but why would a 6x60 be easier to roll and cost less in packaging than a 5x50?
Good question. From my understanding, it has to do with volume and size. I have kids so I'll use playdoh as an example. Trying to roll a thin roll of playdoh and have it come out even is much harder than trying to roll a fat roll of playdoh. The fatter the roll, the less noticeable the inconsistancies are in the roll. As you get thinner, you'll notice even tiny discrepancies in width, and trying to fix or fill those tiny spots is much harder.
I assume the same thing is true with thin cigars and fat cigars.
Also, I was looking at retail prices for a single cigars to try to eliminate some of the other cost drivers.
The problem is you can't extrapolate that from a retail price because the tobacco leaf is only a portion of the cost, and not the most significant.
A good case of this is Liga Privada. Steve Saka and JD have claimed that they price based on a fixed margin, meaning they want to make a similar margin on all their cigars, regardless of cost. If you look at the MSRP, an L40, a Feral Flying Pig, and a UF-13 all retail for about the same price, despite the fact that they're all different sizes and use different volumes of tobacco.
Additionally, large and small cigars in the same line are often blended using different ratios of tobacco, and not all filler leaves are created equal. So, sometimes adding additional filler doesn't mean adding much cost at all.
Furthermore, often the smaller RG cigars cost
more to make, as (among other things) the rollers need to be more experienced, and there's more waste created (pieces of wrapper and binder leaf, for example). However, many cigar companies charge more for the larger sticks because the perception of the consumer is that larger must mean more expensive - people expect to pay more for a longer or larger experience. The higher margin made on the fatties helps offset the smaller margin on the thin ones.
I am just speculating and was wondering if anyone has smoked a 5x50 and a 6x60 of the same line and made the comparison of strength and flavor.
Yeah, I've done it in several cigars, most recently the Undercrown and the MUWAT. The 6x60 is often easier to smoke, and can handle more vigorous puffing without being harsh, but the flavor profiles can be muted. The thinner versions are almost always a little more sensitive to how their smoked, but the flavors shine brighter.