What makes the blanks for pencils. Making a wooden pencil with their own hands

Secrets of complex production of simple items.

While the technical progress with a mad speed changes the world, expanding his borders and our ideas about him, we sometimes stop noticing ordinary things that surround us everyday.

Despite the simplicity of its design, which almost does not change here for several centuries, the pencil is not completely simple in production. One of the last pencil factories in America General Pencil has been creating from graphite, wood, wax and paint items that can be found in all art and stationery stores of the country: simple and watercolor pencils, carbon for drawing, pastel chalk and others.

Pencil rods are made from a mixture of graphite powder and clay mixed with water, which mix for several hours. The finished mass is passed through the hydraulic press and cut into the blanks of the same length. All this is a bit like cooking noodles. Different thickness of the griffel is achieved by using different diameters of stamps.

Billets are still soft and flexible, because they remained water. They are heated in the furnace in order to harden. The longer the heating time, the higher the hardness of the future pencil.

By the way, in Russia there are three types of hardness (soft, hard and firm-soft), in Europe - four (there is an intermediate option between solid and firmly-soft), and in the USA - already five (another super hardening pencil option is added).

Grief firing depending on the desired gradation is carried out at a temperature of from 800 to 1200 ° C. Graphite sands use to evenly distribute heat when heating the griffel in the furnace. After sand is poured for subsequent processing.

After heating, the rods are placed in such perforated banks and dip 12 hours in a container with hot wax. Wax particles fill out all the pores in the rod and contribute to a softer slide of the griffel on paper. By the way, the means used for the so-called gifting bath also affects the hardness of the pencil. Wax is used for the hardest stoves, for seven-way - stearin, and for soft - confectionery fat.

Cooled rods. A little later they will be put on wooden blanks, glue and form a pencil. As it looks, it will be seen on the example of pasteels below.

The basement, where workers handle graphite, is the universe of gray: people in gray shirts with gray hands feed gray ingredients with gray machines. The man depicted in the picture below works at the factory for 47 years. The car behind it processes graphite and charcoal.

Other factory premises are pleased with brighter paints. Colored (pastel) rods are made in the same way as graphite, with the use of white clay (kaolin), and pigments are added instead of graphite.

The machine that turns pastel into soft tubes resembling spaghetti, usually handles one color for a whole week. Then it is carefully cleaned to prepare for another color. White chalks, one of the company's branded products, are made in a special car separately from the rest of the colors.

In the photo, fragile colored rods made by hand are carefully embedded in cedar strips.

Graphite rods are stronger than pastel, so they lays a special machine in the workpiece.

The second layer of wood completely closes the pencil's griffel. The resulting "sandwich" is fasten with glue, clamping in the press and dried.

After applying paint, pencils are returned by the coating conveyor with the following layer (they are usually four usually).

Pencils for editors are usually sharpened on both sides: one leaves red marks, the other is blue. Griffie inside - two different colors, and the paint is also two. Stands with pencils that you see will soon be turned over and dip in the blue paint.

Conventional pencils, sharpened on the one hand, can be equipped with erases or simply plug tips.

Metal rings with the help of which erases are mounted on pencils are called ferrums.

On this conveyor, ferrula and eraser are connected to pencils.

Smooth metal caps are installed on some pencils - without ferrula and elasty.

Sharpening of finished pencils occurs with high-speed grinding tape.

Finally, pencils are cleaned, pack and pack. Finished products are sent to the store to become useful and reliable assistants of their owners.

Pencils we use starting from kindergarten. But few of us know how pencils do what wood is used for this purpose. It is noteworthy that the creation of these stationery is performed at each factory in its own way. But there are general moments that are fundamental for the production process.

What tree?

A classic wooden pencil has an important component - wood, from the quality of which the operation of this accessory depends. It is clear that not every tree is suitable for these purposes. In the past in the industry, Wood Vedizhnsky or Red Cedar, which belongs to the genus of juniper. Long fibers, no bitch, ease of processing - this is what attracted attention in this material. But in view of the high costs, European and American brands producing pencils began to use the wood of California cedar. Moreover, it is based on high-quality products that are used in graphic and artistic purposes.

In most cases, pencils are made from alder, linden, pines, California and Siberian cedar, as well as such a rare tree like Jelutong. What tree do pencils in our country? In most cases from alder and linden, which in Russia has a huge amount.

Olha is not the most durable material, but it has a uniform structure, which makes the processing process easier and retains natural natural color. As for Linden, it meets all operational requirements, and therefore is used in the production and cheap, and expensive pencils. Due to the good viscosity, the material firmly holds the griffel.

The material is unique to create pencils - cedar, which is widely used at factories in Russia. It is noteworthy that not healthy wood is used, but copies that no longer give nuts.

Rod: What basis?

Pencil production is carried out using a special rod. It consists of three components - graphite, soot and yals, which are often added organic binders. Moreover, graphite is a permanent component, including color, since it is precipitated that he leaves the trail on paper.

Rods are created from a thoroughly prepared mass, which has a certain temperature and humidity. It is important that the mixture does not drive, as it affects the wear of the equipment. The dough-smeared with a special press is molded, then passed through the equipment with holes, which makes a lot of noodles. This noodle is formed to cylinders from which rods are squeezed. It remains only to hide them in special triggers. Then the rods are subjected to burning, and after it is made of altitude: the resulting pores under pressure and at a particular temperature are filled with fat, stearin or wax.

How do color pencils do? Here, the principal difference has, again, the rod, which is made from pigments, fillers, grain components and a binder. Here the process of production of the rod is as follows:

• made rods are stacked in special grooves on a skid and covered with a second plank;
• both powder glue PVA glue, while the rod should not stick;
• ends of glued skins are aligned;
• the preparation is performed, that is, the addition of fat in the already existing mixture.

It is noteworthy that the production of pencils is carried out taking into account the consumer properties of products. So, cheap are created from wood not the highest quality, exactly the same is not the highest quality - and the shell. But pencils that are used for artistic purposes are made from high-quality wood, which has a double sizing.

Stage of wood preparation

The production of pencils is conducted from well selected wood, which is processed to obtain bars. Be sure to move the bars along the length of the pencil, and you need to take into account the allowances, as the destruction of the material happens. A special multi-step machine is performed by cutting bars on the plank, which are impregnated with paraffin in special autoclaves. This procedure helps to improve the mechanical properties of the future product.

Depending on what a pencil is made, then its sharpening will be performed. It is believed that the neat chips turns out if the products are made of pine wood, linden or cedar. In addition, it is important that the griffel can be qualitatively pricked with a pencil even when falling will not break.

What is the shell?

The shell depends the simplicity and beauty of the pencil. So they make pencils from the tree, then it must meet the following requirements:

1. Softness, strength and lightness: during operation, the shell should not break or crumble, as well as the entire case.
2. Do not flavor under the influence of natural factors.
3. Have a beautiful cut - smooth and brilliant, while the chips itself should not break.
4. Wood must be resistant to moisture.

What equipment?

Pencil production is carried out using diverse equipment. For example, cleaning clay, from which a graphite rod will later be created, requires special mills and crushers. The processing of the mixed test is carried out on the screw press, where the rod itself is formed from the dough with three different gaps. For the same purposes, a die is applied with holes. Drying of wooden blanks is performed in where products are rotated for 16 hours. With a good drying, wood gains a level of humidity to a maximum of 0.5%. As for color pencils, they are not subjected to thermal treatment due to the presence of fillers, dyes and grain components in them. On the special machine, the pencil strikes are performed in length.

Dried

How do pencils? In the production process, dryness plays an important role. It is performed in special wells with the help of machines, and the plate is stacked so that dryness is as efficient as possible. In these wells, the drying is performed about 72 hours, then the rolls are sorted: all cracked or ugly products are rejected. Selected blanks are enjoyed by paraffin, calibrated, that is, special grooves are cut on them, where the rods will be located.

How do pencils on production further? Now the milling line is used, on which blocks are separated on pencils. Depending on what form of the knives are used at this stage, pencils are obtained or round, or faceted, or oval shape. An important role is played by the fastening of the griffel in a wooden case: this should be made firmly and reliably, which reduces the risk of elements of the elements of the griffel. Elastic glue, which is used for a ligament, makes the griffel stronger.

Features of the coating

Modern simple and color pencils are presented in a huge variety of designs and colors. Since they make pencils in the factory, here you pay close attention to each stage of production. Coloring is one of the important stages, as it must meet a variety of requirements. For finishing of the surface, the extrusion method is used, and the end is separated by dipping. In the first case, the pencil passes through the primer, where it turns over at the end of the conveyor to apply the next layer. Thus, a uniform coating is obtained.

Quality color: what depends on?

The quality of the color depends on how much the requirements are associated with the requirements themselves, the primer machine is adjusted correctly, whether the timing of the drying of the pencils on the ribbon is met. Any pencil factory uses quick-drying compositions that form a solid, durable and elastic film on the surface, well-adhesive with the wood surface.

Coloring is performed by special primer paints that have a certain viscosity and contain pigments. If the pigment part is large, it will reduce the glitter of the film and will require further application to the surface of nitrolac. Even simple pencils are lacquered using nitrocellulose glossy varnish.

If the pencil of dark shades, it is painted at least in 5 layers and in 4 layers of varnish. To achieve light shades, a combination of 7 layers of paint with 4 layers of varnish is used. At the same time, it is important for a uniform and neat coating that the surface has a maximum of 18 layers. Staining the end parts of the pencils is performed in the ochanal machine in which the frame is lowered with pencils located on it.

Right pencil

Depending on how pencils make and from which materials, their frames can vary. In the traditional version, the stylus has a wooden frame, but the modern market offers a wide selection of products in plastic, lacquered and even a paper case. On the one hand, it adds to them beauty and unusualness, on the other, when falling from such pencils, little remains.

Already after painting, pencils are subjected to finishing finish. For this, various stamps and foils of different colors are used. The processing process is called thermostatic.

What hardness?

All colored and simple pencils are distinguished by the stiffel hardness, which is reflected in their marking. It is necessary to choose them like this: the more dense and solid paper, the more solid there should be a graphite rod. But too solid graphite can damage the paper. In Russia, you can buy pencils of the next labeling:

1. M - soft.
2. T is solid.
3. TM - firm-soft.

About marking should be known when choosing pencils for creating drawings or drawing in the appropriate technique.

Features of color pencils

From which pencils are made simple, we have already figured out. Now you need to understand when and how it appeared it was known that the first products with color grydiem appeared back in 1820, the truth, who invented them and remained a mystery. Based on color, the combination of connecting substances, color pigments and fillers is based on. Kaolin adhesive adopted as a connecting substance, at the expense of the griffel. Well crushed high quality colored materials are used as colored pigments, and the pigment may be an organic or inorganic base. Color pigments themselves are created on the basis of materials that have resistance to burnout under the influence of sun rays and environmental safety. To date, pencils are produced in 36 color shades, respectively, the international scale of the shades of Pantone. As for fillers, the kaolin and chalk are used in this capacity, which are under thorough grinding.

Pencil has become a completely indispensable thing in a person's life. Starting from a kindergarten, he accompanies a person at school, university, at home and in the office. Finally, it is simply necessary when the crossword puzzles are solved.

The total cost of a complete set of the necessary equipment, which is required in order to organize the average for the power of the pencils, begins with two million rubles.

There is so much a used line in full configuration. To this, it is necessary to add the cost of renting an industrial premises, which for a small workshop should have an area of \u200b\u200bat least fifty square meters, as well as for the purchase of raw materials, wages of workers and utility costs.

The exact terms of payback of such a business, like the production of pencils, is quite difficult to call. First of all, they depend on the volume of products and from the starting (initial) capital.

In addition, during the initial time, all the profit gained is most often inserted into market promotion, since competition among companies producing not only simple, but also color pencils are quite high, especially among Western factories, with which domestic compete, due to high quality produced by products. However, many specialists have a minimum payback period for small enterprises call two or three years.

Technology

Production of pencils is carried out according to the following technologies. Pre-wooden blank is thoroughly polished, then fourfold printing of the case is performed, since a decrease in the number of passes leads to insufficient smoothness of the surface. Soil, filling all irregularities in the tree, provides him with strength for subsequent coloring. Then the case is painted.

Saving at each stage of the technological process, though reduces the cost of the produced pencils, but leads to a deterioration in their quality. In addition, the ecology of the final product, depending on the composition of the varnish, covering the body of the product. It is known that children, and sometimes adults, very love to nibble writing accessories. Therefore, the varnish must have an aqueous basis and do not contain harmful chemical solvents.

What materials are needed

For the manufacture of simple pencils, it is not only the composition of the griffel - clay and graphite. It affects the quality of wood. From how the manufacturer of a pencil is carried out, it depends on how the finished product will later look like, and how easy it will be hurry. Cheapest products intended for non-sensible buyers are produced from alder. Wood in such pencils and is unsightly in appearance, and has gray, and does not very tightly holds the stylus.

Wood

The most common breed of wood, which quite satisfies all the requirements for raw materials when the production of pencils is organized, is Lipa.

In addition, it grows almost everywhere and is quite viscous material to hold the rod tightly.

More expensive and, accordingly, more expensive pencil is a product made of pine, cedar, as well as the tropical tree of Jeldong, the production characteristics of which are very high. But the most valuable is raw materials from California cedar. Stationery made from this tree are very expensive and are considered prestigious.

Griffel

Initially, a pencil rod is made from clay with graphite. It is precisely the proportions of these components and determine the hardness of the grief. At the same time, the more graphite, the softer will be the structure. And vice versa, if there are many kaolin in the chance, respectively, the composition of simple pencils will be more solid.

It is very important how the stationery turns. Neat and smooth chips ensures wood quality. At the same time, it is very important that the rod is located in the center of the housing, because, if this technology for the production of pencils is broken, the griffel when sharpening is cut off unevenly.

In addition, to prevent the rod of the rod in the event of a falling pencils, many of the manufacturers of stationery use the so-called sv-sizing of the griffel. In this case, it breaks only on the sharpened tip, and not inside the case.

Procracuracy stage

This third and also a very important element in production does not allow less than seven layers of pencils to pencils, otherwise the wood will turn the burrs. Famous companies that are seriously suitable for their product quality, usually begin with twelve layers. Whereas the production of pencils having a high price involves staining to eighteen, sometimes up to twenty times. Then this stationery product will have a high glossiness and literally a mirror surface.

Equipment

Equipment for the production of pencils diverse. For cleaning clay, it is necessary to have a crusher and special mills. The clay, divorced in water, is poured with liquid glass to save it from extraneous impurities, including sand. Then, according to the recipe, graphite and the binder is added, which is made from starch. The rod mass must have a certain temperature and humidity. The slightest deviation leads to a damage of raw materials.

Thoroughly whipped "dough", mixed on graphite and clay, is sent in the screw press, where it is molded with rollers with three different gaps. As a result, the mass is crushed, becoming homogeneous. From it removed air bubbles with excessive moisture. The dough thickness after re-processing is gradually reduced from one to 0.25 millimeters.

Then the mass is passed through a die with holes, where it turns into a "noodle" like - in cylinders, from which the press already squeezes the rod with the required length and diameter. The rods are perfectly dried in drying cabinets, where continuous rotation occurs for fifteen or sixteen hours. Humidity at the finished element should not be more than half of the percent. After drying, they are calcined already in the oven in special triggers.

Colour pencils

A somewhat differently made rods for color pencils. Their composition has pigments, as well as fillers with binders and lifting substances. Clay or kaolin is the main raw material.

Each more or less large manufacturer has its own recipe for the manufacture of griffel, which is kept under a great secret. Many factories in the production of additives use dyes and wax, as well as natural fillers and binding substances on a cellulose basis.

Color pencils of thermal treatment are not passing, because the color pigments may be collapsed under the influence of high temperatures.

At the stage, when fat, giving a color trail and holding it on paper, two different technologies are used: so-called hot or cold "preparation".

In the first case, it is carried out immediately after the drying, while the griffel is wetted in hot fat. Most often, this technology is used in the production of high-quality watercolor pencils.

In 1912, in the decree of the Tsarist government, a factory was created in Tomsk, where they saw a cedar table for pencils produced throughout the country.
Today, the "Siberian pencil factory" is the only manufacturer of pencils and pencil boards from the Siberian cedar, whose wood is used for the production of pencils of the highest price category in the territory of the former Soviet Union.

How do you make pencils familiar from childhood?
The production of pencils begins with a forest exchange, where the prepared cedar is stored. Now there are more than three thousand cubes of wood. Regional authorities helped the factory in providing material and this year it is planned to produce about 85 million pencils.

"The wood, which we buy, does not come to us as a result of the barbaric logging," says Anatoly Lunin, director of the factory. - In the overwhelming majority it is a sanitary cutting of the cedar, which no longer gives a nut. Cedar grows up to 500 years, but the cones on it appear somewhere until 250 years of age, after which it begins to die, it is affected by various insects. If you cut it in this period, a new cedar will grow faster.
Until the cuts of the logs undergo mandatory training: each log need to be washed, so that the slices of the Earth or clay with the stones accidentally did not accidentally damage the saws. For this, a tree with a forest exchange is placed and maintained in a special pool with warm water. In summer, he is held here for a long time, up to twenty minutes, but in the winter it is a log in the pool until it cares - it can go to three hours. And after 369 hours or 16.5 days and 26 different technological operations from the log, ready-made pencils will turn out.


On the sawmill from the logs there are such a bar:


The production of a wooden pencil is extremely demanding on the quality of the material, only clean straight wood is in the case. And if for carpentry products, the presence of such defects, as, for example, the knots, not disastrous, then the pencil from such a tree is no longer done. Therefore, to say in advance how many pencils will be from one bar, it is very difficult.
To reduce the amount of waste, the company is looking for different ways to increase the depth of wood processing. One of these methods is the expansion of the product range. So, from a plate, which is not suitable for the production of a pencil, plan to establish the release of wooden packaging puzzles for children and money from moths. Something goes to the production of short pencils, as for IKEA shops, and a part, to produce such wooden skewers:

The resulting bar of the timber is cut into short segments, each of which is then dissolved by ten dozhek. So that all the dors are the same, they need to calibrate. To do this, they are driven through a special machine. At the outlet of it, the planks have the same size and strictly perpendicular face.

Then calibrated planks are placed in an autoclave. In its appearance, it resembles a barrel to which many pipes of different diameter are connected. With the help of these pipes, a vacuum can be created in the chamber, pump pressure and supply all sorts of solutions.


As a result of these processes, the resins contained in it are removed, and wood is impregnated (impregnated) with paraffin. To date, this is not the easiest, but one of the most effective ways to improve the important properties of the material and protect the tree from the harmful effects of the environment.

The "refined" after processing in the autoclave pencil planks remains to succeed, and then send directly to pencil production. On this, the process of making a plank can be considered completed. So it looks like a plank after processing in the autoclave:

- The basic principle and technology of production since pencils began to make, does not change, "says Anatoly Lunin. - All processes in our factory are well debugged. The equipment modernization is expressed in replacing some nodes, or the transition to more economical motors, the use of new cutters. Some new materials come, we change something in acceptance and evaluation, but the technology itself remains unchanged.


The finished plate enters the White Pencil shop, where the grooves are cut in it on the machine, where the rods will then be laid (the word "white" in this case means that the pencil at this stage is not yet colored). Software are served on one side of the machine, along the way their surface is grinning for gluing, the deepening is cut in a special cutter. On the Middle Edge, the table of spaces are automatically stacked. The thickness of the polished plate with sliced \u200b\u200bgrooves is 5 mm, which is equal to half the thickness of the future pencil.


At the next stage of the plank, glue in pairs to each other so that one pencil block turned out.


The machine smoothly serves the first plank and lays the rods in its grooves. Following this, the second planker, already smeared with water-soluble glue, and gently falls on the first one from another device. The resulting pencil blocks are clamped in the pneumatic press and tighten with clamps.

If the plate at the factory is made independently, then the rod, mostly buys in China. There he began to produce in the "dry" technology, which does not require firing in the furnace at high temperature.


As a result, the cost of the rod was so low that the lion's share of the pencil producers switched to such a rod.

In order for the pencil's griffel does not break inside the housing, the factory uses the technology of additional crossing the rod with a special adhesive system. After this operation, glued blocks are kept in a special drying chamber for several hours.


In the chamber is quite hot. Hot air is injected with a fan, maintaining the temperature of about 35-40 degrees. Wood need to dry well so that later the pencil in one pass is smooth and received the right geometry. A pencil with a "simple" gryphant dry here at least two hours, and color - at least four. Due to the fact that color contains more fat substances, it needs more time to dry.


After this time, the blocks disassemble, laid in the trolley with an indication of all further parameters and are sent to the next machine, which will divide them into separate pencils.
With its form, the machine is similar to the one that makes grooves in skiing, but he has its own features. Billets are placed in the boot hopper.

They pass through the transport nodes, they are thrown away, they turn off and on the output it turns out the usual wooden pencil, just not yet painted.

A double milling cutter that shares the blocks, sets the form of a future pencil, and this is done all in one pass. It is from the type of cutting cutter profile, it depends on how the pencil is hexagon or round.
Most recently, the factory mastered the production of a triangular pencil. It turned out that the demand for such a form is growing. Buyers attracts ergonomics and the naturalness of the location of the fingers on the edges, which, of course, makes it easier for learning the letter of children.


Next to the machine is the desktop desktop. Its task is to sort out the pencils made, select "suitable" and separate defective. The defects include chips of the rod on the end, roughness, wood burns and the like. Above the table hangs a memo with marriage standards. In each table, 1440 pencils are placed on the table.



Sorted pencils on a special elevator rise to the next floor, where they will be painted.

The paint is purchased in dry form and bred to the desired density in the laboratory of paints. Painting itself occurs fast enough.

The device continuously pushes painted pencils to the conveyor. The length and speed of the conveyor belt is designed in such a way that the pencil dried while moving on it.


After reaching the opposite end of the conveyor, the pencils fall into one of the three receivers, from where they go back to the next coating.





On average, each pencil is covered with three layers of paint and two layers of varnish - everything depends on the customer's desire. Parades can also paint in almost any color. The factory produces sets of six, twelve, eighteen and twenty-four colors. Some pencils are covered only with varnish.
After painting, pencils are sent to the finishing workshop. In this place they acquire that final form in which they reach the consumer. A stamp is applied to the pencils, the eraser is worn and sharpened.
The methods of applying stamps are quite a lot, but on the "Siberian pencil factory" make it with the help of foil of different colors. This method is called thermostatization. The working part of the machine heats up, and the stamp through the foil is transferred to the pencil - so it will not break out and pain your hands. The stamp itself can be any, it is specifically ordered by the engraving. Depending on the complexity, it takes about five days.




On a part of the pencils, if necessary, worn eraser.


The last operation is sharpening. Pencils are raised on the grinding skirt, put on the drum and moving at high speed. This happens very quickly, literally in seconds.






In addition to sharpening the machine can be configured to perform rolling - processing the reverse end of the pencil under a slight inclination. Now pencils are ready for packaging, they are sent to the following room. There, the pencils are collected in the set, fold into the box and send to the consumer.


Packaging for the desired number of pencils is printed in Novosibirsk. It enters a flat form, so at first she gives the volume. Then through the complete machines, the required number of pencils are laid out in a given color scheme. A special machine allows you to collect a set of twelve colors. At the end of the pencils lay down on boxes.








To the question, whether the factory does not plan, following the example of Chinese enterprises, switch to the production of a pencil from cheaper wood or plastics Anatoly Lunin admits:
- I thought to try to make an economical pencil from low-grade aspen, but this is another technology, and let the Chinese do it. I'm more interested in the topic of increasing the useful way out by improving the quality of wood processing. And from the point of view of ecology, it is better to produce anything from renewable raw materials. The plastic pencil never rotates, and the wooden for several years will be completely decomposed.
It remains only to wish that in the age of global computerization there is a simple wooden pencil.

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