They harden as they cool. A machine pushes them out of the mold. After that, the crayons are run through a labeling machine. Each label wraps around twice. This makes the crayons stronger. Then workers pick up the crayons. The collator takes one crayon of each color.
It puts them into boxes. Now boxes of crayons are ready to be sent to stores. Soon, kids will use the crayons. Larry Chickola is the vice president and chief corporate engineer of Six Flags theme parks. Growing up, I would visit Cedar Point amusement park. Crayons melt at degrees Fahrenheit 40 degrees Celsius.
The mixture is heated to F 82 C. The liquid is poured into a preheated mold full of hundreds of crayon-shaped holes. Cool water 55 F, 13 C is used to cool the mold, allowing the crayon to be made in 3 to 9 minutes. A single mold makes 1, crayons at a time, weighing a total of about 40 pounds. The operator uses hydraulic pressure to eject the crayons from the mold.
Earlier mold designs used a hand crank to push up the crayons. The just-molded crayons are then manually quality checked for imperfections and inspected for broken tips. The excess wax from the mold and any rejected crayons are recycled to be re-melted.
More than crayon colors are possible. See the new page to learn how they make Crayon labels. The label machine wraps the crayon twice to give it strength. Bare crayons are fed from one hopper while labels are fed from a separate hopper. Label The crayons feed into a big metal drum, where they get labels and adhesive. Then the crayons are stored by color in inventory boxes.
Then operators feed the sticks into funnels, which drop one of each color onto a platform so a mechanical arm can sweep them into a box. Scan A laser etches a date code on the cardboard, and a metal detector makes sure nothing but crayon is inside. At the Crayola factory, a single silo holds as much as , pounds of paraffin wax. Even more impressive, the company uses almost one silo of the wax every day to produce those millions of crayons. When it arrives at the manufacturing facility, the paraffin wax is colorless.
Every color of crayon produced in the factory starts with that same colorless wax, which eventually gets a specific pigment added to produce the final color.
The paraffin wax goes through a pipe system that carries it from the silos into the manufacturing area of the plant. It goes into the large mixing kettles, which are typically on the smaller side for controlled production with a focus on quality. The mixing kettles are heated to degrees where the wax is mixed with the pigments. Then, the wax is cooled by about 55 degrees to begin the cooling process.
Crayon manufacturers typically produce one color at a time on a particular manufacturing line. Large companies like Crayola have multiple production lines running at one time, which means they can produce multiple colors on the same day. The color comes in the form of a powdered pigment, which is typically produced specifically for the crayon manufacturer for consistent, custom colors.
This is due to the petroleum, or oil, base used to make paraffin wax. A powdered pigment may initially be made with water, but the pigment gets dried out and put through filters to remove any remaining water. This leaves behind chunks of pigment, which are kiln-dried. Those chunks get combined with other pigment chunks to create a specific color. These combinations are very specific to produce consistent hues.
The combined chunks of pigment are then pulverized to create the fine powder needed to go into the crayon mix. How colors are mixed to make crayons varies depending on the specific manufacturer and crayon color. With over crayon color options available, manufacturers come up with many different pigment combinations. Crayon manufacturers use very precise, premeasured amounts of the powdered pigment so each batch of a particular color of crayon turns out the same. The amounts of powdered pigment that go into a particular crayon batch often vary by color.
Lighter colors tend to require less pigment than a darker color such as black. Yellow crayon wax, for example, only needs a ratio of a few pounds of pigment to pounds of paraffin wax. A darker crayon would have much more pigment powder in the mix to produce a consistently dark, opaque color. The percent of pigment added by weight typically ranges from 0. For some colors, a single pigment goes into the mix.
Other crayon colors require a mixture of several different pigment powders to achieve the specified color. This is all predetermined with specific ratios of each pigment color for consistency. The color gets added into the kettle with the melted paraffin wax.
The mixing system integrated in the kettle combines the pigment and wax, dispersing the pigment powder evenly through the mixture. At this point, any other additives also go into the melted wax.
The quality control procedures for a particular crayon manufacturer dictate the order that those ingredients go into the mix. The mixing process for crayons is crucial to the success of the finished product.
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