Dyes are mixed with liquid polyester to get buttons for desired color. Chemical catalyst is also added to harden the polyester. 1% wax is added to shining and easily removal purpose.
2. Pouring into the cylinder
RPM 250 After the dye is mixed, the liquid polyester (prepared mixture) is then placed into a large rotating metal cylinder made of steel and lined with chrome poured into a metal beaker Manufacturing process of Button: 3. Hardening the sheet As a result of reaction with the chemical catalyst, polyester, rotating in the cylinder, begins to harden. As the wax rises to the top of the sheet, and also sinks to the bottom, the hardening polyester is held between two layers of wax. After about 20 minutes of rotation, the polyester sheet changes from its liquid state to a powdery solid sheet having consistency of stale cheese 4. Cutting the sheet When the sheet has reaches the proper hardness, the drum stop and sheet need to cut vertically. The wax makes it easy to remove from the drum. The sheet is still not so hard. The top layer of the plastic is rolled and placed to a Blanking Machine. Manufacturing process of Button:
5. Cutting/punching the blanks
The blanking machine moves the polyester sheet on a conveyor belt. As the sheet passes along the belt, circular shaped cutting dies (made of steel) descend over it and punch out button-sized circles, known as blanks.
Standard size of buttons is
specified and the dies are prepared accordingly, dies with different diameters according to the requirements can also be made and loaded into the blanking machine. After the blanks are cut, they fall into a channel, and the punched out Manufacturing process of Button:
6. Cooling/Curing the blanks
As the blanks are still hot, so need
a cooling process, having hot and cold baths. If we directly cool it on air, the blanks may brittle. So need hot and cold treatment. The blanks are placed into a tank of hot water, which is heated at 110°C. As the water slowly cools, the polyester blanks get hardened. Curing time is 10 to 24 hour depending of kinds of buttons. Then Use hydro machine for drying buttons Manufacturing process of Button: 7. Styling the blanks/ Turning (hole making and designing of buttons)
The final stage of button making involves
designing the buttons according to the buttons supplier’s specification. Different cutting tools are used for making different shaped buttons such as beveled edge, or a slightly concave button. The cutting tool is placed in the cutting machine and the buttons are poured into a hopper at the top of the machine. The blanks fall into a holder where they are clamped tightly and moved toward the cutting tool. The spinning blade comes out and cuts the button and then retracts. Then the buttons moves beneath a set of drills, which make the holes in them. The design specification allows two or four holes, and also the diameter of the holes and the distance between them. After the holes are Manufacturing process of Button:
8. Polishing the buttons
Polish of buttons is done to make buttons shiny. Buttons are kept into tumbling drums that contain water, abrasive material, and a foaming agent. The drums spin for about 24 hours. The buttons bounce around in the drum until they are smooth and shiny. Lastly, the buttons are washed and dried by hydro 9. Finishing machine. the buttons Button qty per drum is 30kg. (Quality Checking and Packaging)
After the buttons are polished, they are put on a
conveyor belt and visually inspected for faults. Quality control inspector checks each button for defects and removes any cracked or miscut buttons. The perfectly made and finished buttons are then packaged for sale and send to ware house for