From brass bars into faucets
The production of faucets is partly automated, while most work
stages are still carried out by hand. Briefly put, the work stages
are core building, casting, sawing, machining, grinding, polishing,
chrome-plating, assembly and testing. However, a lot of work has
already been done before these: a new product has been designed and
its production has been simulated on a computer, after which
casting has been tested and adjusted until it is perfected. Makes
all the tools, shell moulds and core boxes required during casting.
Casting starts from brass bars and cores
The most important ingredient in faucet production is brass, from
which the faucet body is made by means of casting. The core is a
central part of the production process, as it forms water channels
in the faucet body during casting. A solid core is made from fine
sand and a hardening agent by heating in a core box.
The core is made from fine sand and it forms the waterways for the
faucet body during casting
During casting, the shell mould is dipped into a water and graphite
solution. The caster (the person responsible for casting) places
the cores inside the mould and removes any loose sand from the
shell mould using compressed air.
The cores are placed inside the mould.
The mould is sealed and placed in the blazing hot casting chamber
of the casting furnace. Three tons of molten brass flow from the
casting furnace into shell moulds. The core maintains waterways
open inside the mould, to which technical components are installed
and through which water flows through the faucet.
Molten brass flows into the shell moulds.
After brief cooling, the caster uses tongs to move the cast to cool
down. Next, the core is removed from inside the faucet body by
whirling it in a mill equipped with metal balls.
Faucets are sawn and ground to their final shape
Cooled faucet bodies delivered from the foundry are separated from
each other by sawing, and any parts that were necessary during
casting but not included in complete faucets are removed.
Brass faucet bodies ready for further processing
Faucet bodies are then placed on a conveyor belt, which moves them
through automated machining, grinding and polishing processes. The
initially produced rough surface is made smooth during a
complicated grinding process. The ground metal surface is polished
flawless. Finally, employees inspect the level of quality visually
and by hand. Small batches of special products may be ground and
polished manually. Minor repairs may also be carried out by hand.
Small batches of special products and repairs are still done by
hand to ensure flawless result.
Chrome plating allows no errors
Finally, faucets are chrome-plated. Chrome makes the surface hard,
shiny and wear-resistant.
After polishing, faucet bodies should no longer be touched by bare
hands to avoid having finger prints in the chrome-plating.
Technical components are installed inside the faucet body
Makes the components installed inside the faucet body itself. These
regulate the water flow and temperature, among other things.
