Overview of Flatware Production Process

Aug 5, 2024

Notes on the Production of Flatware

Historical Context

  • Humans have made eating utensils since prehistoric times.
  • Sterling silver flatware was the norm for centuries.
  • Since the 1950s, stainless steel flatware has become the preferred choice.

Advantages of Stainless Steel Flatware

  • Durable and resistant to tarnishing.
  • Easier to maintain compared to traditional materials.

Production Process of Knives

  1. Material Preparation:

    • Starts with a thick coil of wire.
    • A heading machine cuts the coil into blank pieces, creating a head (called a bolster).
  2. Shaping the Metal:

    • A furnace softens the metal for shaping.
    • A forging press with progressive dies shapes the metal.
    • Grinding machine flattens the bolster end.
  3. Welding and Grinding:

    • The tang is welded onto the knife blade.
    • An automated grinding wheel tapers the blade and scallops the front edge for serration.
    • The thicker back end provides strength for cutting.
  4. Handle Production:

    • Higher nickel content stainless steel is used for corrosion resistance and ease of shaping.
    • Half handles are spot-welded together.
    • A copper-based wire is melted into the handle crevice to fuse halves completely.
    • An edging machine smooths the solder line.
    • Liquid cement is poured into handles and cured in hot water.

Production Process of Spoons and Forks

  • Spoons:

    • Stainless steel is cut into brush-shaped pieces.
    • Heavy rollers stretch pieces to thin the spoon bowl.
    • A trim press cuts the spoon's profile.
    • A coining press punches a pattern into the handle and shapes the bowl.
  • Forks:

    • Follow similar steps as spoons.
    • A press cuts tines in two stages.
    • A support bar keeps tines in place while a coining press bends them.
    • The bar is sliced off and finished forks are stacked.

Final Steps for Flatware

  • Buffing equipment with cloth wheels polishes the surface with liquid buffing compound.
  • Casual flatware is packaged directly, while formal flatware may receive silver or gold plating.