Stage 2: Enamelling
Liquid enamel is made from small glass particles called ‘frit’, which are ground down to form a fine powder. This is then mixed with china clay and water. The copper parts are then carefully dipped or sprayed with the mixed enamel liquid and fired in a kiln for 8 minutes or so at a temperature of 800°C, fusing and covering to the copper. This process is repeated at least five times to ensure that the finish is hard, glossy and flawless. This is essential as a base for the various stages of decorative applications that follow. Stringent inspections are carried out to check for any blemishes and all imperfect parts are rejected as they occur.
Stage 3: Application of lithographic transfer
A transfer is placed onto the enamel providing the outline of the design. The enamel is fired for two minutes at 700°C to fuse the transfer and is then checked for any blemishes that may have occurred whilst firing.
Stage 4: Painting
A highly skilled artisan hand paints the design using enamel paints made from finely ground glass, metal oxides and oil. Depending on the complexity of the design, the painting can take between a few hours and many days to complete. Upon completion, the enamel receives a final firing and is then checked again for any flaws.
Stage 5: Assembly
The components of each design are assembled together by using a mount and to ensure the perfect fit, some of the enamel edges are levelled by a procedure called linishing. The boxes are assembled using an adhesive, which is applied to both sides of the mount and then placed into a low temperature heat for 5-10 minutes.
Stage 6: High quality inspection
A final, meticulous inspection then takes place, ensuring our customers receive the highest quality finished product. Our enamel boxes are then packed into luxurious presentation boxes.