Author Archives: Yahya Y. Kemikoğlu

METALCASTING

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There are several processes to produce a simple faucet. There are two molds for one faucet, 2 casting processes, cleaning process and finally the recycling phase.

1-In the first stage, a mold of the inside of the faucet is made with a mixture of sand. This mold is made to make the final product’s inside hollow.

2-In this stage the second mold gets cast over the first sand mold. The second mold is made out of a molten steel alloy.

3-In this stage both of the cast molds are combined and the faucet is there but the inside is not hollow due to the cast sand mold and the the faucet has excess material.


4-In this stage the faucet is thrown inside big mixer like container that has iron balls inside which vibrates while spinning. With this process the sand mold inside the faucet slowly dismantles and becomes hollow with sand is now gone.

5-In this stage the excess material gets removed and the final product is achived.

6-Finally in this stage the faulty and broken products are thrown inside the molten steel to get melted and reused as a material for the future molds and faucets.

PARAFFIN WAX > PRESSING TECHNIQUE

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Figure1: IKEA FENOMEN Block Candle


In Pressing method, the paraffin wax powder is first added inside the pressing holes Then the machine presses the powder using pressure to make the powder solid and strong in a cylindrical shape with a desired length. While pressing the machine also punches a hole for the wick to be added later. Afterwards the machine lifts the pressed candle and the process repeats.

Figure2: Powder is filled, powder is pressed, the candle is ejected and sent for its wick to be inserted
Figure3: Pressing machine in action

The machine in the video is responsible for a candle to take its shape. It presses the wax powder, punches a hole for the wick at the same time then ejects the finished product. The finished products are the sent for their wicks to be inserted.

GENERAL FEATURES

  • (+) Length of the candle can be adjusted
  • (+) Large quantities can be produced quickly
  • (+) It is cheap
  • (+) Ideal for tea-light and pillar candle productions
  • (+) Process is easy
  • (-) Wick of the candle needs to be added afterwards

USAGE AREAS

Figure4: This technique can be used to manufacture tea-light candles
Figure5: This technique can be used to manufacture pillar candles different thicknesses and lengths

PHASES OF PROCESS

In the pressing method,

Phase 1: The press holes are filled with loose paraffin wax powder

Phase 2: Paraffin wax powder is compressed under high pressure using the stamping press or extrusion press

Phase 3: With the extrusion press, an endless column is produced, which is the mechanically cut to the desired candle length

Phase 4: The cut candle is then ejected and is sent to get its wick inserted

Phase 5: Process repeats

Drawing Method: This process is much slower and is suitable for only household candles.

Casting Method: This process is much more costly, slower and only suitable for unusually shaped candles. Production quantity is smaller.


REFERENCES


PARAFFIN WAX > BLOCK CANDLE

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–Figure1: IKEA FENOMEN Block Candle


A Paraffin wax (or a.k.a. petroleum wax) is a soft colorless solid obtained from petroleum, coal, or oil shale that consists of a mixture between twenty and forty carbon atoms. It is solid at room temperature. It is an excellent material for storing heat. It is odorless and its color white-blueish when it is un-dyed.

GENERAL FEATURES

  • (+) It is odorless
  • (+) It is cheap to produce
  • (+) It is an excellent electrical insulator
  • (+) It is an excellent material for storing heat
  • (+) It is tasteless
  • (+) Un-dyed paraffin wax is white
  • (+) It can be soft or solid
  • (+) Can be easly dyed
  • (+) Manufacturing process is simple
  • (-) It is not recyclable
  • (-) It is not sustainable
  • (-) It is not eco-friendly

WHY DID THEY CHOOSE THIS MATERIAL FOR THIS PRODUCT

Since it comes from petroleum, paraffin wax is very common and easy to produce. It can store a lot of heat and its melting temperature is very high, because of this the paraffin wax controls the candles rate of speed. Thus making paraffin wax a perfect choice for this product.

USAGE AREAS

The common usage areas for paraffin wax include lubrication, electrical insulation, candles and dyed peraffin can be made into crayons.

-Figure2: Crayons are made of dyed wax and they are used for coloring

–Figure3: Wax can be used to soften the skin and can add moisture
–Figure4: Wax is the go to material for producing candles
–Figure5: Wax is an excellent electrical insulator and it is nearly better than all the orher materials

MANUFACTURING TECHNIQUES

There are 3 techniques to manufacture candles: The pressing method, drawing method and casting method.

Pressing Method: In this method, loose paraffin powder is compressed under high pressure using a stamping press. This method allows large quantities to be produced quickly and is commonly used for pillar candles.

Drawing Method: In this method, several hundred meters of wick between two rotation drums are repeatedly drawn through a hot wax bath. This method is mainly used for simple household candles.

Casting Method: In this method, liquid wax is poured into moulds in which a wick has already been fixed. This method is suitable for unusually shaped candles.


SIMILAR MATERIALS

Beeswax: Is often used as a binder in lotions and candles.

Soy wax: Popular substitute for paraffin wax for its affordability and cleanliness when burnt.

Carnauba wax: It is naturally occurring and is often used in polishes and paper coating.

Mineral wax: It is naturally occuring.

Stearate wax: It is naturally occuring and is used in candies, lubricants for plastics and hair products.

REFERENCES