Manufacturing process of Button:
1. Mixing the polyester
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
