Matches | How It's Made

Summary

This video provides an in-depth look at the intricate process of match production, starting with the preparation of the match head compound, including the mixing of potassium chlorate, gelatin, and other chemicals. The splints are then coated and dipped in the compound, dried thoroughly, and inspected for quality. The finished matches are packaged into boxes at a high-speed rate, with the entire production line efficiently processing millions of matches. The video highlights the precision and automation involved in turning raw materials into a single match that can light a fire.

Takeaways

• 😀 The process begins with a worker adding gelatin capsules to potassium chlorate in an industrial mixer, where gelatin acts as a binder for the match head compound.
• 😀 Hot water is added to dissolve the gelatin, which combines with the potassium powder, followed by the addition of silica granules to control combustion.
• 😀 After mixing for 40 minutes, the gelatin compound becomes liquid, and red coloring and other compounds are added to enhance the burning properties of the match head.
• 😀 On the splint production line, splinters of Aspen wood are treated with ammonium phosphate to prevent afterglow, and waste splints are automatically discarded.
• 😀 The splints are moved through a machine that shakes off any residue and discards broken or undersized splints, ensuring only high-quality splints continue.
• 😀 In the match dipping line, splints are coated with paraffin, and the match head compound is kept liquid in a mixer while splints are dipped.
• 😀 After dipping, the splints pass through a drying stage for about 1 hour, allowing the match heads to dry thoroughly and slowly.
• 😀 Once dried, the matches are ready for packaging, but first, the filling machine places them into inner and outer liners at high speeds.
• 😀 The filling machine processes up to 500 boxes per minute and places matches into the boxes at a rate of 200 matches per second.
• 😀 The packaging process ensures that each box contains the correct amount of matches, and any excess matches are rejected by the machine.
• 😀 The final packaged matches are then distributed in different packaging sizes, from small cartons to heavy-duty crates, ready for sale and use.

Q & A

What role does gelatin play in the production of match heads?

Gelatin serves as a binder for the match head compound, helping to combine various ingredients like potassium and chlorate to form a solid, cohesive match head.

Why is hot water added to the mixture in the industrial mixer?

Hot water is added to dissolve the gelatin, allowing it to mix with the potassium powder and other ingredients to form a uniform compound for the match heads.

What is the purpose of adding silica granules to the mixture?

Silica granules are added to act as a combustion-controlling agent, ensuring the match burns at the correct rate and doesn't burn too quickly.

How is the worker ensuring that the mixture is ready for the next step in the process?

After about 40 minutes, the mixture becomes liquid, at which point the worker adds red coloring and other compounds to enhance the match head's burning properties.

What is the purpose of impregnating the splints with ammonium phosphate?

Ammonium phosphate is used to prevent afterglow, which is the unwanted lingering burn of the match after it's been lit.

What happens to the splints after they are inspected for quality?

After inspection, the splints go through perforated plates that shake off any residue or waste. They are then checked for size, and broken or undersized splints are automatically discarded.

How are the splints prepared for the dipping process?

The splints are placed into sockets on a perforated steel match bar, which runs down an endless chain. An automatic feeder inserts up to 2 million splints per hour into these sockets.

What is the purpose of the paraffin coating on the splints?

The paraffin coating helps to protect the splints and ensures they burn consistently when lit. The coating is applied before the splints are dipped into the match head compound.

How is the drying process handled after the splints are dipped in the match head compound?

The splints are dried by rolling down a match bar chain for about 1 hour, allowing the match head compound to dry slowly and thoroughly before they are ready for packaging.

What happens to the finished matches once they are dried and ready for packaging?

The finished matches are placed into boxes by a high-speed filling machine, which processes 500 boxes per minute. The machine ensures that each box is filled with the correct number of matches, rejecting any extras.