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At Hall Eastwell, new product development begins with a vision followed
by days of research. Botanical experts armed with historical manuscripts
search for classic herbal and floral designs that can be adapted to
create unique hand crafted giftware. Recommendations are then made
to Hall Eastwell’s Product Advisory Committee and executive team.
This group, comprised of botanical experts from the United States
and Europe, must approve all product initiatives before we move on
to the manufacturing process. The majority of Hall Eastwell products
involve the use of metal manufacturing. When metals are used, we rely
on a combination of sand casting manufacturing process and lathe manufacturing.
Sand-casting After a product design has been reviewed and a decision is made to produce a product, skilled craftsmen design master molds. These first molds mark the beginning of a long sand casting process. From these master designs sand cast molds are made. All sand cast items require superior soft sand molding and sand separation methods. Using silica sands, mulling machines begin the process by uniformly mixing sand with additives. Clay is used as a cohesive agent to bond sand particles, giving the sand strength. The blended sand is packed into Hall Eastwell designed molds. From this process come individual molds that are filled with molten metals. Once metals have been poured into the sand molds they are allowed to cool. Then each individual sand mold is broken to remove the rough product casting. This casting method allows for production of authentic designs with highly intricate shapes found in original herbals and botanicals which would be extremely difficult to produce using other methods. After each item is sand cast, cooled and removed from the mold, its weight is often as much as twice of the actual weight when completed. After the product is removed from its mold, it is sent to be finished, where the item is reduced in weight, buffered and twice polished. Once a product is finished having been polished it is quality checked and sent to the finish area for final hand packaging. The product will again be randomly checked before it leaves the factory. Lathe This is a second method used by Hall Eastwell to manufacture superior products, often involving one or more days of labor for every piece. Lathe manufacturing is used for cutting and etching the product in a round or oval design by sharp cutting and engraving tools. Hours of intensive labor by skilled craftsmen create a work of art. Each piece is hand tapped until the right design is finished. Only then is the item sent for coating and polishing until it meets design specifications. Most products made this way are so unique that they are awarded both the Hall Eastwell mark and a uniquely engraved or stamped number. Quality Assurance All finished products undergo inspection and if an item does not meet minimum established criteria, it is sent back to fulfill the requirement or discarded. At Hall Eastwell we don’t sell “seconds”. Packaging It is the last process before shipping off the goods. It is made
sure that the products are packed in a careful manner, so that they
are not broken or damaged while transporting or shipping. |
