The making of Crayola's crayons (photos)
As part of Road Trip 2010, CNET's Daniel Terdiman stops by Crayola to witness how the company produces more than 3 billion crayons a year.
Largest crayon in the world
EASTON, Pa.--Do you think you've ever met anyone, in the United States at least, who hasn't played with Crayola crayons? The odds are low. Crayola makes 3 billion of the wonderful colored drawing implements a year. And it's a surprisingly simple process to make them.
On Road Trip 2010, CNET reporter Daniel Terdiman visited Crayola to see how these ubiquitous wax wonders are created.
In its store, Crayola displays this crayon--the biggest in the world, which was made to celebrate the company's 100th birthday. It weighs 1,500 pounds, is 15 feet long, and was created with crayons donated by children around the country.
This crayon could draw a single line 10 miles long, or color in an entire football field.
Click here to read a related story on Crayola crayons and watch videos of their production. Click here to check out the entire Road Trip 2010 package.
Crayola building
Crayola's visitors' center in Easton was created in conjunction with the town, and has helped revitalize it.
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Wax from the faucet
Paraffin wax flows from a faucet into the "kettle." The wax comes out at 150 degrees Fahrenheit and will be poured onto the "hole table."
Click here to read a related story on Crayola crayons and watch videos of their production. Click here to check out the entire Road Trip 2010 package.
The kettle froths
The wax froths in the kettle before being poured onto the hole table.
Click here to read a related story on Crayola crayons and watch videos of their production. Click here to check out the entire Road Trip 2010 package.
The hole table
This is the "hole table," which has 1,200 slots for crayons.
Click here to read a related story on Crayola crayons and watch videos of their production. Click here to check out the entire Road Trip 2010 package.
The holes
A close-up of the holes.
Click here to read a related story on Crayola crayons and watch videos of their production. Click here to check out the entire Road Trip 2010 package.
Pouring the wax
A Crayola employee pours the heated wax onto the hole table.
Crayola does not allow the public--or the press, in most cases--to see its actual manufacturing facility. But at its visitors' center, the company offers its 300,000 annual visitors a demonstration of the process. And though the demonstration is done at a slower speed, it is representative of what happens in the real factory.
Click here to read a related story on Crayola crayons and watch videos of their production. Click here to check out the entire Road Trip 2010 package.
Bubbling
As the scalding wax spreads across the hole table, it bubbles up over the holes.
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Dried wax
It takes about 10 minutes for the wax to cool, aided by cooling liquid underneath the hole table. Here, the just-poured wax sits dried, and still a bit warm to the touch.
Click here to read a related story on Crayola crayons and watch videos of their production. Click here to check out the entire Road Trip 2010 package.
Patterns
After one pour, the wax set like this, with a nice pattern of dimples over the holes.
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Scraping the hole
A roll automatically scrapes the dried wax off the surface of the hole table, pushing it into a bin at the end. The wax is not thrown away. Instead, it's melted again and used in a future pour. Crayola does a lot of recycling, including mixing all colors of defective crayons into its black crayons.
Click here to read a related story on Crayola crayons and watch videos of their production. Click here to check out the entire Road Trip 2010 package.
Crayons in the holes
New crayons emerge from the holes in the hole table.
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Crayons
Twelve hundred new crayons have emerged, and now it's time to get them off the table.
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Lots of crayons
These are the newest red Crayola crayons.
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Defects
In each pour, there are going to be defects. Here, some of them are collected. The wax may not have filled a hole, or it may have settled improperly. The defects are recycled.
Click here to read a related story on Crayola crayons and watch videos of their production. Click here to check out the entire Road Trip 2010 package.
The wrapping drum
This is the wrapping drum, which automatically applies a crayon's label.
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The drum
A close-up of the drum.
Click here to read a related story on Crayola crayons and watch videos of their production. Click here to check out the entire Road Trip 2010 package.
Feeding the drum
Crayons in a hopper are fed one by one into the drum and rotated around until glue is applied and a label is rolled around twice; then the crayons are pushed out of the other side of the machine.
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Applying the labels
One by one, the labels are affixed to the crayons.
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Emerging crayons
The now-labeled crayons emerge from the wrapping drum.
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Different colors
Several colors of crayons in bins that feed onto a conveyor belt, at the end of which the crayons are boxed.
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Into the box
Though the crayons that are boxed at the visitors' center don't go into a 64-color box, visitors can still see how they're packaged.
Click here to read a related story on Crayola crayons and watch videos of their production. Click here to check out the entire Road Trip 2010 package.