How do those same - really - Christmas decorations

As a rule, before the New Year in the shops there are not real Christmas toys, they are bright, beautiful, shiny, and not real - because of the joy they have.

And this topic is just about true!
The ones who do not conveyor-way automaton, and hands.
These toys are made with love and keep warm female hands.






Klavdievskaya factory is one of the few that are produced during the Soviet era Christmas decorations. In total there were four such factories: 3 in the Ukraine and 1 in the Moscow region. (Klin).
The factory was established in 1949 in the village near Kiev Klavdiyevo and initially engaged in the production of various products from laboratory glass. In the 50s it redeveloped and since the factory has been producing Christmas decorations.
For the most part - a Christmas tree balls, but are not limited to the factory and can produce enough glass ornaments of great complexity.

The Union factory occupies the 1st place in terms of volume of production and area (if the factory included two businesses - on Podil and Svyatoshino). Performance of all enterprises in the day reached a volume of flat cars. Now there is only one company in town Klavdiyevo (he recently partially migrated with. Lubyanka), which operates 25% of the "allied" power.
In the past, the factory employs about 600 people, now there are only a tenth.
Almost all the decorations (about 96%) are now being exported (Germany, Belgium, Holland, France, UK, USA and others.) And only 4% are in Ukraine.

Let's see what it looks like the factory and the manufacturing process of Christmas tree decorations.

Externally (and inside) the factory creates the impression of abandonment. Indeed, after the collapse of the USSR for 5 years from the factory carried everything that they brought, and when he finally has a new owner, it took more than a year to restore health at least to the minimum level.




One of the shops:




The first stage of production of ornaments - glass-blowing height of about 1, 5 m bead or other decorations. Different ornaments of glass used and its diameter with its thick walls.
Here we demonstrate a tube head of the factory:




Mechanized blowing with customers are not held in high esteem: at low tide is the seam of the ball on the form, so the whole process of production of the manual.
To start the tube is heated over a gas burner, the temperature of which reaches 1, 5 thousand. Deg., And drawn into long, thin tube with intervals of pristine original tube diameter:




The stocks for future decorations; where the original left tube diameter, and the balls are obtained:



Next warmed untouched gap and blown balloon or other decoration:



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The subtlety of this work lies in the fact that the glassblower must dial in light air as much as you need to create the desired ball diameter:



This ball must constantly rotate around its axis, or simply droop glass still hot from previous:



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Despite the complexity of the process, glassblowers easily blown balls, lying in the tolerance of 0, 2 mm.
When we blew balls 80 mm in diameter:



However, after each blowing the ball, he checked for a special pattern:



For change master can blow up to 200 balls. And this is familiar to many born tip for trees:



The second stage - silver. Running it with the help of such a straightforward installation: yes tank with reagents bath with hot water



Inside decoration injected silver oxide, ammonia, and distilled water in a certain ratio.



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Christmas decorations with this mixture is put in hot water, a reaction occurs and the silver evaporates mounted on the interior walls. Decoration is shaken several times to the silver evenly spread over the walls. Then the remaining water is poured:



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The third stage - painting.



Silver plated beads are wiped with a cloth and dip into the paint. At the same time it is very important consistency: if the paint is too thick, on the ball will begin to flow, if too thin - spaces:



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Painted balls are sent to the oven - they dry out here under the lights. Rheostat regulated voltage supplied to the lamp, and accordingly, temperature:



The fourth stage - decoration. If it is not required, the ball can pass this stage and immediately leave for pruning.
When applied to the design of the artist's drawing of the toy needed:



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How to draw a tiger:



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To put the ball in the pattern of sequins, its pre-coated with glue and then sprinkle with glitter ball:



Ready Tigers close with yet unfinished brothers:



Painters can cause picture for every taste:



Each artist can paint 50 to 100 balls a day.



The fifth stage - trimming tip, the remainder of the glass blowers. It is done with a diamond circle:



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Bzdyn! The tip flies towards:



It only remains to put all the familiar caps with eyelet:



... And pack toys:



Finally a few examples of the diversity of the New Year, which produces factory:



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By the way, when visiting the factory can immediately buy toys "for producer prices" and make an individual picture.



Until such ornaments :-)

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