How,Refills,Are,Made,For,Promo business, insurance How Refills Are Made For Promotional Pens - Detailed Look at

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Pens are amongst the most popular gifts forspecial occasions and we like to think the more expensive the pen wechoose, the better it will perform and consequently the more it will beappreciated. However, when it comes to pens we should distinguish therefill quality from the quality and materials of the pen casing orbody. This also applies to promotional pens. A refill is at the heartof any ballpoint pen, rollerball or promotional pen and this determineshow the pen writes; yet it is always the cheapest component by far. Inactual fact, refills, even in the most expensive brands cost verylittle to produce and their high prices reflect the premium that thebrand can command.Big brands are aware of this so they quiteoften design their pens in such a way that generic refills do not fit.Where big branded pens are concerned you are invariably paying for thename unless it is made from precious metals. The good news is if it isjust writing quality you are after and you are happy with an unbrandedplastic or metal pen then you can get quality as good as the top brandsfor a very small amount of money. It is fascinating to see how refillsare manufactured, particularly the speed, precision and level ofautomation involved. Hopefully, the following will give you an insightinto how an inexpensive refill is manufactured for promotional pens.The Tip (Nib): This is usually manufactured from brassbecause it is ductile and easily machined at very high speed. It startsits life as a roll of brass wire slightly larger than the outsidediameter of the finished tip. The wire is fed into a machining headthat shapes the outside, drills a long narrow hole through the centralaxis and creates a hemispherical shaped indent in the narrow tip. Thedrilled hole will be the channel that the ink travels down from thereservoir of ink held in the tube to the ball that will be fitted intothe hemispherical dome later in the process. This machining is done atincredible speed whilst being sprayed with coolant that also acts as alubricant. Once the tip is machined it is parted from the brass wireand falls into a wire basket in readiness for the next stage. Thesetips are then thoroughly washed to get rid of any swarf orcontamination before going to the next stage. The final stage is whenthe ball is fitted into the narrow end of the tip. Here the tips arefed into a vibrating bowl-feed hopper that delivers each tip, correctlyorientated, to the ball insertion head. The ball is placed in thehemispherical domed indent machined in the tip earlier and a crimpingtool presses the outside of the tip, locking the ball in place. Despitethe fact this is happening at a speed of several thousand units perhour, the accuracy of the operation has to be very high because thisstage determines how smooth the refill will be in action. The overallspeed of operation is of critical importance because refills in promotional pens, or any unbranded pen must be inexpensive.The Reservoir Tube: This can be either plastic ormetal and is fed from a roll and cut into predetermined lengthsdepending on the type of promotional pens it will ultimately be fittedto. These cut lengths are stacked in a feed hopper on an assemblymachine, the finished tips are place in a vibrating bowl-feed hopper onthe same machine and they are assembled together at high speed.Ink Filling: The next stage is where the ink will beinjected into the reservoir tube. This can be part of the tip and tubeassembly machine or it can be a stand-alone one. In any case the ink isinjected in an exact dosage by thin needles and great care is exercisedto ensure no ink falls outside the capillary. Many promotional pens aretranslucent and ink contamination will show if there is spillage oroverfill.Centrifuge: When the ink is injected into the plastictube, air is invariably trapped underneath it. Ink flow from the tubethrough the tip to the ball depends on capillary-action and anypresence of air will prevent this from happening. The air must beexpelled and this is done in a centrifuge. Each refill is placed in avery large round drum, together with thousands of other refills, andgreat case is taken to ensure each tip is facing outwards. The drumrotates at very high speed for several minutes and the centrifugalforces push the ink to the bottom of the reservoir and this forces theair out. Testing: A selection of samples is taken from eachproduction batch and the tips are examined under a microscope to ensurethe balls are rotating freely and that no cracks or burrs appear on thetip. They are then placed on an automatic writing machine and the inkmileage and quality is checked. If everything is within tolerances itis regarded as a successful batch and will be inserted in the nextorder for promotional pens.Thank you for reading this brief overview on refillproduction and please look out for my other technical articles oneverything associated with writing instruments and promotional pens inparticular. Article Tags: Promotional Pens, Very High, High Speed, Next Stage