THE IDEALSPATEN MANUFACTURING PROCESS
Step 7 - Rolling Press Process 3The steel plate is now rolled into a conical shape, which is a special technique that creates the self sharpening ability of our shovel blades. The lower portion of the blade is thinned, while the upper shoulder section is thickened.
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Step 8 - Punching Out the ShapeThis cutting machine punches out the overall shape to the shovel head.
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Step 9 - Reheating the HeadsThe blades have cooled during the previous steps, and now must be reheated. The reciprocating furnace reheats the heads up to 1700°F.
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Step 10 - Creating Double SpringA chisel is used to spread the steel and create the 'double spring', which is the handle mounting area. Due to the carbon dusting pressed into the steel during Step 3, the steel does not re bond during the rolling processes.
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Step 13 - Hardening the SteelThe head is now cooled in an oil bath of cold running liquid. This process quickly cools and hardens the steel into the strong and resilient shovel head.
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Step 14 - SandblastingThe heads are sandblasted in a large chamber booth. This smooths the surface of the steel and removes debris and forging scales, which is an oxide layer that forms during the earlier steps while the hot steel is reacting with oxygen.
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Step 15 - Welding the SpringThe base of the double spring is welded closed, so that as the handle is inserted into the stem, the connection is protected against water, dirt, and debris.
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Step 16 - PolishingA robotic arm precisely controls the head against fine grit sanding belts, polishing the entire head. This smooths the steel surface, reducing friction and adhesion against the dirt, and helps fight against rust.
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Step 17 - Manual PolishingAfter the robotic polish, another stage of manual polishing is performed. At this stage, the worker is taking additional time to check quality and ensure all areas are smooth and finished.
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Step 18 - Wet Lacquer FinishThe heads are coated in a thin and clear lacquer finish to help protect the head from rusting, particularly during storage and warehousing.
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Step 19 - Inserting the HandleA precisely shaped handle is inserted into the shovel's spring housing, and a riveting machine presses and installs rivets, strongly securing the handle the the head.
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Step 20 - Tread AttachmentsOnce the shovels are finished, treads are now installed with a hammer. These provide the additional foot and boot support when digging.
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Handle Manufacturing
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HandlesThe quality of the handle is also a significant measure of the tool’s integrity. Idealspaten handles are proudly crafted from FSC Certified sustainably sourced Grade A Swiss Ash. Idealspaten promotes environmentally sound, socially beneficial, and economically prosperous management of the world's forests.
Our saw mill cuts the Ash logs into planks, which are then stored and softly air dried for 9 to 10 months, depending on the weather in Northern Europe that season. Our proprietary drying process will bring the wood's moisture content down to a precise level, before the wood is ready to be made into handles. |