1. Material: Unsaturated polyester resin is a by-product of petroleum which is a transparent and sticky liquid.After the resin is mixed with catalysts and accelerators in a proportionate manner, pearl essence, raw materials (like wax, salt, sawdust, straw and etc.) and different kinds of color pigment are added.As the above solutions with different colors and densities are mixed and treated by different machine speed with different machine accessories and temperatures, button disks with a wide array of colors and patterns will be created and buttons with a versatility in shapes will be made. Unsaturated polyester resin is one of the most important button-making raw materials in the contemporary world.
2. Sheet: As well-mixed resins are poured layer by layer into the centrifugal cylinder machine (sheet machine), it may produce layers of colors, one on top of the other.When the resin reaches the gumlike state which is called a sheet, the sheet is then cut and unthreaded from the cylinder. The punching machine will cut out disks from the sheet. Each standard sheet will produce standard quantities of buttons for different sizes, such as yielding 47 grs for 24L buttons.
3. Rod: As well-mixed resins at myelosis fluid status are poured into waxed aluminum tubes, the rod will be moved out from the tubes when it reaches the gelling point which is known as the rod production. Rotating blades slice disks from the rod at a speed of 1300 pieces per minute. Each rod can yield 2 grs of 24L buttons.
4. Disks: As all the disks from the rod and the sheet are soft, they will be put into hot water at 80°C for 10 hours. Upon completion of the chemical reaction process, they will be hardened.
5. Finishing: Fully automatic button machines will carve the shape, even engrave logo in front of the disks, carve the back and also drill holes in the same process. For normal shape, about 100 pieces can be produced per minute.
6. Smoothing: It takes about 10 hours to smooth the surface of the buttons in the rotating barrels by adding water and pumice powder If the client requires matte finish button, this will be the final process. If the client needs glossy (shinny) look, it takes about 20 hours to polish the smoothed button in the rotating barrels by adding bamboo tip and wax. By using water polishing machine, it takes 15 hours to finish smoothing and to achieve glossy effect simultaneously.
