Have you ever wondered how are jigsaw puzzles made? What it takes for jigsaw puzzle manufacturers to make a puzzle for enthusiasts to enjoy piecing together the pieces?
While it might seem simple, the process behind creating these intricate puzzles is both fascinating and highly technical. I’ve been so impressed after having the chance to see it first hand.
I had the opportunity to visit a jigsaw puzzle manufacturing facility in Asia, which deepened my appreciation for the craft and made me realize the importance of ensuring the process is environmentally friendly. Additionally, I’ve seen how jigsaw puzzles are made in the United States as jigsaw puzzle manufacturers have opened their doors to enthusiasts.
Table of Contents
All of this information I’ve gathered and want to share with you. It’s a chance for understanding and to explore the step-by-step process of how modern jigsaw puzzles are made, especially with an emphasis on sustainability.
Before we talk about how jigsaw puzzles are made, let me stress that you too can see this process for yourself. Jigsaw manufacturers, for the most part, want people to know how it’s possible to make great puzzles. A brand wants to build an audience so sharing this process (online or in person) is important.
What Materials Are Modern Jigsaw Puzzles Made From?
Jigsaw puzzles made today are primarily from paperboard, a material chosen for its balance between cost-effectiveness and durability. Unlike the traditional wooden puzzles, which were more labor-intensive and expensive, paperboard allows manufacturers to produce puzzles on a much larger scale.
Materials and Process Involved
Paperboard
The core material used for puzzles is paperboard, which offers the right mix of sturdiness and affordability. There are puzzle made out of wood and metals, but what you often find is those are so specialized that it’s impossible to mainstream the process of jigsaw puzzle manufacturing.
Image Layer
The image you see on the puzzle, often a photograph, painting, or artwork, is printed on paper and glued onto the paperboard. This is how jigsaw puzzles made can be so unique.
Puzzle Die
This is a specialized cutting tool made from flat plywood embedded with steel blades arranged in specific shapes. The blades are covered with a compressible material like foam rubber to aid in the cutting process.
How is a Jigsaw Puzzle Made?
1. Image Application
The first step in the manufacturing process is applying the image to the paperboard. The selected image is printed on high-quality paper, which is then carefully glued onto the paperboard.
This step is crucial as it ensures that the image adheres evenly without any bubbles or wrinkles, which could affect the final product.
2. Pressing Process
After the image is applied, the board is placed into a press. This is where the magic happens. The press uses a puzzle die, which is essentially a large, puzzle-shaped cookie cutter, to cut the board into pieces.
The press exerts a tremendous amount of force – approximately 700 tons for a standard 1000-piece puzzle. This immense pressure ensures that the steel blades slice through the board cleanly, resulting in perfectly shaped puzzle pieces.
3. Quality Control
Once the puzzle is cut, it undergoes a rigorous quality control process. Each piece is checked to ensure it fits perfectly with its neighbors. This is the most critical part of the manufacturing of puzzle pieces as you want clean, crisp cuts.
Any defects, such as incomplete cuts or misaligned images, are spotted and corrected at this stage. This meticulous attention to detail ensures that when you sit down to complete a puzzle, every piece fits just right.
4. Packaging
Finally, the puzzle pieces are mixed and packed into boxes, which are then sealed and prepared for shipping. Packaging is another critical aspect, as it not only protects the puzzle but also serves as a marketing tool, showcasing the puzzle’s image and details to potential buyers.
The Importance of Environmentally Friendly Manufacturing
During my visit to the manufacturing plant in Asia, I was struck by how the process, while impressive, also raised concerns about environmental impact. In the United States, I’ve seen massive waste at the puzzle manufacturer I visited in Florida and was appalled. I couldn’t believe they pretended this wasn’t an issue (it certainly was) and I will never buy the brand again.
The production of jigsaw puzzles, like many other consumer goods, involves the use of materials and processes that can harm the environment if not managed responsibly. This should be considered and ideas implemented as the jigsaw puzzles made are coming off the line.
Eco-friendly Practices in Jigsaw Puzzle Manufacturing
Thankfully, many puzzle manufacturers are becoming increasingly aware of their environmental footprint and are adopting more sustainable practices. It’s great to see and I’m glad it’s an issue that puzzle enthusiasts care about.
Here are some ways puzzle manufacturers are doing this:
- Sustainable Sourcing: The paperboard used in puzzles is often sourced from sustainably managed forests. This means that for every tree harvested, another is planted, ensuring a balance between production and conservation.
- Recycling: Many manufacturers use recycled materials in their paperboard, reducing the demand for virgin resources.
- Non-toxic Inks and Glues: The inks and adhesives used in puzzles are now often non-toxic and water-based, minimizing the release of harmful chemicals into the environment.
- Energy-efficient Manufacturing: Modern factories are investing in energy-efficient machinery and processes, which not only reduce their carbon footprint but also cut down on costs. Jigsaw puzzles made with the earth in mind are unique.
Personal Experience and Puzzle Reflection
Seeing the manufacturing process firsthand made me realize the importance of supporting companies that prioritize sustainability. As a lover of jigsaw puzzles, I believe that the joy they bring shouldn’t come at the cost of the planet. By choosing puzzles from manufacturers that use eco-friendly practices, we can enjoy our hobby guilt-free, knowing that we’re not contributing to environmental degradation. Jigsaw puzzles made with care are worthy of supporting on every level.
Complex Jigsaw Puzzle Made Perfectly
The process of how jigsaw puzzles made complete is a complex and precise one, involving several stages from the application of the image to the final packaging. However, it’s not just about how the puzzle is made, but also about how the process impacts our environment. By supporting sustainable practices in puzzle manufacturing, we can ensure that this beloved pastime remains enjoyable for generations to come.
Next time you sit down to piece together a puzzle, take a moment to appreciate the craftsmanship that went into creating it. And remember, every choice we make as consumers can have a positive impact on the world around us. Don’t buy from brands that are looking to make a quick buck while dumping waste in someone’s backyard.
