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Liquid paraffin is poured into molds as part of the crayon production process. Click the image to view a brief 5-second video.
PLEASE VERIFY CREDIT BEFORE USING THIS IMAGENearly everyone has used a crayon or marker at some point. In this article, we’ll take you on a virtual tour of the Crayola Factory located in Easton, Pennsylvania.
Binney & Smith, the creators of Crayola, began in the late 19th century by producing pigments for the red paint used on barns across rural America. Their carbon black was later adopted by the Goodrich tire company to enhance the durability and color of automobile tires, which were originally white due to the natural hue of rubber.
The name 'Crayola' was coined by Alice, the wife of Edwin Binney. She merged the French word 'craie' (meaning chalk) with 'oleaginous' (referring to the oily paraffin wax) to create the iconic brand name.
Crayons are made using two primary components:
- Pigment
- Paraffin wax, stored in massive heated tanks holding 17,000 gallons
The ingredients are heated until they liquefy. While crayons melt at 105°F (40°C), the mixture is heated further to 190°F (82°C). This molten liquid is then poured into a preheated mold containing hundreds of crayon-shaped cavities. The mold is cooled with water at 55°F (13°C), solidifying the crayons in just 3 to 9 minutes.
Each mold produces 1,200 crayons at once, totaling approximately 40 pounds. Hydraulic pressure is employed to release the crayons from the mold, a process that once relied on manual cranking. Freshly molded crayons undergo a manual quality check to identify flaws or broken tips. Any excess wax or defective crayons are recycled and melted down for reuse. The process allows for the creation of over 120 distinct crayon colors.
Binney & Smith utilizes injection molding techniques, enabling the production of 2.4 to 6.4 million crayons daily. Visit the new page to discover how Crayon labels are crafted.
Creating Crayon Labels
To ensure safety for young children who might peel and accidentally ingest crayon labels, Binney & Smith uses a non-toxic adhesive made from cornstarch and water. The labeling machine wraps each crayon twice for added durability. Remarkably, the design of Binney & Smith’s labeling machine has remained largely unchanged since 1943. The process involves feeding bare crayons from one hopper and labels from another. Glue is added to a pot, and the machine is activated. The glue is transferred to a drum slot where the crayon is placed. A roller then presses the label onto the glue, wrapping it around the crayon twice. Before 1943, farmers manually wrapped crayons during winter to earn extra income.
Labels are available in 11 languages, and 18 distinct color labels are used across all crayons.
Crayon ready for labeling.
Crayon label application in progress. The white roller on the right spreads the cornstarch-based glue.
Crayons are packaged in boxes ranging from 2 to 96 crayons per box. Smaller packs of 2, 3, or 4 crayons are often bought for use in party favors and restaurants.
Labeled crayons moving through the packing machine.
Fascinating Facts About Crayola Crayons:
- A 1993 national survey found that blue and red are the most favored crayon colors.
- The scent of a crayon ranks as the third most recognizable smell, following coffee and peanut butter.
- By the time a child turns 10, they’ve typically used around 730 crayons!
Next, discover the process behind making Crayola markers.
How Crayola Markers Are Made
Click the image to watch a 5-second video clip of a new marker being capped.
Mytour.comThe manufacturing process involves the following steps:
- The plastic resin is molded into the marker barrel.
- The barrel undergoes screen printing for designs or labels.
- A filament, similar to cotton, is inserted into the barrel to hold the ink.
- A plastic plug is added to one end of the barrel.
- Ink is injected into the other end using a needle resembling a hypodermic.
- The writing tip (nib) is inserted into the same end.
- A plastic cap is placed on the marker, and the ink gradually saturates the tip.
