There are many stages in processing an order for promotional products, starting with our customer service representatives, which is to analyze the order, check for any missing information, and, if needed, help with suggestions as to the best method required for a specific order.
At this point, an order confirmation is sent and the specifications are given to the graphic department.
Our professional artists will translate the client's artwork into a linear format suitable the production processes.
The artwork is then sent to the client for approval and/or further modifications needed for final approval.
Once this step is done, a work order containing all specifications is prepared for every stage of production.
MODEL & MOLD MAKING
Based on the approval artwork, 2D or 3D models are made ith careful attention to all details and specifications.
The model must be checked and transferred into the production mold.
2D models are 2 superimposed flat levels. This means some of the details or background will be raised and the rest will be recessed (see below).
3 Levels/Multi-Levels models have many flat levels giving a similar look to 3D (see below).
3D models are divided into two categories. The first is the One-sided 3D, this means the front will be in 3D and the back will be flat or 2D (see below).
The other category is Full 3D, and in this form, the models are made as life-like as possible (see below).
The casting method we use is spin casting; the molten metal is poured into a machine which spins the mold.
As with all other stages in production, all castings are inspected, assembled, sanded, etc…for any excess metal or sharp areas.
In order to get the rich look of pewter, the casting is oxidized (blackened) and then carefully hand-buffed.
All pieces are lacquered for protection and a lustrous look.
We offer a large selection of bright and antique finishes to choose from.
The plating process starts by inspecting the parts, putting them on racks and then going through several stages of plating until the final required finish is achieved.
There are two ways to obtain antique finishes.
One is the Econo finish, and in this process, machines are used to remove some of the oxidation.
The second is hand polished, and is done in the same way as the pewter finish.
When colors are required, the process starts by mixing colors in order to get the proper PMS match.
The application of colors requires well-trained personnel and precision work.
The result is a color fill piece with raised metal borders that will separate the colors.
IMPRINTING / HYBRID
When details are very small, or two colors are required to be laid one on top of the other (without any metal separation) a hybrid process is used.
The first step is to color fill the background followed by pad printing on the colored surface.
If an actual photo (4-color process) or a large amount of colors is required, as well as gradation of colors, the PhotoArt process is used.
A printed label is made and cut according to the required shape, then applied onto the product and covered with a clear epoxy dome for protection and beauty (where specified).
Die struck will provide jewelry quality. The surface is polished and the background is matte (sand blasted).
Die struck can applied to pure metal libe brass, copper, gold and silver.
Every stage of the order and protection processes is acompagnied by thoroough quality control checks.
A final check is done at the shipping department before products are sent to our clients.