Enamel Mug

Material

Low-Carbon Steel Sheets, Glass Mixture

Surface

Degreasing, Pickling, Neutralization

Decoration

Screen Printing,  Decals,  Hand-Painting.

ECO

Steel Is Recyclable

    1. Material Selection:
      • Carbon Steel Sheets: High-quality, low-carbon steel sheets are selected for their durability and formability.
      • Enamel Frit: A powdered glass mixture (silica, feldspar, borax) with metal oxides for color and adhesion.
    2. Blanking and Cutting:
      • Steel sheets are cut into circular blanks using hydraulic presses or laser cutting machines.
    3. Stamping/Pressing:
      • Blanks are pressed into mug shapes using deep-drawing dies.
      • Handle Formation:
        • Integrated handles: Stamped as part of the mug body.
        • Separate handles: Cut, shaped, and welded/riveted to the mug body pre-enameling.
    4. Surface Preparation:
      • Degreasing: Remove oils and contaminants via alkaline baths.
      • Pickling: Immersion in acid (e.g., sulfuric or hydrochloric) to eliminate rust and scale.
      • Neutralization: Rinsed to remove acid residues.
    5. Base Enamel Application:
      • Wet Process: Mug is dipped or sprayed with a slurry of enamel frit and water.
      • Dry Process: Electrostatic powder coating for even distribution.
    6. Firing:
      • Mugs are fired in a kiln at 800–900°C to melt and fuse the enamel into a smooth, glassy layer.
      • Double Firing: Some processes apply a second enamel coat for durability.
    7. Decoration:
      • Screen Printing: Designs are applied using heat-resistant pigments through mesh stencils.
      • Decals: Pre-printed designs transferred onto the mug and fired to bond with the enamel.
      • Hand-Painting: Artisan techniques for custom designs (rare in mass production).
    8. Final Firing:
      • Decorated mugs are fired again at 700–800°C to set the colors and ensure adhesion.
    9. Edge Finishing:
      • The rim is rolled or ground to eliminate sharp edges.
      • Optional silicone or rubber grip added to the handle base.
    10. Quality Control:
      • Visual Inspection: Check for bubbles, cracks, or uneven coatings.
      • Adhesion Test: Tap test to detect delamination.
      • Leak Test: Ensure structural integrity (for lidded mugs).
    11. Packaging:
      • Mugs are wrapped in protective materials (bubble wrap, cardboard sleeves).
      • Bulk packaging for wholesale or retail display.
    Key Considerations:
    • Durability: Enamel thickness (~0.1–0.3 mm) balances chip resistance and flexibility.
    • Sustainability: Steel is recyclable, though enamel coating complicates the process.
    • Safety: Lead-free pigments and proper ventilation during firing.
    Variations:
    • Campfire Mugs: Thicker enamel for heat resistance.
    • Vintage Styles: Distressed finishes achieved through controlled oxidation.

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