KOVAP Náchod, s.r.o.Creative brains
and 100 busy hands
The serial production starts with the painting of the sheet-metal (about 0,3mm thick), for this, printing style sheets are made, which are streched on to the printing drum. Then, with the offset-printing-process, the sheet metal is printed.
After that, the tin plates are dried in electronically regulated drying chambers.
In the following these tin plates are punched, shaped with hydraulic presses and bended, until the final form is reached. Therefore one needs tool-inserts like this one, which are put in special mountings, in big machines.
Of these tool-inserts we need up to 15 pieces for every tin toy part (for example the fenders), because some elements are worked on multiple. We build these tools in a close contact to the museums and archives of the manufacturer (for example John Deere), in our own toolmaker department. If possible with the original technical drawings. Therefore we also use very expensive machines, like electric wire-tracers or sparktracers.
For the production of these molds one needs years of experience and specific knowledge of the material, to reach an optimal transformation process and highest quality.
Some extension parts of the toys are manufactured with a pneumatic die-cast machine (for example the wheel rims, the exhaust of the John Deere tractor or the winding up key).
The manufactured parts are fitted to assembly groups and then reach the final assembly, where they are put together with lovingly, skilled handiwork.
At the tractor, for example, 300 steps are necessary, until the model is ready.
After the final assembly, the toys pass through a function control, are packed and go to the shipping department.