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| - Derwents Standards - Manufacturing Process - How Pencils Were Made |
Legend has it that in the early 1500s, a violent storm in the Borrowdale area of Cumberland led to trees being uprooted and the discovery of a strange black material underneath. This material turned out to be graphite, and shepherds began using it to mark their sheep.
A cottage industry of pencil making soon developed, culminating in the formation of the UK’s first pencil factory in 1832.
The factory has had various owners in its 175 year history, but became the Cumberland Pencil Company in 1916. The Lakeland children’s range was launched in 1930, followed by the Derwent brand of fine art pencils in 1938. Since then, a huge variety of artists’ materials has been developed, from traditional to highly innovative. The product range may have expanded beyond recognition but our commitment to excellence remains the same.
Derwents Standards
Quality
Quality is our trademark and we have a clearly defined quality management system that complies with the internationally recognised standard, ISO 9001. In effect, this means that we put quality first in everything we do, from purchasing the raw materials to despatching the finished products. Consistency is a key factor in our success and continuous monitoring of our quality systems ensures the consistent and enduring quality of our products.
Environment
Our factory is situated in one of the most beautiful parts of England, in the heart of the Lake District National Park. We are therefore probably more aware than most how important it is to protect the world around us. We comply with the internationally recognised environmental management standard, ISO 14001 and are committed to ensuring that our materials, processing, products and services have minimal environmental impact. For example, in 2002 we were awarded a Queen’s Award for Enterprise for developing a unique, solvent free paint application system which has greatly improved the air quality in this production area.
We have also been awarded the BOSS (British Office Supplies and Services) Federation Environmental Award for the past 11 years.
This comprehensive award scheme covers a wide range of environmental issues, such as reducing energy consumption and improving our employees’ working conditions.
Health and Safety
The health and safety of our employees is, of course, paramount. In 2006, we were awarded the prestigious RoSPA (Royal Society for the Prevention of Accidents) President’s Award for Occupational Safety and Health. The President’s award is only open to those companies who have already achieved 10 consecutive RoSPA Gold Awards. The RoSPA awards scheme covers all aspects of health and safety, including good health and safety management systems, compliance with legislation, continually improving health and safety performance, employee training and commitment. Actively involving our employees in these issues through training, health and safety audits, meetings and regular communication is one of our greatest strengths.
Manufacturing Process
Derwent combines traditional pencil making skills, perfected by generations of local craftsmen, with state of the art manufacturing techniques. We pioneered many of the processes now in common use and our reputation for quality and consistency is unsurpassed in the art materials world. Let’s take a closer look at how Derwent pencils are made today.
Mixing the CoreThe strip or core of a colour pencil is made by mixing various pigments with clays, waxes and resins. Only the finest pigments are used to ensure maximum lightfastness, smoothness and purity. Graphite pencil strips are made by mixing graphite particles with clay and other binding materials in varying proportions to create different degrees of hardness (H) or blackness (B). The mixture is then extruded to form a strip, cut to the required length and, in the case of graphite pencils, fired in a kiln to remove excess moisture. |
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Creating the WoodcaseAll our Derwent wood-cased pencils are made from the finest incense cedar wood, supplied in specially treated slats. The slats are grooved to accept the graphite or colour strips and, after bonding the strip into the groove, a further slat is placed on top. The resulting pencil ‘sandwich’ is cut into separate units which are made round or hexagonal, depending on the pencil being produced |
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Finishing the PencilsAll Derwent pencils feature a distinctive livery designed to reflect their quality and style. The pencil barrel itself may be natural or coloured, with a contrasting dipped end to aid identification. The pencils are finished using a unique UV process developed by Derwent as a more environmentally friendly alternative to lacquering. After shaping the pencils and rounding the edges, the pencils are imprinted with manufacturing information then automatically sharpened to a fine point. |
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Dipping for DistinctionDipping not only gives Derwent pencils a distinctive look but helps to identify the pencil range and exact colour. They are dipped twice at an angle, but dipped at a different length to create a stripe between the barrel and pencil end. The stripe identifies the pencil range while the end dip identifies the colour. This final dip is done using paints mixed on site to ensure an identical colour match. |
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Packed to PerfectionThe completed pencils are stored in batches according to type or colour, then packed on demand. It can take up to 17 people to pack a tin of 72 pencils while a 12 tin takes eight – packing two tins at a time! Once the tins are full, the contents are shrink-wrapped for protection before the lids are put on. The finished product is then shrink-wrapped again to keep it looking pristine. Despite the manual effort involved, our packers can pack up to 1200 tins of 12 pencils per hour or up to 600 tins of 72. |
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How Pencils Were Made
The basic principles of pencil making have remained the same over the centuries, although production methods have obviously changed considerably. Essentially, a colour or graphite strip is sandwiched between two pieces of wood then cut and finished into the shape required. This is now almost a fully automatic process whereas at one time every single stage was carried out by hand. Let’s take a look back at how pencils were made in the Derwent factory long ago.
Creating the woodcaseEntire logs of incense cedar were shipped to the factory from South America and laboriously sawn up into different lengths. These were then cut into thin planks and a channel grooved out to accept the graphite pieces. A further plank was cut to eventually fit on top. The continual hum of the saw and clouds of wood dust created must have made this a very unpleasant working environment. |
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Assembling the pencilsThe next stage was to glue the graphite pieces into the pencil grooves. Sometimes the pieces had to be rubbed down to fit and up to four might be needed to create a single pencil. Any surplus graphite was simply scraped away. (This was a messy process and the workers looked like chimney sweeps by the end of the day!) A further piece of wood was then glued on top and several of these pencil ‘blocks’ were clamped together and left to dry. Each was then passed through a machine with a revolving cutter to create the familiar round pencil barrel. |
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FinishingThe completed pencils were then smoothed with a plane and polished by manually rubbing them up and down in a leather covered roller and board. Varnishing the pencils was a later development designed to enhance the natural colour of the wood. It also helped prevent the pencils getting dirty during the latter stages. Finally, the pencils were cut into uniform lengths with a saw and trimmed as necessary with a razor blade. The pencils were then stamped with the company name and pencil type, either by a simple impression or by hand gilding in gold or silver leaf. |
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PackingToday, Derwent pencils are presented in a variety of attractive packaging to appeal to artists worldwide. However, in those early days the pencils were simply tied up in dozens and then in half grosses (i.e. 72s), ready for sale. Although highly labour-intensive, the original factory could turn out 5 – 6 million pencils a year (although today it is not unusual for us to produce 1 million in a week!) |
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