Very few people will ever witness the making of an American icon from start to finish. Tours of the Zippo factory in Bradford Pennsylvania are a very special occurrence. But, we have created a four part series, showcasing the creation of the world famous Zippo lighter.
Twenty-two different parts. One hundred eight manufacturing operations. That is what it takes to create the Zippo windproof lighter that collectors cherish.
Zippo currently produces approximately 45,000 lighters per day. Every Zippo lighter begins in the Receiving, Case Fabrication, and Buffing Departments at the factory in Bradford, Pennsylvania.
"Hopefully, by the time you read the last article in the series, you will share the pride and ownership each Zippo employee has in building a classic quality product," Fred Blackburn, Vice President of Operations, said.
Let's start at the very beginning...
Every day, trucks deliver the large coils of brass and other materials we use to build Zippo lighters. "The receiving stage has been streamlined due to the radio frequency system installed last year. Previously, all transactions were entered into the computer by hand," said Sandy Williams, Receiving Department supervisor.
Zippo lighters are crafted from the finest metals including brass, stainless steel, sterling silver, 18-karat gold, copper, and titanium. "Only the finest quality metals are used to make a Zippo lighter," Williams stated.
Things are taking shape...
In the Case Fabrication Department, large coils of metal are made into Zippo lighter cases. Separate machines produce the top and bottom of each case. Two types of presses, progressive die and transfer, are used in this process.
Most brass and copper cases are made on presses that use a series of progressive dies to cut and form the metal. First, an oval-shaped piece, called a blank, is cut from the coil. A metal webbing is stamped out of the blank holding the case in place as it continues through the press. The bottom of each case is stamped and the bottom is formed. The case takes shape as it passes through the press and is trimmed in this same machine. The parts are then sent to welding machines that complete the case.