Silk Flower Basic - part 2

Currently, most silk flowers (or artificial flowers, outside the United States) are made of polyester fabrics, e.g., pongee, taffeta, micropeach, satins, velvets, organza, and others, because the cost of polyester fabrics is low, and this is beneficial to manufacturers and purchasers alike. Some other materials include latex, EVA and plastics, and of course, some real dried plants. Some of the fancier types of flowers are made of silk, rayon and cotton, and dyes and glues are nearly always made from natural ingredients. The manufacturing process for silk flowers is a detailed one. First, the fabrics are cut into shapes using die-cutters made of iron; each petal or leaf shape having its own die-cutter. The fabric is folded into layers and put into the die-cutter, so that many shapes can be cut at once. Approximately 36 pieces are made per each die-cut, depending on the thickness of the fabric. The pieces are then bundled together with a rubber band, each bundle containing 576 pieces. The petals and leaves and other shapes are then dyed, (some finer flowers and flower types require hand-dying, which can take up to an hour per petal). A bundle of petals is first soaked in water and a chemical mixture and then painted with dye, using paintbrushes to touch color onto the petals, beginning with the edges of the petal and working in towards the center. After the dyeing process, several bundles are put into a centrifuge which will remove the water and evenly distribute the dye. The petals are then steamed for one to two hours, and dried in an oven for two to three hours to set the dye.

The leaves and petals would not look natural without their distinct wrinkles, curves and veining, and to get this effect, the petals and leaves are placed into heated molds made of copper. The molds are approximately 200 degrees Celsius, and after this heating process, the proper colors from the dyes appear, and some petals and leaves are then stiffened with plastic veins which are attached onto the backside with a plastic injection machine. Many of the flower parts themselves are made from LDPE (Low Density Poly Ethylene) and are made by large automatic and semi-automatic injection machines, the molds being made of steel. Some final processes can include flocking, so that white glue must be added, and then, a latex coating may be added to stems and petals when necessary, which may take up to several hours. Lastly, the flowers must be assembled and are then packed individually by hand, depending on what the order requires, be it single stems, bouquets, pre-potted flowers, or garlands, and so on.

The manufacture of silk flowers is an involved process requiring skillful handiwork. Two different flower manufacturers might make a similar flower, but it may look completely different because of the varying degree of the quality in the raw materials, and the production methods used. We use only the best fabrics, dyestuffs, and manufacturing processes so that we can provide you, our customers, with a flower as beautiful as Nature made, but one which will last and last.

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