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FIREWORKS MANUFACTURE

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HOW PROFESSIONAL FIREWORKS ARE MADE

Photo by Hanabi Home Page How do they make the shells that are launched at fireworks displays? Here is the general manufacturing process of round shells. Of course, all pyrotechnicians have different methods, but everyone can understand the basic outline of a manufacturing process.

Making shells for fireworks is mainly handcrafted process even today. Naturally, there is some mechanized process involved, like making star pellets, but greater part of the process must be handmade. Master craftsmen used to handle risky powder by the tips of their fingers, carefully evaluating the condition of the powder. The careful work by hands is still unchanged by today's masters.

MAKING ROUND SHELLS

The simple outline above explains the process. The process is divided into three parts, namely: Compound chemicals, Making each unit parts, Setting up into casing. Parts that use powder or chemicals, and Making stars. Others, making breaking powder. Today, parts like casings or main fuses are ready-made goods. But in the case of shells, some pyrotechnicians who aim at high-quality finish are manufacturing each principal parts by hand even today.
For example star, vary in size, color, shape, and change color depending each size and kind of shell. Pyrotechnicians manufacture many kinds of stars and parts. There is a process of drying up shells in the sun between each manufacturing step. It is very important step for making shells safe.

MAKING STARS AND BREAKING POWDER

"Star" is the most important piece of part for making up a shell. All Photo by Pyro Art Int'l process needs conscientious work. But nothing is more important to fireworks than stars. For any pyrotechnician, "Star" holds first important place of parts for making up a shell. All process of making a shell is important. All process needs conscientious work. But nothing is more important to fireworks than stars. For any pyrotechnicians, most concentrate their efforts on making stars. Characteristic color and changing color reveals originality and ability of each pyrotechnician. In case of Japanese round shells "Warimono", one of the condition of well-made shell is keeping pace in changing color of stars. All stars must change color and burst all together. Therefore, all stars packaged in a shell must be manufactured with same quality and in same size.
Coated star (Kake-boshi ) is the strongest point of only Japanese fireworks.
Photo by Pyro Art Int'l Breaking powder in center of each shell that scatters each stars far away is made by the same process like star. It's made by coating black powder using star rolling machine over fruit of cotton that will be core of breaking powder.
Powder is very thin coated and shaped into a star, then placed on drying table and dried in the sun. The process of making stars, is repeated and elaborately molded little by little to finished size. This is never done in a short period of time. Careful attention must be given so that this work (that is little shaping and drying) does not result in a homogenize effect of drying up of the inside content of the star.

DISPLAY SHELL MANUFACTURING PROCESS

Ever wondered how professional fireworks are made? Here is closer look at an example of set up process for display shells.

1. Fireworks start as rocks in limestone caves. Miners dig out the rocks and send them off to a gunpowder factory.	2. The limestone is ground with potassium nitrate, sulfur and charcoal to create gunpowder for use at the fireworks plant.
3. Inside, the gunpowder is combined with a coloring agent and oxidizer.	4. The powders are carefully sifted through a brass screen which does no create sparks.
5. Next, the powder is mixed with water in a tumbler, creating a soft dough.	6. The dough is then cut into different shapes called stars. Stars have a tremendous influence on the end result.
7. Cardboard is cut, molded into shells, and soaked in a special paste to give extra resistance from explosion.	8. Stars and special noisemakers add all the booms and bangs.
9. These are all packed into the shell.	10. Finished stars are placed inside of half package shell. Main fuse is placed into the other half of shell.
11. Wrapped up breaking powder is placed in a separate paper inside the center of shell.	12. This hemisphere represents one unit, two units make one shell.
13. Each half unit is held with both hands. Such set up method is called "Pacckuri".	14. The two halves are then quickly put together at their equator.
15. After remaining paper is cut off, it is temporarily wrapped around with tape holding it together.	16. Face paper is applied over the shell.
17. Next, a Kraft paper is pasted over and over.	18. Kraft paper is rolled into a spherical shape six or seven layers thick.
19. The shells are sealed tightly and allowed to dry outside in the hot sun.	20. This process is repeated several times.
21. The completion of one shell may take several days.	22. Next, a worker attaches three fuses and temporarily wraps it in aluminum foil.
23. A bag containing a lift charge is attached to the bottom.	24. A close-up of lift charge, made of gunpowder mixture.
25. A propellant charge lifts each shell hundreds of feet into the air.	26. A leader, or a fuse, provides a delay between lighting and launching.
27. A bursting charge ruptures the casing and ignites numerous small pellets.	28. Finally, product labels are pasted on each of the shells.
29. Close-up manufacturers' labels on 3" shells.	30. Fireworks storage facility. Shown here are final cases of Sunny brand shells.
31. The fireworks are then stored in bunkers (called magazines) far apart from each other in case of explosions.	32. The final result. A shell break.

MAKING VARIOUS SHELL PATTERNS

Following is a process of manufacturing certain pattern shells. This cutaway view shows how each half of the shell is packed to create certain patterns in the sky.

Single Petal with Pistil Round Shell

Final Result

Red & Green Double Rings Shell

Final Result

Special Pattern Multi Rings

Final Result

Single Silver Ring Shell

Final Result

Red Smiley Face

Final Result

Special Pattern Red Butterfly

Final Result

FACE PAPERS AND DRYING OF SHELLS

Face paper is most important in the set up process. For a round shell to bloom in a fine circle and larger shape, the role of power of breaking powder, and more important "tension of casings" plays a major role. When casings deter burst moderately, shell blooms in larger circle. Size of blooming circle and scattering speed of stars depends on both tension of casings and power of burst balance. Every pyrotechnician has its own balance. So this balance is one of their personalities as far as style. Face paper and drying in the sun give tension of casings to shell.

Photo by Japan-Fireworks Home Page The process is finished with pasting of Kraft paper over and over the outside casings of each shell. This process is also handcrafted. How much of paper pasting usually depends on the size of each shell. This also varies from each pyrotechnic craftsmen. After it is dried in the sun, this process is repeated several times and may take several days. Finally it is ready to be tested in the night sky. When it blooms on a large scale in the night sky, it is only then that the master craftsman's work is truly finished.

(Translated Articles Courtesy of Japan-Fireworks.com, photos courtesy of Pyro Art and Japan-Fireworks.com)