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Modular/stackable set of 14 components that can be easily re-arranged into 5 different iterations. Each iteration is capable of brewing coffee using a different method, giving the brew a unique flavour.

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Includes;
- Description of each component
- Materials
- Manufacturing method
- Manufacturer sources
- Costing

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Steel tube twisted into place within underside of funnel

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Water poured into metal compartment

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- Funnel and tube sub-assembly placed into metal compartment as shown, with funnel resting on internal rim of metal compartment.
- Connector component twisted onto threaded rim of metal compartment

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- Long filter component inserted into hole as shown, the studs holding it in place.
- Glass compartment screwed onto rim of connector component.

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- Ground coffee poured into top compartment.
- Lid screwed on top.
- Place on top of stove, the water in the bottom compartment will boil and the increased pressure will force it up the tube into the glass compartment. Coffee brews at the top.

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- Take off heat, allowing the pressure to decrease and the brewed coffee to filter down into the bottom component.
- Unscrew and remove connector piece.
- Slide handle onto metal compartment and pour coffee.

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This is the concept and design I produced in a project last year. I believe there is scope for improvement, especially considering the complexity of the design.

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- Scale research
- Comparison to existing products

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- Scale research
- Volume calculation

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- Scale research
- Comparison with similar products

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- Adjustable faux leather or rubber straps with handle
- Fits around machine any order to dispense coffee

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price vs thermal conductivity
+water durable

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price vs max temp
+water durable

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Price v thermal conductivity

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- Borosilicate glass is very sturdy. It is more resistant to thermal shock than other types of glass and therefore less likely to break when heated.

The chemical properties of borosilicate glass make it remarkably strong and able to handle temperature extremes. If it does break, it is more likely to crack rather than shatter. American-made Pyrex used to use borosilicate glass for kitchenware, but has since switched to tempered soda-lime glass.

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What is borosilicate glass?

Borosilicate glass is a type of glass that contains boron trioxide which allows for a very low coefficient of thermal expansion. This means it will not crack under extreme temperature changes like regular glass. Its durability has made it the glass of choice for high-end restaurants, laboratories and wineries.

What most people don't realize is that n ot all glass is created equally. Take our high-grade borosilicate Kablo bottles for example.

Borosilicate glass is made up of about 15% boron trioxide, which is that magical ingredient that completely changes the behavior of glass and makes it thermal shock resistant . This allows the glass to resist extreme changes in temperature and is measured by the "Coefficient of Thermal Expansion," the rate at which the glass expands when it is exposed to heat. Thanks to this, borosilicate glass has the ability to go straight from a freezer to an oven rack without cracking. For you, this means you can pour boiling hot water into borosilicate glass if you wanted to say, steep tea or coffee, without worrying about shattering or cracking the glass.

What's the difference between borosilicate glass and soda-lime glass?

Many companies choose to use soda-lime glass for their glass products because it is less expensive and readily available. It accounts for 90% of manufactured glass worldwide and is used for items like furniture, vases, beverage glasses and windows. Soda lime glass is susceptible to shock and does not handle extreme changes in heat. It's chemical composition is 69% silica (silicone dioxide), 15% soda (sodium oxide) and 9% lime (calcium oxide). This is where the name soda-lime glass comes from. It is relatively durable at only normal temperatures.

Borosilicate glass is superior

The coefficient of soda-lime glass is more than double that of borosilicate glass , meaning it expands more than twice as fast when exposed to heat and will break very quickly. Borosilicate glass has a much in comparison to regular soda lime glass (80% vs. 69%), which makes it even less susceptible to fractures. higher proportion of silicon dioxide

In terms of temperature, the maximum thermal shock range (the difference in temperatures it can withstand) of borosilicate glass is 170°C, which is about 340° Fahrenheit . This is why you can take borosilicate glass (and some bakeware like Pyrex-more on this below) out from the oven and run cold water over it without shattering the glass.

*Fun fact, borosilicate glass is so resistant to chemicals, that it is even used to store nuclear waste . The boron in the glass makes it less soluble, preventing any unwanted materials from leaching into the glass, or the other way around. In terms of overall performance, borosilicate glass is far superior to regular glass.

Is Pyrex the same as borosilicate glass?

If you have a kitchen, you've probably heard of the brand name 'Pyrex' at least once. However, borosilicate glass is the same as Pyrex. When Pyrex first hit the market in 1915, it was initially made from borosilicate glass. Invented in the late 1800s by German glassmaker Otto Schott, he introduced the world to borosilicate glass in 1893 under the brand name Duran. In 1915, Corning Glass Works brought it to the U.S. market under the name Pyrex. Since then, borosilicate glass and Pyrex have been used interchangeably in the English-speaking language. Because Pyrex glass bakeware was initially made of borosilicate glass, it was able to withstand extreme temperatures making it the perfect kitchen staple and oven companion, contributing to its huge popularity over the years.

Today, not all Pyrex is made of borosilicate glass. Some years ago, Corning switched the material in their products from borosilicate glass to soda-lime glass, because it was more cost-effective. So we can't really be sure what is actually borosilicate and what is not in Pyrex's bakeware product line.

What is borosilicate glass used for?

Because of its durability and resistance to chemical changes, borosilicate glass has traditionally been used in chemistry labs and industrial settings, as well as for kitchenware and premium wine glasses. Because of its superior quality, it is often priced higher than soda-lime glass.

Should I switch to a borosilicate glass bottle? Is it worth my money?

Gr eat improvements can be made with small changes to our everyday habits. In this era, buying disposable plastic water bottles is just plain silly considering all the alternative options available. If you are thinking about buying a reusable water bottle, that's a great first step in making a positive lifestyle change. It's easy to settle for an average product that is inexpensive and does the job, but that's the wrong mindset if you are looking to improve your personal health and make positive lifestyle changes. Our philosophy is quality over quantity, and purchasing long-lasting products is money well-spent. Here are some of the benefits of investing in a premium reusable borosilicate glass bottle.

It's better for you. Since borosilicate glass resists chemicals and acid degradation, you don't need to worry about stuff seeping into your water. It's always safe to drink from. You can put it in the dishwasher, put it in the microwave, use it to store hot liquids or leave it out in the sun. You won't have to concern yourself with the bottle heating up and releasing harmful toxins into the liquid you are drinking, something very common in plastic water bottles or less expensive stainless steel alternatives.

It's better for the environment. Plastic water bottles are terrible for the environment. They are made from petroleum, and they almost always end up in either a landfill, lake or ocean. Only 9% of all plastic gets recycled . Even then, often times the process of breaking down and reusing plastics leaves a heavy carbon footprint. Since borosilicate glass is made from naturally abundant materials that are more easily acquired than oil, the environmental impact is also smaller. If handled with care, borosilicate glass will last a lifetime.

It makes things taste better. Have you ever drank from plastic or stainless steel bottles and tasted the plastic or metallic flavor from which you are drinking? This occurs because it is actually seeping into your water due to the solubility of the plastic and steel. This is both harmful to your health and unpleasant. When using borosilicate glass the liquid inside remains pure, and because borosilicate glass has low solubility, it keeps your beverage free from contamination.

While the different variations may look similar, they are not the same. Borosilicate glass is a significant upgrade from traditional glass, and these differences can make a big impact on both your personal health and the environment when compounded over time.

We've designed Kablo bottles so that you can maximize the health benefits of drinking water. A wide mouth provides ample room for ice cubes, fruit or herb infusions, and you may use your Kablo bottle to steep your favorite tea or coffee (safely). It saves time and money because you can prepare and enjoy your own beverages in advance, instead of buying pre-bottled health tonics and pressed juices in plastic disposable containers. It takes time to transition to a greener, more conscious lifestyle. But with the right mindset and concentrated effort, we can all get there. An eco-friendly water bottle is just one step we can take towards a smarter, more sustainable lifestyle.

p.s. have you joined our newsletter yet? Subscribe for occasional updates with green-living tips, stories from people who inspire us, special promos and more.

You can also follow along on Instagram: @kablo_official

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What Is Borosilicate Glass And Why Is It Better Than Regular Glass?

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What is borosilicate glass? Borosilicate glass is a type of glass that contains boron trioxide which allows for a very low coefficient of thermal expansion. This means it will not crack under extreme temperature changes like regular glass. Its durability has made it the glass of choice for high-end restaurants, laboratories and wineries.

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- Stainless steel electric kettles do not rust or tarnish. Stainless steel can withstand high temperatures and frequent contact with water and still retain a bright and shiny appearance. This makes it an attractive material for use in electric kettles and other domestic appliances.

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kettle and teapot image by Maria Brzostowska from Fotolia.com

Manufacturers use stainless steel to make electric kettles because it is durable and resistant to corrosion. Stainless steel contains chromium, which, according to The International Stainless Steel Forum is what "makes stainless steel 'stainless.

'"

History

accÃ©ssoires 309 image by Jacques Ribieff from Fotolia.com

Early electric kettles featured metals such as copper, nickel and chrome-plated copper. Stainless steel kettles first appeared in the 1950s. The first fully automatic kettle was the stainless steel K1, produced by the British company Russell Hobbs in 1955.

Benefits

Stainless steel background - pattern / texture image by Suto Norbert from Fotolia.com

Stainless steel electric kettles do not rust or tarnish. Stainless steel can withstand high temperatures and frequent contact with water and still retain a bright and shiny appearance. This makes it an attractive material for use in electric kettles and other domestic appliances.

Considerations

Stainless steel electric kettles get very hot and need careful handling. In the 1970s, manufacturers began making kettles from polypropylene. Plastic kettles offer a safer, lighter and more heat-resistant alternative to stainless steel. Consequently, the majority of electric kettles manufactured today are made of plastic rather than stainless steel.

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Why Is Stainless Steel Used for Electric Kettles?

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kettle and teapot image by Maria Brzostowska from Fotolia.com Manufacturers use stainless steel to make electric kettles because it is durable and resistant to corrosion. Stainless steel contains chromium, which, according to The International Stainless Steel Forum is what "makes stainless steel 'stainless.

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- High-grade steel is typically used for the inner working of all-metal kettles. They are low density, have heat resistant plastics, such as polyethylene(LDPE), polypropylene (PP), or polystyrene(PS).
- For top-quality kettles, high-grade steel is commonly used for the inner structure. In fact, high-grade steel is the most common material used for creating the outer shell of a kettle. The shell is created by using a punch press to cut steel sheets and create steel stampings.
- Stove top kettles tend to be made of sturdier raw materials. This is because they are often placed over very hot heat sources for long periods of time. They can be placed on stoves, gas hobs, fires and conduct the heat from these sources from up to 10 -20 minutes before they are at boiling point.

Some are made with stainless steel and zinc to make sure that this pot doesn’t rust, these high-quality materials and made to retain the heat inside. This means that your water will boil faster and it will actually stay hot a lot longer than with electric kettles.

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While I'm making a hot brew, I look around my kitchen at all the appliances. I then focus back on my kettle, a metal green SMEG. It's gleaming back at me with its metallic sheen. Suddenly, a thought comes to mind, why are kettles made of metal?
So I did a bit of research and found out the following. Most kettles are made of metal because it is required for conducting heat. A substance that didn't conduct heat would make a terrible water heating device. High-grade steel is typically used for the inner working of all-metal kettles. They are low density, have heat resistant plastics, such as polyethylene(LDPE), polypropylene (PP), or polystyrene(PS). In some models, they also make up the upper structure of the unit. While others have metal enclosures on the bases that contain the heating elements.
What else are kettles made of?

Depending on the design of the kettle, the type of raw materials to make it can vary. This depends on the quality of the kettle.

For top-quality kettles, high-grade steel is commonly used for the inner structure. In fact, high-grade steel is the most common material used for creating the outer shell of a kettle. The shell is created by using a punch press to cut steel sheets and create steel stampings.

This steel is also used to create a solid base that houses the electrical components. Some of the cheaper options on the market may just be comprised of aluminum.

In electric kettles, the heating element is the most vital part of boiling water in the unit. Because of this, it needs to be made of metal. If you were to open up an electric kettle and look at the bottom of the container. You will see the heating element. This heating element powers the kettle heat capabilities.

Over long periods of use, i.e a few years these heating elements are susceptible to burning out. It usually cannot be replaced and in these instances are new kettle is usually bought.

What were kettles originally made of?

The tea kettle's origins can be traced back to the cooking kettle that was placed on an iron post in the cooking fire. An external metal hook was turned to move the kettle directly over the fire, and a makeshift tilting process helped to pour water from the kettle.

Originally, kettles were made of iron, one of the first metals to be mined and processed.

I found the following extract from MadeHow:

In Japan, the iron cooking kettle became a small, rounded bowl with two short arms or loops (one on either side of the bowl) for pulling it off the hearth and a lid. A classic example of a bowl-type iron kettle dates from 1517. As methods of casting iron became more sophisticated, the outsides of these kettles were decorated, and the two arms became a spout and better handle. Iron casters who made tea kettles were highly respected.

What is a kettles heating element made of?

Many heating elements inside tea kettles are comprised of Nichrome, 80% nickel and 20% chromium, wire, ribbon or strip. Nichrome benefits from having a relatively high resistance, and therefore is an ideal material for heating water.

According to Kettle Heating Element:

This oxide coating prevents the wire inside the application from burning away or breaking. In most heating elements, the element is well insulated and fully embedded into an outer copper housing which is chrome plated to help delay corrosion from the water surrounding it, which is heated by the element.

When lifting the lid and taking a look at the very bottom of the container, you will see a thick metal called the heating element. Such hidden element work very well, but still holds disadvantages, one being that when the element burns out it cannot be replaced and a new kettle has to be bought.

Are Electric Kettles made of metal?

Electric tea kettles are made primarily made of steel, iron, silver, aluminum, or a combination of plastic and metal.

The electrical components of an electric kettle include the heating element, a thermostat, which turns off the kettle automatically when finished boiling, a wire linking the element to the cord, and the plug.

And for kettles with a base unit, this base container provides power to the heating element.

However, electric kettles can be categorized as either metal or plastic. In both these cases, the heating element will still be made of thick metal.

The advantages of electric metal kettles are that metal, like stainless steel, can be more durable when heated. This can make the water used flavor neutral compared to a primarily plastic electric kettle.

Another advantage of stainless steel teakettles is that being dishwasher safe. Porcelain exterior teakettles i.e some stovetop kettles are not dishwasher safe.

Having the water be flavor neutral leads to a hot brew having an unaffected taste, which is very important.

On the flip-side, after the heat has been removed, electric plastic kettles keep their contained water hotter for longer. This is because they conduct heat more slowly than metal.

This benefits those going back for a second hot brew. and don't want wait around reheating their kettle. Oh and if you didn't already realize from the intro, my green SMEG kettle (Amazon affiliate) is my electric beacon of hot brew. It's a stylish sturdy solid piece of tea making material and I'd recommend you have a gander at it.

Are Stove top kettles made of metal?

Stove top kettles tend to be made of sturdier raw materials. This is because they are often placed over very hot heat sources for long periods of time. They can be placed on stoves, gas hobs, fires and conduct the heat from these sources from up to 10 -20 minutes before they are at boiling point.

Some are made with stainless steel and zinc to make sure that this pot doesn't rust, these high-quality materials and made to retain the heat inside. This means that your water will boil faster and it will actually stay hot a lot longer than with electric kettles.

A lot of stovetop kettles are renowned for whistling at boiling point. Stovetop kettles whistle because they consist of two parallel metal plates with a hole running through them through which steam passes. The whistling sound is the result of this flow of steam making the air vibrate rapidly. Stovetop kettles, in the 17th century, were originally made of iron.

Iron kettles could withstand cooking fires, so they needed to be made out of these harder substances.

While the materials inside both stove top kettles and electric kettles can be varied, they all seem to serve the same purpose. To heat up water efficiently through their own sources of heat. While this might seem obvious, being made with metal appears to be the most efficient raw material to serve this purpose.

It's ability to conduct heat and its availability for manufacturing is unrivaled amongst other raw materials.

Who would have known!?

Recent posts

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Why is a Kettle Made of Metal? | Little Home Appliance

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While I'm making a hot brew, I look around my kitchen at all the appliances. I then focus back on my kettle, a metal green SMEG. It's gleaming back at me with its metallic sheen. Suddenly, a thought comes to mind, why are kettles made of metal?

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- Steel sheets are primarily used in the manufacturing of the electric kettle, as seen in the video “China electric kettle factory”. Hot rolling, a forming technique where heated steel is passed through huge rolls, is used to shape slabs into plates, strips, and sheets. The next step is annealing, in which the steel is heated and cooled to relieve internal stresses and soften the metal; in some cases, it can be used to make the steel stronger. However, annealing causes scales and build up to form on the steel. Descaling can be performed in two ways, the first being pickling, where steel is put into a nitric-hydrofluoric acid bath, and the second being electrocleaning, where an electric current is applied to the surface of the steel through a cathode and phosphoric acid. For steel sheets and strips, cold rolling, a process where steel is passed through rolls at a low temperature, is done to make the sheet thinner. Afterwards, the steel sheets and strips are annealed and descaled again. Next, the sheets are cold rolled and cut into desired shapes. Finally, the steel is polished and a surface finish is applied to the steel.
- The electric kettle requires heat resistant plastics, such as polyethylene (LDPE), for the plastic buttons, displays, handle, lid, bottom casing, and electrical cord (“Electric Tea Kettle”).
- The stovetop kettle simply involves wielding, shaping, and polishing the steel pieces together (BRANDMADE.TV). There are no new materials added in the manufacturing process. The rubber handle is molded to fit snugly onto the shape of the steel handle. It is not affixed by any adhesive, but instead uses the tactility of rubber itself and the tightness to hold onto the steel. The stove top kettle is more environmentally friendly than the electric kettle because it requires less manufacturing steps due to having fewer materials.

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Rochelle Dai

DES 40A

Professor Cogdell

6 December 2018

Electric Kettle Life Cycle Analysis: Materials

Electric kettles are a common kitchen appliance used to boil water for brewing tea or powdered drinks along with cooking ramen and other instant foods. The device must be plugged into an electric socket in order to work. When the consumer presses the "on" switch electricity flows to power the coils stored in the bottom component to heat the water sitting in the kettle. The Hamilton Beach Electric Kettle 40901 has a steel body with plastic components and electric cord. The electric kettle has a larger negative environmental impact than the stove top kettle because the larger variety in raw materials calls for more processes in the acquisition of materials, manufacturing, and recycling.

The electrical kettle requires more processes in the acquisition stage because it is made up of more raw materials than the stove top kettle, but both contain steel and rubber. The electric kettle is composed of steel, low density polyethylene (LDPE), rubber, copper, brass, and zinc. Steel is used to make the body of the water pitcher. LDPE is used for the handle, lid, buttons, bottom casing, heating component casing, and the outside of the electrical cord and plug. Rubber is used for the feet of the kettle, which elevates it from the surface. Copper, bass, and zinc are used in the electrical cord and plug. The stove top kettle only contains steel and rubber. The whole kettle is made of steel, and the rubber is used for the handle cover.

Stainless steel makes up the body, or the pitcher part, of the electric kettle. Stovetop kettles are entirely made up of stainless steel. Rocks containing iron ores are mined from open-pit iron ore mines in Michigan and Minnesota, according to the USGS. Rocks containing iron ore are then refined and ores are extracted by magnetic rollers. Iron ore and carbon are heated together in a blast furnace to create pig iron, which is also known as molten iron. There are two different furnaces that can be used to produce steel: basic oxygen furnaces and electric arc furnaces. Basic oxygen furnaces require molten iron ore to be mixed with steel scrap and alloys to produce steel. For electric arc furnaces, recycled steel scrap is directly melted into new steel ("From Ore to Steel", n.a.). The molten steel is created from the furnace(s) and then casted into slabs for flat sheets, blooms for rectangular shapes, billets for round or square shapes, and rods. Steel sheets are primarily used in the manufacturing of the electric kettle, as seen in the video "China electric kettle factory". Hot rolling, a forming technique where heated steel is passed through huge rolls, is used to shape slabs into plates, strips, and sheets. The next step is annealing, in which the steel is heated and cooled to relieve internal stresses and soften the metal; in some cases, it can be used to make the steel stronger. However, annealing causes scales and build up to form on the steel. Descaling can be performed in two ways, the first being pickling, where steel is put into a nitric-hydrofluoric acid bath, and the second being electrocleaning, where an electric current is applied to the surface of the steel through a cathode and phosphoric acid. For steel sheets and strips, cold rolling, a process where steel is passed through rolls at a low temperature, is done to make the sheet thinner. Afterwards, the steel sheets and strips are annealed and descaled again. Next, the sheets are cold rolled and cut into desired shapes. Finally, the steel is polished and a surface finish is applied to the steel. The Hamilton Beach Electric Kettle 40901 has a bright and shiny surface, which is accomplished by hot rolling then cold rolling polished rolls ("Stainless Steel").

The electric kettle requires heat resistant plastics, such as polyethylene (LDPE), for the plastic buttons, displays, handle, lid, bottom casing, and electrical cord ("Electric Tea Kettle"). Low Density Polyethylene (LDPE) is created under high pressure at moderate temperatures (Lazonby). The process is called rapid polymerization, and it requires oxygen and ethene to work. Ethene itself is produced by heating natural gas or petroleum (Carey).

The bottom of the electric kettle is elevated off the ground/surface by three rubber feet so that the surface does not suffer from heat damage (Stewart). Synthetic rubber is assumed to be used in the electric kettle, contrary to natural rubber, due to the heat resistant qualities and resistance to abrasion (Labbe). Synthetic rubber is made from oil or coal. The refining process of the two materials produces naphtha, which is then combined with natural gas to produce monomers. Monomers are treated by polymerization to form chains of polymers. The end result is rubber substances. Vulcanization processes these substances into rubber products, such as the electric kettle feet and the stovetop kettle handle cover ("Production of Synthetic Rubber").

The electrical wires connecting the electric kettle to the power source are made of copper. Copper ores can be found throughout the Earth's crust as sedimentary or igneous rocks. Chile and the west coast of South America contain the world's largest copper ore deposits. 90% of copper ores are mined using the open-pit method, compared to the underground method which requires a vertical shaft and horizontal tunnels into the earth. The process of producing copper starts with crushing the ore using cylindrical ball mills. Next, the powdered ore is combined with paraffin oil, which is used to waterproof the particles. The mixture is placed into a water bath and foaming agent solution which creates a frothy liquid bath. The copper minerals get caught in the bubbles/ froth at the top and the undesirable rocks fall to the bottom of the bath. The ores floating on the surface of the bath are collected and all remaining materials are recycled. The copper ores are roasted to create copper metal. However, a byproduct of this process is sulfur dioxide, which is converted to sulfuric acid to prevent the gas from being released into the environment. Next, calcine is heated with silica or limestone to create a smelter, which removes the impurities. The remaining liquid is copper and iron sulfides, also known as matte. The matte is oxidised, and the result is called blister copper, which is 99% pure copper. The copper is casted, purified by electrolysis, and finally molded into slabs. After electrolytic refinement, the material is 99.99% pure copper ("Copper Mining").

The power plug of the electrical kettle is composed of brass and nickel plating. Brass is considered a copper alloy because it is a mix of copper and zinc. Zinc is found in the earth's crust and is mostly mined underground, contrary to open pit mining. The mined zinc is heated and then put through the hydrometallurgical process, which involves leaching, purification, electrolysis, and melting. Emissions to the air is a by product of this process in each step ("Zinc production"). To create brass, copper and zinc are melted together and cooled until a solid state. Similar to the production of copper, the production of brass includes hot rolling, annealing, and cold rolling, respectively, to turn the brass into desired shapes ("Brass"). The nickel plating of the brass in the electric plug of the electric kettle prevents tarnishing and discoloration. Similar to copper, nickel is mined underground, crushed, filtered by floatation, and electro refined (Wise, Edmund).

The variety of materials used in the electric kettle compared to the stove top kettle affects how many and what processes occur in the manufacturing stage. Both kettles require welding, the process of bonding metal together, which also means more new metal (assumed to be steel) is needed (Woodford). Producing the electrical cord involves assembling the raw materials together (copper, low density polyethylene, brass, nickel) but also requires the addition of high density polyethylene (Powell). High density polyethylene is created by applying immense heat to petroleum and casting the liquid-like material into shapes ("How Is HDPE"). As for plastic, it is unclear if the Hamilton Beach uses adhesives such as epoxy to join the plastic to metal. It could be that the plastic is designed to be cut into certain shapes to lock and snap into the metal. One can peer into the electric kettle body and see that the plastic handle and lid are joined by screws, which seem to be made out of steel. This joining mechanism may or not be applied for the other plastic parts, such as the bottom casing and bottom heating component. Judging from the bottom of the electric kettle, the rubber is molded into tiny cylinders to fit into the three small, plastic cylindrical feet.

The stovetop kettle simply involves wielding, shaping, and polishing the steel pieces together (BRANDMADE.TV). There are no new materials added in the manufacturing process. The rubber handle is molded to fit snugly onto the shape of the steel handle. It is not affixed by any adhesive, but instead uses the tactility of rubber itself and the tightness to hold onto the steel. The stove top kettle is more environmentally friendly than the electric kettle because it requires less manufacturing steps due to having fewer materials.

The electric kettle and stove top kettle have the same materials in the distribution and transportation stage because both products are packaged in cardboard boxes and delivered to stores via trucks, which require fuel. Cardboard's primary materials are pine trees, corn starch, and paraffin wax. Only the trunks of pine trees are used for the production of cardboard, where wood chips are broken down into fibrous pulp. The pulp is shaped, pressed, dried, and rolled to be used in cardboard ("Corrugated Cardboard"). Corn starch is mixed with water and other chemicals to be used as an adhesive for the corrugated medium and outside cardboard sheets.Corn starch is produced through a process called wet milling, where the corn is soaked in water and then put into a centrifuge to separate the different components. The starch that is separated from this process is dried. Paraffin wax is derived from crude oil and is used for the printed outside surface of the cardboard box, which gives it the waxy and shiny finish ("How Is Paraffin"). The second material, fuel, powers the trucks used to transport the kettles. Fuel is derived from crude oil, which is sucked out of the earth's crust, separated through fractional distillation, mixed with chemicals, and tested to see if the fuel is ready to use (Griffin). Neither the electric nor stove top kettle is better in terms of materials needed in distribution and transportation.

The electric kettle and stove top kettle also share the same material, limestone, in the usage section. Both products rely on a steel water pitcher body. Therefore, both suffer from the same water deposit issues such as limestone. From an environmental standpoint, both kettles are the same, and contain limestone buildup over time.

The electric kettle and stove top kettle undergo similar recycling processes due to the overlapping materials (steel, rubber), but because the electric kettle has a larger variety of materials (and therefore more recycling processes), the stove top kettle is better for the environment. Hamilton Beach offers a recycling program where consumers can mail back their broken Hamilton Beach appliances to be recycled. Hamilton Beach takes care of the recycling process if mailed back, and if not, advises consumers to recycle the electric kettle as an electronic ("Recycling Policy"). It is assumed that Hamilton Beach recycles their electric kettles the same way a recycling plant would, due to the steel body, plastic components, and electrical parts.The materials in the electric kettle, such as steel and plastic, are broken down and extracted to be reused for other products ("Electrical Items"). First, the kettle is broken down. The metals are shredded and sorted using magnets; steel can be smelted and used to make more steel ("Recycling Process"). The plastic is melted and molded into sheets to be sold to other manufacturers ("Hamilton"). Since the electrical cord is composed of metals and plastic, it uses the same recycling processes mentioned. Rubber can can either be re-used or re-melted for other purposes ("Rubber Recycling"). Since the stovetop kettle only contains steel and rubber, recycling it is simpler, and therefore requires less machinery, materials such as magnets, etc. The stovetop kettle is better than the electric kettle in the recycling process because it has less materials.

The electric kettle is worse for the environment because it requires more processes in the acquisition of raw materials, manufacturing, and recycling, due to having more materials than the stove top kettle. However, the materials involved in the distribution and transportation and usage are the same in both the electric kettle and stove top kettle.

Bibliography

BRANDMADE.TV. How the Alessi Bird Kettle Is Made - BRANDMADE.TV. YouTube,

YouTube, 3 Dec. 2015, www.youtube.com/watch?v=3tdr0-TwcDg.

"Brass." How Products Are Made, Advameg, Inc., www.madehow.com/Volume-6/Brass.html.

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Tong Su

DES 40A

Professor Cogdell

5 December 2018
Embodied Energy in the Process of Hamilton Beach Electric Kettle Production Introduction
Humankind has a history of millions of years. During this period, humans began to learn to use fire, through the stone and iron age, until the modern industrial revolution, various technological inventions have brought human civilization to an unprecedented height. At the same time, the energy consumed by humans is also growing. Today, power is the material basis for the survival and development of human society. So we can use this opportunity to explore the energy consumption and impact of modern goods in the process of manufacturing and transportation. The object I observed was the HamiltonBeach electric kettle.

Moreover, in the process, I will focus on describing the environmental impact of energy consumption. Without this, in this article, I will compare the difference in energy consumption between the electric kettle and the stovetop kettle. It should also be mentioned here that when observing the energy use in product development, we tend to focus only on the manufacturing process of the product, ignoring the energy required in the fields of raw material extraction and product transportation. So in this article, we will consider the energy use or overall energy use that is reflected throughout the life cycle of the product.
Material Acquisition
Acquiring raw materials is the first step in producing products. The HamiltonBeach 40901 electric kettle we refer to is mainly made of plastic, stainless steel, electrical components, and rubber. First, the central part of the electric kettle is made of stainless steel, and a small number of electrical components inside it are made of copper. These metal elements are all derived from iron ore or copper ore. The metal refining process mainly uses the heat energy provided by coal. The most commonly applied process for steel-making is the integrated steel-making process via the Blast Furnace - Basic Oxygen Furnace. In the process, Around 0.6 tonnes (600 kg) of coke produces 1 tonne (1000 kg) of steel, which means that around 770 kg of coal is used to provide 1 tonne of steel through this production route. Also, fuel is a non-renewable energy source. Non-renewable energy has been formed in the natural world for hundreds of millions of years. It cannot be recovered in the short term, and with the large-scale development and utilization, the reserves are getting less and less. The energy that is exhausted for one day is called non-renewable energy. When coal is burned, most of the sulfur is oxidized to sulfur dioxide (SO2), which is emitted with the flue gas, pollutes the atmosphere, endangers movement, plant growth, and human health, and corrodes metal equipment. Next is The process of Ladle Refining. Ladle Refining is a process of refining molten steel in a converter, open-hearth furnace or electric furnace to another vessel (mainly ladle), also called "secondary steelmaking or refining outside the furnace." Furnace refining divides traditional steelmaking into two steps. The first step is called primary refining. The melting, dephosphorization, decarburization and main alloying of the charge is carried out under an oxidizing atmosphere. The second step is called refining, in a vacuum, inert atmosphere - alternatively, deoxidation, desulfurization, removal of inclusions, inclusion denaturation, fine-tuning of components, control of molten steel temperature, etc. under controlled atmosphere. There are dozens of methods for refining outside the furnace, but the primary energy used in this process is the heat or electricity generated by coal. Secondly, a large amount of plastic was used in the manufacture of the Hamilton Beach electric kettle. Plastic is a polymer compound obtained by polymerization of polyaddition or polycondensation reaction using a monomer as a raw material. Most of the plastics we use today are high molecular polymers formed by polymerization of by-products obtained from fossil raw materials such as petroleum. Thermoplastics such as synthetic resins for polyolefin systems are direct products of the petrochemical industry. The production of plastics is produced by high temperature and high-pressure polymerization, which generally requires a large amount of heat and electricity. It takes about 62-108 MJ of energy to produce 1 kg of plastic.
Manufacturing, Processing, and Formulation
In general, the assembly of the electric kettle is done on the production line. This process is mainly divided into two parts. First, the factory needs to shape the raw materials obtained. Second, the developed components are assembled by working with workers and machines. In the first step, the workers first need to melt the steel and then mold the iron into different shapes through the mold. The plastic component has relatively high ductility and can be directly shaped after heating to a certain temperature. The production of plastic products generally includes the formulation, molding, joining, modification and assembly of plastics. The latter four processes are carried out after the plastic has been formed into a product or a semi-finished product, also known as plastic secondary. The method of manufacturing an electric kettle and the energy consumed in this process will far outweigh than the manufacture of a stovetop Kettle. After shaping the part, the next step is to assemble the resulting piece to get the final product. The entire assembly process of the electric kettle mainly consumes electrical energy and the chemical energy of the human body itself. By comparing the manufacture of the stovetop kettle, we can see that it takes more energy to make the electric kettle. Because the material needed to produce a stove kettle is almost just iron.
Distribution and transportation
The transportation process of the product also aggregates massive energy consumption. From the production of raw materials to assembly, and finally to the mall, there will be much energy consumption during the period. An airplane train or car transports goods from the factory to the mall. So, this part will consume fuel, which is chemical energy. Hamilton Beach's facility is located in Canada, and its products are sold to the US, Mexico and many other countries. Therefore, the Hamilton Beach electric kettle will go through a long journey after leaving the factory to reach the consumers. The transportation process of the product consumes a lot of fossil fuels, and it also brings a lot of pollution and carbon emissions. We use Boeing 747 as an example. A plane like a Boeing 747 uses approximately 1 gallon of fuel (about 4 liters) every second. Over the course of a 10-hour flight, it might burn 36,000 gallons (150,000 liters). According to Boeing's Web Site, the 747 consumes approximately 5 gallons of fuel per mile (12 liters per kilometer).
Use/Maintenance
The energy consumption of the Hamilton Beach electric kettle during use is relatively stable. Under normal circumstances, the function of the electric kettle is to heat the water under normal temperature to boiling. Since the electric kettle we chose does not have a thermal insulation function, it does not require too complicated considerations. The electric kettle averaged around 1200 watts and took 125 seconds to boil the water, which translates to 0.04 kilowatt-hours (kWh) of electricity consumed. The problem with a stove kettle is twofold; the heat needs to be transferred from the element to the pot, and then the pot needs to warm up before passing that energy to the water. It is already clear that the electric kettle is more efficient than the stove kettle.
Recycling and Waste Management
The central recyclable part of the HamiltonBeach electric kettle is plastic and metal fittings. The recycling of plastics and metals helps to save a lot of energy and natural resources, as these are the main ingredients needed to make raw plastics. Saving oil, water, and other natural resources help to protect the balance of nature. According to the survey, the US recycling rate of plastics in 2015 was 9.1%. Some of them can be used for combustion and power generation, becoming one of the sources of energy. The United States also recycles 150 million metric tons of scrap materials annually, including 85 million tons of iron and steel, 5.5 million tons of aluminum, 1.8 million tons of copper, 2 million tons of stainless steel, 1.2 million tons of lead and 420,000 tons of zinc. Recycling scrap metal reduces the amount of greenhouse gas emissions generated during various smelting and processing operations used in the manufacture of minerals from raw ore. At the same time, the energy used is much smaller. Energy savings from the use of various recycled metals are up to:

- Copper is 90%

- Steel is 56%

There is also data showing that by recycling steel, the amount of energy saved is enough to provide 18 million households with a full year of electricity.

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Waste - Life Cycle Project Bibliography

Stewart, Alice. "Materials Used in Kettles." Hunker.com, Hunker, 8 Mar. 2011,

www.hunker.com/13408612/materials-used-in-kettles.

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Justin Lee

DES 40A

Professor Cogdell

4 December 2018

Electric Kettle Life Cycle Analysis : Waste and Emissions

Convenience, safety, and sustainability. Many consumers cite these as the reason they choose an electric kettle over a traditional stove kettle to heat their water. Electric kettles are designed to have a pitcher connected to a base that has an integrated heating element. This heating element uses a material with high resistance to heat up as an electric current flows through it, which heats the water in contact to boil. Newer electric kettles use a thermostat to shut off the heating element when it reaches a certain temperature for safety. We will focus on the Hamilton Beach 40901 Electric Kettle because it is a simple example of an electric kettle that demonstrates the advantages over a traditional kettle by implementing a removable pitcher and automatic shutoff switch. The use of a heating element allows electric kettles to boil water faster than traditional kettles and the automatic shutoff prevents pressure buildup in the pitcher and boiling dry. Convenience and safety can be easily demonstrated and compared through consumer use, but showing an advantage in sustainability is more complex. Sustainability has to be measured by looking at the impact the product has on the environment, both in the creation and use of the product. While an electric kettle is ten percent more energy efficient consumes less energy to boil water, we must take the full life cycle of the product into account, including the acquisition of raw materials, refinement, production, total energy use, transportation, and disposal, and the wastes and emissions related to these processes to assess how sustainable it really is (Carini 2011). When analyzing the full life cycle of the electric kettle against a traditional stove top kettle, the electric kettle is actually less environmentally friendly.

The first step in the creation of a product is the acquisition of raw materials for production. The most general electric kettles are made of steel, low density plastics, electrical components, and rubber(Stewart 2011). Mining is used to extract iron for steel and zinc, copper, and tin for electrical components, while fracking is used to acquire oil and natural gas for low density plastics and synthetic rubber. Mining and fracking both create waste byproducts and emissions from machinery used. Mining byproducts include waste rock, loose minerals called tailings, and mine water (Chaturvedi 2016). Waste rock is usually non toxic and can be disposed of or repurposed easily, while tailings and mine water can contain toxic, harmful elements ,"fuel spills, flotation reagents, cleaning solutions, and other chemicals" which need to be properly contained or treated to prevent environmental damage through water and soil pollution (Chaturvedi 2016). Fracking uses water mixed with chemicals and other particles to release oil and natural gas. Byproducts produced in fracking include produced waters and fracking fluid returns, which can contain industrial chemicals with "high concentrations of sodium, magnesium, iron, barium, strontium, manganese, methanol, chloride, sulfate"(Sunshine 2018) and hydrocarbons like benzene, toluene, ethylbenzene and xylene (Sunshine 2018). These chemicals can be freed into the environment as flowback and produced during the drilling process and are considered hazardous waste. The machines that are used in mining and fracking also create greenhouse gas emissions. The next step in production is the refinement of these raw materials into secondary raw materials.

Refinement of primary raw materials and secondary raw materials is essential in creating higher quality parts in products. The production of electric kettles require refinement of iron for steel and refinement of oil or natural gas for synthetic rubber and low density plastics like polypropylene or polyethylene. Steel production creates many byproducts including slag, dust, sludge, mill scale, iron oxide, iron sulphate, metal hydroxide sludge, ferric chloride, zinc, tar, benzene and sulphur (Blixt 2018). Many of these materials can be repurposed or reused in smelting other metals or sold to other industries like electronics production. About 21% of steel production byproducts are sent to landfills (Blixt 2018). The other metals used like zinc, copper, and tin are also refined and produce greenhouse gases, but not at the level at which it takes to refine iron to steel. The production of the plastics used in kettles like polypropylene, polyethylene, and synthetic rubber create emissions of greenhouse gases such as carbon dioxide, methane, nitrous oxide, and hydrofluorocarbons (Natural Resources Canada). The refinement of raw materials to steel and plastics create CO2 emissions with the processes and machinery used in refinement. These refined materials are then sent to factories where they are cut and shaped for assembly.

Assembly of materials is done by workers aided by machines. Workers cut and weld steel sheets, shape plastics and rubber, install electrical components, and fit parts together. Most solid waste is produced during the cutting and fitting of parts like excess steel or plastics that can be reused in future production or recycled. Steel clippings are sold to steel foundries and waste plastics are reground and used in other productions to keep quality high. The machines in the factory also create greenhouse gas and CO2 emissions. These factories are located in China and need to be transported to the United States for distribution.

Since 2012, Hamilton Beach has contracted all production to manufacture in China. We assume the transportation of electric kettles from China to distribution centers in the United States is done by cargo or freighter shipping because of the size of the electric kettle and lower cost compared to air shipping. Cargo and freight ships use bunker fuel to power their engines, which contain 2000 times more sulfur than diesel used in automobiles(Evans 2009). The consumption of this fuel by cargo ships releases emissions that include CO2, NO2, SO2, CO, and hydrocarbons and particles like BC, SO4, OC, and ash (Eyring 2005). Many of these are classified as greenhouse gases and contribute to the global warming. Once in the United States, the kettles also need to be shipped to the distribution center and then to retailers. This can be done through trains or trucks which also burn fuels that create similar emissions and greenhouse gases at a lower scale. Once the retailer sells the kettle, the consumer will use it to boil water with electricity as a power source.

Electric kettles use electricity to power the heating element that boils the water. In the United States, almost 70% of the electricity generated is created by burning coal (EIA 2018). Burning coal releases emission like SO2, NOx, CO2, mercury, smog, and some metals (UCS 2017). Methane is also released when coal is extracted. The scale at which we burn coal to produce electricity is a major factor in the production of greenhouse gases and global warming. The other emission are also linked to damages in the environment and respiratory illnesses. Other sources of electricity also include burning natural gas, petroleum, renewable sources, and nuclear.

Once the electric kettle is damaged or broken, it can be disposed of through landfills or recycling. We will assume it will be most likely recycled because it is made of mostly recyclable materials. Recycling the electric kettle involves transportation to domestic or international recycling centers, disassembly, and transportation to foundries, factories, or reject landfills. The parts rejected by recycling plants are not biodegradable as they are mostly plastics or metals that have been contaminated. All these processes require the burning of fuel or electric so they would create greenhouses gasses like CO2 and some particles as emissions depending on the fuel used (Turner 2015).

To determine how sustainable the electric kettle is compared to the traditional stove top kettle, we must look into the life cycle and processes needed to create, use, and dispose of it. The life cycle is filled the production of emissions including greenhouse gases, harmful particles, and other solid wastes that can harm the environment through soil and water pollution, but also includes many places were byproducts can be reused or repurposed. We can assume the electric kettle production to be similar to the traditional kettle because of the materials used except for the added components. The main difference in waste would be in energy use, material, and production. Electric kettles are 10% more energy efficient than traditional stove top kettles when used to boil water, but have more wastes and emissions due to the added materials, like metals for electronics and oil or natural gas for plastics, and the processes these extra materials go through (Jacobson 2017). The wastes and emissions generated from the extraction, refinement, and transportation of these extra materials outweigh the reduction in waste and emissions in electricity production through energy efficiency. Through analyzing the life cycle of an electric kettle, we can determine that the electric kettle is actually more environmentally harmful than the traditional stovetop kettle because of the extra wastes and emissions generated to add the defining features of convenience, safety, and energy efficiency to the electric kettle.

Bibliography

Stewart, Alice. "Materials Used in Kettles." Hunker.com, Hunker, 8 Mar. 2011,

www.hunker.com/13408612/materials-used-in-kettles.

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# data[].attributes.attachment_link.description
Rochelle Dai DES 40A Professor Cogdell 6 December 2018 Electric Kettle Life Cycle Analysis: Materials Electric kettles are a common kitchen appliance used to boil water for brewing tea or powdered drinks along with cooking ramen and other instant foods. The device must be plugged into an electric socket in order to work.

# data[].attributes.body
-The development of stainless steel happened during the Industrial Revolution, today this is one of the main materials that kettles are being produced from. Stainless steel is an alloy based on iron, and has many of the physical characteristics that are also seen in iron: . High strength . Good toughness . Easy to shape . Easy to recycle . Relatively cheap . High density and poor conductor of electricity and heat
- Polypropylene has also been used to make the whole kettle, rather than just the insulated parts. Polypropylene is a thermoplastic which means that it becomes soft and malleable when heated which hardens as it cools. Parts are formed by injection moulding, pellets are heated and forced into moulds where they are cooled and removed. Joining is easily achieved through friction welding, and colourings can be added to the material in the production stage. Although the material offers high toughness, relatively high stiffness and is relatively low cost to produce, it does have some drawbacks. The material is a hydrocarbon; produced from the refining of crude oil through fractional distillation which requires a fair amount of energy, and the world’s sources of crude oil are being depleted so it may not be available for future use. Other problems with polypropylene are that it absorbs water during its life, and it reacts with UV light, causing the material to discolour and become brittle. Polypropylene is cheap and easy to manufacture, however, it is unlikely to be a material used in the future due to the lack of availability of the raw material.
- An alternative material that is currently being used is glass, an amorphous solid based on a silica compound. The material is blown or rolled while hot to produce the required shapes. Nontreated glass would not be able to cope with the temperature variation that is experienced in the boiling of water and the heat from the element. However, new manufacturing techniques have been developed to improve the properties of the glass so that it does not fracture under these extreme conditions. The new technique involves producing a more regular crystalline structure within the amorphous structure, which in turn gives the properties required to withstand impact and temperature variations.

# data[].attributes.attachment_link.readable_text
This article reviews the materials used in the production of kettles since the Victorian times, why they have changed over time, and what material may be used in the future for kettle production, but first, to investigate what materials have been used in the production of kettles, the use of the item needs to be understood. The definition of a kettle is: "A covered metal or plastic container with handle and shaped opening for pouring used for boiling water."

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# data[].attributes.attachment_link.title
Materials in the design of kettles on JSTOR

# data[].attributes.attachment_link.description
This article reviews the materials used in the production of kettles since the Victorian times, why they have changed over time, and what material may be used in the future for kettle production, but first, to investigate what materials have been used in the production of kettles, the use of the item needs to be understood.

# data[].attributes.body
Electric tea kettles are made predominately of steel, iron, silver, aluminum, or a combination of plastic and metal. High-grade steel is typically used for the housing of all-metal kettles. Heat resistant plastics, such as low density polyethylene (LDPE), polypropylene (PP), or polystyrene (PS), comprise the upper housings of the kettles in some models with metal enclosures on the bases that contain the heating elements.

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Background

The sole purpose of the tea kettle is to boil water. Water for coffee and for many cooking uses does not have to be boiled, but fresh, cool water that is brought fully to a boil is essential for tasty tea. Although it is associated with making tea, the kettle's contents make excellent instant drinks or soups that are also best with boiling water or to produce steam for remedying colds.

History

Tea itself has been processed into three different forms in its history, making specific utensils essential. In its beginnings in China, tea was processed in blocks or cakes that had to be boiled after roasting and shredding; this required a tea kettle. The Japanese method was more refined; powdered tea was whipped in porcelain bowls with bamboo whisks. Leaf-tea (the most common form in the Western World for about 200 years) consists of different methods of picking and processing tea leaves. This tea requires steeping in boiling water, so leaves are put in pots filled with boiling water from the tea kettle. Block, powdered, and leaf tea must all be steeped in boiling water.

The tea kettle evolved from the cooking kettle that was hung on a hook on an iron post in the cooking fire. The hook was turned to move the kettle over the fire, and a "tilter" helped to pour water from the kettle. Kettles were made of iron, one of the first metals to be mined and processed.

In Japan, the iron cooking kettle became a small, rounded bowl with two short arms or loops (one on either side of the bowl) for pulling it off the hearth and a lid. A classic example of a bowl-type iron kettle dates from 1517. As methods of casting iron became more sophisticated, the outsides of these kettles were decorated, and the two arms became a spout and better handle. Iron casters who made tea kettles were highly respected.

Beautifully decorated examples of Japanese iron tea kettles with the spouted tea kettle shape known today date from the late nineteenth century. Iron kettles could withstand cooking fires, but serving ware emerged from the porcelain industry. Kettles obviously existed before tea pots because pots copied the shape, spout, and handle.

In Russia, water is heated in a samovar (literally, self-boiler), which is not a tea pot but an elaborate tea kettle made of metal with a central chimney for containing fire and boiling water in the surrounding vessel. Russians learned about the samovar from Persians during border disputes and trade efforts. A strong concentrate of tea is kept in a tea pot and warmed constantly on top of the samovar. Concentrate is poured into tea cups, and boiling water from a spigot on the samovar fills the cups and dilutes the concentrate.

The English began making tea pots of unglazed earthenware in the mid-seventeenth century, but silver became a popular material in the early 1700s. The first known silver tea pot is dated 1670, but, by the turn of the century, all tea servingware was made of silver including kettles. Silver kettles are still made today, but they have been surpassed in importance by aluminum and stainless steel for both stove-top and electric types.

In both England and the United States, the tea kettle's development was closely linked to the evolution of the stove. When stoves replaced cooking fires, the kettle was pulled from the fire and given a place on the stove. Most kettles are shaped like modified globes with flat bottoms to sit on stove plates. Kettles became ornaments for kitchens when they were manufactured with different metals like copper and decorated with interesting handles and enamel.

Electrifying the kettle followed in the early twentieth century. Although the first kettles were seated on individual electric coils, heating elements were soon built in and more refined models appeared.

Raw Materials

Electric tea kettles are made predominately of steel, iron, silver, aluminum, or a combination of plastic and metal. High-grade steel is typically used for the housing of all-metal kettles. Heat resistant plastics, such as low density polyethylene (LDPE), polypropylene (PP), or polystyrene (PS), comprise the upper housings of the kettles in some models with metal enclosures on the bases that contain the heating elements.

Design

Depending on the quality of the kettle, the types of raw materials can vary greatly. For higher grade kettles, a higher grade of steel or even silver may be used. Lower quality kettles may be of simple aluminum. Ideas for electric kettles arise from several different sources. The Research and Development (R&D) Department in the manufacturer's firm develops its own concepts for entirely new designs and for freshening its existing models. Fashions for cookware and other kitchenware change along with many household conveniences and accessories. Fashion is not limited to color but includes up-to-date overall shapes, changes to parts such as bases or handles, and improved safety features.

The electrical components of a tea kettle include the heating element, a thermostat that turns off the kettle automatically if it is boiling dry, an on-off switch and its attachments, a connection linking the element to the cord, and the plug. These are received at the plant as assembled units. Their assembly is out-sourced (subcontracted) to other factories, often outside the United States. These manufacturers further subcontract the making of individual electrical parts.

The Manufacturing
Process

1. Metal is received at the tea kettle factory in sheets or rolls appropriate for presses that will stamp out the parts. Stainless steel sheets are checked for thickness; a bill of lading specifies the alloy, but the receiving department checks the thickness of the steel with precision instruments. Polypropylene plastic that is usually heat reinforced is delivered as tiny pellets in the color the kettle manufacturer requests. Plastic pellets are randomly inspected for color and impurities. From large hoppers above the injection molding machines, the pellets flow into the machines by gravity. The electrical components are complete when they are shipped to the plant. One set per tea kettle is provided as a bundled or wrapped set; parts do not need to be sorted or assembled. The receiving department randomly inspects and tests some of the electrical sets.

2. In the factory, the sheet steel is mechanically placed in the die of a punch press. A hydraulic punch is released, creating a hollow shell in the shape of the kettle base. This piece is then removed. The second sheet of steel is placed in a punch press with a die shaped to hold the heating element. The steel shapes are called stampings. One piece forms the base of the tea kettle and the connector between the element and the cord. The second piece sits in the first like one bowl inside the other.

3. The metal stampings are attached to hangers on a conveyor system and carried through two different processes. The base stamping is conveyed to a paint booth where it is given a small electrical charge that attracts fine a paint mist to its surface. The base stamping is painted to match the upper plastic housing. The stamping that will house the electrical components is conveyed through an different coating process that treats the upper surface of the metal piece (the surface that will come into contact with water) so that mineral deposits will be easier to remove. These coating processes are called anodizing. This protects the steel parts from corrosion and gives the

stampings a small electrical charge that attracts the coating.

4. Meanwhile, the upper part of the kettle is formed. The polypropylene plastic pellets are released through a hopper with a funnel-shaped bottom into an injection-molding machine that melts the pellets under high heat until the plastic is liquid. Under high pressure, the liquid plastic is forced into a steel box (called a die) with two halves. When the halves are locked together, the die contains a void that is an exact image of the plastic housing of the kettle. The two parts in the die form the outside and inside surfaces of the kettle. The cavity relief surface of the die shapes the outside of the kettle including the solid plastic handle, and the core relief surface is the inner surface. When the injected plastic has filled every tiny nook in the die, the die is opened and the plastic kettle housing, which is still hot, is ejected. The housings are allowed to cool until assemblers can handle them.

5. The painted and treated metal stampings are welded together to form the base of the kettle. The two major processes-injection molding and the punch press-allow large quantities of these to be made continuously. The kettle base is then placed on an assembly line conveyor belt, then equipped with power components at a workstation where the electrical set is removed from its packaging, and an assembly worker manually sets the connector between the heating element and the cord into the shaped opening in the base. The kettle's rubber feet are also attached to the base.

6. The metal base (with its electrical components in place) and the plastic housing are sealed together to complete the tea kettle body.

7. At the next assembly station, metal flip-up covers are manually pressed onto the plastic spouts so the spouts will open and pour water; these wide spouts are also the openings for filling the kettles. Other models have metal lids with small plastic handles that are also injection molded. These models are filled through their opened lids.

8. The completed kettles are conveyed to the shipping department. Each kettle is wrapped in a plastic bag that also contains the instructions and boxed. The boxes are packed into shipping cartons.

Quality Control

Electric tea kettles are the subject of quality control in multiple locations in the factory. The steel and plastic materials are prepared, tested, and examined for any defects such wear, discoloration, or scratches. The sets of electrical components are also inspected in the subcontractors' factory where they are made. Underwriters' Laboratories must also test and approve electrical components before they become parts of larger products. At the manufacturer's plant, electric tea kettles are subjected to multi-tiered inspections that begin when all materials are received and continue through each manufacturing step. As a final quality check, each tea kettle is plugged in and operated before it is packed for the customer's use.

Byproducts/Waste

Metal and plastic wastes result from handling and processing both materials. Metal waste is steel only and trimmings are sold to iron or steel foundries. Plastic trimmings or flawed molded parts are reground and recycled. Only a small percentage of reground plastic can be used for other tea kettles in order to maintain the high quality of the plastic housings, but the remaining plastic can be used in other products.

The Future

The future of electric tea kettles is in the hands of consumers and retailers. Retailers provide sales data, consumer comments, and other input to the manufacturers. This information helps the producers to decide on new designs. Stove-top tea kettles have always had stronger sales figures than electric kettles, but electric models also have a devoted public.

The recent popularity of tea and flavored teas has awakened interest in electric tea kettles. Tea infusers and electric tea makers with water filtering systems are the newest ideas in this area of manufacture. The British have pioneered both of these developments that look something like coffee makers with glass tea pots above heating chambers. Unlike coffee makers, these appliances heat the water until it is boiling, which is a must for tea. A filtering system has a filter as a third layer or as a column on the back of the maker, and some can be connected directly to water faucets. These devices seem to point to the future of electric tea-making, but their stacked structure looks curiously like that Persian invention.

Where to Learn More

Books

Huxley, Gervas. Talking of Tea: Here is the Whole Fascinating Story of Tea. Ivyland, PA: John Wagner & Sons, Inc., 1956.

Kakuzo, Okakura. The Book of Tea. Rutland, VT: Charles E. Tuttle Company, 1972.

Papashvily, Helen, and George Papashvily. Russian Cooking. New York: Time-Life Books, 1969.

Pettigrew, Jane. Tea & Infusions. Carlton Books Limited, 1999.

Von Bremzen, Anya, and John Welchman. Please to the Table: The Russian Cookbook. New York: Workman Publishing Company, Inc., 1990.

Other

"About Tea Kettles." Kyoto National Museum Web Page. December 2001. < http://www.kyohaku.go.jp/mus_dict/hd11e.htm >.

Calphalon Corporation Web Page. December 2001. < http://www.calphalon.com >.

Nezu Bijutsukan Museum Web Page. "Tea Kettle of Shinnari Type." December 2001. < http://www.nezu-muse.or.jp/99-10-03/30187_e.html >.

TenRen.Com Web Page. December 2001. < http://www.tenren.com >.

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How electric tea kettle is made - material, manufacture, making, history, used, processing, parts, components, structure

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The sole purpose of the tea kettle is to boil water. Water for coffee and for many cooking uses does not have to be boiled, but fresh, cool water that is brought fully to a boil is essential for tasty tea.

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As this project was nearly a year ago and quite complex, I had to look back and create new information sheets to remind myself of how each technique works.