The manufacture of cutlery made in Thiers by Jean Dubost
|Cutting of the blade.
||The blade after heat
||Blade undergoing grinding.
|Satin polished ground blade.
||Automated mirror polish.
||Traditional mirror polish.
||Mirror polished ground blade.
||Polishing of the outer
periphery of the blade.
|Fixing of the Laguiole bee.
|Smooth edge sharpening
1- Cutting of the blade
The blades are cut from rolls of steel that comply with the AISI 420 and 430 steel standards. These batches are controlled by an independent SGS laboratory in order to ensure that they are food safe.
NB: Some of our Laguiole blades (only those which have a stainless steel thickness of 2.5 mmm), are guilloched, which means that an engraving is carried out on the back of these blades.
2- Heat treatment of the blades
So as to ensure a high quality hardness of the blade, it undergoes a heat treatment in duly adapted stoves. It undergoes a treatment at an extremely high temperature: 1050 °C. This stage is essential for providing the best possible hardness and thus preserve the knife’s cutting quality.
So as to ensure an exceptional cut, the blade is bevel ground (close to O bevel). This first stage to prepare the edge of the blade is called grinding. It consists in removing metal from a given area of the blade.
Satin polished blade: Using special grinders, the blade is also polished in order to give it its final satin appearance.
Mirror polished blade: This state of the surface is obtained by polishing the steel with rolls of cotton either by hand or using specific machines.
Blade outer parts polishing: This operation consists in polishing the back of the blades in order to remove any asperities and to give them the smooth surface required for comfortable use.
5- Sharpening of the blade
This consists in giving the knife its final cutting quality. So as to meet our customers’ requirements, we carry out either a smooth edge sharpening or micro-serrated sharpening in our workshops.
- Smooth edge sharpening (can be re-sharpened) is obtained using a diamond grinder either by hand or using specific machines.
- Micro serrated sharpening is obtained using a profiled grinding wheel either by hand or using a micro-serrating machine.
NB: a sharpened smooth edge can be re-sharpened using sharpening steel or a sharpener. On the other hand a micro-serrated blade does not need to be sharpened again.
6- Marking of the blade
The marking (printing of our trademark logo) can be either engraved in the steel or obtained by electrolytic marking.
|Cutting the wood.
||Shaping of the wooden
|Rough olive wood
|Oak kitchen handle.
||Green ABS Laguiole handle.
|Positioning of the blades.
||ABS injection on the handles.
The blade now has to be equipped with a handle. This handle can be made in two different ways:
- Wood shaping for handles made of different types of wood, but also for real horn and acrylic: raw material manufactoring using specific machines in order to give it its final shape. This handle will then be assembled with its blade.
- Plastic material transformation and injection: ABS, POM or polypropylene. We use the colourless material and then make our own colourations in order to follow new trends. This method consists in heating the plastic until it becomes liquid. The blades are arranged on the injection mould and the liquid plastic is then injected to form the handle. The shape of the mould thus determines the design corresponding to each of our ranges.
Thanks to our latest generation equipment we can make handles using one or two different materials: hard body and flexible body (soft-touch/rubber grip) so as to offer an easy grip when using.
Jean Dubost offers you its vast expertise in the transformation of materials.
|Assembly by gluing.||Traditional nailing.||Automatic nailing.||Traditional riveting.||Automated riveting.||Automatic riveting.|
The wooden, real horn or acrylic handles are then assembled with their blade.
Assembly can be carried out:
- Either by gluing for our top of the range Jean Dubost flatware which have no nails or rivets on their handles. The glue we use is specific to our activity and won't spoil
- Or by nailing: our Laguiole and Le Thiers by Jean Dubost ranges
- Or by riveting: our original Pradel by Jean Dubost range
Nailing and riveting are carried out according to traditional methods or using an automated process.
|Traditional hand polishing.||Automated polishing.||Knife cleaning.||Packaging of the knives.||Boxing.||Packaging before dispatch.|
All our knives and flatware are then polished according to traditional or automated methods.
This final polishing stage gives our products their final aspect: high gloss, mat or satin depending on the required polishing technique.
Our knives and flatware can now be cleaned, prepared and packed before shipment.
We have a quality procedure manual that allows us to follow the various manufacturing stages of our products from reception of the raw materials: steel, wood, plastics… to the finished product. For example, our PEFC certification helps us to find from which forest the wood we use was cut.
Our steels are also controlled by the SGS Laboratory, to confirm they are food safe.
We are regularly audited by our customers, either by their own quality departments or by independent laboratories.
Products we manufacture are certified 100% made in Thiers France, thus offering you the guarantee of the origin of the items directly from manufacturer to consumer.
Quality is an integral part of our company’s culture, the products are controlled at each stage of the manufacturing process, keeping in mind that a job must be « well done » so as to offer users comfort and pleasure every day.