Bohemian glass works

We took a tour today of one of the 200 glass works factories in the Czech Republic.  The oldest factory has been blowing glass and cutting crystal since 1300.  The first step in the process involves mixing the chemicals and ingredients into the melter (approx 1400 degrees C).  The ovens used to be heated by wood (thus their location in the forested areas), but are now heated by gas.  The liquid glass is stirred constantly, and 3 shifts of glass blowers work from the melted glass around the clock.  The glass blowers draw out the liquid glass on their poles and keep it turning constantly, then they blow a small bit of air into the mass and shape and smooth it with a tool (dipped frequently in water).  After that they place the blob into a mold (also cooled with water) and slowly blow into their tube, expanding the mass to fit the shape of the mold.  After hollowing out the blob and shaping it, it cools enough to break off from their long poles.  The vase / goblet / bowl, or whatever is then put in the "cooling oven" for 8-12 hours where the temperatures are gradually lowered to room temperature so the crystal doesn't break.

"Tools of the trade" - the glass blowers swigged orange pop often, and took long drags on cigarettes just before blowing the glass into the molds.  Interesting.

After the crystal cools, the excess part is removed with a gas 'knife'.  This picture shows a lady turning these bowls around with a small gas flame.  The top part of the shape that was attached to the blowing pole is not needed for a bowl, so the flame cuts it and she breaks off the top and recycles that glass back into the molten glass again.  Then inspectors look closely for imperfections (small air bubbles) and mark them.

The crystal then goes for 'drawing' where someone carefully marks out grids on the class for the cutters to follow.  The cutters use sand saws with water to hand-cut every line on the crystal. Beautiful!