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On Aug. 28th thru Sept. 14th 2001 my daughter Nicole and I visited the Czech Republic in center Europe.
Our trip was planned for both business and pleasure. I was invited by my Czech glass vender who lives in Jablonec (Pronounced Ya-blow-nuts) Czech Rep. to experience first hand how my buttons are manufactured.
We spent 9 days in Jablonec, the metropolis of North Bohemia, dating back to the 1300's. It is know as the 'Glass Capital' of the world, rich in glass history dating back to as early as 1376. We loved every minute we spent there. The whole city was just oozing of glass no matter where you went.
Original Button Factory (Over 100 yrs)
On our first day we visited a 100 year old button factory located in Jablonec.
This factory is the only original remaining factory still producing buttons in the Czech Republic today! My Czech venderTomas who spoke enough English to understand most of what we were saying had hired a translator. She helped explain in more detail how Tomas and his mother in-law Mrs. Strakova run their factory which was purchased from the state about 8 or 9 years ago. They produce strictly buttons.
Glass Canes
We began our tour on the back side of the factory where a little metal shed was located. As we walked to the shed I noticed on one side of the factory's wall was not only covered with stucco but also with buttons! I also noticed glass canes cemented into sidewalks and into a cement railing post. I was told this was for good luck. I guess it is the same thing we do when we see a newly laid sidewalk with fresh cement? Either way it was fun to see.
Inside this shed were hundreds and hundreds of glass canes.
Some as old as 50 to 60 years still being stored for future button production.
They came from another factory, also located in Jablonec, which strictly makes only glass canes. Each cane is melted down over a furnace and pressed into a buttons.
I was interested in the different types of glass canes that I saw. One cane in partial was a bit more unusual then the others were. I was told this type of cane is used for moonglows with lines 'DUGS' in them. Many other types of glass canes including: intermixed, opalescent, imitation tortoise shell, black glass, along with transparent colors in every shade of the rainbow.
Machinery Used
After viewing the canes we walked back to the factory.
Years ago when the factory was running at full force they employed over 100 workers. Now with the declining demand for glass buttons the factory has been down sized to about 30 employees.
Most of the work is now being done in a smaller building next to the original factory. The reason being that it is much more economical for heating and maintenance.
As we walked thru the empty factory and all it's rooms I couldn't help feeling or imagining all the workers from years ago. Still working at their tables still painting with their brushes. I swear I could still hear their chatting echoing among the empty walls. Each room I entered I felt the same way. Pridefully working our on little buttons from so long ago.
In one room there stood two machines. One was enormous and over 12 feet tall, used for making button molds. On the other side of this room stood another machine used in manufacturing buttons. It is called a "copy saw" which is used for coping/tracing the button molds from wood to metal.
One of the most notable rooms we visited was the 'mold' room. There all the molds were kept in wooden crates. Each precious mold is oiled to prevent any rust from occuring which would ultimately destroy the molds.
Making Buttons
On our way towards the smaller factory I suddenly noticed what looked like a bunch of huge metal crates all piled onto each other. Sure enough these crates were packed full of buttons! Only to find to my disappointment, these buttons were all seconds, or broken. This still did not stop me from taking a few. Just for Luck! Upon entering into the smaller factory's door I noticed how low the door was and a obscure little sign posted above, which I have no idea what it read.
Pressing Buttons
Once inside the smaller factory we were told of the many different steps (14) it takes to make just one button. All done by hand or hand/machine. One of the machines was saw was a pressing machine.
Years ago button pressing was done mainly in the homes of most Czechs, employed by their factory. Today most of the pressing is mainly done in the factories. One reason why calling the production of Czech glass buttons a "Cottage Industry" is slowly fading away and someday may not be true?
Pressing buttons is done in two different ways depending on the type of button.
Each button has it's own "Tongs" for pressing. These tongs are also called "Matrixes" or "Forms". Buttons with a wire shanks are harder to press. Each shank must be carefully placed into the tongs one at a time before it is pressed, which is more time consuming.
Once pressed the button/cane is then cut with a heavy metal scissors.
It only took me 3 times to get it right so I know how hard it is!!
Buttons with self shanks are much easier to work on because they can be pressed in groups of 4 or 5.
Once the pressing is finished each button will have it's excess glass trimmed off. This extra glass is either cut or faceted off. Realistic buttons or shaped buttons are hand faceted on a wet stone wheel. Any type of polishing, shaving, or faceting needs to be done with water. This prevents friction as well as keeping any tiny glass molecules away from the person doing the work.
Piercing is also done on the wheel faceting machine. Pierced buttons are pressed with an excess of glass where the piercing needs to be done. On the faceting wheel this excess of glass is faceted off until the hole appears thru the glass.
Round buttons are not faceted but are cut on a machine with 2 round blades. While turning a wheel these blades grid off the extra glass around each button. After the cutting is finished round buttons are placed on another machine which holds up to 8 buttons at one time. This machine finishes off the button edges and gives them a polished look.
Each button must be placed by hand on one of the eight places before its ready to be polished. After the polishing, faceting, or cutting is completed the buttons are then placed into a wooden box with wood shavings. Here the buttons will be completely cleaned.
To View My Newest Moonglow
Painting Buttons
Now its time to start painting each button. Every single button is hand-painted with some buttons having as many as six different colors applied, some taking up to 2 to 3 minutes for each color to be applied. Each color needs to be dried before applying another color. A special metal holder is used while painting & drying as well as separating the buttons. Each holder can store up to two grosses of buttons. Buttons are then placed on a wooden rack for drying.
Special boardsare also used for painting buttons. These boards are also used for comfort. Each painter has their own board and each one is different. They also have a rotating metal wheel used for painting concaved buttons.
Some buttons have paint applied to them with a spray painting machine. This machine also sprays the pearlized finished used on many different types of glass buttons including moonglows.
Firing Buttons
After each button is painted they need to be fired in a kiln to bake the newly applied paint. The type of paint used on today's buttons is called "Hot" paint. Years ago they used paints which were called "Cold" paints which didn't need to be baked on, but were easily scrapped off. Cold paints were also different looking than today's Hot paints. One reasons why is the chemicals used years ago are total different than today's paints.
Just like glass. Today's glass is also different looking than from years ago. Environmental restriction for using lead in glass is one of the reason why. Less lead leads to harder, and more easily broken glass especially during the heating process.
Once the buttons are baked in the kiln the door is slowly opened slightly, just enough to allow for a slow cooling. It normally takes up to three to four days to complete.
Shaved Buttons
SHAVED A collectors term used for buttons which look like their tops have been "Shaved" off. It has been unclear for many years as to exactly how these buttons were actually made. If in fact they were really shaved or not.
In my resent publication of Moonglows Past and Present 1950's to 2001 I listed shaved moonglows under Construction and not under Mechanical Make-Up. From my research which included many other authors, bulletins, and magazines I found shaved moonglows generally considered or listed under construction. After further research and after visiting the Czech Republic I realized this is not true. Having seen the shaving machine and actually shaving a button I would consider these types of buttons to be listed under mechanical make-up, and not under construction.
Buttons are physically shaved by hand after heat fusion and liquefying has taken place.
Visiting a Button Museum
Belveder Gallery located in Jablonec nad Nisou Czech Republic is situated in a two-story house with attics built in the late *Baroque style. The house is one of the oldest buildings in Jablonec nad Nicou. First mentioned in 1773 as being owned by the farmer and the village magistrate. 20 years later, the house was purchased by the glass jewelry producer and exporter Josef Dressler.
The building was reconstructed several times the first time being at the end of the 19th century. It has served many purposes and named Belvedere later by the Museum of Glass and Jewelry as its new gallery.
It was opened in 1998 and reconstructed between 1994 - 1998 which was carried out according to the original design. On the first floor of the museum are exhibits of beads and jewelry. The lower half of the building houses the buttons. There you'll find about 10 glass cases of buttons including a superb collection of Lacy Glass buttons on sample cards!!!! Words cannot explain how magnificent, marvelous, stunning, and fantastic these buttons are. Truly a Bohemian treasure, to behold and be extremely proud of. I highly recommend every button collector try to visit this most substantial and notable button collection. Visiting this museum was definitely the high light to our trip.
While there I was asked by the museum curator to help in sponsoring a postcard. These postcards are printed up with 1/2 going back to the museum and the other 1/2 I will receive. I had a chance to pick out 12 Lacy Glass buttons for my postcard. These lacy glass buttons have been stored away and had never been on display before. These postcards help in keeping this most notable exhibit alive and available to everyone visiting Jablonec. My postcards will be for sale by the beginning of November. Please check back then if your interested in purchasing any of these cards.
PART II
Our Visit To the Czech Republic
To View
Vintage Moonglows
To Order My New
Moonglow Book
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