Ribbons and bows are usually made of polypropylene (PP), which can be produced into any color or finish. The below images all consist of either mirrored metallic or iridescent laminated polypropylene, which I pronounce shinny and super shinny.
Above, from top to bottom and left to right, is the monster machine that magically produces rolls of PP. I didn't ask for details, I just took their word. As you can see by the Pantone board, the color options are endless. The rolls of PP are loaded onto cutting machines. These machines cut the large rolls into smaller widths. The workers take the smaller cut ribbons (which in this case had been spooled) and place them into the retailer's packaging. Once packaged, the workers then place the UPC sticker to the outside of package. Typically, every detail is directed by the buyer or product manager. In this case, we wanted the package to read from warm to cool, so the silver and white ribbons went in the package first (the bottom), followed by the gold and bronze ribbons last (top of package). If these instructions weren't provided, each worker would place the ribbons in different orders, which would cause each package to look different. UPC placement instructions are needed so store cashiers aren't searching all sides of a package, looking for the barcode. We also need to make sure the UPC label isn't covering important parts of the product.
The cut ribbon is also used to make bows. Below you can see the smaller cut ribbon being curled and cut into 6 inch lengths. The 6 inch strips are then counted, (in this case they used 6 ribbons for each bow) and staple by hand to a small square adhesive paper that will later secure the bow to your package.
The workers below are producing folded bows. Along with making sure the machines have adequate ribbon supply, as the machines finishes each bow, (one at a time) the worker removes the bow and tosses it into one of those boxes. Once the boxes are filled, they are taken to a table of workers for packaging and labeling.
These workers are folding sheets of tissue paper and placing into the retailers packaging.
Below is matte finished polypropylene being twisted. This machine feeds a 2.5 inch strip of PP and slowly spins the PP into a tightly twisted ribbon called Raffia.
And once again, here's a group picture of the factory's owners and management, along with my team as we head back into our home away from home… the VAN!
So, there you have it, Ribbons and Bows 101. I remember when I first learned workers stapled the curled ribbons by hand, or when I saw workers folding tissue paper (both being products I have purchased as a consumer a thousand times), I couldn't believe an actual person completed those tasks. When I tour factories, I don't have many questions when standing before a machine, as I would much rather see humans work. I am fascinated at what is still produced by humans and to learn why. For a manufacturer, the less people needed the better. Machines are consistent and never require pay increases or holidays. But as a consumer, I still like knowing as I rip into a package, that someone, somewhere, made it.
Merry Christmas!
