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COBI blocks are famous for their original sets. Not only have historical collections won children’s hearts, but also and perhaps most of all, adults’ hearts.
Today we are going to see how Polish COBI blocks are made, produced entirely in Mielec, in the Podkarpacie region. It was the owner of the company who several years ago came up with an idea to start the production of historical blocks.
Over time, new series were introduced, i.a. automotive classics or a series with tanks, referring to the popular game: World of Tanks. Currently, COBI introduces on average 3 new products into the market each month.
Let's take a look at the production. We start with a department that probably every enthusiast of blocks would love to visit. This is the place where new models are prepared, but the process of designing them is not only good fun. It is primarily an in-depth work on historical sources and precise elaboration of details.
First, a prototype is created with the use of available bricks. Then, elements characteristic of a model product which cannot be built with classic blocks are designed - they must be prepared using a 3D printer. Subsequently, elements printed in this way are fitted to the initial prototype, and at the same time, an electronic 3D model is prepared. It will be the basis for the instruction. A design prepared in this way, together with new elements, can be put into production.
Our next stop is the tool room. In order to start production of blocks, molds are needed. They are prepared with the use of CNC numerical machines. Great accuracy is crucial in their production, as ultimately, it will decide upon whether those blocks fit or not. Places that cannot be milled, e.g. sharp corners, are made with an EDM machine.
As molds are ready, the block production can start. The raw material is ABS plastic. Under the influence of high temperature, the granulate is plasticized and then injected into the mold where it obtains its shape. Once cooled down, the mold opens and blocks are pushed out of it. There are about 70 injection molding machines at COBI, which are able to produce 3.5 tons of blocks during one shift: starting from small elements with the diameter of 2 mm to larger ones, about 30 cm long.
In the printing department, heads of characters get their own character, and bodies of figurines and car body parts are prepared. COBI tends to discontinue using stickers. Prints are made using the pad printing method.
Now the packing department. This is the place where bags are packed and entire sets are completed. Single elements are automatically picked from the drums of the packing machine. When a bag consists of more types of elements than the number of available drums, remaining blocks are separated manually. Once filled, bags are sealed, and individual sets are cut off.
Then, bags are put into cardboard boxes with instructions attached. Here we see how the Konigstiger set with the largest and heaviest tank of World War II is being completed.
Subsequently, sets are taken to collective packages and transported to the warehouse with the use of a conveyor and from there, they will be shipped to toy stores and wholesalers. Each year, the production plant in Mielec produces 1.5 million sets, i.e. 1 billion 200 million blocks. COBI sets have their fans all over the world. The biggest number of blocks is shipped to the United States, followed by Germany. Our native Polish market occupies the third place. COBI blocks reach even such distant places as Australia, the Philippines or Greenland.
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Factories is a journey through production plants. We are visiting industry. We were inspired by the popular program "How it's made?" Known from the Discovery television channel. Every week, together with our viewers, we visit the production plant to check how the selected production process is going. Every week, our channel receives a documentary film, from which you learn how things are produced. Among others machines, rope slings, yachts, wires, windows, railroad switches, radiators, polystyrene etc. You are probably also interested in how food is made? On our channel we showed, among others frankfurters, Pepsi, kebab, salty sticks, mustards, ketchup, mayonnaise, cheese and many more. It's amazing how exciting production can be. Science and technology carry so much interesting information. Every week you get to know with us the curiosities of factories. The factory has no secrets for us.