Umbrella Manufacturing Process
Modern umbrellas are generally made by a hand-assembly process. Quality control and material choices occur throughout the manufacturing operation. Rain protective units that telescope into a length of a couple feet are the most recent innovations in umbrella industry. The differences between a stick umbrella and a collapsible umbrella is that the collapsible uses a two piece shaft that telescopes into itself, and an extra set of runners along the top of the umbrella. The manufacturing operation can be broken up into fourteen simple steps. The process generally starts with the production of the main support pole. This vital part of the unit is made from wood, aluminum or fiberglass. Depending on what size the umbrella canopy is will change the diameter of support pole that is needed. On smaller six-foot umbrellas, a 1 ½ inch diameter pole is sufficient whereas with a larger nine-foot umbrellas, a 1 ¾ to 2 inch diameter pole is used to create a stronger structure to prevent damage. The types of wood used range from Rowan wood from Asia, to a higher grade Marenti Hardwood. Higher quality materials will last longer and are great for any commercial setting at a hotel, restaurant or country club as well as your backyard.
The next step in the process is to attach the support ribs (support arms). The support ribs run underneath the canopy or top of the umbrella. The ribs are then attached to the main support pole, locking in or being connected into a top notch to create a secure and strong connection point for durability. New modern innovation has created fiberglass ribs that are made of 100% fiberglass to allow the support arms to flex, preventing any damage that may occur from high winds. This feature is becoming increasingly more popular through the commercial and residential users. The ability to have this commercial quality available to the residential user prevents any frustration from support ribs being broken by wind saving the customer time and more importantly, money. The next main point in the process is the creation of the top or canopy. Having many different options including but not limited to Polyester, Spun Poly, Olefin, Solution-dyed Acrylic. Each of these fabrics offers different colors and qualities. Read about the different descriptions of these fabrics with the patio umbrella buying guide. This information is provided by our experts to inform the consumer on the different types that are available to help them choose the best one to fit their personal needs.
The very tip, above the canopy is the finial (top cap). The finial is used to secure the canopy fabric to the main support pole. If the finial is broken or not used, the user will run the risk of the fabric flying up and off the support ribs. The finial is generally constructed from a hard plastic or metal (depending on the type of umbrella) and is uniquely designed for many different styles of taste. The finial color will match the main support pole and ribs to create an elegant, classy looking backyard. Now that the patio umbrella is complete with the main support pole, support arms, canopy and finial, it is now packaged up per the needs of the customer and is shipped out through the nation. Most patio umbrellas have available replacement parts available, preventing the user to need to replace the entire umbrella if any part of the unit is damaged by Mother Nature.
Specifically, what are the processes? Let me introduce the process that our company needs to make an umbrella.
1. Large Cut
It is necessary for the cloth to be pulled back from the cloth, and each piece is cut into several parts. This requires the cutting staff to have sufficient strength. This process is to pave the way for the second process.
2.Fabric Edge Locking
Fabric Edge Locking is to take the needle thread on both sides of the cut fabric to ensure the beauty of the umbrella. At the same time, the umbrella will not appear off-line, drawing, and it is also a subconscious behavior to ensure quality.
The role of the small cut is to cut the fabric with the edge to the size of the umbrella, and ensure that the size of the cut triangle is accurate in the middle, otherwise the next process cannot be carried out.
If we choose machine printing, the machine will print before Large Cut.
If we choose manual printing, the triangle will be sent to the silk screen shop after cutting. The silk screen shop will make the silk screen stencil according to the silk screen content or pattern requested by the customer. After receiving the cloth, the silk screen master will according to the size and silk screen of the triangle. The position is adjusted to the screen printing station. The requirement is to make the position of the silk screen of each piece of the film uniform. This step takes a long time. When the screen printing table is adjusted, it can be glued and the umbrella cloth is laid on the screen printing table. Flatten the pendulum, and then the silk screen master will adjust the color of the silk screen (to test multiple times, to ensure the color is accurate), then print the pattern on the umbrella cloth, and finally wait for the ink to dry and close the umbrella cloth.
The Canopy Assembly is a piece of umbrella triangle that has been cut by a small tailor. They are pieced together one by one. Usually, each umbrella has 8 pieces of fabric stitched together.
Topping is to fix the same size needle coil on the spliced umbrella surface. This purpose helps the umbrella surface to be smoothly placed on the umbrella frame, and also ensures the firmness of the eight spliced triangle pieces.
7.Sewing the umbrella strap
Sewing the umbrella strap, as the name suggests, is to sew the finished umbrella strap on the fixed umbrella surface. Because it is machine-sewn, it is called: “Sewing the umbrella strap”
8.Umbrella Tip install
The tip is a piece of metal or plastic stick at the end of each rib to stable the canopy with the ribs. In this process, we use a special sewing machine to sew the tips on the fabric. The number of installed tips is the same as a number of ribs.
9.Join the frame and canopy:
Join the frame and canopy is to sew together the ribs at each place on the umbrella surface, which can increase the firmness of the umbrella and facilitate the opening of the umbrella.
There are several methods to install the handle with the shaft such as screwed on, heat up shaft or glue to secure the handle.
To check the umbrella is to check the umbrella surface, the umbrella stand, the bead tail, etc. For the umbrella with high quality requirements, we usually carry out three inspections, and each umbrella will not be let go.
There may be some umbrella factories in this process, but we have this process in the umbrella factory, because the products we make are all medium and high-grade umbrellas. After three times of inspection, we have to go through this process, which may be complicated. But such a rigorous test actually guarantees the quality of the umbrella.
Rolling umbrellas are also called “stacked umbrellas”. They are to fold the checked umbrellas. To ensure the beautiful appearance, this requires skilled workers to do it. Especially the double-layer umbrellas made in our factory are complicated and time-consuming to roll up. So you need experienced people to cope.
Packaging, is to put the finished product in the packaging box requested by the customer, preferably in a large cardboard box, waiting for shipment.