Raw Materials

Toasters and toaster ovens are constructed from a long list of intricate parts that
includes a heating element, spring, bread rack, heat sensor, trip plate, level, timing
mechanism, electromagnet, catch, and browning control. The various parts are
constructed on site from a variety of metals and molded plastics. Screws, nuts, bolts, and
washers are used to join the parts together.
To make heat-resistant plastic cases, flame retardants and smoke suppressants are
added to the petroleum and coal compounds of plastic. If the toaster case is to be metal,
aluminum is generally used. Mica is also used because this fire proof, flat sheet made of
aluminosilicate minerals holds the nichrome wire.

Design
Design is an integral step in the manufacture of toasters. Toasters are made with a
variety of features and are in a constant state of redesign. Design innovations of the last
two decades include wider slots for larger slices of bread and bagels, heat resistant
plastics for toaster bodies, and microchip controls. The construction process is a
complex one; therefore, detailed designs are needed to insure the proper assembly of the
toaster's countless parts. The manufacturer's design staff creates prototypes of updated
innovations. The prototypes are then subjected to a battery of tests. Some of the
prototypes may be test-marketed for consumer approval.
The type of toaster dictates the number and types of parts. Manual toasters, those with
turnable toast racks, are of the simplest construction. Semi-automatic toasters
incorporate some type of signal features, such as a buzzer, to announce the end of the
toasting cycle. These toasters may also have a thermostat that is controlled by the
surface temperature of the bread and a regulation dial to adjust the level of brownness.
Semi-automatic toasters do not have a pop-up feature.
Automatic toasters use an electrical current to brown the bread. The pop-up feature
appears in all automatic toasters in which the heating element is connected to a
thermostatic switch or timing device.

The Manufacturing
Process
Making the case

1 Today, toaster cases are generally made out of pressure molded plastic. Plastic
pellets are fed into a hopper and heated to 350F (177C). As the compound
heats, it becomes semi-fluid. It is then poured into a toaster case mold and
cooled. After the plastic cools and hardens, it is removed from the mold. If the
toaster case is aluminum, a sheet of aluminum is placed on a conveyor belt and
taken to a punch press. The punch press has a die that quickly exerts pressure

The basic components of a toaster.

on the aluminum sheet, punching out the specific size needed.

2 The punched aluminum sheet is then conveyed to a backward extrusion press.

The sheet is placed inside of a toaster-shaped die and the press forces a punch
against the sheet. The metal flows backwards around the punch forming a hollow,
toaster-shaped shell.

3 Batches of Nichrome wire are shipped from a manufacture to the toaster

factory. These wires are loaded into a machine that automatically wraps the wire
around a mica sheet.

4 The mica sheets wrapped with Nichrome are then placed back on the assembly
line and two are bolted to the toaster base.

5 In between the mica sheets is the spring-loaded tray. This tray is manually set
and screwed into place.

6 A single bi-metallic element is connected to a support bracket, which is then

mounted onto a second bracket that allows for a pivoting motion. A spring is
installed between the two brackets. A stop is mounted on a mounting bracket to
lock the support bracket when it is activated by the toaster carriage assembly. A
release assembly is attached to the bimetallic element.

Assembling the terminal board

7 Two rectangular sheet-metal conductors are layered above and below a sheet of
insulation. The terminal board is then screwed or welded to the toast rack. The
terminal ends of the temperature-sensing device are attached to the ends of the
conductors by screws.

Installing the base

8 The electrical cord is threaded into the molded plastic base. The various toaster
parts such as the wire brackets and terminal board are attached to the base. The
toaster body is then fitted over the base.

Byproducts/Waste
Very few byproducts result from the manufacture of toasters. However, there is
frequently excess waste from the plastic molding or metal stamping processes. Plastic
waste is collected and reprocessed for use in other plastic products. Scrap metal such as
aluminum can be recycled into a new metal form as well for reuse.

Quality Control
Toasters are regularly tested on the assembly line. They are tested for durability and
functionality. Companies typically generate toasting reports consisting of how well the
bread was toasted, at what temperature the heating element turned off, and how quickly
the bread toasted. This can result in large amounts of toasted bread. One company
donates the toast to ranchers who use it as livestock feed.

The Future
The toaster continues to be modified according to new technology. Designers create
new, versatile looks that fit into any kitchen. Size and capabilities range from simplistic
to extreme. In 1996, two University of Washington engineering students designed and
created a talking toaster. This toaster allows the user to specify verbally what setting
they would like (light, medium, or dark) and the toaster verifies this aloud. Although the
design specifications are available, there is no sign of its mass production.
The toaster itself has become an icon. Toasters can be found on clothing and on CD
covers, as salt-and-pepper shakers, and as artwork. The most outrageous example of the
latter is a mosaic made with 3,053 pieces of toast for an Italian art gallery.

Where to Learn More

Books
Alphin, Elaine Marie. Toasters. Minneapolis: Caroirhoda Books, 1998.
Travers, Bridget, ed. World of Invention: History's Most Significant Inventions and the
People Behind Them. Detroit: Gale Research Inc., 1996.

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