How kinder is made in factories. Kinder Surprise: amazing manufacturing technology

The famous chocolate eggs with an unexpected gift have long become a favorite souvenir for children all over the world. The question of how to make a Kinder Surprise is asked by many of them. At its core, this is a simple but very original idea, which is a chocolate egg, inside of which there is a plastic container with a small toy or a nice souvenir.

Gift idea

In order for you to understand how a kinder surprise is made, we will lift the veil of this secret. In fact, this is a rather long and lengthy journey, which takes about two years in total. It all starts with an idea.

Ideas for producing toys for chocolate eggs arise in different ways. Some are the result of persistent and painstaking work of designers, others are completely spontaneous, but this makes them no less interesting.

A classic example of a sudden successful idea is the creation of the famous series of hippo toys. She appeared to the head of the Ferrero company at the moment when he went on a trip to Taiwan. This impression was made on him by a huge statue of a hippopotamus installed in one of the central cities of this country.

He came up with another idea at a concert of a popular musical duet. This is how the “Musician Bears” series appeared.

Toy sketches

The next stage is the creation of designs and specific sketches of invented toys, which will then be placed in Kinder Surprise eggs. Usually, souvenirs are created in large collections at once. After the first drawings appear, it becomes clearly clear whether the initial idea was successful and whether it can be successfully implemented.

In the 70s, when the production of Kinder Surprises was just starting, sketches were drawn by hand on paper. A detailed description was always left under the picture. Today, progress has reached the development of toys. Everything is done on a computer; there are dozens of specialized graphic editors for this.

Those who evaluate sketches of future toys have a complete idea of ​​what they will look like - right down to the shades of color. They are prescribed using a special alphanumeric designation. They also indicate the availability of parts and accessories that the figure will need.

The main thing that you should also pay attention to is the size of the toy. After all, Kinder surprise eggs are very small, and there is no extra space in the plastic container that is placed in it.

License issues

This step does not accompany every series of toys, but only those associated with the use of famous characters from fairy tales, films or cartoons.

Even before developing a design, manufacturers are required to purchase a license to use a specific image in their work. Then you also need to agree on the resulting figurine with the owner of the copyright for the character. This is how they make a kinder surprise with famous characters. This, of course, adds additional organizational concerns and financial costs, but the result justifies all the losses.

If the owner of the copyright for a character is dissatisfied with something in the embodiment of the image, then he has the right to make changes that he deems necessary. For example, when releasing a collection dedicated to the film "The Lord of the Rings", each actor approved a figurine with his character.

Toy presentation

After the design of the toy is agreed upon by everyone, a prototype is made. It is several times larger than the final figure. It is important to make this toy larger, since they make Kinder Surprise at the factory, so it is necessary to evaluate new toy models, discuss all the details, accessories and necessary proportions.

It is especially important to make a presentation when a licensed series of new toys is released. After all, they must be approved by the copyright holders of the characters. Changes are made both at the stage of developing sketches and when discussing prototypes.

One of the undisclosed secrets about how Kinder Surprise is made concerns the fate of the enlarged prototypes that are prepared for presentation. Nothing concrete is known about this; most likely, they are simply destroyed.

Toy release

The most important final stage is the production of the toys themselves. For each new collection, special forms are developed, with the help of which it is possible to organize mass production. Each figurine is cast in this mold.

Most often, a toy that appears to be one piece consists of several parts. At least two or three. This can be easily determined by the gluing seams that are present on the figure. This means that the number of molds for casting corresponds to the number of parts from which the figurine is made. This is how they make a kinder surprise.

Trial consignment

A trial batch of toys from the new collection is produced without fail. The goal is to debug the production process, listen to the assessments of all experts and copyright holders of the characters. Unlike prototypes, the trial run is much larger. Therefore, copies from it rarely leak onto the market. Then we become the owners of variants of the figures and can observe with our own eyes how the artist’s thoughts changed.

It is also important how Kinder surprises are packaged. Instructions and special inserts must be placed in plastic capsules.

Due to cheap manual labor, the main production of toys is located in Asia. All one-piece toys are painted by hand. At the same time, Ferrero, one of the world leaders, produces chocolate eggs. confectionery market. Their factories are located in many countries on several continents.

At the final stage, the containers with toys are packed in a chocolate shell at one of the confectionery factories, where the eggs are wrapped in foil and packaged in boxes.

You can no longer surprise modern children with ordinary Kinders. According to survey results, 93 percent of the Russian population aged four to fifty years are familiar with these products. Someone has tried this delicacy, someone collects toys, and someone just saw an advertisement. But not everyone knows about Kinder Surprise Maxi. The chocolate with a toy inside is initially produced in the shape of an egg. Even the plastic container is colored to resemble the yolk. And if we compare Kinder Surprise with eggs, then Maxi is not a chicken egg, but a real ostrich egg. Such delicacies are produced in collections - New Year's, spring, summer. And such an “ostrich egg” costs the same as four ordinary ones.

Many parents would like to give their child a big Kinder surprise. What's inside this treat? This is a question that worries many. What did the manufacturer put in the container for such a lot of money? We will try to answer this question in our article.

The idea of ​​creating a treat with a toy inside belongs to Swiss designer Henry Roth. The Ferrero company, which produces not only chocolate, but also candies (the well-known Raffaello in particular), cakes, dragees and Nutella paste, decided to try this marketing ploy. It turned out to be not just successful, but stunningly successful. The first batch of Kinder Surprises, released in 1974, was sold out by customers in an hour. Since then, chocolate eggs can be bought on all five inhabited continents, in more than 60 countries... Except the USA. Yes, you heard right. In this country, which is considered the birthplace of fast food and various candy bars, Kinder Surprises are prohibited for sale. The fact is that a 1938 federal law prohibits the inclusion of inedible items in food products. Both the small and large “Kinder Surprise” (we’ll find out what’s inside later) contain two parts in their name. The first - kinder - remains unchanged for all countries where products are sold. And the second - “surprise” - is translated into different languages. So, Kinder Niespodzianka is sold in Poland, Kinder Sorpresa in Italy, Kinder Uberraschung in Germany, and so on. It is known that children love to play with eggs before eating them. Therefore, for countries with hot climates, Kinder Joy is produced from non-melting chocolate. Ferrero produces collections in which toys are connected by a specific theme.

Adult passions based on Kinder Surprises

All children love chocolate eggs with fun inside. But adults are often crazy about Kinder Surprises. True, their interest is more pragmatic. The fact is that recently, collecting toys from yellow containers has emerged and is gaining momentum. A particularly rare copy from the first collections can fetch up to a thousand euros! And in 2007, eBay auction presented an amazing lot: a complete collection of 90,000 toys. It was purchased for 30 thousand euros. Every year Ferrero produces one hundred new toys. All of them are unique and are made by various designers specifically for the company. And now “Maxi Kinder Surprise” has appeared. What's inside the big egg? This question haunts many collectors.

Gifts for girls and boys

What kind of toy does Kinder Surprise contain? Many adults, even without being collectors, would like to know the answer to this question. After all, such sweets are given to children. And parents would not want their daughter to receive a car, and their son to receive a doll. In regular Kinder Surprises, the manufacturer sometimes produces series intended exclusively for girls or boys. Suffice it to recall “Disney Princesses”, “Barbie” or “Cars 2” and this year’s collection “Infinimix”. There are series that will be a pleasant surprise for children of both sexes. They contain toys depicting characters from acclaimed cartoons (“Masha and the Bear”, “Despicable Me”, “Minions”, etc.). What's inside the big Kinder? There are a lot of surprises in them.

"Skylanders"

In Western Europe there is a beautiful Easter myth. Bunnies come to the garden of the house where there are children and leave eggs under the bushes. On the day of the Resurrection of the Lord, children begin to rummage through flowerbeds and thickets in search of gifts. Of course, these are not ordinary eggs - they are a big Kinder surprise. What's inside depends on the release date. For example, this year, for Easter, a series of “Maxi Kinder Surprises” was released with the characters of the video game for the Skylanders smartphone. Despite the fact that the heroes Spiro, Eruptor, Fizz and Jet-Vak are known mainly to teenagers, kids also liked such weirdos. Therefore, the video game characters appeared in Germany and in the 2017 Christmas special.

Cartoon characters

In June, the animated film Despicable Me was released. As soon as it became clear that the cartoon was a box office success, Ferrero immediately released a new series of toys. What's inside the big Kinder Surprise in this collection? This is Drew, sitting on Gru’s motorcycle with Lucy standing on his shoulders, or the three minions loved by all the kids. Moreover, each of them comes complete with a piece of a prison wall. Kids love to play with the toys in this collection, regardless of whether they have watched the cartoon or not.

“Superhero Girls” also became a popular series. After the release of the cartoon, plastic dolls appeared in both regular and large Kinders. But in “Maxi” the figurine comes with a bracelet with a box and a mirror inside with the heroine’s emblem. In the collection big eggs four girls: Supergirl, Batgirl, Wonder Woman and Harley Quinn.

New Year's collection 2017

Ferrero has been producing Christmas episodes for many years now. After all, it is under the Christmas tree that Santa Claus (or rather, parents) puts gifts for children. And on such a holiday as New Year, this should not be an ordinary one, but a big “Kinder surprise”. What's inside the 2017 collection? It's already on sale. Ferrero pleased both girls and boys. The toys in the capsules are quite large and look like cute snowmen. There are five of them in the series: on a sled, on skis, on a snowboard, on skates and on an all-terrain vehicle. Parents can be sure: their children will be delighted with such a gift. All snowmen have moving parts, and these figures are fun to play with.

Old New Year's big "Kinder surprise": what's inside?

In Russia, the 2016 collection with deer is still in use. These toys are even funnier than the new ones because they are winding. Here, for example, is a deer on a sled. The volumetric capsule also contains a long drive key. It needs to be inserted into the hole on the sled and pulled out with a quick movement. The key activates a simple mechanism, and the deer actually moves! It is enough to show your child how the sled starts up once, and then he will play on his own. What is interesting about the Kinder Surprise Maxi toys is that, unlike ordinary eggs, the figures are solid. This means that children will not lose, much less swallow, fragments. Such toys are easier to grasp with clumsy fingers than the miniature figurines of regular Kinder toys.

How toys are made from Kinder Surprise?

Taking out another toy from chocolate egg“Kinder Surprise”, you have probably wondered more than once how these same toys are produced? Few people know about this, and long searches for an answer on the Internet provide practically no information. So how are they actually made?

Let's try to lift the veil of secrecy over this issue a little - in this short article we will talk about how one-piece serial figures from Kinder Surprise are made" Go…

The development and production of one new series of one-piece figurines for Kinder Surprise chocolate eggs is a long journey, which takes about two years. Conventionally, it can be divided into six steps - six large stages in the birth of a new unique collection.

Step 1: Idea
Of course, no new series can be discussed without an idea. Ideas can be born as a result of long-term planned work by designers, or they can come completely spontaneously, but turn out to be no less successful.

For example, the idea of ​​​​creating a series of hippopotamuses appeared to the head of the development department of the Ferrero company at the moment when he saw a large statue of a hippopotamus installed in Taiwan. When the same manager watched the performance of the pop duo Marianna and Mikhail at one of the exhibitions, he, again, accidentally came up with the idea of ​​​​creating a series that eventually received the name “Musician Bears” (“Top Ten Teddies” 1995).

Step 2: Sketches
The second stage, which brings closer the moment of production of the toys conceived in the first step, is the creation of drawings of individual characters of the new collection. Drawings, as opposed to intangible thoughts, allow you to understand how successful the idea of ​​​​the series itself is, and how best to implement it.

Working drawings for the series " Behemoths - Star Wars"("Das Hipperium spielt verruckt") 2002

Previously, each sketch of a future figurine was drawn by hand and supplied detailed description, now the work of designers is computerized: drawings are made in specialized graphic editors, and descriptions of toys are recorded in a special file - the so-called “profile”.

In order to have as accurate an idea as possible about the future figurine, its colors must be written down in the profile. Moreover, not just “blue” or “pink”, but a coded alphanumeric designation of a specific shade. In addition, the profile indicates the presence of individual parts or accessories included with the figure, and their quantity.

An important point What is given special attention in the description of the toy is its size. Because everyone understands that a plastic capsule placed in a chocolate egg has a strict limitation on the amount of free space in it. For this reason, the task of designers becomes more complicated - they need to develop not only an interesting and detailed, but also a compact figure.

Step 3: License
This step is optional and skipped if the series is the result of the work of Kinder Surprise's own designers. However, in recent years, we are increasingly finding licensed collections inside our favorite chocolate eggs, which means it would be a grave mistake not to mention this stage.
So, before planning a new series, a toy company must buy a license to use the characters from the person who owns the copyright to them, and then approve the finished figures from him.

To purchase licenses, representatives of developers visit specialized fairs, or owners of new animated films (for example) can themselves offer cooperation, since it is mutually beneficial for both parties and can simultaneously increase both the box office of the new film and the sales of Kinder Surprises.

After a preliminary agreement, all graphic and text information on future figures is provided to the license holder. At the same stage, the name of the new series is invented.

If the licensee does not agree with anything presented, then appropriate changes are made to the working documents. It is worth noting that a license may be refused in the event of the slightest change in the series without the consent of its (license) holder.

Interesting fact: In the Lord of the Rings series, each actor in the film personally approved the sketches of his character.

Step 4: Presentation of the version
After an agreement has been reached on the appearance of the figures that suits both parties (in the case of a licensed series) or satisfies the designers, “prototypes” are made - models of future toys enlarged several times. This is done so that you can really evaluate the new collection, determine the details and proportions, which is difficult to do based only on the image. Moreover, the same character can be represented by several slightly different models at once (in the end, only one option is selected from them).

Presentation is especially important for licensed series, because, as in the previous step, toys are subject to criticism or approval from the licensee. And, just like at the stage of approval of sketches, any changes can be made here appearance future figures.
The enlarged prototypes made for presentation are probably being destroyed because there is still virtually no information about them.

Step 5: Latest Changes
This stage follows the successful presentation of future figures, where the final approvals are made on the toys before they go into production. Usually during this period, if any changes are made, they concern small and insignificant details. The license holder's final stamp is then applied, after which work on the appearance of the toys is considered completed and they are sent to production. If this does not happen for some reason, then the character development process may again go back several steps.

Step 6: Production
Production is the final and perhaps the most important stage in the process of creating a new collection of Kinder Surprise toys. In order to launch mass production, special molds are made for casting the figures. You've probably noticed that even if at first glance the finished toy seems solid to us, in fact most often it consists of at least two parts, as evidenced by the presence of gluing seams. Thus, the number of molds for casting corresponds to the number of parts of the figurine.

First, a small trial batch of toys is made. If something goes wrong during the production process or does not turn out the way the designers intended, then changes may be made to the appearance of the figures again (for the umpteenth time).

So, for example, if it turns out that it is easier to initially pour colored plastic into the mold than to later manually paint the finished figures, then this nuance will be reflected in the design documentation, and Production Line will be reconfigured.

The trial batch is intended to fine-tune the manufacturing process and evaluate the resulting series, but sometimes toys from it still leak out for sale (when the difference between the project and the actual implementation is insignificant), as a result of which we get so-called variant figures at our disposal.

After the blanks of future toys are cast, they are sent for painting and then packaging in plastic capsules along with instructions and inserts.

It is interesting that the production itself is located in Asia, due to the fact that manual labor is much cheaper there (let me remind you that the one-piece toys from Kinder Surprise are hand-painted). And here the main thing is not to confuse the production of toys with the production of chocolate eggs themselves. Chocolate is the work of confectionery factory specialists “ Ferrero", whose representative offices and factories are located in many cities and countries around the world, but the company has been developing toys since August 2004 MPG» (« Magic Production Group»).

After all the work is completed, the capsules with toys “go” to one of the confectionery factories, where they are melted into a chocolate shell, packed in foil, packaged in boxes and delivered to stores to the delight of us – lovers and collectors of Kinder Surprises.

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Kinder Surprise is a chocolate egg with a surprise in the form of a plastic container with a toy inside. The idea of ​​such a delicacy arose at Ferrero Rocher in 1972. But how do they make a kinder surprise?

WHAT IS THE ARTICLE ABOUT?

How is it made?

Production begins with the loading onto the conveyor of the molds in which the chocolate shell for this sweet will be made. The shapes are of different colors and each will contain half of a chocolate egg, which will later be combined into one, but more on that later. Pours into the mold liquid chocolate, after which they are turned over and the chocolate flows out, but a layer of glaze remains which will be enough to form a shell. Next, the same method is used for the second layer of white glaze. This is how you get two halves of a delicious chocolate egg.

They continue to move along the conveyor and have time to freeze a little. At this stage, they carefully place plastic containers with toys into one half of the egg. After this, the forms are connected and tapped a little so that the halves from the top part move away from the mold.

Since the chocolate is still soft, the halves are fastened together to form a whole egg with a surprise. And now the time is coming for the final stage of the production of Kinder Surprise! All of them are wrapped individually in foil using special equipment at great speed. This is how it is made. All this work is carried out on well-functioning machines with the highest precision and this entire process is carried out automatically.

How to make a Kinder toy?

As for the toy itself, this is also a rather capacious and interesting process. It all starts with the fact that designers come up with a whole series of these toys. This can be exclusively the author's work, but also figurines from popular cartoons and the like. If we consider the second option, then the company buys a license for the right to develop such series.

The second stage is drawing sketches and thinking through the toy itself. This process involves such aspects as what parts it will be divided into and which parts will be movable.

The third stage is the creation of a test sample according to the sketch. They make a model larger than the one that will be in the kinder to identify shortcomings.

Well, the final stage is itself industrial production. Mostly parts and toys are cast from plastic, but there were series with metal toys, cardboard puzzles, and even wooden figures. “Surprises” are always painted by hand, and this mainly happens in Asia, from where they are sent all over the world. The entire process from coming up with an idea to a finished toy lasts about two years, and about 100 different series are released per year.

Kinder surprise do it yourself

Now let's talk about how to make a kinder surprise at home.

For this you will need:

• Egg halves molds;
• Lactic dark chocolate;
• Lactic White chocolate;
• And of course the surprise itself, what would we do without it.

Let's prepare everything for the water bath and crumble the dark chocolate into a convenient bowl. Heat it until liquid and carefully spread the egg halves into the molds. Let it sit for a while and once again spread the chocolate that has accumulated in the middle. After this, put it in the freezer for 10-15 minutes, depending on the power freezer. We don’t remove the remaining dark chocolate from the bowl; we will need it later.

Now we do the same procedure with white chocolate, but we try to add a little less of it and immediately put it in the freezer so that the dark chocolate does not melt. We wait another 10-15 minutes and take it out.

Now we put a surprise in one half; you can use the yellow container from the original Kinder for this. In order to connect we will need the same dark milk chocolate. Melt it a little and carefully spread it on the bottom half of the shell and immediately cover it with the other half on top, send everything to the same freezer to consolidate the result. 10 minutes and you can take it out. You have created a delicacy that no child, and maybe even an adult, can resist!