The Caledonian

A DAY AT THE BRITISH NEEDLE MILLS, REDDITCH.—[Concluded.]

In the month of August, 1821, Mr. Abraham of Sheffield sent to the Society a model of a mouth-guard, to be used by the needle-pointers and dry-grinders. He was not at the time aware that a premium had been offered by the Society on this subject; but in October of the same year he sent a second communication, in which, among other details, he stated:—"The Society may not perhaps be in possession of the information that thousands of individuals in this country, besides the needle-pointers, who have been regularly employed in dry-grinding, have been cut off at the age of thirty to forty years." After describing the nature of the apparatus, Mr. Abraham proceeds to remark that the needle-pointers and dry-grinders, "after the grinders' asthma begins to afflict them, which generally happens to those regularly employed in dry-grinding, when they arrive at the age of twenty-five or twenty-seven years, linger out a miserable existence till they arrive at the age of thirty or thirty-five years; beyond the age of forty years very few dry grinders are known to live."

The apparatus consists of two parts. The first is a screen, so suspended from the ceiling as to shield the man from the greater part of the grit and steel-dust set in motion by his work. The second is a mouth-guard, to arrest the progress of such particles as might reach his lips. The mouth-guard consists of a small frame of wood, the upper and lower pieces of which are made circular to fit the lips. On this are fixed two or three layers of crape or muslin; and it is studded with several small magnets, calculated to arrest a considerable portion of the deleterious matter before it can reach the crape. To the upper part of this wooden frame is attached a bent wire, to which crape is fixed for the purpose of protecting the nostrils; and the whole is fastened by two strings passing round the head and tying behind.

Such are the two pieces of apparatus contrived by Mr. Abraham for protecting the workman not only from the particles of steel, but also from the grit detached from the grindstone during the process. It may now be asked, how far these contrivances were efficient? Let the evidence of the needle-manufacturers attest. The volume of the Society's 'Transactions' before referred to contains several memorials or testimonials, among which is one signed by several surgeons, to the effect that the apparatus completely succeeded in arresting the particles; the mouth-guard becoming wholly coated with particles, which would otherwise have passed into the mouth of the workman.

Another is a letter from the proprietors of a needle-factory in Derbyshire, expressing their anxious wish that these humanizing arrangements should be adopted, and stating, among other things, that the needle-pointer who used them most had "not more dust floating about him in a whole day than he used to have in a quarter of an hour." The third is a letter from Redditch, signed by five needle manufacturers and two pointers, to the effect that the arresting of the steel particles was successfully performed by the mouth-piece. A similar letter was afterwards formed by nine of the manufacturing firms at Redditch, twelve of the pointers (whose state of education may be guessed by the fact that ten out of the twelve made their marks), and other inhabitants of the place.

Might it not be supposed that such contrivances would be eagerly caught at by the men? Such would seem to be reasonable; as it was understood that Mr. Abraham had no other motives than those of kindness for promulgating his inventions. Yet has the whole become a dead letter. We believe we are correct in saying, that the needle pointers as a body, of whom there are about a hundred and thirty at Redditch, refuse to adopt these arrangements, perhaps that their wages may not be lowered by rendering the work less injurious. Their earnings sometimes amount to so large a sum as a guinea a day; and are at all times considerably above the average of artisans' wages.

The handkerchief which is tied loosely round the mouth of the needle-pointer is a poor safeguard. The steel and gritty particles enter his lungs in abundance; and he is still, what he has ever been, a short lived and ill-conditioned man. It excites regret to see (as any may see without much difficulty), in the Museum of the Society of Arts, the models of Mr. Abraham's inventions, memorials only of the unwillingness on the part of the workman to adopt a plan which is intended for his benefit, which is looked on favorably by his employers, which society sanctions by its approval, which would give him better health and a longer life, and which would raise him in the scale of respectability as a man.

We have dwelt somewhat at length on the process of needle-pointing, because it involves matters of more than usual interest in connection with the well being of those who are employed in it; but we may now resume the thread of detail.

The reader will bear in mind that the state of our embryo needle is simply that of a piece of dull straight wire, about three inches long (supposing '6's' to be the size), & pointed at both ends. The next process is one of a series by which two eyes or holes are pierced through the wire near the centre of its length, to form the eyes of the two needles which are to be fashioned from the piece of wire. A number of very curious operations are connected with the process, involving mechanical and manipulative arrangements of great nicety. Those who are learned in the qualities of needles—as that they will not 'cut in the eye,' and so forth—will be prepared to expect that much delicate workmanship is involved in the production of the eyes, and they will not be in error in so supposing.

Most of the improvements which from time to time have been introduced in needle-making relate more or less to the production of the eye. In the commoner kinds of needles many processes are omitted which are essential to the production of the finer qualities; but it will show the whole nature of the operations better for us to take the case of those which involve all the various processes.

After being examined when the pointer has done his portion of the work to them (an examination which is undergone after every single process throughout the manufacture), the wires are taken to the 'stamping-shop,' where the first germ of an eye is given to each half of every wire. The stamping-machine consists of a heavy block of stone, supporting on its upper surface a bed of iron; and on this bed is placed the under half of a die or stamp. Above this is suspended a hammer, weighing about thirty pounds, which has on its lower surface the other half of the die or impress. The hammer is governed by a lever moved by the foot; so that it can be brought down exactly upon the iron bed. The form of the die or stamp may be best explained by stating the work which it is to perform. It is to produce the 'gutter,' or channel, in which the eye of a needle is situated, and which is to guide the thread in the process of threading a needle.

But besides the two channels or gutters, the stampers make a perforation partly through the needle, as a means of marking exactly where the eye is to be. The device on the two halves of the die is consequently a raised one, since it is to produce depressions in the wire. The workman, holding in his hand several wires, drops one of them on the bed-iron of the machine, adjusts it to the die, brings down the upper die upon it by the action of the foot, and allows it to fall into a little dish when done. This he does with such rapidity that one stamper can stamp four thousand wires, equivalent to eight thousand needles, in an hour, although he has to adjust each needle separately to the die.

To this process succeeds another, in which the eye of the needle is pierced through. This is effected by boys, each of whom work at a small hand press; and the operation is at once a minute and ingenious one. The boy takes up a number of needles or wires, and spreads them out like a fan. He lays them flat on a small iron bed or slab, holding one end of each wire in his left hand, and bringing the middle of the wire to the middle of the press. To the upper arm of the press are fixed two hardened steel points or cutters, being in the size and shape exactly corresponding with the 'eyes' which they are to form. Both of these points are to pass through each wire, very nearly together, and at a small distance on either side of the exact centre of the wire. The wire being placed beneath the points, the press is moved by hand, the points descend, the two little bits of steel are cut out of the wire, thereby forming the eyes for two needles. As each wire becomes thus pierced, the boy shifts the fan-like array of wires until another one comes under the piercers, and so on throughout. The press has to be worked by the right hand for piercing each wire; and the head of the boy is held down pretty closely to his work, in order that he may see to 'eye' the needles properly. Were not the wires previously prepared by the stamper, it would be impossible thus to guide the piercers to the proper point; but this being effected, patience, good eye-sight, and steady hand effect the rest.

There are several processes about this stage which are effected by boys: groups of little incipient workmen being distributed here and there, each group under the direction of an older hand. Some have hairy caps on, some cloth caps; some aspire to the dignity of a workman's paper cap; here is one with a pinafore, there another who thinks he is man enough to wear an apron; some have eyes as sharp as the needles which they are piercing, while others look as if they would rather be playing at marbles or at 'hop-scotch,' than piercing needles at all; in short they are true boys, and, we doubt not, as fond of fun as any other boys. Their earnings are from two shillings per week upwards, according to the importance of the work at which they are placed and their skill in executing it. In many cases they are the sons or apprentices of workmen employed in the factory, who receive the earnings of the boys, and are responsible for the work done by them; in other cases the boys receive the wages which they earn.

Some of these little laborers take the needles when they have been 'eyed,' and proceed to 'spit' them; that is, to pass a wire through the eye of every needle. Two pieces of fine wire, perhaps three or four inches in length, are prepared, the diameter corresponding exactly with the needle eye. These two pieces of wire are held in the right hand, parallel, and at a distance apart equal to the distance between the two eyes in each needle-wire. The pierced needles, being held in the left hand, are successively threaded upon the two pieces of smaller wire, till, by the time the whole is filled, the assemblage has something the appearance of a fine-toothed comb. A workman then files down the bur, or protuberances left on the side of the eye by the stamping.

It must be borne in mind that throughout all these operations the needles are double; that is, that the piece of wire three inches in length, which is to produce two needles an inch and a half long each, is still whole and undivided, the two eyes being nearly close together in the centre, and the two points being at the ends. Now, however, the separation is to take place. The filer, after he has brought down the protuberances of each wire, but before he has laid the comb of wires out of his hand, bends and works the comb between his hands in a peculiar way, until he has broken the comb into two halves, each half 'spitted' by one of the fine wires. The needles have arrived at something like their destined shape and size; for they are of the proper length, and have eyes and points. In the annexed cut we can trace the wire through the processes of change hitherto undergone.

But although we have now little bits of steel, which might by courtesy be called needles, they have very many processes to undergo before they are deemed finished, especially if, in accordance with our previous supposition, they are of the finer quality. There are very many workshops which we have yet to glance through, the first of which is that of the 'soft-straightener.' The filer and his two 'spitters' (who together get ready about four thousand needles in an hour) are very likely to bend in a slight degree the needles under operation; and, indeed, so are likewise the 'stampers' and the eye'-makers. To restore the straightness of the wire is the office of the 'soft-straightener,' who is frequently a female. And here we cannot refrain from remarking on the neat and respectable appearance of the females engaged in the needle-manufacture. Their earnings are on an average from eight to twelve shillings a-week (except the youngest girls); and their appearance and general demeanor are creditable both to themselves and to those by whom they are employed. The writer happened to be passing through the main street of Redditch at a time when the work-people were pouring from the different needle-factories, on their way home to dinner; and an opportunity was thus afforded of observing not only the large number of persons employed in this manner, but also the air of respectability which generally pervaded them,—in which many of the operatives of the 'Great Metropolis' might imitate them with advantage.

The 'soft-straightener' is seated in front of a bench, near the front edge of which is placed a small steel plate. On this plate the needles are placed, parallel or nearly so; the straightener employed is a steel bar, from a foot to half a yard long, an inch or two in width, and perhaps a quarter of an inch thick. It is turned upwards a little at the ends, so as to be somewhat convex at the lower surface; and is held by both hands at the two ends. By a curious management of this instrument, the soft-straightener separates each individual needle from the group of which it forms a part, and rolls it over two or three times with the lower surface of the instrument, pressing it against the iron plate, and thus working out any curvatures or irregularities which may have been given to it by the previous operations. It would seem much more simple to place the needles, one by one, on the iron plate, and roll them with the bar of metal till straightened; but a great expenditure of time would result from such a plan. As it is, the heap of needles is placed parallel on the iron plate, and by touch each one is separated from its fellows, straightened, and passed into a tray beneath. So quickly is this done, that three thousand needles can be thus straightened in an hour by one person.

The needles are by this time pointed, eyed, and straightened; but before they can be brought to that beautifully finished state with which we are all familiar, it is necessary that they should be 'hardened' and 'tempered' by a peculiar application of heat. After being examined, to see that the preceding processes are fitly performed, the needles are taken to a shop provided with ovens or furnaces. They are laid down on a bench, and by means of two trowel-like instruments, spread in regular thick layers on narrow plates or trays of iron. In this way they are placed on a shelf or grating in a heated furnace. When the proper degree of heating has been effected, the door is opened, and the needles are shifted from the iron tray into a sort of colander or perforated vessel immersed in cold water or oil. When they are quite cooled, the hardening is completed; and if it has been effected in water, the needles are simply dried; but if in oil, they are well washed in an alkaline liquor to free them from the oil. Then ensues the tempering processes. The needles are placed on iron plate, heated from beneath, and moved about with two little trowels until every needle has been gradually brought to a certain desired temperature.

We now leave the furnace-room and proceed to one of the upper rooms of the factory, where a multitude of minor operations are conducted incident to the finishing of the needles. Notwithstanding the 'soft-straightening' which the needles underwent after they were pointed and eyed, they have become slightly distorted in shape by the action of the heat in the processes just described, and to rectify this they undergo the operation of 'hammer-straightening.' A number of females are seen seated at a long bench, each with a tiny hammer, giving a number of light blows to the needles: the needles being placed on a small steel block with a very smooth upper surface. This is rather a tedious part of the manufacture, the workwoman not being able to straighten more than five hundred needles in an hour, a degree of quickness much less than that which we have had hitherto to notice.

We leave the tinkling hammers and follow the needles to the only part of the manufacture which involves apparatus other than of a very small size—This is the 'scouring' process. In one of the lower rooms of the factory are twelve machines, looking like mangles, or perhaps more correctly like marble polishing machines,—a square slab or rubber working to and fro on a long bed, stone, or bench. The object of this process is to rub the needles one against another for a very long period, till the surfaces of all have become perfectly smooth, clean, and true. This is effected in a curious manner. A strip of very thick canvas is laid out upon the bench, and on this a large heap of needles, amounting to perhaps twenty or thirty thousand, is laid, all the needles being parallel one with another, and with the length of the cloth. The needles are then slightly coated with a mixture of emery and oil, and tied up tightly in the canvas, the whole forming a compact roll about two feet long and two inches in thickness. Twenty-four rolls of needles being thus prepared, comprising probably six-hundred thousand needles in all, they are placed under the rubbers of the scouring-machines, two rolls to each machine. A steam engine (most of the Redditch factories, we believe, have water-wheels) then gives to the rubbers, by connected mechanism, a reciprocating or backward and forward motion, pressing heavily on the rolls of needles, and causing all the needles of each bundle to roll one over another. By this action an intense degree of friction is exerted among the needles, whereby each one is rubbed smooth by those which surround it. For eight hours uninterruptedly this rubbing or scouring is carried on; after which the needles are taken out, washed in suds placed in new pieces of canvas, touched with a new portion of emery and oil; and subjected to another eight-hours' friction. Again and again is this repeated, insomuch that for the very finest needles the process is performed five or six times over, each time during eight hours' continuance. This is one of the points in which the difference is shown between various qualities of needles. the length of the scouring being correspondent with the excellence of the production. The pieces of canvas become coated within with a mixture of emery, oil, and steel; but the quantity of steel rubbed off in this process is not so much as might at first be supposed.

Again we accompany the needles to another part of the factory, being that which is technically termed the 'bright shop,' in which many processes are carried on in reference to the finishing of the needles. The needles are examined after being scoured, and are placed in a small tin tray, where, by shaking and vibrating in a curious manner, they are all brought into parallel arrangement. From thence they are removed into flat paper trays in long rows or heaps, and passed on to the 'leader,' generally a little girl, whose office is to turn the head one way and all the points the other. This is one among the many simple but curious processes involved in this very curious manufacture, which surprises us by the rapidity and neatness of execution. The girl sits with her face towards the window, and has the needles ranged in a row or layer before her, the needles being parallel with the window. She draws out laterally to the right those which have their eyes on the right hand, into one heap; and to the left those which have their eyes in that direction, in another.

About this time too the needles are examined one by one, to remove those which have been broken or injured in the long process of scouring; for it sometimes happens that as many as eight or ten thousand out of fifty thousand, are spoiled during this operation. Most ladies are conversant with the merits of 'drilled eyed needles,' warranted "not to cut the thread." These are produced by a modern improvement, whereby the eye, produced by the stamping and piercing processes before described, is drilled with a very fine instrument, by which its margin becomes as perfectly smooth and brilliant as any other part of the needle. To effect this the needle is first blued,' that is, the head is heated so as to give it the proper temper for working. Then the eye is 'counter-sunk,' which consists in bevilling off the eye by means of a kind of triangular drill, so that there may be no sharp edge between the eye itself and the cylindrical shaft of the needle. Next comes the drilling. Seated at a long bench are a number of men and boys, with small drills working horizontally with great rapidity. The workman takes up a few needles between the finger and thumb of his left-hand, spreads them out like a fan with the eyes uppermost; brings them one at a time opposite the point of the drill, governs the handle or lever of the drill with his right hand,— and drills the eye, which is equivalent to making it circular, even, smooth, and polished. He shifts the thumb and finger round, so as to bring all the needles in succession under the action of the drill; and he thus gets through his work with much rapidity. The preparation of the drills, which are small wires of polished steel three or four inches long, is a matter of very great nicety, and on it depends much of that beauty of production which constitutes the pride of a needle-manufacturer.

We next pass to a large room, where a multitude of little wheels are revolving with great rapidity, some intended for what is termed 'grinding' the needles, and some for polishing. The men are seated on low stools, each in front of a revolving wheel, which is at a height of perhaps two feet from the ground. All the wheels are connected by straps and bands with a steam engine in the lower part of the factory. A constant humming noise was heard in the room, arising from great rapidity of revolution among a number of wheels; and it is not difficult for the ear to detect a difference of tone or pitch among associated sounds, due to differences in the rate of movement. The grinding-wheels are very small, not above five or six inches in diameter; they are made of gritstone, and are attached to a horizontal axis. The grinding here alluded to is not such as might be supposed, relating to the points of needles, but has reference simply to the heads, which have not yet had a rounded form given to them. The workman takes up a layer or row of needles between the fingers and thumbs of the two hands, and applies the heads to the stones in such a manner as to grind down any small asperities on the surface. As the small grinding wheels are revolving three thousand times in a minute, it is plain that the steel may soon be sufficiently worn away by a slight contact with the periphery of the stone.

The grinders and the polishers sit near together, so that the latter take up the series of operations as soon as the former have finished. The polishing-wheels consist of wood coated with buff leather, whose surface is slightly touched with polishing paste. Against these wheels the polishers hold the needles, applying every part of the cylindrical surface in succession first holding by the pointed end. About a thousand an hour can thus be polished by each man; and when leave his hands the needles are finished.
We have still to see the needles prepared. In one of the rooms a number of females are cutting the pa-pers, separating the needles into groups of twenty-five each, and folding them in the neat oblong form so well known to all the users of a paper of needles.' So expert does practice render the workwoman, that each one can count and paper three thousand needles in an hour. The papered needles then pass to another room, where boys paste on the smart-looking labels which deck every paper of needles. Even here there are sundry contrivances for expediting the process, which would scarcely be looked for by common ob-servers.
When the papers have dried on an iron frame in a warm room, they are packed into bundles of twenty papers each; which are further packed in square parcels containing ten, twenty, or fifty thousand needles, enclosed, if for exportation, in soldered tin cases.
As a means of judging the bulk of needles we may state that ten thousand '6's' form a packet of six inches long, three and a half wide, and under two in thickness.
Thus we have followed the manufacture to its close. None but the finest needles undergo the whole of the processes enumerated; but we have wished to give them as a means of estimating the complexity of the manufacture of an article apparently so humble. The arrangements of the factory, as to apparatus, &c. are adapted to the production of a hundred millions of fine needles per annum.
As to the whole quantity made in the Redditch factories and in the houses of the workmen in the vicinity, it has been estimated at so high a number as seventy millions per week! These are startling results, and show that in considering the seats of manufacture in England, we must not forget to include the remarkable Worcestershire village of Redditch.