Manufacturing of music rolls is a challenge, but a greater problem was
getting the proper boxes made to hold the finished product.

San Antonio has six box factories.  Only one would consider making
nickelodeon roll boxes for me.  All of the others wanted runs of 2000
or more, in my case, a lifetime supply.

I spent a number of years in the printing trade, and die cutting
operations were a fairly routine operation.  Most fancy greeting cards
are die cut in some manner as are most of the food product boxes on
your pantry shelf.  Steel rule dies are used and differ from what one
usually thinks of when the word die is used, since there is only a
male die.

Making of steel rule dies is an art, and San Antonio has one of the
best in the business.  Needless to say, the dies are expensive, but
will last for up to 50,000 impressions!

The plant that made the boxes, allowed access to the operations
department to document the process.  They also agreed to let me use
the photographs I took on my website.  The whole illustrated story is
at:

   http://www.edgaida.com/rollbox.html

Enjoy!

Ed Gaida
San Antonio, Texas...Where the sunshine is SUPPOSED to spend the winter!