Tin and lead, combined in a variety of ratios, are the ingredients of our metal pipes. Varying the proportions of tin and lead in the alloy allows us to customize the sound quality of each stop. More tin in the alloy provides better structural resistance, a shinier appearance, and favors the development of upper harmonics in the sound. This is the reason our façade pipes are manufactured with an extremely high percentage of tin: 95%.
The metal is melted in a crucible, or melting pot. It is then transferred to a special container at the end of the casting bench, and cooled to reach the right temperature to flow evenly.
The metal is then poured into a though at the end of the casting bench. A slit across the back of the trough allows the metal to flow out as the trough is slid along the length of the bench.
Sliding the trough along the length of the casting bench leaves behind a glistening layer of metal. The top of the casting bench is made of very thick marble covered with canvas. The marble provides for uniform cooling, allowing the formation of the ideal molecular structure of the metal.
The long metal box over the casting bench extracts the fumes produced by the hot metal and filters them out, releasing clean air into the atmosphere. Both the safety of the work environment and the protection of the natural environment stand high on our list of priorities.
The sheets of metal are attached to the rotating drum of a planer and planed to the desired thickness. When this is finished, the metal can be cut into parts for pipes.