How a puzzle is created

Discover the secret of Ravensburger puzzle production!

How a Ravensburger puzzle is created

Have you always wanted to know how a puzzle is produced? Ravensburger shares the secret of the unique Ravensburger puzzle production with you.

Experience the production process of a Ravensburger puzzle from the professional image selection to vibrant printing on special linen-embossed paper and finally to the strict quality controls and packaging. Learn more about the secrets of form diversity and the unique fit of Ravensburger puzzle pieces.

Image processing -

the puzzle image is processed on the computer. For example, the editor changes colors or intensifies contrasts to not only make the picture look better, but also to create good puzzle pieces.

Printing -

the “Underwater Paradise” image is printed on special linen-embossed paper with an offset printing method to minimize reflections and flaring on the puzzle.

Printing quality control 1 -

the employee checks whether the printing result is optimal. If not, the color values must be precisely readjusted. Only when the ideal result is achieved, can mass-printing of the image begin. This applies to the printing sheet of the puzzle image...

Printing quality control 2 -

...as well as for the printing sheet of the box.

Lamination -

the printed paper sheets are too thin for use as a puzzle. They are subsequently mounted on blue cardboard, which has been specially developed for Ravensburger – in a lamination process, which provides greater stability. A press roll joins the sheet with the image and the cardboard backing.

Design the punching tool -

the puzzle pieces are punched with a handcrafted punching tool. The corresponding template is first drawn by hand, which requires great expertise. This is the only way to ensure the unique diversity of Ravensburger puzzles: among 1,000 puzzle pieces, no two are alike!

Build punching tools -

based on the drawing, razor-sharp steel bands are bent into shape by hand and mounted on a wooden plate. To build the punching tool for a 1,000-piece puzzle, toolmakers need around 160 hours. And beyond mere technical expertise they also require dexterity, dedication and patience.

Punching -

the laminated puzzle sheets are placed in the punching press, to cut a puzzle image into 1,000 pieces. The razor-sharp punching tool is placed in the press and with a force of hundreds of tons, cuts the puzzle sheet into many little puzzle pieces featuring recesses and tabs.

Punching quality control -

an employee spot checks the punched puzzles. Are the edges cleanly cut? Are any pieces still stuck to the punching blade? If the punching tool has become dull it is replaced with a new tool.

Sealing the bag -

the punched puzzle is separated into 1,000 pieces and heat-sealed in a bag. Both steps are done fully automatically.

Placement in the box 1 -

even the box covers are printed – just like the puzzle image. An “enrobing machine” folds the cardboard into a box and the box top and bottom are each laminated with the printed sheets. The puzzle bags are placed by hand in the bottom of the box...

Placement in the box -

… and manually pressed down flat by an employee, so that the puzzle pieces are evenly distributed in the box.

Covering the box -

the so-called “coverer” closes the puzzle box by placing the box top over the box bottom.

Shrink-wrapping with plastic film -

after the cover is is placed on the filled box bottom, the entire box is shrink-wrapped in plastic film to protect it during transport and guarantee an original Ravensburger puzzle.

Quality control at the production line -

before the puzzles are placed on pallets and transported to high-bay storage, the production line employees final-check the boxes.

Finished puzzle -

1,000-piece puzzle “Underwater Paradise”. The puzzles are distributed from Ravensburg to vendors around the world, where puzzle fans buy them and bring them home to assemble.