01Steelmaking
The first step in the production process is steelmaking. The steel is heated to a high temperature of 1000 degrees using coke, preparing it for forging and welding. The heated steel is then shaped and prepared for the next step of connecting the steel pieces.
02Forging
This traditional technique, also known as boiling and bonding, involves heating the steel to over 1000°C and bonding it to the base material using borax, boron sand, and iron oxide. The bonded steel is then reheated in a furnace and hammered to ensure complete bonding.
03Shaping
Once the base material and steel are fully bonded, the craftsman gradually shapes the blade using a hammer. It is crucial to control the temperature carefully during shaping as excessive heat can cause carbon, a critical factor in sharpness, to escape, resulting in a less sharp blade. Craftsmen meticulously forge each knife while facing the challenge of temperature control.
04Cooling
After shaping, the knife is left to cool and stabilize for a period of time. During this time, the craftsmen inspect the blade for any scratches or connection errors.
05Cutting
The excess parts of the knife, depending on its shape, are carefully cut off by hand without any mechanization. Each Okingjoy knife is crafted with precision and skill by the hands of the artisans.
06Hammering
Through repeated strikes on the cold metal, the molecular structure of the steel becomes finer and sharper. During this process, concave marks are also made on the backside of the blade.
07Mud Coating
As the temperature distribution during quenching affects the longevity of the blade, a thin layer of mud is applied to the entire blade to ensure even temperature transfer. Additionally, the formation of bubbles during water and oil cooling, which can hinder rapid cooling, needs to be controlled.
08Quenching
After the mud coating on the blade is dried, it is heated to around 800 degrees and promptly cooled. Temperature control is not achieved mechanically; rather, it relies on the experience and skill of the craftsmen. Quenching is a highly focused process conducted solemnly under dim evening lighting. Sakai knives are known to use pine charcoal for rapid heating
09Tempering
Hardened knives lack ductility and cannot be used directly. To impart ductility, the blade is heated again to around 200 degrees and then naturally cooled. This process results in knives with excellent hardness and toughness.
10Shape Adjustment
After the hardening and tempering processes, the blade enters the final stage of the forging process. This stage involves checking for any slight distortions or scratches before sending it to the grinding machine. Even the slightest distortion is corrected, and no imperfection is overlooked.
11Rough Grinding
This is the first grinding process performed on the knife using a homemade, further precision grinding is carried out to achieve the desired level of cutting performance. Overgrinding the knife can permanently damage it, so this step tests the craftsmanship of the artisans.
12Fine Grinding
Once the rough grinding is completed, the knife needs to undergo even finer grinding in order to enable effective cutting. Over-grinding a kitchen knife can permanently damage it, so this step requires a high level of craftsmanship and technical skill.
13Polishing
To create a glossy finish on the blade, it is polished using a polishing cloth attached to a rotating polishing wheel. Starting with coarse polishing and gradually refining it until the blade exhibits a beautiful shine.
14Beautification
Grind the powder of the grinding stone into a clay-like texture and rub it onto rubber or wood to create impressions on the blade. The choice and quantity of powder used are crucial in achieving aesthetic appeal and are kept confidential.
15Rough Grinding
The handle and bolster are manually bonded together, and our craftsmen meticulously
polish them to ensure a comfortable and ergonomic grip.
16Sharpening
After the beautification process, the final step involves hand sharpening the blade. This step determines the sharpness of the knife and unlocks its full potential. It is a time-consuming and labor-intensive process, requiring the use of different types of sharpening stones for each operation.
17Inspection
Preliminary inspection is carried out by certified craftsmen associated with Okingjoy. Only blades that meet all of Okingjoy's standards are packaged into elegant white waxwood boxes.
18Shelving
After the final certification and approval by the three master bladesmiths of Okingjoy, the flawless Okingjoy knives leave the workshop and are shelved in our online store.
19Service
The most perfect Okingjoy blades are now ready to serve you.
