We were recently in Philadelphia to perform our concert with Philadelphia Bronze – our first-ever visit to Philadelphia! This seemed like an ideal time for a tour of the Malmark handbell factory. It’s the place where our handbells were made!
The Malmark Bellcraftsmen factory is located in Plumsteadville, PA. We were strangers to the area, but still managed to get on the right road and find the place we were looking for. This big sign helped a lot:
Our tour started in a room full of history. We were able to see the “1st production” Malmark handbell, made in December 1974, and a selection of various handbells made many years ago and in other countries. Our tour guide, Martha, talked about the process of making the bells, starting from the design itself, where the sound and overtones are determined by the shape, diameter and wall thickness of the bell. Handbells are made of bronze; 80% copper and 20% tin. You can read about the casting process at www.malmark.com.
The smallest and largest handbells ever made!
Here’s a picture of the largest and smallest bells ever made by Malmark; the G0 and the C9.
Larry’s a bass bell specialist, and he was pleased to be allowed to try playing the G0 bell – with great care! People have observed that it sounds more like a gong than a bell.
We visited the machine shop next, and admired the obvious skill and dedication needed to operate the lathe and tune the bells in the next part of the tour. It’s precision work, and a fascinating process to watch. We have to admit that all those golden, gleaming turnings – the shavings from the bells, which sparkled all over the machinery – made us think of Christmas!
The polishing department was an exciting place! It was impressive to see the difference between the bell at the start of the process and after machine-polishing.
So many shiny bells!
We discovered that walking into a huge room full of bells can be an awe-inspiring experience. Was Carla the first person to CRY when she saw this? We don’t know, but ohhh… so many bells! So much bronze! So much SHINY!
Skilled and dedicated people
Something that really impressed us at the Malmark factory was the obvious skill and dedication of the people working there. It’s great to meet people who are knowledgeable and enthusiastic about the work they’re doing. They are all aware of the important part they play in the creation of the finished product. If we lived near Plumsteadville, we’d definitely want to work there!
We found out that bells can be “rejected” at any stage of the production process. This can even happen in the very final stages, when they’ve already gone through several stages of tuning, been polished and given their handles and clappers. Some of the rejected bells are returned to the foundry to be melted down again, while others become beautiful gifts.
Others are not so fortunate and end up gathering dust, as makeshift doorstops.
Bass handbells!
Next… those great big bass bells. Larry calls them “aluminum”, and Carla tries hard not to call them “aluminium” (there’s a subtle US/UK difference there!) . Whatever you call them, they’re large, and they start off very heavy before some of the weight has been tuned out of them. For the last few years, Larry has played these aluminum bells at the Bay View Week of Handbells, which takes place in Michigan every August. That’s where his t-shirt came from!
Malmark also manufactures Choirchime® instruments, which also go through a tuning process. It was unusual for us to see so many handchimes in one place!
We finished our tour of the Malmark factory in the Demonstration Ringing Room, where we rehearsed a few pieces for the following evening’s concert with Philadelphia Bronze.
If you’re ever in Pennsylvania, we’d recommend taking a tour of the Malmark factory. There’s so much to see there, and you’ll have the opportunity to meet a group of people who are really passionate about the instruments they create. Even if you don’t play handbells, it’s a fascinating place to visit. We took lots more photos, so please click on this link to see the complete set!
And no, Malmark didn’t pay us to write this!
Someone asked us if Malmark paid us to write this review of their factory tour – and the answer is no. We really did enjoy our time there!
