The largest and oldest organized crafters of the bronze bell in India is in Mannar. Each bell is individually made using lost wax techniques developed over centuries of practicing the master bell-makers art. The moulds used in traditional bronze bell casting are only used once, and new moulds must be made for each bell. As a result, each bell is truly unique. We are providing a platform either to design your own bells or choose from our own designs with special icons of your needs to be cast in your bell. Your custom lettering can be casted into a bell when it is made. You can also choose special icons to be cast into the rim of your bell.

Only the finest bell bronze alloys that produce the pure musical tones of genuine bell bronze are used in these custom-made bells. High purity, quality works of bas-relief and inscriptions on bells, unique tone and high resonance explain its survival over two centuries.

We assure full satisfaction to our customers. The bells are cast in such a way that they guarantee 100% quality. Our traditional craftsmen cast the bells in pure bronze according to the specifications of our ancestors. The bells are made manually. We ensures good sound and longevity. We make bells of various sizes varying in weight. After completion of the work, the bells can be inspected by the customers at our premises before despatch.

Quality of Sound

First-rate bronze guarantees the best quality

The correct alloy is the key to the quality of the sound of our bells. It also influences their appearance.

Our bells are cast with a top quality alloy consisting of copper and tin in proportions of 78:22 with no addition of other materials. There is no compromise! Right proportions, metals well mixed and proper temperature of casting material influence not only the sound of a bell but also are the key success factors for ideal sound and structure appearance. The higher tin content increases the rigidity of the metal and increases the resonance. This composition turns out to be perfect for maintaining proper aesthetics and the top quality sound of a bell. Price of bell metal is increasing day by day. To solve economic problem and reduce cost zinc and lead were added to the alloy called brass. The quality of bronze started to get worse and create problems with mechanical properties of bells, their surface did not cover with patina and their sound became distorted.

Mannarcraft provide only pure and high-quality bronze! Our alloy is constantly reviewed and analyzed to ensure that each casting will deliver bells with superior quality.

Specification

Average size and weight of the bell
Size in cmsWeight in kg
3020
3530
4045
4570
50100
60150
70200
80250
90350
100400
120500
130600
1521000
1601500
1682000

25kg

50kg

60kg

100kg

800kg

3500kg

Production process

Every mould is individually prepared according to the order placed. All visible elements of the bell, ornaments, images, and scripts are generated by a single cast with lost-wax casting method. Therefore it is very important to work carefully on every detail of the mould because it influences the final quality of the casting. The moulds are made of special clay which dries slowly in sunlight, so it could keep its shape and preserve all details of the bell.

Base Mould

It is a basic element of the mould. Its shape reflects the bell’s interior where the clapper will be mounted. The base mould protects the mould from the inside. It is usually made of a mixture of clay, cow dung and casted soil of the previously used and broken moulds.

Waxed Mould

The second layer of the mould is Waxed mould. It reflects the shape of a real bell. On this part all ornaments, images, and scripts made of wax are put.

Clay layer on waxed mould

This layer of the mould is mixture of clay, finely cut jute sack pieces and powder of casted broken pieces of previously used moulds. Is also applied to leave an opening for inlet of the molten alloy while pouring in the later stage.

Clay piece covered layer

On top of the clay layer; small tile pieces, of baked-broken moulds, are fixed to provide it necessary strength so that it can withstand against the high temperature while melting the wax in a furnace.

Coat

A coat is the last, external and protective layer of the mould. It is dried in sunlight few days.

Melting wax in furnace

Melt the wax by heating in the furnace.

Casting

After the molten wax is completely drained, the casting mould is buried in the foundry pit in front of the furnace. Crucibles are filled with the required quantity of the metal and placed in the furnace for melting. The crucible is removed from the furnace and molten metal is poured into the mould through the holes provided. After the alloy solidifies in the mould it is taken out from the ground and the clay is broken using hammers and chisel.