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Once the graphics are finalized, manufacturers move to the creation of the tin boxes themselves. The process involves cutting and shaping sheets of steel, which are coated with a layer of tin to prevent rusting and ensure durability. The pieces are then pressed into shape and assembled—usually featuring a hinged lid and a sturdy handle, reminiscent of the lunch boxes popularized in the mid-20th century.
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Leading manufacturers typically offer a range of galvanizing processes, such as hot-dip galvanizing or electro-galvanizing. Hot-dip galvanizing involves immersing the metal in molten zinc, resulting in a thicker coating that provides superior corrosion resistance. On the other hand, electro-galvanizing applies a thin layer of zinc through an electrochemical process, often resulting in a more polished finish, but may not offer the same level of protection as hot-dip galvanization.
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