Photo Gallery – The secret of our puzzles
From the image selection to the finished puzzle product. In our photo gallery we walk you through all the details of our elaborate puzzle production process!
Our puzzle editors review thousands of photos and pieces of art to find the most beautiful fit for your puzzle!
Our puzzle images are computer-edited. All colors, contours and contrasts are optimized and the original image is cropped to ensure a perfect puzzle result.
Before a puzzle is send to production, our editors receive print proof in the actual puzzle size to approve the cut out and colors of the image.
Once the editor signs off on this proof, the files can be used for production.
Printing Part 1
Ravensburger Puzzles are printed on our fine, linen-structured paper to create a glare-free puzzle image.
18,000 piece puzzles cannot be printed in one piece. Our machines print the puzzle in 4 pieces on individual sheets.
Printing Part 2
Our printers use the approved print from the editor to scale the colors on the printing machine. They print a test sheet to make sure that the colors match the proof. Once the colors are matching the puzzle sections can be printed.
The printed sheets are now glued on our exclusively developed, extra-thick cardboard. A pressure roller presses the paper and cardboard together. Then each of the 4 sections is divided in half so that the 18,000 piece puzzle consists now of 8 sections.
Cutting Part 1
The bonded puzzle sections are now brought to our cutting machines. Both halves of each sections are fed into the machine at once.
Cutting Part 2
Our steel cutting tools are designed and crafted by hand. This ensures that no two pieces are alike and guarantees a perfect interlocking fit. Our machines use hundreds of tons of pressure to cut the image into small puzzle pieces.
Each section undergoes a quality check to ensure the completeness of the puzzle.
The puzzle pieces of each section are packed into separated polybags. You can puzzle the puzzle in sections or throw all pieces together to increase the challenge!
Puzzle Box Part 1
The layout of the puzzle box is printed on sheets and then bonded to cardboard. Both halves of the box are then transported to the next machine.
Puzzle Box Part 2
The polybags with 18,000 puzzle pieces are really heavy which is why we add another cardboard layer to the sides and bottom of the box.
The puzzle boxes are now put on a conveyor belt so our employees can add the poly bags with the puzzle pieces. To avoid confusion, each employee adds just one polybag.
After the lids have been placed onto the box bottoms a special machine adds shrink wrap to protect the puzzle during storage and transport.
Final Quality Control
Before the 18,000 piece puzzles are send out to puzzle fans around the world, they go through one final quality control.
With a puzzle size of 109” x 75.5” the 18,000 piece puzzle is a true challenge for experienced puzzle fans! With patience and a good eye each piece will eventually fit in its proper place!