Foundation Production Equipment

Beeswax foundation making equipment covers the tools used from melting and cleaning the wax collected in the apiary, through forming it into sheets and embossing the cell pattern, to cutting it to frame size: wax melters, strainers and settling vessels, block moulds, dipping boards, foundation mills (rollers) or press moulds, and cutting templates. A beekeeper who makes foundation from their own wax largely eliminates the risk of fake wax and of treatment residues brought in from outside. On this page we go through the production chain step by step, with the equipment for each stage.

How does foundation production work?

Whether in a small apiary or a large operation, foundation production goes through the same stages. The scale of the equipment changes; the principles do not.

1. Sorting the wax: Cappings wax, honey combs and old dark brood combs are collected separately.
2. Melting: The wax is melted in a water bath, with steam or with the heat of the sun.
3. Straining and settling: Coarse dirt is strained off, and the wax is cooled slowly so that fine sediment settles to the bottom.
4. Moulding blocks: The clean wax is poured into blocks, and the layer of dirt at the bottom is scraped off.
5. Making sheets: The wax is turned into flat sheets of even thickness.
6. Embossing: The sheet is passed through patterned rollers or a press mould.
7. Cutting and storage: The sheets are cut to frame size and stored between sheets of paper.

What equipment is used to melt wax?

Solar wax melter

An inclined box with a glass lid and a dark-coloured interior. The sun's heat melts the wax, and the molten wax runs through a strainer into the container below. It uses no energy and, because it does not overheat the wax, gives light-coloured, clean wax; it is ideal for cappings wax and scraps of new comb. Old brood combs full of cocoons, however, give a poor yield.

Steam and water-bath melters

These melt the wax with steam or by means of hot water in a double-walled vessel. Because the heat is controlled, the wax does not burn or darken. Steam melters and wax presses are used to recover wax from old combs; this wax should be kept separate.

Vessel material and temperature

• Use stainless steel vessels. Iron, copper, brass and zinc vessels darken the wax and spoil its quality.
• Beeswax melts at about 62–64 °C. Heating the wax more than necessary darkens its colour and spoils its aroma.
• Never melt wax over a direct flame: overheated wax can catch fire. Always use a water bath or steam.

Straining, settling and moulding blocks

The molten wax is first passed through a fine straining cloth or a stainless wire strainer. It is then cooled slowly in an insulated container; during slow cooling, fine dirt, pollen and cocoon fragments sink to the bottom. The dark layer at the bottom of the blocks, once cooled and turned out of the mould, is scraped off with a knife and discarded.

• Block moulds: Slightly tapered stainless or sturdy plastic containers let the blocks come out easily.
• Re-melting: Wax intended for foundation is melted and settled twice if necessary.
• Contact with water: When wax is melted with water, the water sinks to the bottom; do not let it mix in when pouring into the mould.

Equipment for making sheets

Dipping board

The most common method on a small scale. A wetted flat board is dipped several times into molten wax and lifted out; with each dip a thin layer of wax sets. The edges are trimmed and the wax sheets on both faces are peeled off. Keeping the board wet stops the wax sticking.

Sheet casting moulds

With flat trays or two-part moulds, wax is cast directly at sheet thickness. Even thickness determines the quality of the subsequent embossing stage.

Release agents

A release agent such as soapy water is used to stop the wax sticking to the board, rollers or mould. The release agent should be diluted enough not to leave residues on the sheet and should be drained off well.

Embossing: foundation mills and press moulds

The key equipment that turns a flat wax sheet into foundation is the rollers or moulds engraved with the cell-base pattern.

• Foundation mill (roller machine): Consists of two patterned rollers set against each other. A warm, pliable sheet is passed between the rollers and both faces are embossed at the same time. Hand-cranked models are for small operations, motorised models for mass production.
• Press mould: Two half-moulds of metal, silicone or resin. Molten wax is poured into the lower mould, the upper mould is closed and pressed down, and a patterned sheet comes out in one step. Silicone moulds are common among small producers.

Whatever equipment is used, the cell size must be chosen correctly: for the brood area a standard worker-cell pattern (about 5.3–5.4 mm) is used.

Cutting and storage equipment

• Cutting template: A wooden or metal template slightly smaller than the inside of the frame, set so that a gap is left at the bottom bar and at the sides.
• Knife or wheel cutter: A warm, sharp knife cuts the sheet without crushing it.
• Interleaving paper and flat boxes: The sheets are stored between paper, flat and in a cool place, so they do not stick together.

Wax purity: guarding against fake wax and residues in production

The biggest benefit of making your own foundation is knowing what the wax is. To keep that benefit:

• No additives: Do not add paraffin, stearin or any other fat or wax to make sheets easier to cast or to cut costs. Comb containing paraffin collapses in the heat; brood losses have been reported with foundation containing stearin.
• Do not share equipment: Do not share wax melting and casting vessels with paraffin wax or candle-making work.
• Prefer cappings wax: The light-coloured cappings wax produced during uncapping is the cleanest source in terms of treatment residues.
• Keep old brood comb wax separate: Fat-soluble varroa treatment and pesticide residues build up in dark combs that have been in the hive for years; use this wax for other purposes rather than foundation.
• Disease risk: Normal melting temperatures do not kill American foulbrood spores. Wax from hives suspected of disease must never be used to make foundation; this disease is notifiable and must be reported to the official veterinary service / local agriculture authority. Commercial producers use special equipment that sterilises wax at high temperature for a long time.

Safety, cleaning and common mistakes

• Fire: Molten wax is flammable; work away from open flames and keep a container with a lid and a suitable fire extinguisher close by. Never pour water on burning wax.
• Burns: Hot wax sticks to the skin; wear gloves and long-sleeved clothing.
• Cleaning: Wipe vessels and rollers while the wax is still soft; remove wax that has cooled by softening it with hot water.
• Melting wax over a direct flame or at excessive heat.
• Using iron or copper vessels and darkening the wax.
• Trying to pass a cold sheet through the rollers; the sheet cracks.
• Adding old dark comb wax to foundation.