Are you a Disney fan and an avid puzzler? Then “Memorable Disney Moments” is the puzzle for you! With over 40,000 pieces, “Memorable Disney Moments” is confirmed as the largest commercially made Disney puzzle in the world, both in number of pieces and overall size.
Further interesting facts: • Piece Count: 40,320 • Format: 22.3' x 6.2' • Area: nearly 140 square feet • Weight: approx. 44 lbs. • Estimated Completion Time: About 600 Hours
The 40,320 piece puzzle measures 22 feet long and over 6 feet wide – a huge puzzle with an amazing Disney design. The image showcases 10 scenes from the most popular Disney films and will take you on a little journey through time from “Snow White and the Seven Dwarves” in 1937 to “The Lion King” in 1994.
But the illustrations are not 100% identical with the original: a hidden Mickey Mouse symbol has snuck itself into each scene. To discover all ten, you have to look very carefully…
A Disney authorized illustrator designs each individual scene by hand. After spending about 650 hours at his computer, his completed work is sent to Ravensburger.
Step 2: First Design Inspection
Two editors inspect the first color proof of the design. They need to ensure that the color reproduction is correct, that it doesn't have blurrs or blemished, and that the transitions between the scenes are optimal. Once the design is consistent with their vision, they give the approval to begin the printing process.
Step 3: Production Begins
The scene of Snow White & Co is in the pre-printing stage. In preparation for offset printing, the operator sets up the exposure for each of the four printing plates
Step 4: Preparing for Print
Here, the print operator inspects the color of each individual printing plate. After a ten minute set up time, the printer is ready to go.
Step 5: Paper by the Pallet
During the set up process, the offset printer is filled in preparation for series production. A special linen paper is used that is purchased directly from the Black Forest.
Step 6: Print Inspection
An employee inpects the images to ensure the color replication is correct and to ensure the printing plates are correctly calibrated.
Step 7: Up to Speed
One color after the other, the printer rolls the yellow, cyan, magenta, and black ink over the white paper. This printer is capable of printing up to 18,000 images per hour.
Step 8: Onto the Board
The lamination machine precisely adheres the images to the Ravensburger board. Our high quality cardboard ensures that the pieces will continue to fit together after countless uses without air pockets, image lift, or puzzle dust.
Step 9: 10 Times Through
The process is repeated for all 10 puzzles. Once they are all completely printed and applied to the boards, they are ready to be sent through the press to be cut.
Step 10: Shaping the Form
The craftsman designs the blade to be used to cut the puzzle in the press. It takes him about 400 hours to design each unique curve.
Step 11: Under Pressure
The boards are then put into the puzzle press where they are pressed onto the blade with about 2 thousand tons of force. Each section of the puzzle is cut into 4,032 pieces then falls into a plastic bag for packaging.
Step 12: Last Quality Inspection
Is the bag properly sealed? Are the pieces all cut correctly? To ensure everything is in order, all 10 bags are put through personal inspection just before packaging.
Step 13: All Packaged and Ready to Go!
This 44 pounds of puzzle is all packaged and ready to be shipped all over the world.
Step 14: From the Warehouse to the World
The puzzles are placed in the warehouse for storage in preparation to be shipped to puzzlers throughout Germany, Europe, and the rest of the world.
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