Stick of Rock - Making Rock - Lettering

Lettering

The letters are not made in order of appearance in the name (B, L, A, C, K, P, O, O, L) but by their shape; 'square' letters, (B, E, F, H, J, K, L, M, N, P, R, T, W, X, Y and Z), are made first, as they will not lose their shape, while 'triangle' (A and V) and 'round' (C, D, G, O, Q, S, U) letters are made last to prevent them from losing their shape, as the toffee is still reasonably soft at this point. For example, the letters that make up 'BLACKPOOL ROCK' may be made in this order: B, P, R, K(x2), L(x2), A, C(x2) and O(x3). The individual letters are placed between blocks or sticks at this point, to prevent them from losing shape and going flat. The letters are then placed in their correct spelling order with a 'strip' of white, aerated toffee between each letter to make it readable. Capital letters are the most common form of lettering as small case lettering is far more complicated, owing to their tails and high backs.

The now aerated white toffee from the pulling machine is divided into three parts; one will form the centre and two will form the 'flaps'. The flaps are kneaded and spread thinly and evenly before being placed directly onto the letters; these form the space between the casing and letters, and are then wrapped around the stiffened centre. The casing is then kneaded and evenly rolled out, using a rolling pin, and this is then wrapped around the assembled 'boiling', which is one very large bar of rock that is still pliable and warm. This is then placed into a 'batch roller', which has several tapered rollers and heaters. The rollers keep the boiling of rock round and the heaters keep it just soft enough to work.

A craftsman known as a 'Sugar boiler' then proceeds to 'spin out' the boiling onto a long flat surface, known as a 'slab', where a 'rollers' make sure it is kept rolling until it has 'set' hard enough to maintain its round shape. Once set the strings of toffee are cut to length and wrapped in clear paper with a label, known as a 'view' as it usually has a view of a landmark.

The whole process of making lettered rock is done by hand by skilled workers. Smaller sticks of rock, without letters or a 'view,' can be machine manufactured.