Making a Beard Brush

How a Beard Brush is Made: Harvesting and Preparing Pearwood - Part 1 of 5

Most of our brushes are made with pearwood handles. We chose pearwood because of the grain and fibers in the wood which are extremely fine. This makes the handles smooth without needing to lacquer them.

We try to avoid lacquer not only because of the chemicals that can be avoided but also because lacquer creates static when brushed against hair and beard.

The pearwood is harvested from Austria where it is grown in sustainable forests. All the wood we use is FSC certified. What that means is that it is grown in forests that managed responsibly and every tree cut is replanted. All FSC certificates are issued by independent inspectors who verify that the forest is being managed properly.

Pearwood arrives and is put to dry

Storing pearwood for beard brushes - Zilberhar.jpg

The wood arrives on large pallets from the timber mill. Once it arrives it is measured for humidity content and stored under roofs. If the weather is warm it dries naturally and relatively fast. The reason there are no walls on the structures is to facilitate air flow which helps remove humidity.

In winter and when it rains a lot the wood needs might not dry fast enough just under the roof. In those cases the wood is moved to a drying tank. The structure is heated by recycling the air that is used to cool the machines in the factory - that air is channeled to the drying tank in order to speed up the drying process.

But accelerating the drying process also brings some challenges since the wood can warp so it needs to be managed carefully.

Once it is dry, it is cut

Cutting wood for beard brushes - Zilberhaar.jpg

The circular saw runs pretty much all day. With a pneumatic lift, the operator can lift the large blocks of wood and cut them to the right thickness.

The first part cuts the wood into large strips, which are then planed top and bottom.

Wood blocks are ready for routing

Wood blocks for beard brushes - zilberhaar.jpg

The wood which is now in strips and planed (smoother than what the saw provides). Are now ready to go through the next machine which turns them into blocks.

This is the last step in preparing the wood before it goes to the handle making line.

Getting the wood ready and right is one of the most important steps to getting precise and durable beard brush handles.

For more “behind the scenes” of how beard brushes are made. See these articles:

Making a ZilberHaar Beard Brush

The art of crafting a great beard brush is one mastered by a few. As producers of one of the best beard brushes we pride ourselves in working with the some of the best brushmakers in the world.

We thought we’d share a bit about how a great beard brush is made.

Crafted in the Black Forest of Germany, this is important for the quality of the wood, the pear-wood we use is all from renewable sources and being in the forest (literally) the transport of the lumber doesn’t cost mother nature as much.

The wood comes in in large blocks where it is verified for quality and grain.

It then gets cut into smaller units that can be machined into handles for the brush.

Once it is cut intro handles it goes through a long sanding process where the handles are tumbled to remove any rough edges. After the machine tumbling is done, each brush is hand sanded to ensure everything was taken care of.

The brush handles are then oiled for protection and for feel. We specifically don’t lacquer our brush handled as the natural wood is much nicer on the touch plus for people with longer beards, it doesn’t generate as much static electricity.

The boar bristles arrive in bundles and are tested for quality and authenticity.

They are then plugged into the wooden handle and tested again. Over time it is quite normal for individual bristles to fall out, but if an entire plug falls out that would be a reason to return the brush.

Afterwards they are printed or engraved, then packaged and shipped.

Our packaging has a fine coating to protect the brush from humidity and keep the oiled wood contained.

A few things to note, the brush bristles are intentionally irregular, they are never cut after they’ve been plugged to keep the irregular bristles which allows them to get through the beard and exfoliate the skin beneath them.

A good beard brush well kept, should outlast even the oldest beards.

To take care of your brush, wash it under lukewarm water with a mild handsoap and immediately let it dry - bristles down. Visit our Care page for more on that. 

It’s good idea to oil it with your beard oil when it’s dry to keep the wood from drying out. Oil it with your beard oil, but always when it is fully dry.

Beard on!

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