The Sandwich Press UK “Pie iron”, Aus “Jaffle maker”, S Africa “Snackwicher", US “Sandwich Toaster”

(When “Sandwich press” is used it includes Panini press and Jaffle maker.)
1. History of the sandwich press:
The sandwich press is a commonly used household appliance used for cooking sandwiches or various
meats in a small timeframe as a snack. The sandwich press was invented recently in the late 1920s
by Thomas Edison the famed American inventor in the after math of the 1880s ‘war of the currents’
between Thomas Edison (DC) and Nicola Tesla (AC). The sandwich press was one of 1,093 patents
created by Thomas Edison including the phonograph and lightbulb, the sandwich press was
forgotten as the invention of the light bulb simply out shone all other inventions he created. Edison’s
original design featured a heating element that required an electric current that would directly heat
two metal plates made from cast iron which featured hinges and would clamp closed like a sea clam.
Two currents would be sent through wires and conductors which would heat both metal plates,
cooking the bread and melting all inside ingredients.

‘Edison’s Sandwich Grill’

Materials development changes:

Unfortunately, Thomas Edison’s design was not popular as it was a high-priced luxury, and the
production was discontinued in 1934 during the great depression. The design was copied and
tweaked by Brevel 40 years later in 1974, it was wildly successful in Australia and the UK where it
today is called a Jaffle maker or Pie iron. Since the 1920’s and 70’s many changes have been made to
sandwich presses. Most household plug in and stove top sandwich makers are made from aluminium
and a non-stick surface of ‘polytetrafluoroethylene’ or more simply Teflon. This non-stick surface
was designed for removing the bread easier and making the process of cleaning residue such as
cheese and butter much easier and prevents elements such as aluminium to be indirectly ingested.
Aluminium was used instead of cast iron because It was lighter, cheaper to produce, held heat
shorter and heated up faster, making it perfect for fast hot meals that average families can
affordably use in their household.
 Modern sandwich press (Breville)

Method of operation:
The heating elements to the sandwich press have also progressed significantly, a filament of Copper
a highly heat conductive and ductile metal is placed on the outer facing sides of the heating plate. An
electrical current of approximately 700 watts is distributed by the PowerPoint directly to this
filament heating the metal plate to around 375°C (over a third of coppers melting point), toasting a
standard ham and cheese sandwich in 3 minutes. This is amazingly fast and intricate compared to
the original design of cast iron and cables in the late 1920’s which was significantly less complicated,
more expensive and took longer to cook.

Impact on society:
The sandwich press has shaped many habits and lifestyles of young and older people since its first
introduction into society. In today’s age fast paced is an understatement, ever since the industrial
revolution families has left home every day to work always in a hurry always missing out on meals
that take too long. This is where the sandwich press comes in, its simplicity, speed in cooking and
convenience has made it one of the most popular forms of food for the both the young generation
and the working generation. In 1974 when Breville started selling their sandwich maker up to 10% of
Australian households had purchased it in the first year on the market, but it wasn’t just young
people in a hurry who could utilise the convenience of this appliance but also people financially
struggling. In a recent 2020 study by the UNSW on ‘poverty in Australia’ found that 3.24 Million
people (13.6%) in Australia are living below the poverty line, and just under 1.2 Million of those are
young adults or children. Buying food like meat and vegetables can be expensive especially since
most fresh produce expires soon after it’s been bought, the sandwich press is the answer to this. The
sandwich press though it may not look like much it is the key to warm food and an affordable source
of nutrition that not only is easy to use but also requires cheap and easy to access ingredients. The
sandwich press can be found in establishments like Kmart, Spotlight, eBay etc for as little as $7.50. A
simple loaf of bread and stack of cheese could at a minimum feed someone for a week, the
sandwich press does not take expertise to use and is incredibly simple and homeless shelters in the
CBD provide free electricity and supplies. The sandwich press is so popular amongst Australians and
the world because of its simple nature, affordability and speed, and because of these properties it
has become a defining feature for snacks and meals for middles class families in Australia in the 20 th
and 21st century
Free hand sketch:
 2. 3 components.

Heating filament Heating plate Handle

Image

Material Copper, silver, polymer Cast iron or aluminium Stainless steel, thermo plastic
and insulators polymer
structure

Shaping After the complex Cast iron heating plates are formed by Stainless steel is moulded into a
process process of refining smelting iron ore or melting pig iron rod where a thermo plastic
pure copper, the and mixing it with scrap metals and polymer is slipped onto it where
copper is heated and other various alloys. The liquid mixture it is glued in place. The rod is
stretched into a thick is then poured into a shell with a mould then bolted to another more
wire. A machine cuts inside and allowed to cool and solidify. complex mould of stainless steel
off the appropriate The mould is pulled apart and the which connects it with the main
amount and the plates are polished with anti-stick body of the press. This more
copper is shaped into minerals. OR. Aluminium is smelted and complex configuration includes
any desired shape (see shaped into desired shape where it is size adjustments and notches in
above). The new let cool. Teflon is added and it is the metal for the handle to rest
copper shape is implemented into the design and vary in height.
cooled, and insulators
are added to wither
end ready to be
implemented into the
design.
Structure Copper is a metallic Since cast iron contains carbon it is The handle is made from a
crystalline solid (FCC), crystalline (BCC), 26 protons and 30 polymer and stainless steel. Iron
the nucleus of copper neutrons plus 26 electrons in four and chromium atoms are
consists of 29 protons, different shells around the nucleus. arranged into a BCC structure but
34 neutrons and 29 Cast iron heating plates are made when Nickel is added it turns into
electrons. It is not a entirely of cast iron meaning it is not a FCC Austenite/stainless steel.
composite but mainly composite. Stainless steel is a mixture of iron
copper. Aluminium is a crystalline metal (FCC) and carbon making it an alloy.
and has 13 protons, 14 Neutrons and The polymer is an insulator and is
13 Electrons. Similar to the cast iron atomically cross linked.
variant heating aluminium plates are
composed entirely of aluminium.
3. Heating filament: Copper
1st property: Ductility
Ductility in this sense is essential. The chosen material must be highly mouldable and plastic
to be able to be bent and stretched into a long cylinder without fracturing, copper is perfect
and it is highly ductile and holds its shape after deformation. The reason why the material
must be able to be bent and stretched is because the heat across the plate must be evenly
distributed across the heating plate. Bending the filament to cover as much surface area as
possible is both cost effective and efficient.

2nd property: electrical conductivity, 2nd best of all elements

Electrical conductivity is the backbone to the use of copper in this mechanism. Electrical
currents of 220 volts are distributed to the copper filament, because copper is such an
amazing electrical conductor very little electricity is wasted and all the current is sent
through the filament. Therefore, copper is used as it requires less electricity to power and
conducts voltages more powerful than something like iron.

3rd property: Thermal conductivity, 3rd best of all elements

Along with copper being a great electric conductor it is also an amazing heat conductor. For
a material to be used as a heating element thermal conductivity is absolutely required.
Coppers electrical conductivity paired with its thermal conductivity make it one of the best
elements for cooking as it conducts and utilises almost all electricity input and outputs that
into thermal energy which is essential for a device that’s power source is electricity and its
job is to cook at high temperatures.

Heating plate: Aluminium & Teflon (‘polytetrafluoroethylene’ )

1st property: Thermal conductivity
The sandwich press is known for its fast and hot cooking and is one of its defining features.
The main reason for its fast cooking is the aluminium heating plate used in more recent and
advanced builds. Aluminium absorbs heat much faster than most metals like steel and iron
and can reach very high temperatures for extended times due to its high melting point. As
mentioned earlier in this report with the use of aluminium as a heating plate is very efficient
and using a gas stovetop a sandwich press can heat up from 0°C to 375°C and cook a
sandwich in around 3 minutes. Other materials like cast iron which were originally used as
two plates and a handle over a fire and take double this time and encounter the problem of
sticking.

2nd property: Low friction co-efficient

Teflon is used today as an anti-stick substance on pots, pans and the heating plates of the
sandwich press. Teflon is a polymer, and its secret is the fluorine enveloping its molecules,
this Fluorine repels almost all other molecules which prevent them from adhering to Teflon.
Teflon is applied in a thin strip across the aluminium plate, its property makes it very useful
for cleaning and removing objects that would otherwise have been stuck. Teflon also solves
its own problem of being toxic to humans as when it is scraped off and ingested humans can
encounter polymer fume fever, though this may seem bad Teflon will never have to be
scraped off along with cheese and bread because of its non-stick property which means the
bread and cheese will simply slip off.
3rd property: light weight
Aluminium is very light weight with a density of 2.7 kg per dm3, that’s is a third of the
density of steel. A standard cast iron electric sandwich press weight around 30kg but when
the heating plates are replaced with aluminium the net weight equals 25kg. This is a
significant deficit in weight considering the only material change is the heating plate. This is
helpful for travel and makes the use of the object easier since the only part of the machine
being moved when stationary is the heating element.
 Handle: Thermoplastic polymer & stainless steel
1st property: lack of conductivity, good heat insulator
The sandwich presses as mentioned before can reach temperatures of around 375°C this
heat will transfer from the heating plates and to the handle of the press in turn burning the
hand of the user. To counter this modern sandwich presses, use a thermo plastic polymer.
Polymers are naturally good insulators as they do not have free electrons moving denying
them the property of electric and heat conductivity.
2nd property: Toughness
In metallurgy toughness is the ability of the material to absorb energy and plastically deform
without fracturing. This is very useful in the making process of the handle as the polymer is
melted and stretched over a steel rod requiring high ductility and strength (all qualities of
toughness), if the polymer shatters or breaks during the application of it to the handle it
cannot be used. Therefore, plastic is suitable for this application and is used in modern
designs.
3rd property: Low conductivity, steel
Steel is used as the hinge and handle for its durability but mainly for its low heat
conductivity. Steel is used for this application because steel operates well under high
temperatures and does not transfer heat well. Steel coupled with a insulator like a polymer
is perfect for a handle since it’s the closest to the heat and needs to be at a cool
temperature at all times.

4. 3D sketch of heating plate:

 5. Describe how the appliance operates
The sandwich press is plugged in and turned on. The first operation that happens in an electric
current is sent through internal wires to the thermostat and the heating of the copper filament
begins. The electricity flows through the filament and through the process of joule heating the
copper becomes very hot. Joule heating is the process where a voltage difference between two
points of the copper creates an electric field that accelerates charge carriers in the direction of the
electric field, giving the electrons kinetic energy. This heats the copper and as the filament heats up
so do the heating plates directly adjacent to it, though the thermostat regulates how hot the
filament will get. When metal heats up it expands and the thermostat recognises this and switches
off power to the filament if it gets too hot halting all heating, this is for safety otherwise the press
would burn the ingredients and be too hot for use as it could pose a serious threat to exposed skin
and parts of the human body. The plates heat up with the filament and start to cook the bread (or
meat/cheese does not matter). The plates toast the bread and transmit their heat to the ingredients
inside cooking any meats and melting cheese. When the sandwich has reached its desired
temperature, the chef removes it and cuts off the power, eventually the copper and aluminium will
cool down due to room temperature. Aluminium is used as it heats up quicker than most metals
making the press more efficient and because it cools down quicker making it safer to clean after use.

Diagram of electronic components, how they interact:

6. Design engineer, Electrical engineer
1. Design engineer

During the design and manufacture process of the sandwich press the design engineer is solely
responsible for the design of the product. The definition of design engineer According to
‘Indeed’- “Design engineers use computer-aided design (CAD) software to develop, test and
improve manufacturing processes and product designs. They often work in teams to boost the
functionality of a company's products and advance the methods by which they are made.” The
design engineer will design and evaluate each element of the design including the heating
plates, size and weight of the appliance, materials used (e.g. stainless steel and aluminium) and
aesthetics of the appliance. They are usually employed to create an example in CAD or to sketch
the design on paper to apply for a patent licence and provide basic instructions on how to build
said appliance and the materials needed. Advancements in the heating elements have increased
the speed at which the press cooks and design elements like material choices have made the
sandwich press more affordable than ever. The impact this has had is many people now have
access to technology like this. In the late 1920’s when Thomas Edison first invented the panini
press (sandwich press) it was unaffordable and considered a luxury item due to its expensive
nature. Today you can find a sandwich press in any appliance store in multitudes all at an
affordable price and with this increase in accessibility it has bridged gaps in society between the
top percent and the lower percent. All technological advancements in the sandwich press can be
credited to design engineers who have made it complex and efficient but more affordable than
ever.

Training courses needed:

Disclaimer: SOLIDWORKS is a CAD program developed in 2021

SOLIDWORKS Simulation Premium Dynamics

“Analysing structures subjected to various types of dynamic loading. This course is targeted for
users who would like to become productive in analysing structures subjected to various types of
dynamic loading. The material covered includes the time dependent analysis, harmonic analysis
and random vibration analysis.”

Best Practices in SOLIDWORKS

Improving the efficiency in SOLIDWORKS- File Management, Navigating the User Interface,
Sketching and Editing Tools, Modelling Technique

Improving SOLIDWORKS performance- Managing Parts and Sub-assemblies, Drawings, Tools and
Tips, Hardware considerations

Minimum ATAR required: 92.00

2. Electrical engineer
During the design and manufacture process of the sandwich press the electrical engineer is
responsible for partially the design regarding wiring and the application and testing of currents
during the manufacture. The definition of electrical engineer according to UNSW- “Electrical
engineers create, design and manage electricity to help power the world. They are problem-
solvers who study and apply the physics and mathematics of electricity, electromagnetism and
electronics to both large- and small-scale systems to process information and transmit energy”.
The electrical engineer will advise and work with the design engineer to find the most effective
method of powering the appliance, usually helping with the transfer of electricity to heat in the
copper filament. During the manufacture process the electrical engineer will evaluate the
prototype and final product by conducting experiments e.g., confirming a completed electric
current, checking for correct voltage, evaluating efficiency and calculating expected lifetime of
the appliance. Thanks to the electrical engineers of the world all our appliances have an energy
rating system that determines its efficiency. Electrical engineers make it their priority to reach 5
stars and have perfect efficiency and consumption in all things related to electricity to save
money for people who need it and reduce electricity waste and carbon emissions that could
affect the larger world.

Training courses needed:

DDS-CAD: The Open BIM solution for MEP engineers

Bachelor of Electrical and Electronics Engineering (Honours)

Minimum ATAR required: 80

7. State how it has affected The Individual, Society and The Environment.

The sandwich press has affected the individual positively and negatively. The sandwich press
provides a fast and hot meal that is easy to make and tastes delicious, teenagers and children
need to eat regularly to develop and having an appliance that does this in a few minutes is great
for the physical development and the necessary basic cooking skills of operating hot surfaces.
There are also some negative effects attributed with the sandwich press. The sandwich press
creates a reliance on fast and unhealthy food, especially when growing up it is important to eat
vegetables and fresh fruit to maintain a healthy lifestyle, but the sandwich press is designed for
foods like Ham, Salami, Eggs, Bacon and bread. Admittedly all these foods have a high protein
value, but they do not have the necessary vitamins needed to sustain health and too much
protein and meat can cause long term health effects.

In society the sandwich press is most widely used in the workplace. Like the watercooler and the
microwave when its lunch time white collar workers and blue-collar workers bring their lunch to
heat up and enjoy. The sandwich press has created a gathering place for people to socially
interact and relate to while also providing a tasty and well needed sandwich. Negatively the
sandwich press is just another appliance. Appliance stores feature hundreds of machines that
can do any range of things, Microwaves, kettles, sandwich makers, blenders, toasters etc. The
sandwich press just isn’t essential and crowds’ homes and pantries and overall can just be a
waste of money and something that many families end up not using.

Environmentally the sandwich press is great. Before the electric sandwich press was invented
people had to start fires and cook plates of cast iron and apply it to the sandwiches directly.
Trees would have to be cut down for wood, the carbon being released into the air contributed to
climate change and even newer versions were not nearly as efficient as todays being inefficient
and using excessive amounts of electricity. A modern and advanced sandwich presses use very
little energy in comparison o the heat it creates and does not directly contribute to any carbon
 emissions. Negatively the sandwich press and all its variants create electronic waste. Various
metals such as aluminium, cast iron, silver, copper and stainless steel are used in the creation of
the press, these metals take tons of coal to smelt releasing carbon dioxide and various other
gasses during the smelting process. Mining for metal like this contributes to deforestation and
the contamination of the local air, water and ground. Not only does the creation of this have a
negative impact but also after it has been made. Some of the materials are recycled but most of
the product is thrown to land fill which plagues the oceans and wildlife.

Before the sandwich press individuals would have to settle with nothing or they would start a
fire in the oven being expensive and slow. Society had less applications to sell in stores and less
opportunity for warm food. The environment took tolls through the burning of coal, gas and
wood from every household whenever a family wanted to cook food.

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