Here is a fascinating account of how printed music was produced by a leading engraver in the late 19th century. It comes from a souvenir booklet produced by C. G. Röder of Leipzig for a souvenir booklet given out at two international exhibitions in 1885.
"The following few notices of the Origin and gradual development of this establishment will be gratifying, as they testify what can be accomplished by energy and perseverance and strict attention to business.
The founder, Mr. C. G. Röder, commenced business in 1846 in a very small way; as the son of a small baker, he had been obliged at an early age to look out for himself, but his endeavours were not successful, until, when 26 years old, he learnt to engrave music, which was the first step in the right direction, and gradually led him to that honorable position, which he occupied up to the end of his life. Without any means, and assisted by only one apprentice, he started in business on his own account, as a Music Engraver and Printer on the 21st of October 1846. He was not at first very successful in business, but as his superior method gained favor it also gained him more customers, and as he continued to give great satisfaction the number of his customers gradually increased, and the business was now established on a sure basis.
In 1853, Röder was enabled by the assistance of a friend to purchase, and amalgamate with his own, another business (Paez) and to remove to more extensive premises in the Tauchaer Strasse. He selected only the most talented artists and best workmen, and their number was increased by his apprentices, who had benefited by his good teaching and example; his reputation spread rapidly and orders increased from far and near. It was soon obvious that the above premises would not be sufficiently large to carry on the ever increasing business, and Röder resolved to build a more convenient factory according to his own plans. Before, however, this idea could be carried out, a most important change took place. Röder, finding that he could not execute his orders with sufficient promptness with the 24 hand presses already in use, had in 1860-61 made several attempts to render the lithogr. steam printing machines (constructed by G. Sigl, of Berlin and Vienna) available for the purpose of printing music. After repeated endeavours he finally succeeded in overcoming all obstacles, and also to ease the minds of his printers, who were afraid the new method would endanger their earnings. The earlier productions of the new process were not quite perfect, but with great trouble and perseverance the shortcomings were remedied and in 1863 the first steam press was started, and thus the way opened for the printing of those cheap editions, which later on, were to have such enormous and hitherto unheard of circulation. In 1864 a second press had to be added and in 1865, with increased steam power, a third one.
On March 1, 1863, Röder's Son-in-law, Mr. L. Hugo Wolff entered the business. In the meantime the premises had again become too small for the ever increasing business, and Röder bought a piece of ground (Dörrienstrasse No 13); and after the necessary buildings were erected in 1867, the business was transferred there, with 4 steam presses and an engine of 10 horse power. But before long the number of steam presses had to be increased to 10, and the number of employees rose accordingly. A great lift was at that time given to the enlargement of the business by the enormous success of "Peters' Edition" which began in 1867 by first issuing an octavo volume of Beethoven's Sonatas, price five shillings complete. The improved steam printing process now gave rise also to the printing of other cheap editions. The new building at first contained in the three lower floors the business premises, whilst the upper floors were used for private residences, these however were required one after the other for the business, and in 1871 the entire building, with the exception of Röder's own private rooms, was devoted to the business.
On the 1st of July 1868, Röder and his employés founded an infirmary, which proved to be a great boon to all concerned, until December 1884, when a new law coming into operation, it had to be amalgamated with a public institution.
On the first of February 1871 Röder's second Son-in-law Mr. Max Rentsch entered the Firm.
On the 21st of October of the same year Röder celebrated the 25th Anniversary of his establishment in business by a festival dinner followed by a ball, when not only all his employés, but also a great nnmber of his customers assembled at the "Schützenhaus". On this joyful occasion, he set apart a large sum of money, which was considerably increased by the liberality of several friends, for the purpose of creating a fund for the benefit of invalids. The musical papers "Musikalisches Wochenblatt", and "Signale" fully reported this interesting festival in their columns.
It was also in 1871 that His Majesty The King of Saxony honored Röder, by personally inspecting his establishment and conferring on him the title of "Königl. Commerzienrath". On the 15th of November 1872 Röder admitted his two Sons-in-law as partners in his firm. In the same year another and still larger piece of ground on the Gerichtsweg was bought for the erection of the factory now occupied by the firm, and which contains 6 large workrooms (125 and 180 feet long, by 42 feet wide) a new 40 horse power engine, etc. In 1873 Röder exhibited at the great International Exhibition at Vienna, and received the order of "Franz Josef" and the medal for progress in Art. In. May 1874, Röder finally retired from active business, leaving the management in the hands of his two Sons-in-law. C. G. Röder died on the 29th October 1883, having enjoyed only for a few years his retirement, so well earned after so many years of toil and incessant labour. During the first year or two of his retirement, he still continued. to devote occasionally a few hours to business, until his failing eyesight rendered it impossible. The large number of friends who attended his funeral, and the numerous notices about him in the daily and the musical papers testify to the respect with which the deceased was regarded during his long life. Honor to his memory! A few more particulars about the Röder Establishment may be interesting. In June 1874 the removal of the business to the premises now occupied by the firm took place. Also in this, the fourth abode, the business continued. to increase. Agreeably with the intentions of the founder new and approved machinery were constantly added, and the employés working continually together, have attained a high degree of perfection, and every new improvement is at once introduced, when found to be practicable. Although it was thought that the new premises would prove sufficient for all requirements, in 1879, a new (third) wing had to be built, and in 1882 a third floor had to be added to the central block, after the erection of a new 75 horse power engine; and in 1884 another story was added to the two side wings. In February 1881, the business of Messrs. Graichen & Riehl, letter press printers, was bought and added to Röder's business as a new branch. The electric light introduced into part of the building in 1883 was found to be so satisfactory, that in 1884 more. machines were added to carry the light through nearly all the buildings, and now and now the Engravers, Type printers, Lithographers and Lithoprinters work with Electric light. To form an idea of the way in which the business is carried on, in this, the most extensive establishment of its kind in the world, it will be best to give a description of the various stages through which a manuscript has to pass before it is printed and ready for circulation. After all necessary notices and instructions have been entered in the books kept for that purpose, the manuscript is given into the hands of the "Engraver's preparer", whose business it is, to calculate the number of plates, and how many bars are to go on each page, paying attention to the turning over. Then the M. S. is sent up to the engraving department, where the foreman gives it with the requisite number of plates, to the engravers, who, after preparing the plates, measure and mark the staves on them, then draw the lines of the staves, with a tool made for that purpose, and dot the notes, each according to their respective value and position in the scale. To the dots are then added, with the help of a ruler, the perpendicular tails, and the text or words are marked in according to the M.S. with a pencil. After this the heads of the notes, the brackets, clefs and text are stamped in. As this proceeding brings the plate out of shape, it has to be straightened again by a polished hammer and anvil; the slurs, ties, bar and ledger lines, marks of expression, crescendos or diminuendos are then engraved by hand and the chips removed by a triangulur scraper; after which the engraving is completed.
The 136 Engravers, now employed at Röder's, finish about 200 plates daily, or 60 000 a year. The Engraver's department is well supplied not only with all necessary tools, but also with all available works for instruction or reference.
The finished plates go then to the Corrector's press, and one copy is pulled off for the Corrector, whose duty it is, carefully to compare the proof with the M. S. and to note any mistakes made by the Engraver, who then has to correct the same, by hammering the plates at the faulty places from the back, to remove the wrong notes and to produce a smooth surface, after which the right notes are punched in. Should many corrections be necessary, part of a plate has sometimes to be cut off and another piece to be soldered on. In such cases another proof has to be taken, and the corrector has again to examine it. When required, the corrected proof is also sent for revision to the composer or publisher. Three correctors attend to this department. The plates are now ready for printing, and according to the edition required, they are delivered to either the department of printing by hand, or by steam.
There are now eight hand presses going, each served by two printers, one of whom, has to ink the plate and the other to pull it through the press. This is done by first laying the plate on the press table, putting the moist paper on the plate, covering both with an elastic cover, and then pulling the whole through iron cylinders. This hand printing is now only used for very small editions, or for "Editions de Luxe".
By far the largest part of Music printing is done by steam, even when the editions are as small as 50 Copies. There are 26 Steam presses of various dimensions constantly at work, and they are worked after this manner: - After an impression has been taken from the plates by a hand press on transfer paper, this impression is transferred by another handpress on to a smoothly prepared Litho Stone, which is then cleaned and etched, after which it is ready for printing.
These transfers for the steam presses are done in 7 divisions, each of 2 Music printers, 2 Lithographers and 3 cleaners. The grinding with sand and water and the polishing of the Litho Stones by 14 machines occupies 12 men, who can finish about 300 Stones daily.
After the transfer has been prepared as above, the stone is handed to the printer in the steam press room, and it is his duty to superintend the inking and moistening of the stone, and also the printing. The paper is put in its proper position, marked near the roller, in single sheets by a girl, whilst the machine in motion takes hold of it, and after a turn of the cylinder on the transfer stone, it is withdrawn on the other side by another girl and then the printing is completed.
From 3000 to 5000 imprints can daily be taken by each press. These presses are managed by 1 foreman, 26 printers and 52 girls.
The requisite paper is provided from the paper store room, and it takes 5 men to count and deliver it. Before it is used, it has to be moistened by machinery, and has to lay one night to get properly saturated.
The glazing is done by four large calandars and one smooth hot rolling machine. These machines are worked by 8 girls and 2 men. The hand press printed Music is however glazed after the printing by two hydraulic presses, worked by 4 men.
For cutting the edges of the paper there are four machines.
The plates are made on the premises. They are cast by two men in two moulds and then planed into shape by two machines. Last year 100 000 pounds of metal were used for plates.
For the production of the Titles 3 Artists and 27 Lithographers are employed. The titles are either engraved, or drawn with pen or chalk on stone. The printing is done in a special department by six steam presses and fifteen hand presses.
After the printing is finished all sheets are examined by the foreman, and then the last stage to be undergone is the folding up or stitching or binding. This department has lately been completely fitted with all the most modern machinery.
The plates are then stored in the arched basement, shut off by iron fire proof doors. They are numbered like books in a library, and arranged in such order that they are at once available when required for reprinting. There are two storekeepers to attend to this business. In the adjoining basements on one side are the store rooms for the Litho Stones, in which about 25000 Stones, each with two titles, are stored, also numbered, on shelves; and on the other side the paper stores to the value of about £7500. The various qualities and sizes, of the paper are also known by numbers.
Finally, the department for type and letter press printing has to be mentioned. It was found that often titles, or advertisements for the back of Music were wanted in type, and in order to execute these orders promptly, the firm purchased in 1881, as has been already mentioned, the letterpress printing business of Messrs. Graichen & Richl, which at that time was worked with 4 steam presses. The extensive stock of working material and type has since then been increased by the addition of the newest ornamental type, especially by all that is necessary for Music type printing. As all modern improvements have been made use of, also this branch of the business is continually growing and orders are received not only from the Music trade, but from book publishers as well. At present there are 7 steam presses at work, one of which prints in 2 Colors. There is now about 65 000 lbs of type in use and 25 Compositors, 5 Machinists and a corresponding number of assistants male and female are employed.
To form an idea of the extent of Röder's establishment, it may be mentioned that at the commencement of this year 488 persons were employed in the various departments distributed as follows: 136 Engravers, 30 Litho printers, 30 Artists and Lithographers, 37 Engineers and Attendants, 75 layers on and takers off, 16 handpress printers, 50 transfer printers, 20 bookbinders, 15 Stone grinders and plate moulders, 10 glazers, 25 Compositors, 5 Blacksmiths & Stokers, 25 Paper Storekeepers and packers, 3 Carpenters, 11 Bookkeepers and Clerks, and the following Machines are constantly at work, 7 Letterpress printing machines, 32 Litho steam-presses, 18 hand presses, 4 rolling machines, 1 hot rolling machine, 14 Stone polishing machines, 2 hydraulic presses, 4 paper cutting machines, 2 planing machines, besides several auxiliary machines, worked by an engine. of 75 horse power and two boilers, another boiler being now in course of construction.
The present members of the firm can look with genuine satisfaction at the results of their management of the business, which they have carried on in the spirit of the founder C. G. Röder. The productions of their establishment are to be met with in all parts of the world, for not only German publishers have their music printed at "Röder's" but also publishers in Belgium, Holland, Denmark, Sweden, Norway, Russia, Greece, France, Spain, England, and North and South America.
Always anxious to take advantage of all new inventions and improvements the firm trusts also in the future to give satisfaction to all who will honor it with their patronage.
Leipzig, March 1885."
