Inside Zildjian, a 400-year-old company that makes cymbals in Massachusetts

Cymbal maker Peter Nelson works on a cymbal on a lathe at Zildjian's cymbal factory in Norwell, Mass. (Robin Lubbock/WBUR) — Cymbal maker Peter Nelson works on a cymbal on a lathe at Zildjian’s cymbal factory in Norwell, Mass. (Robin Lubbock/WBUR)

From symphonies to rock music, marching bands and commercial jingles – we hear Zildjian cymbals everywhere. Drummers all over the world know that name because it’s emblazoned on every shiny record. What is less known is that the Zildjian family has been making their famous cymbals – using a secret process – for more than 400 years.

Since the 1970s have Avedis Zildjian Co. has been operating under the radar in Norwell, Massachusetts. We jumped at the chance to enter the world’s oldest cymbal manufacturer.

A Zildjian cymbal signed by Ringo Starr hangs on a wall of famous drummers at the Zildjian cymbal factory in Norwell, Mass. (Robin Lubbock/WBUR)

Even in Massachusetts, many people have no idea that an industrial factory outside of Boston designs, casts, blasts, rolls, hammers, polishes and tests at least one million Zildjian cymbals every year.

“There’s a lot of mystery and a lot of history at this facility,” said Joe Mitchell, the company’s director of operations, as we walked past loud, terrifying machines. He is one of the few privy to a Zildjian process that has been shrouded in mystery since the height of the Ottoman Empire. It begins in a room off-limits to the public.

Joseph Mitchell, operations manager at Zildjian's cymbal factory. (Robin Lubbock/WBUR) — Joseph Mitchell, operations manager at Zildjian’s cymbal factory. (Robin Lubbock/WBUR)

“Behind this door is where we have our foundry,” Mitchell explained. “This is where we melt our metal and where we pour our castings. I’ll show you what the castings look like—but obviously we can’t go beyond this point.”

He leaned over a container filled with thick, rough-hewn sheets of metal. Even in their nascent state, Mitchell said the castings hold the secret to Zildjian’s sound. He struck one lightly to release an enchanting, reverberating ring.

Eliot Carduff weighs and sorts castings, which will soon become cymbals. (Robin Lubbock/WBUR)

The company’s proprietary alloy was alchemized 13 generations ago in Constantinople (now Istanbul) by Debbie Zildjian’s ancestor, Avedis I. He tried to make gold, she said, but ended up cooking up a combination of copper and tin. “The combination of these metals produced a very loud, resonant, beautiful sound,” she said.

Debbie Zildjian shows some visitors around Zildjian's cymbal factory in Norwell, Mass. (Robin Lubbock/WBUR) — Debbie Zildjian shows some visitors around Zildjian’s cymbal factory in Norwell, Mass. (Robin Lubbock/WBUR)

Debbie explained that in 1618 the Ottoman Sultan called Avedis to Topkapi Palace to make cymbals for elite military bands. The metalsmith’s work pleased the ruler, who gave him permission to found his own company in 1623. The sultan also gave Avedis the family name “Zildjian”, which literally means cymbal maker. He went on to make cymbals that were used extensively, including in churches and by belly dancers.

Debbie Zildjian's grandfather Avedis III immigrated to the United States in 1909. Two decades later, he relocated the family's cymbal business from Turkey to Quincy, Massachusetts with his uncle. (Courtesy of Zildjian) — Debbie Zildjian’s grandfather Avedis III immigrated to the United States in 1909. Two decades later, he relocated the family’s cymbal business from Turkey to Quincy, Massachusetts with his uncle. (Courtesy of Zildjian)

In the 18th century, European composers, including Mozart and Haydn, added Zildjian cymbals to their symphonies. “So, that’s how the word grew,” Debbie said.

Zildjian became synonymous with cymbals after her grandfather Avedis III, an ethnic Armenian, emigrated to the United States in 1909. Two decades later, he relocated the family’s cymbal business from Turkey to Quincy, Massachusetts with his uncle.

At the time, jazz was exploding, so Avedis III traveled to New York City so he could develop new sounds with pioneers, including Gene Krupa. “Not only was he a great drummer,” Debbie said, “he was also very flamboyant in his style.” This made Krupa an ideal ambassador for Zildjian.

The company really took off with a little help from The Beatles’ 1964 appearance on the Ed Sullivan Show. “Everybody wanted to be a musician,” said Debbie, “and within a few months we were completely reordered because Ringo was a big celebrity. So that catapulted our business into the modern era.”

In 1973, Zildjian moved to a state-of-the-art factory in Norwell. Debbie said her father Armand, who then ran the company, loved music like his own father. “What my father really understood — and kind of preached to all of us here — was that we have to follow the music,” she said.

Armand, who started working in Zildjian’s melting room when he was 14, eventually brought Debbie and her sister Craigie with him to teach them the secret process. The family business had always been passed down to the eldest male, but Debbie and Craigie were their father’s heirs.

“For us it was very natural on the inside, but the music industry had a hard time accepting women in the industry,” said Debbie. “The players were all men, the manufacturing was mostly done by men, the salespeople were all men.”

Mill operator Matt Fraser feeds slabs of hot metal into a roll at Zildjian's cymbal factory. (Robin Lubbock/WBUR) — Mill operator Matt Fraser feeds slabs of hot metal into a roll at Zildjian’s cymbal factory. (Robin Lubbock/WBUR)

After coating, cymbals are hung out to dry. (Robin Lubbock/WBUR)

Craigie became CEO in 1999. She is now president and executive chairman of the board. Drawn to fabrication, Debbie oversees Zildjian’s proprietary alloying process that her father taught her.

Over the decades, drummers across all genres have embraced Zildjian cymbals – from Metallica’s Lars Ulrich to Grammy-winning jazz drummer Terri Lyne Carrington.

A cymbal printed with the Zildjian trademark. (Robin Lubbock/WBUR)

“I normally play about six cymbals plus hi-hats,” she said, “they’re the sound I’ve been playing my whole life because most jazz drummers play Zildjian cymbals.”

Carrington founded and directs Berklee College of Music’s Institute of Jazz and Gender Justice in Boston. She is also a Zildjian artist, meaning she exclusively endorses and plays the company’s cymbals. Carrington said they have helped shape her musical identity since she was 10 years old.

“Your cymbals are your signature,” she explained. “So when you play, you’re generally recognized by your cymbal sound, your touch, and your cymbal patterns—at least in jazz.”

Carrington’s drum kit is like a painter’s palette. The sound of each cymbal guides her to the next beat. She has visited the Zildjian factory many times and still marvels at what they do. “I don’t know the secret sauce,” she said, “but to make a piece of metal sound so beautiful — and become this beautiful instrument that’s part of all kinds of music that you hear — is pretty remarkable.”

Zildjian’s manufacturing has evolved to keep up with demand for its 600 models of cymbals sold in more than 100 countries. According to the company, it takes at least 15 people to complete a single cymbal. Today, machines hammer the alloy instruments, but their forms are still honed by skilled craftsmen.

Eric Duncan tests cymbals for quality and sound. (Robin Lubbock/WBUR)

Before each cymbal is deemed worthy for artists or retail, it must pass a human ear test. That’s Eric Duncan’s job. “This is the make or break point,” he said in the test room.

One by one, Duncan lifted cymbals from a rack to compare their sound with a pristine example. “We test anywhere from 1,000 to 4,000 cymbals a day, depending on how busy we are.”

Each approved cymbal is stamped with the surname. They call it the “Zildjian kiss.”

A display of cymbals at Zildjian's cymbal factory in Norwell, Mass. (Robin Lubbock/WBUR) — A display of cymbals at Zildjian’s cymbal factory in Norwell, Mass. (Robin Lubbock/WBUR)

Although much of the cymbal-making process hasn’t changed since the 17th century, Debbie Zildjian said expansion and innovation have been key to the company’s longevity. She pointed to merging with the drum stick company Vic Firth 2010 and this year’s debut of Zildjian’s first electronic drum set.

“We’ll never abandon acoustic,” said Debbie, “but electronic is the wave of the future.”

Debbie loves to share her family’s storied past, but as the custodian of their carefully guarded 400-year-old alloy, she doubled down, “The secret part will remain a secret.”

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Inside Zildjian, a 400-year-old company that makes cymbals in Massachusetts

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