Each Kinder Surprise egg consists of a chocolate shell, a plastic capsule, the contents of said capsule, and an external foil wrap.
The chocolate shell is shaped like a chicken's egg, and is of similar size. It is only about a millimeter thick, and consists of two layers: a milk chocolate layer on the outside, and a white chocolate layer on the inside. The shell is not a singular piece of material, but rather two identical halves split down a vertical line. These are lightly fused together just before the egg is wrapped, to prevent the halves from splitting apart under the light pressures expected during transportation.
During the egg's production, before the halves are fused together, the plastic capsule containing the toy is placed inside. This capsule is made from thin, flexible plastic, and is often yolk-yellow (though in the past it was also manufactured in a variety of colors). The capsule is made of two non-symmetrical, overlapping pieces: its bottom piece is almost as long as the entire capsule, and has two ridges protruding along its outer rim; the top piece is about half as long as the entire capsule, and has two corresponding ridges along its inner rim. When the pieces are pushed together, the ridges interlock and do not come apart without manual manipulation. To separate the two pieces, it is often necessary to apply pressure to the interlocking region at its opposite ends, bending it and causing the ridges to separate inside so that the halves can be pulled apart. Once the capsule is opened it can be re-closed effortlessly by pushing the two pieces back together.
The plastic capsule contains the toy itself (either in a single piece or in several pieces requiring assembly) and at least two pieces of paper. One paper lists the "choking hazard" warnings in multiple languages. The other paper shows assembly instructions for the toy and a picture of the assembled toy (if applicable), and/or an illustration of all toys belonging to the same line as the one contained within this particular capsule. Furthermore, many capsules include a small page of adhesive decals that may be placed on the assembled toy after construction.
Once the egg is assembled in the factory, it is wrapped in a thin metal foil bearing the Kinder Surprise brand name and various production details. The eggs may then be sold in any of a number of forms, often either individually or as a boxed set of 3 eggs. Some retailers will sell a tray of eggs containing 24 eggs in total.
Assembly of the toys requires no additional tools, as the pieces will simply lock ("snap") together. Assembly rarely takes more than a few simple steps. Most toys can be disassembled and reassembled freely, while a few cannot be disassembled without causing permanent damage. Over the years, Ferrero have also created a variety of no-assembly toys, whether more complex toys that can be used immediately or simple character statuettes made of a single, pre-painted piece of hard plastic.
During the 2000s, Ferrero redesigned the Kinder Egg's internal plastic capsule. The new design is visually and functionally similar to that of the original capsule, but it now consists only of a single piece of plastic with a hinge on one side. The size and specific design of each half of the capsule have also been slightly altered accordingly. The new capsule design is always made from yolk-yellow plastic.
Read More : http://en.wikipedia.org/wiki/Kinder_Surprise
