Creating ceramics step by step
The complete process of making ceramic objects – from the first shaping of the clay to the finished product – usually takes about two weeks. During this multi-stage process, each one must pass through our hands many times before the finished, glazed and gold-decorated faience or porcelain can be removed from the kiln.
We publish the film thanks to the courtesy of the Museum in Nieborów and Arkadia.
1. forming
The shape of faience plates and bowls intended for majolica decoration is given by applying and modelling a sheet of plastic clay of the appropriate size and thickness on a special plaster mould. In the case of objects such as cups, mugs or figurines, this is done by casting faience or porcelain slips in plaster moulds. The semi-finished products made in this way are then subjected to slow drying, which lasts from 5 to 7 days. After this time, the already dry vessels are cleaned and their walls and edges are levelled by hand.
2. firing of raw clay
The cleaned objects are hardened by firing them in a kiln for about 10 hours at a temperature of 1000 °C. The biscuits, as the pottery is called after the first firing, are taken out of the kiln and covered with a ceramic glaze.
3. majolica decoration
At this stage, the vessels are decorated with majolica, which involves painting with paint on raw, unfired glaze.
4. firing of glaze
It takes place at a temperature of 1100 °C – in the case of majolica or 1250 °C – in the case of porcelain. After the firing is finished and the kiln cools down, which takes about 48 hours, the glazed and fired ceramics are marked with the factory's signature and decorated with gold or overglaze decal. In order to fix them, another, third and final firing is necessary. This time the kiln is heated to a temperature of 850 °C, at which the decal melts into the glazed surface and the gold takes on its characteristic shimmering yellow colour.
