We’ve often had this question asked, as why does it take so long for a ceramic product to be made. Even though, we strive to combine the value of manufacturing and handmade quality, the process of making ceramics is slow as a turtle. Hence, we did some prep work to briefly explain the process of how we go about it.
To start off with, we source our stoneware clay locally. It is made up of mined ingredients such as ball clay, silica, and feldspar. This clay is durable and denser compared to Terracotta & Porcelain, therefore allowing us to create complex shapes. All the dry ingredients are mixed with water and wedged thoroughly (like bread dough) to avoid air bubbles from breaking the products during firing.
Once our clay is ready, the most effective way to bring ideas to reality is by getting our hands dirty with traditional wheel throwing pottery, or hand building.
As a design gets finalised, we move towards a big step - production. We work with craftsmen to get patterns made in MDF wood. The solid patterns help us in making multiple plaster moulds for production. These hand constructed plaster moulds absorb water from the liquid clay a.k.a slip (a process called slip-casting), which once removed, forms a silhouette of the product inside the mould.
Once the products are air dried and cleaned up, they are bisque fired (943 degrees celsius) to provide them strength needed for the next step - glazing. Our clear glaze is mostly made of liquid glass - silica, & mixed with water in correct proportions. It is applied to the interior of each piece leaving the exterior with a vitrified stone-like surface that becomes smooth with handling.
Lastly, the glaze melts while the clay gives strength, and both are fused together at 1225 degrees celsius.
All your Box T is handmade in our Ahmedabad-studio by our staff of professional and amateur ceramicists. Each piece is designed to last and manufactured using the best materials available. Oven, microwave, dishwasher and food safe—making it ideal for domestic and commercial use at the table and in the kitchen.