Behind the process
How our ceramics are made
Basically speaking, the production of ceramics consists of three physical elements. We offer product development and creative design expertise, sourcing based on decades of experience, production management and industry leading quality control, and this is what that looks like, step by step.
Body • Glazing • Decoration
Phase one
The body
Every piece starts as sand and clay. It is mixed, formed into its shape, and fired once so it holds together for everything that follows.
The body
Mixing of sand and clay.
Forming
Forming the shapes of each individual item.
Hand • Casting • Stamping • Jiggering
Using machines
Jiggering machine. Makes mugs, dinner plates and bowls.
Machine pressed. The most efficient method to produce oversized platters. Our turkey platters, for example, are made from machine pressed.
Casting. Liquid clay is poured into a mold and then allowed to set. This process duplicates the shape of the mold. Teapots, cookie jars and any other three dimensional products are casting items. Slower production, therefore, more costly to create.
Sample mold
- Sculpting the shape with soft clay
- A plaster mold is made from the sculpture
- This process takes five to seven days
- Once the sample mold is approved, a production mold must be made
Production mold
- Duplicating the plaster mold, making as many molds as necessary depending on the size of the order
- Each mold is usually good for 60 to 80 turns before a new production mold is made
First firing
Product is placed through the first oven.
- Temperature is set at 175 degrees F
- Purpose is to remove the excess water content from the formed item and harden the formed shapes
Phase two
Glazing
The glaze is what gives a plate its smooth, hard, glossy surface. It is applied to the fired body and then fired again in the bisquit kiln.
Glazing process
The glaze is a smooth and hard shell that is applied to the outer surface of the body. The components are of a variety of additives specialized by each individual country, region and factory where the product is made.
The end result being:
Smoothness • Strength • Color • Shine
Bisquit kiln
The glazed body goes through the bisquit kiln. At this stage each item is solid and hard.
Phase three
Decoration
Pattern and color are added by decal, by hand, or by stamp, then locked in with a final firing before every piece is inspected and packed.
Decoration application
Decal. Decal is a design technique where dot screenprints of different colors are mechanically transferred onto a transparent surface and glued onto a paper like base. During production, the transparent layer is removed with water and positioned on the ceramic's body. The decal layer is then baked onto the ceramic, creating a solid surface.
Overglazed or underglazed. Decal decorations can be overglazed or underglazed. Overglazed decals are more common and have noticeable bumps, while underglazed decals require an additional glazing step and are typically more expensive. When you touch an underglazed product, you won't feel the typical decal bumps found in overglaze.
Handpainted
Handpainted designs are today's most popular decorations for dinnerware. In this case, skilled workers use paintbrushes or sponges to apply a series of colors on the surface before glazing. This process is naturally more time consuming and may be more costly, but the end result is a beautiful, unique item, different from anyone else's.
Stamped
Stamped decoration is yet another way to create a special design on a product. A ready stamp is dipped in paint and then applied either by hand or machine to the product. Some factories have been able to skillfully utilize a combination of the above methods to better suit economic and aesthetic needs.
Glost kiln
The final firing. At this stage each item is solid and hard, and the decoration is locked in under the glaze.
Quality control
The product should be inspected against the following during all production stages:
- Smoothness and finish
- Warpage
- Breakage
- Chipping
Packing
Depending on the complexity of the specific manufacturer, the product is inspected again before packing against:
- Warpage
- Breakage
- Chipping
Made by a family that has done this for over 45 years
From the clay body to the glaze to the decoration, Gibson designs the piece, chooses the factory and stands behind the result. Read more about how our dinnerware is made on the blog.