Product Design

To allow for shrinkage, during firing, models are developed 12.5% bigger than the finished piece size.

|

Modeling

From the design, a model of the finished piece is created. The speed of a machine and the skill of the modeler ensure that the model is accurate.

|

Mould making

From the model a negative master mould, (“block”) and a positive “case” is made. From this case working plaster moulds are produced. One mould may consist of many parts.

|

Raw Materials

Water, china clay, ball clay, silica, sand, talc, quartz, zinc, pyrofilite, cobalt, feldspar, barium, silicate, calcite, POP, etc.

|

Blunging

The “blunger” in the “sliphouse” is a huge mixing vessel where all the raw materials are blended to form clay “slip” – a bit like thick, dark custard

|

Refining

Raw slip is passed over sieves to remove over-size materials and contaminants which would create a fault in the fired piece

|

Casting

Various methods are used to cast product.

|

Sponging

Each cast piece is carefully hand finished to create the right type and then water sponged to fixing holes and remove clay blemishes

|

Drying

Drying is thorough to ensure no moisture remains before the piece is glazed and fired

|

Inspection

Inspection and final cleaning ensures the dry clay piece is perfect before glazing

|

Glazing

Glaze (which is powered glass in water) is applied by spraying. Two coats are applied to the exposed clay surfaces

|

Firing

Product is then “fired” in a tunnel kiln at 1210°C. The clay body and the glaze mature and change to become hard & glossy

|

Final Inspection

Final inspection ensures that no faulty product is dispatched to the

customer. Every single piece undergoes inspection

|

Packing

Packing may be the simple wrapping of each piece in polythene.

Or it may be the packing of complete bathroom suites into boxes on pallets

|

Warehousing

Home décor warehouse is the size of a football ground. It holds almost one lac pieces of different types of refresh wares.

|

Order & Assembly

Customer orders are picked from stock and carefully assembled onto dispatch pallets. These are then shrink-wrapped or box packed to minimize damage.

Domestic deliveries are made on lorries and in containers for exports.

|

Dispatch

Home Décor is the India’s biggest exporter of refresh ware products with dispatches to almost all developing countries, world-wide.