Production Process

Production Process

Product Design

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

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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.

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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.

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Raw Materials

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

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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

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Refining

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

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Casting

Various methods are used to cast product.

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Sponging

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

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Drying

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

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Inspection

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

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Glazing

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

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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

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Final Inspection

Final inspection ensures that no faulty product is dispatched to the

customer. Every single piece undergoes inspection

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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

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Warehousing

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

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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.

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Dispatch

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