To allow for shrinkage, during firing, models are developed 12.5% bigger than the finished piece size.
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.
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.
Water, china clay, ball clay, silica, sand, talc, quartz, zinc, pyrofilite, cobalt, feldspar, barium, silicate, calcite, POP, etc.
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
Raw slip is passed over sieves to remove over-size materials and contaminants which would create a fault in the fired piece
Various methods are used to cast product.
Each cast piece is carefully hand finished to create the right type and then water sponged to fixing holes and remove clay blemishes
Drying is thorough to ensure no moisture remains before the piece is glazed and fired
Inspection and final cleaning ensures the dry clay piece is perfect before glazing
Glaze (which is powered glass in water) is applied by spraying. Two coats are applied to the exposed clay surfaces
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 ensures that no faulty product is dispatched to the
customer. Every single piece undergoes inspection
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
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.
Home Décor is the India’s biggest exporter of refresh ware products with dispatches to almost all developing countries, world-wide.