Ceramic Making Process

Radio Italia

Step One: "Il Torniante" Molding the Piece

In a process used for centuries, the art of Italian Ceramics begins with a plain lump of
refined clay that is slowly brought to life by "Il Torniante". Masterfully hand-shaping the raw
chunk of clay on a wheel, the potter transforms it into a vessel, a plate or a large urn. The
molded clay piece is referred to as "In Terra" (Earthenware) and is placed in the open air
for natural drying. It dries to a grayish color, and is ready for its first firing in the kiln.

Step Two: "La Prima Cottura" The First Firing

The naturally dried piece is then loaded into the kiln to be processed at the "Prima Cottura".
The clay item that emerges from the kiln after this first 950-degree firing is referred to as
"Biscotto" (Bisque), a baked terracotta piece featuring the typical red color.

Step Three: "La Smaltatura" The Glazing

Once cooled, the Bisque is dipped into the "Smalto", a fast drying chalky liquid glaze. This step, while
simply described, represents an important part of the entire process because the next firing will melt
the glaze with the colors, determining color tones, glazing texture, and uniform quality of the piece. The
chemical composition of the "Smalto" is complex and every factory has its own formula that is kept very
secret! The Bisque, now wholly covered by the white powdery glaze, is ready for painting.

Step Four: "La Pittura" The Painting

Step Five: "La Seconda Cottura" The Second Firing

The painstaking process of painting the Bisque is the essence of Italian Ceramics. The Painter, "Il Pittore", may
paint a decoration freehand, or use a type of pounce, "Spolvero", to stencil sketches of the design. This fine
powder prevents the colors from spreading and blurring into each other. The painter must fully understand the
complexities of coloration, as the raw glazes used for painting all have a very similar Gray/Black tone. The true
and brilliant colors will be produced only after the finished product emerges from the final kiln firing.

In this final step, the painted item is loaded again onto the kiln for a second firing at about 920-degrees. This
delicate process requires great care to avoid scratching or touching any item to be fired. Since the painting was
done over the "chalky" Smalto surface, it can literally be wiped out by a simple touch of a thumb! The final firing
may take up to 24 hours. Prior to loading, the kiln must be pre-heated at a low temperature. Depending on the size
of the item(s), the ceramics may require up to 12 hours of firing at a constant high temperature. It is very important
that the "cool-off" period be a "natural" cooling. The kiln's safe-type door must not be opened until the temperature
is low enough to avoid "thermal shock", which would literally destroy (crack) the entire kiln load.

Ceramic Making Process