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The Process
The clay arrives a tonne at a time in 12.5 kg bags and is then put through a de-airing pugmill which brings the clay to a useable consistency for throwing. All of the pots are handthrown on an electric potters wheel. There are three production throwers in our studio and each one has certain forms designated to them.
Once the pots have been thrown they are set in a racking system to air dry before the lengthy process of decorating, altering, handling, turning, cleaning, sponging and finishing is begun. Throughout the different stages of drying the decoration is applied and all other aspects of shaping the pots into useable vessels are completed. It is imperative that the work is done on the pots at the proper stage of dryness or wetness otherwise the desired effect will not be achieved.
   
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When the pots have been finished they are air dried for a further 3 to 5 days depending on the size of the item. From there they are packed into an electric kiln for their first firing which is called a bisque firing. The kiln is fired overnight to a temperature of 960 degrees Celsius and takes a day and a half to cool down enough for the pots to be unpacked and have their bases waxed before being glazed. It is necessary to wax the bases of the pots as the wax forms a resistance to the glaze and prevents it from covering the bottom of the pot.
The pots are glazed using a variety of methods including dipping, pouring, and brushing the glazes on, these techniques help to enhance the spontaneous and random nature of the glaze so that no two pieces will ever be exactly the same. After glazing, the pots are individually checked and wiped clean of any glaze remaining on the base and then they are packed into the gas kiln. |
  
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The gas kiln was designed and built by Ciaran and has a packing space of 75 cubic feet. It is fired up to a temperature of 1300 degrees Celsius. The use of gas as the fuel for firing the kiln allows Ciaran to fire the pots in a reduction atmosphere which enhances the glaze further giving it it's drippy, earthy effects.
A reduction atmosphere is achieved during certain stages of the firing by "reducing" the amount of oxygen in the atmosphere of the kiln thereby creating a chemical situation where the carbon monoxide produced from the combustion of gas is searching for an extra oxygen molecule. The oxygen molecule is found within the organic components of the clay and glaze.
The glaze firing takes approximately eight and a half hours to reach top temperature of 1300 degrees and a further two days to cool down. Once the kiln is cool enough the pots are unpacked and their bases are rubbed with a carborundum stone to remove any excess refractory material. Now they are ready for sale.
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Celtic Clays, 2 Riverlane, Carlingford, Co Louth, Ireland, Ph: + 353 (0)42 9383996, E: info@celticclays.com
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