2.   Clay-mixing & casting

Half-processed clay solids are first grounded into smaller pieces before mixing them with water and sodium inside the clay mixer. Clay mixing is normally done first thing morning for approximately 1 hour to ensure all solids are softened and melted. Regular mixing is repeated whenever necessary to ensure appropriate clay consistency for immediate casting.

Casting involves the pouring of liquid clay into plaster molds until the whole hollow mold is filled up to the brim. The liquid clay is left inside the mold for 20-40 minutes, depending on the clay thickness preferred, to allow a layer of hardened clay to be formed on the inner surfaces of the mold. Once the desired thickness is achieved, remaining liquid clay is poured out, to be re-used for other castings.

3.   Clay-forming & drying

Hardened clay layer is left unattended inside the mold for a further 30-50 minutes to dry-up. Once half-dried, the plaster mold is opened to reveal the shape of the product. By this stage, the clay-form should be able to stand on its own without any mold support, or else, it may need more unattended drying period.

Our smallest items and knick-knacks occasionally skip liquid clay-casting procedures, but instead, half-solid clay is pressed into the mold to achieve an instant product shape.