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Decals Craftsman
Camel & Yak and the new Green Gate range
All Greengate Stoneware is designed to complement Greengate Soft Furnishing, fabrics and colour wares. Greengate Stoneware is manufactured in Shantou, China. Located in the Guangdong district, Greengates pottery manufacturers have a long heritage of stoneware and porcelain production. With the reputation of producing high quality, craft based products. They use brush and moulding techniques that have been perfected over the centuries.
Stoneware has its origins in the Shang dynasty in China from circa 1400 BC. Their breakthrough was to produce kilns hot enough to complete the process. The craft still has its roots firmly placed here ever since.
Filling the mould is the first step of the process. Plaster of Paris moulds provide the master outer shape for products such as cups and mugs. This method was first used in stoneware making in Staffordshire, England in 1745 and the methods used are almost identical to this day. The unfired items called 'Greenware', are rather larger than the final product, in fact all items need to be made up to 20% larger at this stage to allow for shrinkage that is inherit in the process. Modern techniques mean that finished items will be more or less identical in shape but there will be a very slight difference between each item. About 10% of production is an unacceptable size of shape and therefore do not make it to the second stage and are destroyed for recycling.
To create the internal shape of a vessel such as a cup, the craftsmen employ a device called a jigger or a jolly, first introduced in the 18th century, the jigger carves out a perfect negative shape of the inside of the cup.
The pieces are then subjected to a process called turning, the Greenware items are dried until they reach a leather-like hardness, so they can be handled and shaped more thoroughly. The turning process is used to smooth and finish foot rings and undercut places on moulded and jiggered pieces.
The oversized turned pieces are then washed and inspected again, once dried further, the pieces are then ready for stage one of the glazing process. Once glazed they are burned in the kilns at a temperature of over 1400 degrees celsius. When burning is complete, they are again inspected before being submitted to a second glazing. After the second glazing inspection, they are passed to the department responsible for white work. Only 70% of the products undergoing glazing will be passed.
While the craft of stoneware has been relatively unchanged for centuries in the processes seen until now, decorating the items has seen newer techniques which allow for more accuracy in mass production. That said, the process is still one that demands enormous skill and dexterity by hand. Greengate Stoneware manufacturers have a long tradition of fine brush skills, it is in this art that they developed a reputation. More recently though, the larger demand for high quantities and the western demand for identical products, a team of decal applicators are expanding their reputation into new fields.
Adhering to a traditional craft based approach, each crafts person is solely responsible for their own items, which leads to a greater sense of ownership and a higher more perfect piece rate. First the decals are printed from computer files created by the Green Gate design team onto a special sub straight, these are submerged into water and then carefully moved onto the products, using hard brushes, applying the decals is one of the most painstaking parts of the process, requiring enormous skill and dexterity of the craftsman, each item can take up to twelve minutes, depending on the shape of the product.
The colours at this stage are very different from the final result, as the burning process will alter the colour dramatically, only years of experience and testing can tell the craftsman what colour to begin with to achieve the correct final colours. Once the pieces have been fired again, they are ready for final inspection, only items with a maximum of only one very minor imperfection will make it successfully to cleaning and packing.
The overall atmosphere in the factory is more of a fine craft workshop than that of a mass production factory. Combining the extraordinary skills of the crafts people with the painstaking series of inspection processes, means that have the quality of high craft and the perfection levels demanded by the mass market.
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