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1st Cycle
Moulding / Modelling / Casting
Creation of the shape using methods suitable for the item to be produced. Lathe shaping enables creation of any shape or size as long as it is round. Other shapes (hexagons, ovals, complex shapes, etc.) will require various traditional procedures such as modelling by hand with plaster casts etc. The most commonly used raw material is "red clay". Apparatus used: Lathes, mother moulds, plaster casts, spatulas and various small tools, spray and powder filter booths, etc.
Sambuco creates a number of special decorations that require etching on the model when the clay is still soft. This process is inspired by special designs and comprises etching or engraving the object with a steel tip, all performed by hand. An example of this type of manufacturing is "Byzantine" style decoration, inspired by Byzantine era floor and wall finishes Apparatus used: Steel tips for the totally handcrafted etching, pounce-bags.
After drying the model produced at room temperature (whether it has been etched or not), the object will then be placed in a chamber for its first firing at just under 1000°C. This will take just under a day, then the chamber can be opened to remove the fired piece, called "bisquit". Apparatus used: Flame and electric kilns.
2nd Cycle
The
"bisquit" item is then dipped in a glaze that may be one of several
colours (usually it is white, cream or slightly ivory). Apparatus
used: Bowls, pliers, strainers, ladles.
Usually the paint is applied over the glaze since it is only performed by hand over the base colour (glaze) applied in the previous stage. The colours used for decorating are produced with ground minerals, which are then diluted with water and applied to the object by hand using various types of paint brush, depending on the type of painting or detail required on the surface. One of the problems encountered when painting pottery is that the colours used for the decoration will change hue after the second firing, so the artist will need to foresee the end effect of the applications. Our company currently produces more than 130 lines of decorations; all manufacturing processes are performed only by hand and there is ample capability for creating new decorations, even personalised to customer request. Apparatus used: Paint brushes, pounce-bags, lathes.
This process is performed after the object has been decorated and consists of its being sprayed with a glass paste called "crystalline glaze". Apparatus used: Spray gun, powder filter booth, lathes, tables.
Second firing is at about 920°/950° C and is needed to bond the decoration to the object. During this firing the previously applied crystalline glaze will melt and become transparent. After this phase the item will acquire brilliance, impermeability and the colours will change their initial appearance, with their real beauty coming to the surface. A day must pass before the firing chamber can be opened to admire the craft object that has been produced. Apparatus used: Flame and electric kilns
3° Cycle
Since its establishment Sambuco has also specialised in creation of traditional and contemporary decorations that require the application of gold, ruby, platinum, metal lustres. For these lines (e.g: "Bizantino", "Rubino", etc.), where one or more of the precious materials mentioned above are applied, a second firing phase is required. In order to complete the design that has been decided, gold or other precious metals are applied in the spaces predefined on the object, always by hand and using a paint brush. Apparatus used: paint brushes and lathes.
Third and last firing is only required for objects where gold and/or other precious materials have been applied. When the kiln is opened the splendour and brilliance of the precious metals applied is obvious at first glance. Apparatus used: Flame and electric kilns.
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