Step One: "IL TORNIANTE" (The Potter):
In a process used for centuries, the art of Majolica
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" (Green ware) 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 750-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 it's 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):
The painstaking process of painting the Bisque is the
essence of Majolica. 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.
Step Five: "LA SECONDA COTTURA" (The Second Firing):
In this final step, the painted item is loaded again
onto the kiln for a second firing at 750-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.
The finished product emerges from this final firing, its
brilliant colors safely protected by a robust and uniform glaze. It is a
Majolica piece! - a prestigious name earned with this centuries-old process!
