Only the best selected pot-clays available are used, and every endeavour
is made to keep them clean and free from foreign contamination. Only the
best portions of the seam are taken for this purpose, and a considerable
amount of diligence and stringent precaution is taken to procure the
best qualities. As the clay is raised from the mine, clay pickers look
over the lumps and select out the best portions. A foreman of long
experience is stationed at the head of the mine, and it is his duty to
supervise the clay pickers and see that every care is exercised to guard
against any unfortunate results which would naturally attend any
indiscriminate or indifferent selection. The best portions having been
selected and placed aside, the lumps are scraped on the surface to
remove any dirt, and broken into pieces about the size of an egg, which
are again carefully examined on all sides and cleaned from foreign
matter such as pyrites or bluish parts. If this is carefully done, and
the clays analysed and tested from time to time, a good pot-clay is
obtained.
The clay for burning is treated similarly and dried. It is then burnt to
a very high temperature and taken to the mill to be ground to the
necessary fineness of grain. All pot-clays are well seasoned and
weathered before use. They are first ground to a very fine flour and
then mixed with a ground-burnt clay, or “chamotte.” The proportion of
raw clay to burnt varies with most manufacturers but depends very much
upon the plasticity or binding property of the raw pot-clay used. The
burnt clay is preferable if ground to a size about 1 to 1-1/2 mm., being
sieved to take out any coarser particles. Some clays are more plastic
than others, so the proportions in the pot-clay mixtures may vary from
six parts of burnt clay to five of raw, down to one part of burnt clay
to three of raw clay. The proportions are reckoned by volume, not by
weight. The mixture is sieved into a trough and mixed with water to form
a stiff paste, and removed into a large tank, where it is allowed to
soak for some time. It is then well-tempered by treading with the bare
feet until the whole mass becomes plastic and tough. The clay mass is
turned and trodden several times, in order thoroughly to consolidate the
clay particles. Many efforts have been made to do this work
mechanically, but without success. The fact remains, and experience has
proved that, in the process of treading, the clay is more consolidated
than by any mechanical method of preparation. The tempered and toughened
clay is then allowed to sour and mature for a few weeks before use. It
is then ready for the pot maker to begin the work of building the pots.
The room in which the pots are to be made is kept evenly warm using a
series of hot water circulating pipes arranged around the outer walls.
Usually a temperature of between 60 to 70° Fahr. is maintained.
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