I went to Shoukotoudo in Ureshino this morning to check out some of the new clay bodies they’ve been working on. Matsuo San, the owner, showed me some fired samples from a new body made to mimic the properties of the old Yamase clay. It looked so good I bought 135kg for testing. Really looking forward to playing with it.
Here’s a picture of one of the machines in the factory, one ton batches!
And here is a freshly pugged batch, he was just feeding in the filter press cakes when I pulled up.
Today I thought I’d show how my clay gets processed. It’s pretty primitive.
First, I shovel out some from my stock. This is high iron clay from my kiln site, that I collected when I dug out my kiln hole. It makes a nice body for applying white slip, but until now I’ve never processed it, just dumped it in my Peter Pugger with some water and flipped the switch.
Doing it this way made a great rough clay with stone eruptions etc, but I also got a lot of burn out holes from organic material, and worst of all, lime pops from some sort of material in the matrix that swells when it sucks up water after being fired.
So, I take the raw clay and dump it in a big tub with water and mix it up really good, then wait and let the big chunks settle, and skim off the fine clay into the upper bucket.
After a few hours, or less, I drain the clear water back down, mix it up, and repeat, until all the clay is out and only sand and rocks remain. Then I mix up the contents of the upper bucket and pour into a drying basket, or plaster vessel, or similar.
After a few days, I have a nice clay cake to bag or wedge and use. I’ll also sometimes take the leftover sand, sift out the crap, and mix it back in.