Maiolica Production Process
The history of the term "maiolica" is almost just as fascinating as the development and spread of the maiolica style itself, which is to say that both are fascinating aspects of this art form.
Manufacturing of the shape and first firing.
To make "biscotto" terracotta, the clay artefact is dried and fired at 980 °C (biscuit). Majolica is made by throwing or moulding clay into the desired shape and drying it before firing it in a kiln at 980 °C. "Bisque firing" hardens the clay and removes moisture, making it more stable for glazing and decoration.
Today, Clay can be shaped using three main methods: turning, pressing in a mold, and casting.
1. Lathe Shaping (Turning):
Clay is shaped on a lathe, traditionally powered by a foot pedal, now electric. The potter centers a ball of clay, gradually shaping it into a desired form by hand while the wheel spins. After drying, the object is refined, burrs are removed, and additional elements like handles or decorations are attached with slip. The piece is air-dried (not in sunlight) until it is ready for firing.
2. Pressing in a Mold:
This manual process involves pressing clay into plaster molds with the negative shape of the object. Starting from the center, the clay is shaped outward using the fingers. Once removed from the mold, the piece is air-dried and treated like a turned object before firing.
3. Casting:
For intricate shapes like figurines or candlesticks, liquid clay is poured into a closed plaster mold. The mold absorbs the water, creating a clay thickness that forms the object. After drying and refinement, the piece is fired at around 980°C, resulting in a durable ceramic known as "biscuit."
Each method highlights the skill and craftsmanship behind Castelli ceramics, transforming raw clay into art.
Immersion sprinkling on majolica (a background white glaze)
Immersion or sprinkling implement majolica glaze. The glaze is applied as a liquid and dries into a glossy surface. The object is delicate during glazing since the glaze is still wet and easily damaged.
The “biscuit” or terracotta is carefully dipped into tanks filled with liquid Maiolica glaze. Once dried, this glassy coating allows the artist to begin the intricate process of manual decoration. Castelli ceramics are characterized as “Maiolica” due to this distinctive glaze, which provides both a protective layer and a smooth surface for painting.
While the glaze is typically white, each decoration often requires a specific hue, achieved by blending mineral pigments into the glaze. A notable example is the Renaissance Maiolica known as *Turchine*, celebrated for its vibrant blue created with cobalt oxides. The enameling process demands exceptional skill and precision to ensure the glaze evenly coats the biscuit, creating the ideal surface for the artist’s brush to glide seamlessly during decoration.
"Spolvero" designs and manufactures.
After firing, the glaze can be decorated with traditional patterns. First, create a "spolvero," or design guide. The "spolvero" is made by drawing the decorative pattern on transparent paper and piercing holes along the lines with a thin needle. After carefully positioning the "spolvero" on the glazed object, charcoal powder is passed over the paper to transfer the design to the glaze.
The artist can use this guide to paint the final decoration. The charcoal powder's carbon residue disappears during kiln firing, leaving the finished design. Many majolica artists use this traditional technique to create "spolvero" for precise decoration.
Brush decoration
The art of decoration is the heart of Castellana ceramics, where skilled hands and fine-tipped brushes bring each piece to life. Using powdered pigments—metallic oxides dissolved in water—decorators meticulously apply vibrant colors to the glazed surface. Under the guidance of a master artisan, they recreate timeless designs and motifs, weaving together history and craftsmanship.
Each stroke of the brush transforms the majolica into a masterpiece, showcasing the Castellana tradition’s signature style. Warm, bold hues and intricate patterns give the ceramics a refined and elegant finish. The process demands not only artistic skill but also deep knowledge of how colors will transform during firing. Certain pigments change when exposed to high kiln temperatures, requiring precision and foresight to achieve the desired results.
The design begins with a "spolvero," a guide used to trace fine contours onto the surface. Layers of color are then carefully applied, with the artist balancing pigment thickness to prevent cracking or peeling during firing. Finally, the piece is signed by the workshop to guarantee its authenticity and, upon request, personalized with the client’s name—a mark of both quality and distinction.
Crystalline Majolica.
This transparent, glassy substance is sprayed or brushed on. The final firing melts and fuses the crystalline glaze to the object, creating a bright, lustrous finish that is typical of many ceramics, including majolica.
Crystalline glazes can give objects a unique and striking appearance, making them popular in decorative and artistic pieces. Crystalline glazes are fired at high temperatures like the Gran Fuoco technique, but the exact temperature and time depend on the glaze and desired effect.
The second "gran fuoco" firing.
The second firing, conducted at approximately 900°–920°C, is a pivotal moment in the creation of majolica. During this process, the colors and glaze fuse seamlessly, transforming the collective efforts of many skilled hands into a singular work of art.
An interesting detail lies in the intricate technique of *Lumeggiatura*, used in the renowned *Turchine* production. This method requires an additional "third firing" or "small firing" at a lower temperature of 720°C to affix delicate gold, silver, or platinum embellishments onto the already-fired majolica.
For the artisans, the daily unveiling of the kiln is the most rewarding and exhilarating step. It is in this moment that the majolica reveals its final, exquisite brilliance—ready to bring timeless beauty and artistry into your home.
The firing process takes 12 hours to reach the desired temperature and 12 hours to cool the kiln to a safe opening temperature. To avoid cracking or damage, the firing temperature must rise and fall slowly. High-fire majolica plates and bowls are more durable and utilitarian.