Production Process Features
For the production process in single-firing at very high temperature, Laboratorio Pesaro produces internally both the stoneware mixture that the enamels on the basis of its own and exclusive recipes.
All raw materials are selected and secure following an environmentally friendly production process.
The ceramic mixture
Control of raw materials
All raw materials are rigorously tested before use.
The conditions of use of these raw materials are particularly strict, high temperatures (1250 ° C) and long cooking cycles.
Preparation of ceramic body
Stoneware used by Laboratorio Pesaro is a mixture consisting of clays, feldspar and silica that are properly proportioned in the mills and mixers.
The glazes used by Laboratorio Pesaro are made with selected components and mixed thoroughly in jars until the final compound of high-quality ceramic.
It is on a constant research and development of the enamels for single firing.
Glazes are made with very special colour tones and chromatic combinations which, simultaneously, give the surface an excellent resistance to chemical, scratch and abrasion attack: uncommon performance for ceramic use objects.
This allows the realization of ceramic projects with forms, finishes, colours and shades of enamels absolutely “distinctive and unique”.
Products of complex shape with trends of non-homogeneous and uneven thicknesses require special measures in the realization of the models and moulds.
The main steps
All the raw materials and the production cycles are constantly monitored to ensure the objects the highest level in quality and craftsmanship.
The manufacturing operations are performed by hand by skilled craftsmen ensuring human intervention on any object: each piece becomes a “unique piece”.
The objects are produced with the technology of “casting” at low pressure and in the press moulding. In the “casting” the aqueous solution with the clay in suspension, “slip”, is cast in plaster moulds.
The plaster absorbs the water and the ceramic material in suspension is deposited over time on the walls of the mould until reaching the required thickness.
In the “press moulding” the ceramic mixture in a plastic state, is pressed between the two parts of the mould.
The objects require a drying cycle particularly accurate and specific handling equipment.
It is possible to create and customize countless finishes required by the different specifications of use: finishing of the surface edges, shapes of the profiles, low relief surface finishing.
The application of the enamels is performed manually, and always allows control of an homogeneous glaze distribution on all the parts of the piece, even the most critical.
All pieces are fired directly after drying at a maximum temperature of 1240°-1250° C, the technique of single-firing, with the simultaneous sintering of the mixture and the vitrification of the enamel.
To fire without breaking objects of irregular shapes, with strongly unbalanced thick walls and with sudden variations of the same, it is essential to use only specially designed kilns so to ensure a correct temperature distributions inside the firing chamber.
Even the kiln loading systems are designed so as to ensure a correct support of the pieces without altering the correct and homogeneous temperature distributions within the firing castle.
The thermal equilibrium, during heating and cooling, and the value of the air pressure inside the kiln require a constant and simultaneous control through a special computerized programming unit.