Porcelains

The recipe for porcelain paste is 50% kaolin, 25% quartz and 25% feldspar. These substances are diluted in water, then ground, mixed, sifted and filtered

From Slip, Semi-hard paste then add powder, the pastes are complete. The first step in the manufacture of a porcelain piece is the creation of a model. From an image of the finished object to its final scale, the modeler must create the object in plaster in “raw size” scale that is 14% larger than the actual size of the finished piece. This is to anticipate shrinkage during firing.

Casting is a process used for hollow pieces (e.g. coffee pots, vases and soup tureens), and Calibrating is a process used in the manufacture of round and raised pieces (e.g. cups and salad bowls). After the pieces are taken out, the drying process begins. The time will vary between 12 to 24 hours depending on the size of the objects. During the drying process, the pieces shrink by 3%.

Pieces undergo a first firing at 980°C during 24 hours in kilns, which are currently gas-fired. After the first firing, the pieces are brittle and porous. Each piece is hand-dipped into a glaze slop to obtain a smooth, shiny appearance. Pieces then undergo a second, “grand feu” firing at 2,552°F for 24 hours in gas-fired kilns. During this operation, the piece undergoes significant shrinkage (10 to 12% compared to the model) and reaches its final size..

They are dipped in water to detach the motif from its paper support and placed on the piece. These decals are made using different printing processes (originally lithography, currently serigraphy). Bernardaud is one of the very few factories to have its own printing plant. Lines and fittings (e.g. handles and spouts) are all hand-painted. These are the most common decorative techniques. Special techniques, such as incrustation or gold relief, are sometimes used for bespoke work.

A decal printed with a protective varnish, rather than color, is applied to a piece. This varnish, which is an acid-resistant material, is applied by brush to the rest of the piece, except for the motif, which will be engraved. Next, it is dipped into a bath of hydrofluoric acid that “attacks” the glaze, engraving the cavities called for by the design. Before shipment to a final destination, every piece is given a careful final check to make sure that the Bernardaud products sold around the world are of the highest quality.