Everyone knows the iconic "Grüngeflammte" crockery from Lake Traunsee, but only a few people know how the elaborate manufacturing process takes place at the manufactory in Gmunden. To give you an insight into this impressive craftsmanship, you can see the production process of a water jug here.
The special thing about Gmunden ceramics is that each individual piece passes through around 60 hands during production - from the initial moulding to the final finishing.
The entire production process, from the preparation of the raw mass to the finished, ready-for-sale work of art, takes place in Gmunden. Each phase of production is carried out with the utmost care and precision craftsmanship to ensure the unmistakable quality and unique charm of Gmundner Keramik.
1. PREPARATION OF THE BODY
The raw material for Gmundner Keramik is a natural product: purified earth. This is obtained in powder form from the Westerwald in Germany and consists of 3 basic materials: feldspar, quartz and kaolin.
In the body preparation department, the raw materials are processed into a liquid and a solid body according to in-house recipes.
2. MOULD MAKING AND THE FOUNDRY
Even the development of the moulds and the production of the plaster moulds take place in the manufactory.
In the foundry, the so-called "slip", i.e. the liquid clay, is poured into the plaster mould. The plaster removes the liquid from the mass and the clay shards form on the mould. The longer the clay remains in the plaster mould, the thicker the ceramic piece becomes. This water jug, for example, is left to stand for approx. 1 hour before the excess clay is tipped out.
Plates, cups and bowls are turned by cutting a clay rod into a slice and pressing it with pressure to create a round shape.
Angular pieces, such as the star-shaped bowl, are pressed in a mould.
3. RETOUCHING & GARNISHING HANDLES
This is where the characteristic strong and round shapes are created: Each individual piece is cleaned, deburred and sponged by hand and the mould is finished.
All handles are added by hand. Whether it's a jug, a breakfast cup or a soup bowl, this process is called garnishing the handle.
4. GLAZE - THE WHITE GOLD
In contrast to porcelain, the glaze is not transparent but has a special white glaze. This gives the ceramic that unique deep lustre and the typical radiant white.
Here in Gmunden, a distinction is made between two types of glaze application: Dip glazing and spray glazing.
With dip glazing, the crockery is dipped into a vat of glaze using tongs.
With spray glazing, on the other hand, the ceramic piece is turned on a rotating disc and the glaze is sprayed onto the ceramic using a fine spray gun.
5. THE IN-HOUSE LABORATORY
We attach great importance to tradition and quality, which is also reflected in our in-house production of colours and glazes. The unique colour nuances and glazes are developed and carefully matched in the laboratory. This makes it possible to produce the characteristic designs - such as the famous "green flamed" - in unique quality and colour intensity.
6. THE FLAMMEREI - TRADITIONAL CRAFTSMANSHIP
This is where the unmistakable design that is immediately associated with Gmundner is created.
The craft of flaming requires a great deal of diligence and practice. Only after 2 years can a painter flame every item in the range. Flaming is a technique that is unique in the world and is carried out here in Gmunden. Flaming is the application of colour using a spraying technique. Each item has a certain number of arcs, strokes or loops that must be adhered to.
Since 2021, ceramic flaming has even been a UNESCO intangible cultural heritage site!
You can find more facts about ceramic flaming here: www.dasflammen.at.
7. PAINTING - THE CENTREPIECE OF THE MANUFACTORY
Design classics, such as deer or scattered flowers or the Herzerl design are painted by hand on the ceramic with brushes.
The typical Gmundner green is the result of an elaborate and secret recipe. Another special feature: when the paint is applied to the ceramic, the Gmundner green initially appears grey. It is only after firing that the beautiful vibrant colour can be seen.
8. FIRE & FLAME: THE KILN HOUSE
The ceramics are fired twice in total. The first firing - the "raw firing" to be precise - takes place before the glaze. In the second firing, the "glost firing", the ceramic is fired with the decoration. Both firings have a duration of 16 hours.
Did you know? The temperature in the kilns is between 1020 and 1070 degrees.
9. QUALITY CONTROL
Great importance is attached to the quality of the ceramics. For this reason, quality tests are carried out between the individual production steps. After the first firing, a sound test is also carried out to determine whether each individual shard is flawless. After the second firing, each Gmundner piece is scanned and scrutinised to ensure that it is flawless. Only then can it go on sale.
10. GMUNDNER CERAMICS: PERFECTION IN A UNIQUE PIECE
It is the craftsmanship that makes our unique pieces so valuable. Our honest craftsmanship stands for the highest quality and perfection, the Austrian location and the uniqueness of our products. This special value of Gmundner Keramik should be experienced, appreciated and recognised by all of us. Our ceramic products: from mixing the clay to moulding and painting - everything is done by hand here in Gmunden!
Would you like to experience production up close? You are welcome to visit the factory!
