How Denby Pottery is Made

Denby's raw materials stoneware clay which is still sourced locally and processed In house to ensure its quality and integrity.
Denby's own Glaze Technicians, in partnership with the design team, strive to create the unique Denby glazes, searching for new finishes, depth of colour and texture. All denby glazes are made to original recipes. It is this attention to detail that sets Denby apart from the competition The real challenge is to control the process in greater volumes.
Each piece of pottery is painstakingly glazed by skilled craftsmen, trained in the necessary control and precision. Regulating the firing process is then critical. Even minor fluctuations, such as a degree or two change in temperature, can alter the chemical reaction of a glaze, dramatically changing its colour and texture. Denby has built its reputation on producing consistently high quality products which they strive to continue to do into the 21st century.
The Manufacturing Process

The clay is left outside to weather naturally. Cleaned thoroughly, it is then filtered and pressed to remove impurities and expel air. These stages are vital to ensure the clay maintains strength and stability when fired.
Different pieces of tableware are created using different processes. A teacup is formed by "jollying". handles are made separately and applied by hand to each cup, using only "slip" (liquid clay) to hold it in place.

Complex Shapes like jugs are made by "casting". Slip is poured into plaster of Paris moulds which slowly absorb the water, leaving a layer of clay inside the mould.

Large Large cookware items are formed using a large "Ram Press" which literally squeezes the clay between plastic dies. Air is then forced through to release each piece.

The firing process involves several controlled stages. The first stage known as "biscuit" firing, is at 950°C. "Biscuit" is very fragile as it is still porous, allowing the glaze to adhere to the surface.

Applying glazes looks simple, but it can take years to perfect. Many pieces are individually dipped by hand into a bath of glaze, where exact positioning and timing is paramount. The second or "glost" firing at 1175°C is the most significant stage. It is during this firing that the transformation from pale powdery glaze to vibrant colour is complete. this process also makes it full "vitreous" with a surface which is harder than steel, incredibly durable and totally water resistant.

Decorative elements, such as bands of colour, are either sprayed or brushed by hand onto the plates, a skill that has remained unchanged for Denby's 200 year history. All patterned pieces have meticulously applied transfers, made up od tiny layers of glaze pigment. Once fired they fuse to the surface leaving a colourful design

Every piece is finally inspected, to ensure that there are no cracks or crazing, scratches or chips. This is done by the last pair of hands which have been involved in the production of each piece of Denby pottery making each unique.