-
Photos 1:
Muddy clay is delivered to the Kamado factory in Hekinan after being dug
from the native “TANBO”(rice paddies) post-harvest and while
still damp. (The first step required is to get an
even mix of the soil)
 |
 |
|
Photo 1 |
Photo 2 |
-
Photo 2:
Soil blocks are cut from the raw material in proper size & weight.
-
Photo 3:
The blocks are then carefully shaped inside the mold.
 |
 |
|
Photo 3 |
Photo 4 |
-
Photo 4:
After drying the shaped clay in the protected indoors for about 2 days,
the new creations must be removed from the molds at a critical time.
-
Photo 5:
Each separate part is assembled as sown for perfect fit. The contact
surfaces for lid and base must be smooth. Any adjustments of
irregularities must be done before the clay is
completely dry.
 |
 |
|
Photo 5 |
Photo 6 |
-
Photo 6:
The pre-dry of the clay products occurs inside the factory but the final
24 hours must be in the sun away from rain and again at a critical time.
Experience is needed to determine when the fledgling Kamado can
be taken to the kiln.
-
Photo 7:
The new items are then “Kiln-Dried” at 850 degree using coal as fuel.
The photo shows the kiln-dried 20 sets of #5
Kamado at the time of removal. Note that there is
no “door” to the kiln. Instead the opening was sealed with
bricks & mortar and had to be sledged out in order to remove the
final results.
 |
|
Photo 7 |
-
Photo 8:
This shows the finishing process of surface smoothing.
 |
 |
|
Photo 8 |
Photo 9 |
-
Photo 9:
Spray-painting, done on a foot-operated turn-table completes the
earthenware Portion of the final production.
