Kevala Ceramics is renowned for its luxurious, kevala plates that graces the tables of high-end restaurants and luxury establishments around the world. However, the creation of these exquisite pieces is a meticulous and carefully crafted journey, beginning with raw clay and ending with beautifully finished tableware. This article takes you through the production process at Kevala Ceramics, highlighting the artisanal techniques and attention to detail that go into every piece.

Step 1: Sourcing High-Quality Materials
The journey of Kevala Ceramics’ tableware begins with the careful selection of raw materials. Kevala uses only the finest clay, sourced from trusted suppliers who share their commitment to quality and sustainability. The choice of clay is critical, as it determines the texture, strength, and color of the final product. Kevala’s clay is chosen for its exceptional plasticity and ability to withstand high firing temperatures, ensuring that the finished ceramics are both durable and visually appealing.

In addition to clay, Kevala also sources natural minerals and pigments for their custom glazes. These materials are selected for their purity and consistency, allowing for the creation of unique glaze finishes that enhance the beauty and individuality of each piece.

Step 2: Design and Prototyping
Once the materials are sourced, the design process begins. Kevala’s design team works closely with clients to create custom tableware that reflects their brand’s aesthetic and functional needs. This collaborative process often starts with sketches and digital renderings, allowing the client to visualize the final product before it is made.

Prototyping is a crucial step in the design process, where initial versions of the tableware are created to test form, function, and finish. These prototypes are carefully reviewed and refined, with adjustments made to ensure that the final product meets the client’s specifications. The prototyping stage allows Kevala to experiment with different shapes, sizes, and glaze finishes, ensuring that the end result is both beautiful and practical.

Step 3: Forming the Pieces
With the design finalized, the production process moves to the studio, where skilled artisans begin the task of forming the pieces. Kevala Ceramics employs a range of traditional techniques, including wheel-throwing, hand-building, and slip-casting, depending on the design and requirements of the piece.

Wheel-throwing is one of the most iconic techniques used in ceramics, where the artisan shapes the clay on a spinning wheel, using their hands and simple tools to create the desired form. This technique is ideal for creating round and symmetrical pieces, such as plates, bowls, and cups.

Hand-building, on the other hand, involves shaping the clay by hand without the use of a wheel. This technique allows for more creative freedom, enabling the artisan to create unique, asymmetrical forms and intricate details. Hand-building is often used for custom designs that require a more sculptural approach.

Slip-casting is a technique used for creating complex shapes or reproducing designs with consistent accuracy. In this process, liquid clay (or slip) is poured into a mold, where it hardens into the desired shape. Once the clay has set, the mold is removed, and the piece is left to dry.

Step 4: Drying and Bisque Firing
After the pieces are formed, they are left to dry slowly and evenly to prevent cracking or warping. This drying process can take several days, depending on the size and thickness of the pieces. Once dry, the ceramics are ready for their first firing, known as bisque firing.

During bisque firing, the pieces are placed in a kiln and fired at a lower temperature than the final glaze firing. This process transforms the clay into a hard, porous material that is more durable and ready to absorb glaze. The bisque firing also removes any remaining moisture from the clay, reducing the risk of defects during the final firing.

Step 5: Glazing
Glazing is one of the most crucial steps in the production process, as it determines the final color, texture, and finish of the tableware. Kevala’s artisans apply glazes by hand, using a variety of techniques such as dipping, pouring, or brushing to achieve the desired effect. The glazes are carefully formulated in-house, allowing for complete control over the final appearance of the pieces.

Once the glaze is applied, the ceramics are left to dry before being placed in the kiln for the final firing. This firing is done at a higher temperature, which melts the glaze and fuses it to the surface of the clay, creating a smooth, glass-like finish that is both durable and beautiful.