How a Handcrafted Butter Dish is made at Emerson Creek Pottery

We've had lots of requests for a covered butter dish. This article will show the process of making and producing a new form - the butter dish.

The first step is to get some butter for size. We're going to use the small frilly tray as a base and then make a cover to fit it.

The first step is to make a model. A shape like this is easier to make out of plaster than clay. We start with a sheet of plaster the correct thickness. We measure the tray and butter and then cut the plaster to form the sides, ends and top.

These are then joined together, smoothed and shaped with sandpaper to get the final form. Small imperfections in the plaster are filled in (the red color in photo).

After a final wet sanding with very fine sandpaper we give the size a final check. The completed model is then thoroughly dried.

The next step in the process is to cast the model in plaster. This will produce an inside and outside half of the model. Here we see the model being released from the two cast’s. This gives us a "master" which, after it has been cleaned up and detailed, then has to be reversed. We do this by casting each half of the master again with a special industrial plaster. This cast, called the case is then separated from the master. After the case has been prepared we are ready to make the working die.

Here is the case on the casting bench ready to be made into a working die.

We use a special plaster to make the die; it has to be mixed very carefully.

Here is the completed die after the plaster has set. Notice what looks like steam rising, this is really water vapor being forced out of the die by compressed air. After the die has cured compressed air will be used to release the finished piece from the die.

Next the die is placed on the press. This is a special hydraulic press which develops 75 tons pressure to form the piece.

A properly sized piece of prepared clay is placed on the press, the two parts come together to squeeze the clay, then when the press opens we have a butter dish! Compressed air released into the die at the right time keeps the clay from sticking to the die.

After the butter dish is dried, we then use a sharp knife to scrape off any scrap that formed where the two edges meet in the press. Next the seam is further smoothed with a wet sponge. It takes a lot of careful handwork to complete the process.

Next comes glazing. We prepare our own glazes, which are specially formulated to be compatible with our clay. Here the glaze is tested before being used.

The shape of a pottery form dictates how it will be glazed. The butter dish cover we are making here will be individually dipped in glaze. After drying it will go to decorating.

Each piece will be individually hand painted using our special Sumi brushes. We never use stencils or patterns. This way each piece is an individual work of art.

Loading the decorated piece into the kiln. Then, fired and glossy, the piece is unloaded from the kiln.

Last, we have final quality control, and clean the bottom. Next step to warehouse. As you can see, Emerson Creek Pottery is lovingly crafted by hand, every step of the way. View our line of Ceramic Butter Dishes >>