STEP 1 Choice of raw clays
The shaping clay dedicated to Pottery JAMET ceramics requires 6 raw clays (4 for the Ollas-ORIGIN) exclusively from French quarries and free from any pollution.
Each of the raw clays have specific properties of porosity, mechanical and thermal resistance, ease and resistance for shaping (essential for large pieces).
They are first extracted from quarries and then left at rest to the elements for a long time.
This allows the fermentation of organic matter which naturally improves the elasticity and the homogeneous mixing of the different clays.
STEP 2 Grinding
Each raw clay is dry-crushed separately in a mill and then sent to a sieve and de-ironing to reduce it to a fine dust state. They are then always dry-mixed in precise proportions for each collection.
Depending on the collections and sizes of the pieces to be manufactured, the JAMET Pottery will carefully adjust the size of the grain of the "fine clays" and the proportions for each batch.
This essential operation ables to obtain ceramics with a natural and homogeneous grain of "fine clays" without any little rocks or « chamotte ».
The various "homemade" Pottery JAMET clays have an internal structure that is much more solid and homogeneous than "classic" clays with or without the addition of a "chamotte".
This unique process gives the JAMET ceramics an exceptional resistance and durability, making them insensitive to frost and allowing you to choose various degrees of porosity according to the collections.
Even being thicker, the Ollas-Jamet® provides excellent porosity for a perfect irrigation thanks to the precise "grains" developed by the JAMET Pottery.
STEP 3 Mixing and Adjustments
Raw clay from the same quarry may have a different composition from one extraction stratum to another.
This is why we adjust each preparation with one or more of our crushed and sieved clays in order to obtain the perfect mixture and guaranteeing the technical characteristics of porosity/resistance.
Dry mix water absorption tests are then performed to control the level of porosity and elasticity of the future clay to be shaped before wetting and mixing.
If necessary, the dry mix is readjusted with one or more fine dusted clays until the correct mix is obtained.
STEP 4 Mixing
The dry mixture is humidified with water and then kneaded in a kneader.
Depending on the desired shaping clay and depending on the collections, the wet mixture can be adjusted if necessary one or several times with water and / or fine clay.
STEP 5 Resting the JAMET clay
Once the mixing is complete, the dough is left to "rot" (at rest) between 8 and 15 days (depending on the climatic conditions at the time and the schedule), so it can ferments again ensuring perfect homogeneity. This will help to avoid the subsequent risk of micro-cracks and makes a clay that is easier to turn and that has high resistance.
STEP 6 Extrusion
This is the final phase of preparing the clay for shaping.
The humidified and rested clay is kneaded one last time then placed in an extruder which extracts the air contained within in order to make compact clay loaves. It is calibrated according to the size of the model to be worked.
The shaping clay is now ready to be used for turning or stringing the Ollas-JAMET®.
STEP 7 Manufacturing at the TOUR
The tour manufacturing concerns all standard size Ollas (<50L).
The potter takes his breads calibrated on a lathe with the marks corresponding to the model to be produced.
The production of these collections by turning can only be manual "because only the human hand, by controlling the pressure exerted on the clay to be shaped, can guarantee the ideal balance between resistance and porosity" says Laurent Jamet.
The experience and mastery of turning of the Jamet family allows:
a fast production rate of small or medium volume parts
regular production of large volume parts
turning of parts> 15 kg
STEP 7 ROPE Manufacturing
Rope manufacturing only concerns the Ollas-BEE Jamet® (tailor-made> 100 L and 200 L for professional beekeepers for large colonies transhumed or not), Dolias-Jamet® or Terres d'Iza®.
This ancestral knowledge has been taken up and perfected by the Jamet Pottery since 2005.
The potter first makes a wooden template reproducing the internal shape of the piece to be made. A hemp rope is then wrapped around the template over its entire height.
The JAMET in-house clays are re-worked then applied to the rope in 3 stages.
Once the model is finished, its surface is smoothed or decorated and for some cases, can be engraved with the name of the domain (wine or beekeeping).
After the clay has hardened, the wooden template is disassembled and removed. The first turns of the rope are removed to finish the neck. The rest of the rope will be slowly removed 5cm to 20cm per day depending on the weather conditions. It will leave her mark inside the room.
The interior of the ceramics is smoothed or left rough with traces of rope according to the customer's requests.
All collections are gently dried out in one of our 3 ventilation rooms, most of the time at room temperature.
Ventilation, temperature and humidity are constantly monitored and readjusted according to weather conditions.
This allows the ceramics to dry gently, without rushing them while keeping intact the homogeneity of their internal structure.
This simple but essential operation takes time because it contributes to the mechanical resistance of ceramics and prevents them from any micro-cracks.
This guarantees the Ollas-JAMET® their capacity for radius of action and irrigation autonomy
The 45 years of experience of the JAMET Pottery have taught us to never force this crucial step for the high quality of the Ollas-JAMET®. It is decisive to avoid at the end of the cooking process cracked or non-cracked ceramics but with micro-leaks.
The natural drying of these varies between 3 and 10 days depending on their size and weight.
Rope-mounted JAMET® Ceramics, including rope removal, will last between 3 and 8 weeks depending on the weather, the size and complexity of the pieces.
Ceramics at Tour Ollas-JAMET® drying from 3 to 10 days
Rope Ceramics Ollas-BEE® drying from 2 to 4 weeks
JAMET® Ornamental Ceramics 3 to 5 weeks drying
JAMET Vinification Ceramics drying from 1 to 2 months
STEP 9 Cooking process
Once the Ollas are dry, they are placed in the oven methodically so that the heat circulates evenly around each room. We carry out a long cooking process with different levels and cooking times, as well as an overcooking phase.
The cooking takes place in 2 ovens, one of a small to medium capacity and the other of a very large volume.
Our cooking technique and programming have been designed solely for the purpose of optimizing and finalizing our entire manufacturing process. This ensure a superior quality that meets the expectations of demanding professionals and end users.
Ceramics made « Tour » style Ollas-JAMET® baking 10 to 12 hours with overcooking at 1,100 ° C
Ceramics made « Rope » style Ollas-JAMET® 14 hour firing with overcooking at 1.100 ° C
JAMET® Ornamental Ceramics 14/16 hour firing with overcooking> 1,200 ° C
JAMET Vinification Ceramics 14/18 hour cooking with overcooking at 1,200 ° C
Quality control specific to each collection is carried out on a few samples of each batch. This protocol based on more than 45 years of experience validates the quality of the entire batch.
The loss rate of ceramics that do not comply with the "JAMET professional quality" charter from the start of shaping to the end of the cooking process is less than 1% including prototypes, which in pottery craftsmanship is exceptional.