Narrator: Sculpting, glazing, and firing
are just a few of the labor-intensive steps
required to make ceramics.
Handmade ceramic dinnerware isn't cheap,
but porcelain dinnerware can be even more expensive.
The price of porcelain varies,
but some dishware, like this plate,
can cost over $400.
So how are ceramics made,
and why is porcelain so expensive?
There's a good chance that you sit on porcelain every day.
It's the most common material used to make toilets.
The reason why
is also why it's a popular choice for dishware.
Compared to other ceramics,
porcelain is more durable and nonporous,
so it lasts a long time and it's easy to clean.
It has a distinct white color,
and unlike opaque stoneware, some porcelain is translucent.
The secret to these differences is in the clay.
Clay used for porcelain
contains a high percentage of kaolin.
This is what makes porcelain white.
Kaolin is found all over the world,
but large high-quality deposits are rare.
Narrator: Porcelain is often referred to as china,
which is where it was first created.
But today, it's made all over the world.
This is the Arita Porcelain Lab in Japan.
Artisans young and old have made porcelain here
for over 200 years.
There are countless recipes for porcelain clay,
but in addition to kaolin,
they usually contain materials like quartz,
feldspar, and ball clay.
Each one changes the properties of the clay.
Ball clay makes it more malleable,
and feldspar helps it become glass-like when fired.
The whitest translucent clays
need to be free from impurities
and generally cost more than other ceramic clays.
But even for experienced potters,
porcelain can be tricky to work with.
In order to produce a large number of pieces,
this workshop has an artisan
for each specific step in the process.
Even though 10 people work on each piece,
producing new dishware can take over a month.
Narrator: Compared to other ceramics,
many porcelain clays are challenging to mold by hand.
It's also more prone to cracks when drying.
To help with this, and to produce more uniform pieces,
this workshop uses molds for complex shapes.
Katsumi Yamashita has been working with porcelain
for 60 years.
Narrator: One of those difficult steps is glazing.
Glazing seals the clay,
but it also adds color and patterns,
and it's one of the reasons
that ceramics can be so expensive.
At this workshop, each design is delicately painted by hand.
Narrator: Another challenge in making porcelain
is temperature.
In order to achieve that glass-like surface,
porcelain is fired at a higher temperature
than most other ceramics,
usually around 1,300 degrees Celsius.
At this workshop, pieces are fired three times,
a lengthy but crucial process.
The first firing is done without glaze,
at 950 degrees for two days.
Slow firing ensures that pieces don't break in the kiln.
Once they've been fired,
artisans apply what's called underglaze.
The main firing, at 1,300 degrees, takes three days.
Loading this kiln is a daunting task,
but it has to be done carefully.
Otherwise, pieces could be destroyed inside.
Thankfully, this firing was a success.
Now the final design starts to take shape.
Narrator: The price of porcelain varies
based on the size and complexity of the design.
A simple rice bowl costs around $7,
but the most expensive platter from this workshop
costs a few thousand dollars.
This blue and white design
is a traditional look for porcelain,
but in order to maintain interest in this ancient craft,
the Arita Porcelain Lab has tried
to create more contemporary designs
that fit into a modern home.