Bouisset Brickyard is an EPV (Entreprise du Patrimoine Vivant = Living Heritage Company), decerned by the French Industrial Ministere, this label recognizes the excellence of Frenck Know-how.
THE PREPARATION OF THE CLAY
The clay we use since 1878, is extracted form our own quarry, located at 300m from the factory.
We usually run one quarrying per year. Trucks are brought to extract the clay and store it under a shelter at the entrance of the quarry. We used this stored clay during the year.
The clay is then crushed and mixed with other substances, depending on the qualities expected : heat resistance, insulating capacities, plasticity, colour, the quality touch… A person is needed to check, every moment, the quality of the clay during the manufacturing process.
our knowledge of the clay is our great pride. Thanks to it we offer you frost resistant products.
About half of our production is made by spinning. More than hundred spinnerets are used to give at the clay th final shape of bricks. A cutter given then the dimension.
STAMPING AND PRESSING
Some of our products need hand made production, for exemple our range of roofing decoration. The stamping require plaster mould, the clay is applied against the wall of a mould. The plaster absorbs humidity, the product beginning to dry, shrinks. It can be demoulded and finalized.
The pressing needed plaster mould too, but special to be used in a mechanical press. It’s the same technique as stamping but the mechanical force allows to made large dimensions items.
For items like baluster, roof finials… we used the pouring technique. The clay is worked in a liquid state, cast in a plater mould. Plaster absorbs water from the clay, then becomes gradually firmed.
When the time comes, the mould is turn up side down in order to remove the excess of clay and to obtain the desired thickness for the wall.
When it begings to dry, the piece is pulls away from the mould, it’s time to do finishing.
This is the tricky part of the process. Each product will dry differently, a part quickly and freely and another part needs to be spoiled to get the next step without crack or flatness defect.
A large range of our items are finalized in natural terra cotta color : red, Flammé Ocre and Flammé Yellow… They are dyed in the masse, it’s the natural colors of mixed clays.
We can glazed all our items. “Pastel”, “Biot yellow”, “copper”…Each colour required about ten tests before being considered for addition to our colour chart.
We provide you with a standard colour chart, but we are pleased to customized colours, according to your specific requirement.
Depending of the type of products, we apply the enamel with different techniques: by brushing, by ladling, by dipping, or by spraying with air pressure gun.
For a part of our production, we have robots to made the charging for the firing, they help us to reduce the penibility of this part of work. For others items, the charging is made by hand.
We have 7 kilns with different sizes and specificities.
The firing with natural gas is about 48hours for each cycle. The highest temperature is approx 1100°C. Despite our significant experience and the high quality of our clay, sometimes when openning the kiln some of the productions are split or even broken… We have to start over again!
PACKAGING AND TRANSPORT
The packaging is made upon order and depends the final destination. Generally on wood pallets, and plastic wrap. We take great care of packaging of our terra cotta for a perfect transport to your home.
Items are ready to go in France, Europe and world.