mong
the ten major artisan groups in India, potters comprise the fourth
largest and second
poorest group, with an estimated ten lakhs people
directly or indirectly involved in this vocation. Despite the existence
of a stable and consistent demand for a narrow range of pottery ware,
these traditional potters are in a deep crisis due to the severe
competition from industrial products like plastics and aluminium goods.
They are
unable to meet this challenge since there has been a drastic depletion
of raw materials as suitable clay becomes more and more scarce, while
there is no innovation or upgradation of their skills and technologies.
The shrinking market for traditional wares threatened the livelihoods of
the artisans whose skills were very limited.
Bundelkhand
(14 districts, 1200 villages) and Datia (Badoni village) are the two
regions adopted for the pottery kiln technology dissemination.
Presently, all the villagers use the conventional firing method for
firing their pots. The fuel they are using is mainly dung cakes and
small branches of dried wood. Pipra and Datia have relatively large
kilns, with a typical pottery kiln being a pit,6-7 feet deep and about
25 feet in diameter. In the Niwari cluster, the kilns are very shallow
and the wares are in small lots. Wares are even fired in a 5-6 feet
patch in front of the potter’s house.
In
traditional firing, the consumption of fuel is very high. In traditional
kilns, the fuel and the green wares are stacked in layers and then
ignited.
The fuel
used for firing the wares is cow dung cake, paddy straw and small twigs.
In deeper kilns in Datia sector, firing takes about one to two days and
in the Niwari cluster, where the number of wares fired in a batch is
small, firing takes a single day. Each firing in the large kiln requires
5000 dung cakes and two bags of paddy straw (100 dung cakes cost Rs.50
and paddy straw costs Rs.30).
The kilns
to fire pottery wares were one of the challenging products we adopted
under the SHELL Project. Potters use these kilns to bake pots of
different size and shape. Improved pottery kilns were taken up for
dissemination under the project. For several reasons, the new kiln would
offer considerable advantages over the conventional kiln. An Improved
kiln would add to the profits of the artisans by saving in terms of the
fuel cost and reduction in the percentage of breakages. It is less
accident-prone, because of the closed firing method and it uses less
manpower while in operation.
Pottery
kilns would have a universal appeal, as firing of pots is not confined
to any specific season or cluster.
It is
important to understand the traditional method of firing of wares,
because the use of an improved kiln would require that the potter
deviates significantly from this conventional practice. Improved pottery
kilns offer
reduction in the cost of fuel as well as a considerable
reduction in the percentage of breakages , which results in an improved
profitability in the pottery firing operation.
Improved
pottery kilns installed in the Karnataka have shown a 30% reduction in
fuel consumption over the traditional kiln, but this percentage may
differ in the Bundelkhand region. Improved kiln would also reduce the
firing time from the current days having a positive impact on the
productivity of the operation.
The
atmosphere in the vicinity of the kiln is much cleaner due to its
environment friendly system of operation.
The
improved kiln designs are currently available in two sizes, which are -
80 cubic feet and 180 cubic feet.
Results of Pottery Firing at Datia |
|
Material Required for the Construction of
180-cft Kiln |
Particulars |
Improved Kiln |
Traditional Kiln |
|
Sl. No. |
Raw Material |
Capacity |
No. of pots |
150 nos. |
150. nos. |
|
1. |
Red Bricks |
4,400
nos. |
Dung cakes |
1300 nos. |
1800 |
|
2. |
Soil |
180 cft. |
Baked |
134 nos. |
98 nos. |
|
3. |
Sand |
80 cft. |
Unbaked |
7 nos. |
38 nos. |
|
4. |
Cement (53
grade or 43 grade or portland cement) |
5 bags |
Over baked |
none |
none |
|
5. |
M S Rod 10
mm Dia |
75 ft. |
Broken |
9 nos. |
14 nos. |
|
6. |
G I Wire |
2 kg. |
The kiln
consists of two chambers separated by a brick vault construction with
gaps to withstand high temperature and to bear the load of the wares.
Fuel is burnt in the lower chamber and the wares are stacked in the
upper chamber.
Advantages of Improved Pottery Kiln |
Ø |
safety |
Ø |
convenience / ease |
Ø |
cleanliness |
Ø |
less polluting (apparent) |
Ø |
less laborious (arrangement, firing) |
Ø |
storage for baked pots when kiln is not in use |
Ø |
can fire during intermittent rains |
|
The
volumetric ratio between the lower combustion chamber, and the upper
chamber where wares are loaded, is 1:1.3 to maximize the capacity of the
kiln and also facilitate a good draft. Metal clamps are fitted to the
external wall of the kiln to enable it to withstand the thermal
expansion.