Each Royal Doulton character jug begins its journey in the creative mind and on the sketch pad of the sculptor who then proceeds to bring his character to life in the form of a clay model. Once the clay model meets the extremely high Royal Doulton standards, the master mould maker’s expertise are then called upon to create a master mould from plaster of Paris. This is a highly specialised process that has to capture every nuance and all the character of the original clay model. From the master mould a working case is made and it is from this that all future moulds are produced. In order to ensure accurate reproduction of the sculptors original creation, each mould is used only a small number of times.
A liquid mixture of clay and other finely ground ingredients prepared to ‘Royal Doulton’s own formulation is poured into the working mould, once the mixture is set to the correct thickness it is carefully removed from the mould.
Each character jug is then left to dry thoroughly in controlled temperatures before receiving its first firing – at temperatures up to 1150 degrees Celsius.
Skilled artists then take over and hand-paint each character jug with Royal Doulton’s own specially developed ceramic colours to give each character jug an individual quality, the jug is then fired once again.
The character jug is then dipped in a specially developed liquid glaze and fired for a third time to create a permanent transparent coating that protects the colours and gives the character jug the unmistakable Royal Doulton luster.
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