Excavations in the Near East, showing that primitive fired-clay vessels were made more than 7,000 years ago.

Potters were working in Iran by about 550 B.C.

Earthenware was speculated to have been produced even earlier in the Iranian high plateau.

In the Far East, the ancient Chinese potters have developed characteristic techniques as far back as 500 B.C.

From these Chinese potters, the ceramic industry took its roots in our country. By the opening up of trade between the Chinese and Spanish governments during the Spanish period, the Chinese eventually formed settlements in the Ilocos coast in Luzon where they put up their first ceramics production sites.

Eventually, they moved and spread to the south where there were more clay deposits. It was in the province of Pampanga that new techniques and product lines were developed - like the use and design of the tunnel kiln for firing --- finally giving the potters a strong base for their products.

The first clay products that were made were the clay jars, or tadyaos, which were used as sanitary receptacles for drinking water. Up until now, some households, especially those with no refrigerators, still use the tadyao to keep the water cool for drinking.

At present there are now 20 major ceramics manufacturers in Lilo-an. These include those who export, and those who supply for the local market.

Two methods for extracting clay:

1. Random method of extracting clay - excavating it where it can be traditionally found. However, this method is prone to flooding where the excavating of the clay is seriously hindered during the rainy season. The raw clay is then cleaned manually, removing small twigs and pebbles, after which it is softened by water when kneaded.

2. Systematic approach to excavating - Raw clay is excavated in layered steps from a pre-measured parcel of land. Manufacturers first consume all the clay in that area before transferring to another site. By doing this, flooding and run-offs are minimized during the rainy season. This form of excavation is able to maximize the material and ensures steady production of ceramic material. Cleaning of the raw clay differs from the first method because electrical grinders and kneaders are used to reduce the non-clay materials into minute particles, instead of manually removing them.

These manufacturers use three kinds of kiln technology for the production of ceramics products.

Wedging - a very important process in which air bubbles are forced out to align coarse particles to develop homogeneous consistency.

Wheel (throwing) - a process whereby a potter’s hands takes a ball of clay, throw it on the wheel (if he is using potter’s wheel) and produce forms that evolve and change shapes in minutes. This skill needs four months of constant practice and study of the proper sequence of operation to create even the smaller pieces of pottery.

Measuring each part of the pot - this process involves the measuring the different dimensions of the pot - such as the width of the mouth opening, the length from head to neck, neck to shoulder, shoulder to waist, waist to thigh and thigh to feet - with the use thin coconut ribs or tukog differing in length.

Press molding - a process used to make decorative molds on the jars. This consists of pressing stabs of clay in the carved out inside of the concave plaster mold. After they’re made smooth, the designs appear beautifully in the exterior.

Casting - in this process, clay is liquefied into what is called “slip” which is then poured into a plaster mold. Plaster draws the moisture from the “slip” and causes the clay surface in contact with the plaster to harden or set. After the excess slip is drained and the piece has further dried, the mold is then removed. The surface is scraped or sanded to remove join marks of mold sections. As final touches, a glazing process is applied either before putting the piece on fire or after it has dried enough.

The Business Situation

Government Support

The government, through the Department of Trade and Industry and the Department of Science and Technology have extended loans to cooperatives in Asturias and Sibonga for a number of brick-making machines. However, said cooperatives were unable to produce sufficient volume to justify continued production for the local market.

Market

Ceramic products are used as:

• decorative items

• cookwares

• cooking utensils and containers

• garden pots - horticulturists are one of the big buyers of ceramics. Flower lovers and garden enthusiasts buy flower pots by the bulk and its demand is constantly growing. Even school children buy these flower pots for their home economics and practical arts classes

• construction materials such as roof tiles and walls because of its sturdiness and insulation

• interior decorations for hotels and restaurants

• accessories or decorations of Individual households

Our ceramic industry has not only conquered the local market, but it has reached out to foreign consumers as well. Based on information provided by local exporters, demand for ceramic decorative items in foreign countries tends to follow that of furniture exports from Cebu like rattan, wrought iron and inlaid stone. Countries like Australia, Belgium, Germany, Japan, Kuwait, New Zealand, Singapore, Sweden, and the United States are some of the countries importing our ceramic products. Of these, Japan and the U.S. constitute about 90% of the total ceramics export with a value of $1,184, 953 for 1995.

• lack of diversified products

• lack of adequate skills due to no formal schooling

• no ready market

• lack of sheltering facilities to meet unfavorable weather conditions

• lack of finances

• potters do not have an association to protect and assist their interests

• stiff competition form products such as aluminum pots and pans, electric stoves, and modern utensils

• small time potters do not earn much