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Establishing a trade
In 1977 Ernie Childs founded
Gt. Yarmouth Potteries. Originally
being housed in a small shed at the bottom of a yard in Hawkins Avenue, it
was later moved to larger premises in Middlemarket Road in Gt. Yarmouth
town centre. At this time all moulds were bought in and only slip
casting (such as cherub figures and fairy lamps) and spun pots were made.
Two years later the Potteries needing expansion, moved to the 700 yr.old
SE Tower on Blackfriars road. (The NE Tower, on the quayside near the Post
Office sorting depot was also rented during the summer season a couple of
years later in 1982). It was at this time that the present day
Limited Edition tankard shape was first designed. Originally the
shape came after an order was placed for 25 grey mugs for use on the
Stirling Imp oil boat, approx. 1979. A tankard had to be designed
which would be stable enough to use on a boat, therefore a flat bottomed
tankard was made, today's Limited Edition Tankard.
Closely following
this came the Poem tankard (much like the one still made today) consisting
of a rope ring on one side and a rope ring with anchor carving on the
other. Pictures to go in the centre of this rope circle were all
bought in at the time, as the facilities to make lithographs were not
present.
About a year later, the first ever carved-in tankard was
produced. This is larger than the present one, being about 9ins.
tall, and of similar width from top to bottom.
The Making of a Limited
Edition Tankard
Process1
After initially researching his
intended subject, Ernie makes a drawing of what he wants the tankard to
look like, incorporating all the necessary detail.
Process 2
 From
the original drawing, Ernie makes an exact carving, including all the fine
detail that will feature in the final product. From this process, which
can take anywhere between 20 – 100 hours of meticulous work, the master
mould is made.
This is then used to produce up to 30 working moulds.
Process 3
Clay slip is poured into the moulds and left to stand for around an hour,
by which time the clay will begin to stick to the sides of the mould as it
draws water out of the clay. . The excess slip is then poured out leaving
a hollow tankard.
One tankard may consist of up to 8 individual pieces and these pieces are
now fitted together using clay slip and when dry the piece is “fettled” to
remove the seams and any slight imperfections.
Process 4
All the separate pieces are then stuck together using clay slip,
and, (once dry) are then fettled to remove seams and any imperfections.
Process 5
The piece is then
fired into what is termed “biscuit” and glaze is sprayed on with an air
gun to ensure an even coat, smaller features are individually sprayed to
ensure no detail is lost and the tankard is fired again to around 1100
degrees C. This melts the glaze and changes it to a shiny brown colour.
(Note:- smaller features on the tankard, such as the man's jacket, are
sprayed on to the tankard with a much finer spray gun) The tankard is then
fired again to approximately 1100C, whereupon the glaze melts and changes
to a shiny brown colour.
 Process 6
The lithographs or
prints are then screen printed and covered in a cover coat (yellow colour
on the picture opposite) which enables
them to be removed from the paper sheet and placed in position on the
tankard. When fired the cover coat will burn away leaving only the detail
required.
Process 7
The fine detail and small items such as hair detail and eyes (see picture
opposite) are then
painted on along with any 22ct gold to be used and the pieces individual
numbered.
Process 8
The tankard is then
fired for a third time melting the transfers into the glaze. At long last
the tankard is complete and ready for sale.
Tankards
Limited numbers of which are still available
All Limited Edition Tankards come with numbered certificates of
authenticity
Click
on thumbnails below to see a larger picture
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