The traditional process of creating Moroccan terra cotta tiles involves several steps:
1. Clay Collection: The first step is to gather the clay used to make the tiles. The clay is usually collected from local riverbeds or deposits with suitable clay content.
2. Clay Preparation: Once the clay is collected, it is soaked in water for several days to soften and break down any impurities. Afterward, the clay is mixed and kneaded with water to achieve a workable consistency for tile making.
3. Molding: The clay is then shaped into large blocks or balls, which are called "raw tiles" or "biscuits." These raw tiles form the basis for the final tile designs.
4. Drying: The raw tiles are left to dry in the sun for several days or weeks, depending on the weather conditions. This drying process helps to remove excess moisture from the clay and prepare it for firing.
5. Firing: The dried raw tiles are stacked in a kiln, a large oven-like structure, and fired at very high temperatures. The firing process helps to harden the clay and transform it into durable ceramic tiles. Traditional kilns, called "furns," are usually fueled by wood or olive pits.
6. Glazing: After the initial firing, the tiles may be glazed to enhance their appearance and provide a protective layer. Glazes are often made from natural materials like metal oxides, silica, and feldspar combined with water. The glaze is applied by hand, using brushes or sprayers, and the excess is wiped away.
7. Second Firing: Once glazed, the tiles go through a second firing in the kiln at a lower temperature, which fuses the glaze onto the surface of the tile and gives it a glossy or matte finish.
8. Cooling and Sorting: After the second firing, the tiles are left to cool down inside the kiln. Once cooled, the tiles are carefully examined, sorted, and categorized based on quality, size, shape, and color variations.
9. Finishing: Finally, the tiles undergo any additional finishing processes like trimming, sanding, or polishing to perfect their edges and surfaces before they are ready for packaging and shipping.
Throughout the traditional process, skilled artisans work meticulously to ensure the handmade quality and unique characteristics of Moroccan terra cotta tiles, often incorporating intricate patterns, geometric designs, and vibrant colors.
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