How Cotto is Made
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Cotto (derived from the Italian terra cotta or ‘baked earth’) is part of a long linage of fired clays that date back to the dawn of civilization itself. From Egyptian water jugs to Chinese roof tiles to Roman bricks – terra cotta has been part of the human story for as long as we’ve had an alphabet. The materials that go into making our Cotto haven’t changed much over the millennia, but the way in which they’re fired has evolved; from kiln furniture to mold designs to firing method, our handmade and high-fired Cotto is our modern take on an ancient world tradition.
Read article07 / 13 / 2021
Cotto – a Terra Cotta love story.
We make Cotto in Mexico, a country with an incredibly rich history in ceramic arts. The techniques to manufacture our modern terra cotta have their roots in the arrival of the Spanish and the establishment of San Miguel de Allende in 1551. A UNESCO World Heritage site, San Miguel is arguably one the most important colonial cities in all of the Americas, and it is covered in historic terra cotta. From ancient roof tiles to 400 year old floors, this is a city that takes fired clay to a whole new level – and is the fitting home of our Cotto line.
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How It's Made
Made from locally sourced organic clays, our hand crafted Cotto elevates the storied tradition of terra cotta. Each clay formulation is mixed with water and blended to the ideal consistency. The hydrated clay mixture is pressed to shape in a mold and allowed to dry for 1-2 weeks until the right moisture level is achieved for firing. It’s also at this point that wood ash is added to the surface of our ‘Fired Earth’ tiles to give them their distinctive surface coloration. An important note here – this process is highly dependent on the weather; San Miguel has a distinct rainy season that can delay drying times by quite a bit! Once dried, tiles are brushed and stacked, ready for the kiln.
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Unlike most Cotto or tradtional terra cotta, we high-fire our clay at 1260° Centigrade (2300° Fahrenheit). What this means is that the terra cotta becomes ‘semi-vitrified’, increasing in density and decreasing in porosity. Special kiln furniture is needed at such high temperatures to ensure the tiles don’t warp or bend. It is also the most difficult step in their manufacture, requiring a skilled technician throughout the day and a half firing period. The result is an incredibly durable, highly unique tile that is unlike any other terra cotta on Earth.
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