A diverse and thorough knowledge of raw materials is the potter's only recourse in the present environment of fewer material options.

Albany slip open pit mine.
Once widely used as a glaze material, Albany slip clay is no longer commercially
available, and any stockpiles held by potters will eventually be exhausted.
This event is predictable when you consider the history of raw materials in the
pottery industry. At some point while working in ceramics, one or more of the
essential raw materials used in your clay bodies or glazes will become
unobtainable.
To add to the confusion, several materials are
still listed in glaze and clay body formulas even though they are not being
mined. Once they are depleted from potters' storage bins, these materials will
not be available from ceramic suppliers or commercial distributors. With this
in mind, it is always a good practice to research the availability of any raw
material before using it in a glaze formula. When a raw material is no longer
available, potters have to develop a suitable substitution that will offer the
same effect in glazes and clay body formulas.
In most
instances, a material's departure from the market is based on economic justifications
and not the actual depletion of the ore, feldspar or clay. For instance,
geologic deposits of Albany
slip clay still exist, though it is no longer being mined.
History of Albany Slip Clay
Albany slip clay is an
alluvial deposit formed by the transportation of material through glacial
action in the Albany Hudson River region of New York state.
1 It
is less refractory and darker than residual clays like kaolins, which are
formed on site and are highly refractory and white. Albany slip clay has an intricate mineralogy
with high levels of alkalis and irons. It is a hydrous alumino-silicate clay,
dark brown and non-plastic, and has a silty texture.
2 It
is often described as a loose sedimentary material with rock particles of
generally 1/20 mm or less in diameter. Potters used this clay for over 250
years.
The northern Hudson Valley of New York State was an
active pottery-making region; by the 1840s, almost 60 potters produced and sold
ware in and around the city of Albany.
The newspaper and sales records of Albany slip clay, commonly called
"Albany mud," date back to the Revolutionary War period.
3
The newspapers of the 1800s advertised Albany slip clay as a substitute glaze
for the toxic lead glazes that were commonly used on functional pottery of the
period.
The most distinctive feature of the ware is characterized
by an "orange peel" texture on exposed non-glazed fired clay
surfaces. The onset of prohibition in the U.S. led to the demise of stoneware
crocks and salt-glazed jugs, and coincided with the popularity of mass-produced
glass containers. Today a trip to any antiques store will reveal many crocks,
jugs and other functional pottery containers that were glazed with Albany slip in the salt firing process, as well as other Albany slip glazed pots.
Numerous glaze variations were formulated using Albany slip clay (a slip
clay is a naturally occurring clay that forms a glaze) as the minor or major
ingredient. It has also been used as a decorative slip (engobe) applied over a
raw glaze on functional ware. At higher temperature ranges above cone 9 (2300°F),
Albany slip clay is almost a glaze by itself and is characterized by a glossy
flowing surface ranging in color from light yellow/green to dark brown/black in
reduction kiln atmospheres.
Due to its high iron content, Albany slip was used in
"Temmoku" iron crystal glazes, producing a wide range of glaze
effects such as "hare's fur" (light streaks in the glaze) and
"tea dust" (small crystals formed in the glaze upon cooling).
4
Albany's long history of easily available supply and extensive distribution
resulted in its use as a glaze material by many generations of potters.
However, due to its lack of plasticity, it was not used extensively in clay
body formulas for wheel throwing or hand building.
Albany
slip clay had a history of use in commercial pottery production and industry.
Rowe Pottery Works, maker of museum- quality reproductions, and Pfaltzgraff
Pottery used the clay extensively. Rival Pottery, manufacturer of the Crock-Pot
®,
used Albany
slip as a glaze on its ware as well. Albany
slip has been also employed on such diverse applications as electrical
insulators, vitreous coatings for structural clay products, and stoneware
pottery. This versatile clay was used as a smooth, non-absorbent glazed coating
for sewer pipe, and has been employed as a bonding agent on abrasive wheels for
over 90 years.
In 1962, Industrial Mineral Products acquired the Albany slip mine, formerly owned by Rex Clay Co., which
was located at Prospect Ave.
and Livingston Ave.
in Albany, N.Y. Hammill & Gillespie, Inc., an
importer and distributor of ceramic raw materials, was appointed exclusive
agent for distribution of the clay. Hammill & Gillespie continued to supply
ceramic supply companies, individual potters and commercial/industrial users
with the clay.
The open strip mine a few blocks from the capitol in Albany encountered
mounting economic problems, including higher insurance rates, increasing
processing costs, fuel costs for trucking, and stricter U.S. Environmental
Protection Agency (EPA) regulations. After the extraction of clay, the pit had
to be completely covered until the next harvesting. Once the raw clay was
removed from the site, it went to the processing plant for grinding, screening,
bagging and palletizing. It was then ready for shipping to Hammill &
Gillespie's warehouse.
The raw clay had a moisture content ranging between 18
and 23%, which meant that for every 1000 lbs of raw clay extracted from the
mine and shipped to the processing plant, 180-230 lbs. was lost, though it
still incurred transportation and milling costs. Translating these percentages
into actual costs offers a more precise explanation of the financial
requirements to bring Albany
slip clay to market. A $50,000-$75,000 capital outlay was required to cover
mining, transportation, processing, bagging and storage costs to produce an
18-month stockpile.
During this period, the predominant percentage of clay
sales was to potters purchasing a few pounds or one or two 50-lb bags, which
meant a slow payback on a low-profit material for a large capital investment.
The same financial process was required every time a stockpile was exhausted.
Such a financial structure for any raw material supplier was vulnerable to a
price increase at any point in the processing or distribution process.
The last stockpile of Hammill & Gillespie's Albany slip clay was
depleted in 1987. Keep in mind that, as with other discontinued raw materials, Albany slip clay remains
in some potters' existing inventories but at present is not to be found in any
ceramic suppliers' inventories.
Material Properties
Albany
slip clay changed over the years since it was first mined. The three sample
analyses shown in Table 1 are "run of the mine," which means the
properties can shift from batch to batch. A definitive analysis of any one shipment
is often not possible.
The clay was shipped in 50-lb brown bags with black side
lettering, and some bags were not marked with production lot numbers. The
subsequent variations in chemical analyses of the slip and the variation in
potters' kiln firing atmospheres, clay bodies and glaze application methods can
account for the variations in the fired glaze. Remember, just because the name
on the bag stays the same, what's inside may not be.

Albany slip glazed jug,
1900s Albany
slip top, clear glaze bottom (2300°F, approximate height 11 in.).
Finding Substitutions
Due to its unique natural mineral content, which has
changed at various intervals during its availability, Albany slip clay has proven somewhat
difficult to reproduce either through other slip clays or by building a
substitute from duplicating its oxide content. As with other naturally
occurring ores like Gerstley borate and Barnard slip clay, there are no
definitive chemical analyses of the materials to use as a baseline when
considering a substitution. Additionally, trace materials found in the deposit
can contribute to unique firing qualities that often do not lend themselves to
duplication. In the past, Michigan slip clay
was an acceptable substitute for Albany,
but it was discontinued in the 1970s.
When a raw material is no longer available and potters
exhaust their own supply, there is always a rush to find adequate substitutes.
Unfortunately, many raw materials are unique in chemical composition, trace
elements, particle size distribution, handling characteristics and organic
content, and do not lend themselves to a one-to-one substitution suitable for
every temperature range and kiln atmosphere. In the past, ceramic supply
companies rushed to sell substitutes, which sometimes did not yield the desired
results. Potters have often stockpiled reserves of the original raw material,
which can tie up money and studio storage space.
Several Albany slip
substitutes work quite well in various glaze formulas; however, none of the
substitutes will work in every glaze formula exactly like the original Albany slip clay.
Therefore, as is the case when using any substitute material, it is advisable
to test it in a small batch of glaze and see the results in your own production
kiln, not a small test kiln. Price should never be a consideration when
choosing a substitute, since the cost of any raw material is insignificant when
compared to the time and labor used to create and fire the ceramic ware. In any
situation, if a substitute material works, pay the price.
Orphan Ores
When large industries abandon the use of a raw material,
the limited pottery market does not have the buying power to sustain its
production. Orphan ores are ceramic raw materials that are left without viable
market support. Small raw material buying markets, such as potters and ceramics
suppliers, do not order sufficient volume to sustain raw material production.
Moreover, there is a delicate balance between the cost of
mining, processing and shipping the material compared to the price potters are
willing to pay for the material. If any cost of production increases while
bringing a raw material to market, it becomes unfeasible to substantially
increase the price to the eventual user.
One or more of the following characteristics describe
materials that have a high probability of becoming unavailable to potters:
- There was once a viable economic basis for
their production.
- They currently do not have large and diverse
industrial or commercial markets.
- They have increasing processing costs vs. low
selling prices.
- They are used in products that have low
intrinsic resale value (i.e., pottery).
- After being dropped from the larger markets,
they are still used by limited individualistic markets that purchase small
quantities intermittently.
Gold and Raw Materials
What does gold have in common with the raw materials used
by potters? Nothing, except as a model of opposite values and their
relationship to the marketplace. Gold is relatively scarce and has a very high
value and wide market appeal. The current price of gold is $500/oz or $8000/lb.
Compare that figure to the last quoted price of Albany slip clay by Hammill & Gillespie,
which was $.35/lb. There is an obvious difference between a rare, high-value
ore and a common ore of low value with limited market appeal.
What does this mean in terms of supply and demand? The
rarity of gold and its intrinsic value means a great many individuals and
industries are willing to pay a premium price. Furthermore, there is a high
markup on gold jewelry that far exceeds the actual price of the gold itself.
The costs of locating, mining, processing and distributing gold are worth the
effort based on the perceived value, high retail selling price, and large and
diverse market demand.
Albany
slip, on the other hand, has a low value with limited market demand. In
addition, the endpoint users of the clay-whether individual potters, commercial
potteries or industry-are using it in products with small profit margins. The
profit margins for mining, processing and distribution of clays and other
ceramic raw materials are much lower than that of gold, and are subject to any
number of increasing processing and transportation costs as well. The rising
cost of transporting the clay often exceeds the actual cost of the material,
forcing ceramic suppliers to use clays and raw materials from their immediate
geographical area whenever possible.
The lands containing deposits of Albany slip clay are still undeveloped and
covered by overgrowth. The site near Prospect
Ave. and Livingston
Ave. in Albany has
been used as a landfill and contains the remains of the Empire
Plaza site in Albany. The other mine site, across from North Lake Ave.
near the Tivoli Lakes
Wildlife Park
(also in Albany),
is overgrown with weeds. The vacant mine sites illustrate that the land is not
presently being used for more profitable commercial enterprises, and that the
demise of Albany slip clay was brought about by the increasing production costs
associated with bringing the clay to market.

Contemporary salt glazed Albany slip glazed jug (2300°F, reduction
fired to cone 9, height 13 in.).
Ceramic Raw Material Economics
A closer examination of why Albany slip clay is no longer available
reveals the economic factors that control the entire spectrum of raw materials
available to the pottery market. Many of our favorite raw materials are on a
precarious balance of profitability to the companies that mine and supply them.
Specifically, Albany
slip was on an economic knife-edge of profitability during its production life.
As we have examined, small changes in mining, processing and shipping resulted
in its demise.
Overall, potters represent less than 1/10% of the entire
raw material market in the U.S.,
which translates into little or no buying power in comparison to the larger
commercial and industrial users that dictate the supply and quality control
parameters of any given material. Individual potters or ceramic suppliers do
not purchase in the quantities that guarantee any material will remain
consistent in chemical makeup, particle size distribution or future supply. The
inequitable buying position potters find themselves in is not brought on by
their need for a specific raw material, but by the simple fact that they can't
buy enough of that material to guarantee future supplies.
A stable market means that the cost of producing a raw
material is often below what potters will pay for it, leaving comfortable
profit margins for the miner, processor, wholesale distributor and retail
seller. If a raw material has a long chain of intermediate suppliers each
making a small profit, any increase in production costs can upset the system
and make it uneconomical for supply to potters. Potters purchasing raw
materials are largely unaware of mining and processing costs, as well as small
distributor profit margins, but they are very aware of the price they will pay
for a raw material.
Potters are caught between the unique qualities of making
handmade functional objects and their inability to achieve economies of scale
through mass production or economies of technology through less costly
machine-made ware. In practice, potters have discovered the market for handmade
ceramic objects is very small, and the sub-group within that population that
will pay $50 for a coffee mug is even smaller. If potters could consistently
sell coffee mugs for $50 each, they could then afford to pay a higher price for
their raw materials, thus keeping orphan ores in production, or at least giving
a greater economic incentive for suppliers to find a substitute.
What can potters do to counter market forces beyond their
control? Several strategies can be effective in avoiding a situation where your
favorite raw material is no longer available. The first and most useful tool is
to learn how raw materials function within clay body and glaze formulas.
Potters often know they need a certain feldspar in a glaze formula but do not
understand its function or know which other feldspars can be substituted. While
there are many substitute materials that will produce the same glaze or clay
body color, surface texture, or handling characteristics as the original
material, many clay body and glaze formulas can be duplicated by the use of
totally different formulas.
Awareness of the current raw material market is
essential. While every one of the hundreds of materials do not have to be
monitored, it is advisable to keep in touch with your ceramics supplier about
the raw materials used in your glaze and clay body formulas. Do not assume that
the material is still being produced just because the bin in your studio is
full.
Another option, which ties up capital and studio
space, is the stockpiling of raw materials in the eventual case one or more
might be discontinued. However, this strategy often reflects a static view of
ceramics and a potter's inability to manipulate raw materials to achieve
functional and aesthetic goals. The economic forces behind Albany slip's demise are still in place, and
they will remove more of our favorite raw materials in the future.
The Future of Domestic Raw Materials
Ceramic raw material markets in the U.S. have changed more in the last
five years than in the preceding 25. Greater numbers of ceramic products are
now being produced in China,
Spain, Vietnam, Mexico and other foreign countries
that rely on cheaper labor and their own domestic sources of clays and raw
materials. Mines and raw material processors in the U.S. are beginning to limit their
production due to the domestic lack of demand.
Does this mean all domestic ball clays will be
discontinued? No, but a mine might produce 12 vs. 20 different ball clays. At
some point, a reduced inventory of clays and other raw materials will again
cause potters to look for substitutes for their clay and glaze formulas. A
diverse and thorough knowledge of raw materials is the potter's only recourse
in the present environment of fewer material options.
Author's Acknowledgements
I would like to thank Dorna Isaacs for her help
in supplying technical information and the history of Albany slip clay. I have relied in part on
the articles and notes of Richard P. Isaacs, past president of Hammill &
Gillespie. Richard L. Lehman, Ph.D., technical director of Hammill &
Gillespie, Inc., supplied information on Albany
slip clay. Barbara and Dennis Reeley of River Street Pottery (621 River St., Troy,
NY 12180)
contributed photographs of the Albany slip clay
site in 2005 as well as information on the location of Albany slip clay. Photos of the Albany slip mine are from
the Hammill & Gillespie archives. Photographs of pottery are from the
author's collection.SIDEBAR: Finding Albany Slip Clay and Substitutes
A 10-ton stockpile of original raw Albany slip clay is available and can be
purchased in small or large quantities from The Great American Wheel Works,
N.Y. The clay comes with an instruction sheet on how to screen the small
pebbles that constitute approximately 1% of the total clay content. Call (518)
756-2368 or e-mail
tflitto@msn.com for additional details. Albany slip clay substitutes include:
- Alberta Slip Clay, a Canadian blended
substitute distributed by Laguna Clay Co., 14400 Lomitas Ave., City of
Industry, CA 91746 or (626) 330-0631; and Axner Pottery Supply: 490 Kane Ct.,
P.O. Box 621484, Oviedo, FL 32765 or (407) 365-2600.
- Arroyo Slip Clay, a naturally occurring slip
glaze mineral distributed by Laguna Clay Co.
- Albany Slip Substitute, Alberta Slip,
Ravenscrag Slip (Alberta Slip II), distributed by Bailey Ceramic Supply, P.O.
Box 1577, 62 Ten Broeck Ave., Kingston, NY 12402 or (845) 339-3721.
- Albany Slip Substitute, a blend of Sheffield
clay, which is a high-iron-content earthenware clay, and frits, Sheffield Pottery, U.S. Route 7, P.O. Box
399, Sheffield, MA 01257 or (413) 229-7700.
- Seattle Slip, a naturally occurring slip clay
distributed by Seattle Pottery Supply, 35 South Hanford, Seattle, WA 98134 or
(206) 587-0570.