Glaze and Color Consistency: Managing Inventory Without Losing Reproducibility
You make a beautiful midnight blue glaze. Customers love it. Six months later, you mix a new batch and it's navy, not midnight blue. You've lost color consistency and customer trust. This guide teaches you to batch glazes reproducibly and manage inventory efficiently.
The Documentation System
Consistent glazes require exact documentation. For every glaze batch you make:
1. Recipe (Exact Weights, Not Percentages)
Example: Midnight Blue = Cobalt Oxide 15g + Iron Oxide 8g + Feldspar 100g + Silica 50g (Total: 173g)
Don't use percentages like "12% cobalt". When you scale, rounding errors accumulate.
2. Source and Batch Number for Each Material
Cobalt from Supplier X, Lot #2024-03. Different suppliers have slightly different colors.
3. Firing Log
Date mixed, date fired, kiln temperature, hold time, cooling speed. Environmental conditions affect final color.
4. Sample Tile Photos
Photograph each glaze on a standard tile under consistent lighting. Archive with date and batch number.
This system takes 15 minutes per glaze batch but prevents customer dissatisfaction and remakes.
Managing Glaze Inventory
Too much inventory ties up cash. Too little means stock-outs. Use this framework:
Core Palette (Always Stocked)
3-5 bestselling colors. Keep 5-10 liters on hand. Replenish every firing.
Seasonal Palette (Limited Runs)
2-3 new colors per season. Make in small batches (2-3 liters). Test before committing to customers.
Archive Old Recipes
Document popular colors that you've retired. Keep sample tiles. You can revive them if customer demand returns.
Cost of consistency: Stocking glaze inventory costs ~$300-$500 upfront, but prevents customer refunds (worth 10x that).
Key Takeaways
✓ Document every glaze batch with exact weights, source, and firing conditions
✓ Photograph sample tiles under consistent lighting and archive by date
✓ Maintain core palette (3-5 colors) always in stock
✓ Test seasonal glazes before offering to customers
✓ Archive retired recipe documentation so you can revive popular colors
Document. Batch. Deliver Consistency.
TrueCraft tracks glaze batches and firing logs.
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