A small clay mining and processing company located in Medicine Hat, Alberta, Canada. Plainsman makes dry and pugged clay bodies for potters, hobbyists and schools in the west. It is the only company in North America (among about 45) that mines its own clay to make most of these products. Plainsman also produces powdered clays that are used by other pottery clay manufacturers and special purpose clays that are used across North America in range of industries (e.g. manufacturing, smelting, health products, construction, refractories).
Plainsman’s existence is due to the convergence factors. It was started in a city having a ceramic manufacturing legacy since 1900, natural gas resources and a dry climate conducive to ceramic manufacture. At the time brick, tile, sanitaryware, stoneware, tableware, porcelain insulators and glass products were all being produced. This made available factory space and the mining and machinery expertise that was needed. And it had the stories of the capable people who started each of the companies. The city also had a tradition of the “craft of ceramics”. Thus, when Luke Lindoe, a combination artist, sculptor, potter, teacher, geologist, lab technician and dreamer came to the city in the 1960s magic happened when he discovered the quality of the sedimentary clay despots in the area. He was joined by John Porter, a British trained technician and potter with a flare for business. They set up shop and quickly developed a dealer network across Canada and the Pacific Northwest of the US.
Over the years Plainsman has maintained focus on supplying clay for pottery (resisting pressure to develop other markets that would distract from that). The vast majority of its products are sold wholesale through a dealer and store network. It has developed a solid product line and has large warehousing so that dealers can order at anytime and expect quick delivery. Plainsman also buys a wide range of materials, supplies, equipment and tools from around the world, both for resale and incorporation into its products. A potter can walk in the front door and buy almost anything he/she needs to begin product immediately. Recent years have seen much growth in pottery as a hobby and cottage industry, Plainsman now has as many as 10,000 customers using its products.
Plainsman Clays has also taken a leading role in providing online resources to assist its customers (and potters and manufacturers around the world) to have all the practical and technical guidance needed to make any type of product or to solve any problem.
The Plainsman Clays factory is right beside a baseball park. A beautiful place in the summer where children play and teams compete. But in the afternoon and evenings the deer move in. And mow the grass! The deer stay around all winter, in this residential area they are away from the coyotes and occasional mountain lion in the nearby river valleys.
This was built just after the turn of the 20th century and was one of about 25 at the Alberta Clay Products company. It was used to fire salt-glazed ceramic pipe, these were used for municipal sewer and water lines. A ceramic industry quickly grew in the city because it had good clay, natural gas, plenty of water, a dry climate, industrious people, a large river and it was on the Trans Canada highway and railway.
M2 is a dark red burning, middle temperature, moderate plasticity, low contaminant stoneware clay. It makes a great base for brown firing low and medium temperature clay bodies, less than 50% is needed for good body color. Plainsman Clays has been surface-mining it in Montana and importing it to Alberta since 1980.
Situated in the majestic Eastend river valley. The river has cut this valley over millions of years from the flat tableland 100 meters above, revealing all the layers of clay. These sediments were formed by the Western Interior Seaway. Today's river divides into two just west of here, leaving and strip of hills along the valley bottom. The hill being mined has minimal overburden to remove to uncover the layers of the “Whitemug Formation”. The reserves here are vast, the company has been mining just this one hill for 40 years, removing about 100,000 tons. Yet these layers stretch across the province and into Alberta. They are hidden from view except where valleys like this expose them.
Plainsman extracts 6 different sedimentary clays from this quarry (Mel knows where the layers separate). The dried test bars on the right show them (top to bottom). The range of properties exhibited is astounding. The top-most layer is the most plastic and has the most iron concretion particles (used in our most speckled reduction bodies). The bottom one is the least plastic and most silty (the base for Ravenscrag Slip). The middle two are complete buff stonewares made by mother nature (e.g. M340 and H550). A2, the second one down, is a ball clay (similar to commercial products like OM#4, Bell). A2 is refractory and the base for Plainsman Fireclay. The second from the bottom fires the whitest and is the most refractory (it is the base for H441G).
This is a "badlands" slope in the Frenchman river valley. The valley exposes the "Whitemud Formation" in many places (clearly visible here half way down on the left). Two surface mines of Plainsman Clays are nearby (over the top and down the other side), in a place where lower lying rolling hills leave much less over-burden to remove. To the left of this is a former mine of I-XL brick. This is also the site of a mine for the former Medalta Potteries. These materials were laid down as marine sediments during the Cretaceous period. Below the Whitemuds are formations from the Jurassic period. The skeleton of the world's largest T-Rex, dubbed "Scotty", was found nearby.
This is the top layer. Battle clay is highly bentonitic, it is the "super hero of plasticity" in the quarry, it is unbelievably sticky. We have considered it "over-burden" in the past, but now will be looking for ways to employ Battle clay in our products and seeking special-purpose markets for it. Only 10% of this can turn a silt into a plastic throwing body! It is also high in fluxes (melts by cone 6). That means we can use it to improve the fired maturity of bodies, reducing the need for talc. Removal of this layer has exposed the top of the White-Mud Formation, the "A1" layer. A1 is employed in high fire bodies to impart brown color and fired speckle.
The machine has been reassembled after cleaning and is ready for startup. This pugmill is powerful and capable of injecting alot of energy into the material. Premixed powder and water are fed into the main mixing chamber by a screw conveyor at the far end. Dozens of blades on the rotating shaft inside cut and mix the material so that by the time it has reached half way in the main chamber all traces of powder are gone. At the end of the main chamber an auger delivers the materials to a venturi terminated by a shredder. This slices the material with dozens of tiny blades as it enters the vacuum chamber (yellow cover). This exposes as much surface as possible to the vacuum. Additional blades on the main shaft further mix the material and finally an auger compresses it and delivers it to the nose where a column is extruded for cutting to length and packaging.
The machine is being cleaned in preparation for a porcelain run. The machine has been stripped down completely and all the casings and augers and other parts have been washed and dried separately. These must be installed (in the main chamber, the vacuum chamber and in the nose). Clean-downs like this are an indicator of the quality delivered by the production crew.
These are two pallets (of three) that went on a semi-trailer load to a Plainsman Clays store in Edmonton this week. They are packed with hundreds of bags of powders used to mix glazes. More and more orders for raw ceramic materials are coming in all the time. Maybe you are using lots of bottled glazes but for your cover and liner glazes it is better to mix your own. And cheaper! And there are lots of recipes and premixed powders here to do it. One of the big advantages is that when you dip ware into a properly mixed slurry it goes on perfectly even, does not run and dries on the bisque in seconds. No bottled glaze can do that.
All of the equipment has been washed in preparation for a porcelain run. Original container bags are broken in the dust-hood unit on the right and augered and elevated into the rotating blender/mixer. It feeds a vibrating screen (not visible) that removes paper and other contaminants. For wet clay bodies the screen feeds hoppers on the other side of the wall, they in turn feed the pugmill. For dry bodies and glazes the powder goes to one of the hoppers and that feeds a bagging unit. This type of equipment can handle 1200 lb batches (doing one every five minutes for some products, longer for others).