Nambu Tekki is a representative traditional craft of Japan, and its manufacture condenses skilled artisans’ handwork and techniques cultivated through a long history. Known worldwide for its beautiful design and high practicality, what kind of ingenuity and procedures are involved in the manufacturing process of Nambu Tekki?
This article will explain in detail the basic manufacturing process of Nambu Tekki. We’ll introduce a series of processes from the selection of iron as the raw material to mold making, casting, and finishing, and delve into the charm of Nambu Tekki created by the artisans’ skills and passion.
What is Nambu Tekki?
Nambu Tekki is a traditional iron product made in Iwate Prefecture, with a wide range of products from daily necessities to tea ceremony utensils, including teapots, iron kettles, and pots. Its history is long, and it is highly valued both in Japan and abroad as a craft that combines the beauty and functionality of iron.
Here, we’ll explain in detail the history and characteristics of Nambu Tekki.
History of Nambu Tekki
Nambu Tekki is a metalwork product mainly made in Iwate Prefecture. Iwate Prefecture was rich in iron resources, and also had abundant sand and clay necessary for casting, as well as charcoal, providing the foundation for the development of the casting industry.
Particularly, Nambu Tekki in Morioka originated when the lord of the Nambu domain invited a caster from Kyoto to produce tea ceremony kettles in the early Edo period. The casters of Morioka were nurtured by families such as the Arisaka, Suzuki, Fujita, and the Koizumi family of kettle makers. The iron kettle as a tea ceremony utensil was devised by the third Jinzaemon in 1709.
This is considered the beginning of Nambu iron kettles, and Nambu Tekki became widely known with the spread of the tea ceremony. During the Edo period, it was also valued as a gift during the sankin kotai (alternate attendance) system and began to circulate throughout the country. In 1975, it was designated as a national traditional craft.
Characteristics of Nambu Tekki
The main characteristics of Nambu Tekki lie in both its design and functionality. Many Nambu Tekki products have traditional patterns such as the “Arare pattern” on their surface, which not only provide visual beauty but also incorporate functionality such as non-slip and ease of holding.
In modern times, products are made in a variety of styles from simple designs to modern Japanese styles, but all have a finish that conveys the weightiness and elegance of iron. In terms of functionality, water boiled in a Nambu Tekki iron kettle is said to become smoother and make tea or plain hot water even more delicious.
This is because boiling water in an iron kettle removes calcium and magnesium, softening the water. Also, continued use of the iron kettle causes yuaka (calcium) to adhere to the inside, which also plays a role in preventing rust.
Furthermore, Nambu Tekki pots have high heat retention, allowing for quick cooking of ingredients and are suitable for use in cooking. Iron pots are ideal not only for grilled dishes but also for stewed dishes and cooking rice, and have the effect of locking in the umami of ingredients.
In this way, Nambu Tekki is a craft that can be used as a lifelong tool, allowing you to enjoy your own unique texture as you use it for a long time.
Manufacturing Process of Nambu Tekki
The manufacture of Nambu Tekki is completed through many processes by the skilled techniques of artisans. Here, we’ll explain in detail a series of processes from design to mold creation.
- Design and drawing
- Mold creation
- Iron casting and demolding
- Polishing and finishing
Design and Drawing
The production of Nambu Tekki begins with design. Artisans draw full-scale drawings to determine the shape, pattern, and size of iron kettles and teapots.
As the mold is created based on the created drawing, the appearance and functionality of the product are almost determined at the design stage. The specific flow is as follows:
- Drawing creation
- Wooden pattern making
Once the design is decided, the artisan draws a drawing to accurately express the details of the product. This drawing is a very important process as it determines the beauty and dignity of Nambu Tekki. Next, a wooden pattern is created based on the drawing.
In the past, wood was used as the material, but nowadays, iron wooden patterns with high durability are commonly used. The wooden pattern determines the shape and pattern of the product, requiring delicate and accurate work.
Mold Creation
Mold creation uses the “baked mold method” using sand and clay. This is an important process for creating the unique patterns and textures of Nambu Tekki.
- Mold making using the baked mold method
- Applying patterns
- Surface treatment work
- Baking the mold
A mold is made by mixing sand and clay using a wooden pattern. This method is called the “baked mold method,” and by drying and baking the mold, the shape of the product can be firmly maintained. The mold is created by rotating the wooden pattern by hand, forming the shape of the product.
Next is the work of pressing patterns that will emerge on iron kettles and teapots onto the surface of the mold. Patterns of Nambu Tekki include the “Arare pattern” and animal/plant patterns.
Patterns are pressed onto the mold by hand using tools like “ezo” and “ehiki,” which are like spatulas, and a device called an “arare oshi-bo.” This process is an important part that determines the dignity and elegance of the iron kettle, and shadow and perspective are expressed with great care.
After pressing the patterns, “hada-uchi” is performed. This is the work of lightly pressing dango-shaped balls of clay mixed with river sand onto the surface of the mold.
This gives the surface of the iron kettle a unique texture and expression. There are also methods of placing sand using a tampon made of rolled-up cloth or a brush, which showcases the artisan’s skills.
Finally, the mold on which the pattern and surface treatment work have been completed is completely dried and baked with charcoal fire at about 1300 degrees Celsius. By baking, the mold gains strength and can withstand casting.
The baking time and fire intensity vary slightly depending on the shape and size of the mold, requiring the long-standing experience and skills of the artisan.
Iron Casting and Demolding
Iron casting and demolding are the most spectacular and important processes in Nambu Tekki manufacturing. The shape of the product is created by pouring molten iron into the mold and cooling it to solidify.
The main processes are as follows:
- Iron melting
- Casting
- Cooling and demolding
First, iron is heated to 1300-1400 degrees Celsius and melted using equipment called a “melting furnace (cupola or koshiki).” During melting, wind is blown in and coke (fuel made by carbonizing coal) and cast iron are alternately added to maintain high temperatures.
Before casting, “oil smoking” is performed on the inside of the mold. Oil smoking is done to prevent the heated iron from adhering to the sand on the mold surface.
Next, the molten iron is taken with a ladle-like tool and poured into the mold. At this time, the thickness of the iron kettle is determined by the gaps in the mold and the core. As gas is generated inside the mold due to the high temperature, ingenuity such as securing gas escape routes is necessary.
After pouring, weights are placed on top of the mold to prevent floating. This series of operations is called “fuki,” and it’s the moment when the artisan’s skills shine the most.
Afterwards, the mold with the poured iron is cooled, and when the product has solidified, a process called “demolding” is performed to remove the mold, but the product is still rough at this stage. Therefore, the core of the product is also removed at this stage, and work is also done to remove burrs formed at the seams of the mold.
Polishing and Finishing
The demolded product is still in a rough state, so it finally moves to the polishing and coloring processes. These processes are important parts that determine the final beauty and durability of Nambu Tekki.
- Polishing
- Coloring
- Finishing
The removed iron kettle is polished to remove the oxide film and burrs adhering to the surface. It is carefully polished using wire brushes and files to smooth the surface. The final luster and texture of the iron kettle greatly depend on the method and thoroughness of polishing.
Next, the iron kettle is heated to about 300 degrees Celsius, and lacquer is baked on as a base coat. Then, a mixture of iron acetate solution called “ohaguro” and boiled tea juice is applied for coloring and rust prevention. By adjusting the mixing ratio of ohaguro, subtle color variations from black to brown can be achieved.
Finally, the handle called “tsuru” is attached to the iron kettle. The attachment of this tsuru is considered an important process that determines the quality of the Nambu iron kettle. The tsuru itself is made by a separate artisan, colored, and attached to the body, completing the texture of the iron kettle.
Through these processes, Nambu Tekki is completed as a product. Production requires years of experience and skill, and each of these operations is imbued with the artisan’s heart.
Nambu Tekki Production is a Craft that Shines with Skilled Techniques
Nambu Tekki has over 60 manufacturing processes, most of which are done by hand by artisans. To finish a single iron kettle or teapot, the skilled techniques and experience of artisans are essential.
Manufacturing includes a wide range of operations from design to mold making, casting, and finishing, and artisans’ skills are demonstrated in each process.
Made by Hand by Skilled Artisans
In the production process of Nambu Tekki, artisans’ handwork is required in every detail from design to finished product. In particular, there are many processes that depend on the artisans’ manual skills and experience, such as mold making, applying patterns, polishing, and finishing.
Through these processes, life is breathed into the ironware by the artisans’ years of experience and skills. Production requires long training and experience, and beautiful Nambu Tekki is created by artisans who have honed their skills.
Product Making Tailored to Purpose and Rich Design are Also Part of its Charm
Nambu Tekki has variations in patterns and shapes for each product. Various designs are applied according to the purpose, such as iron kettles, teapots, and pots, and these unique patterns and textures are the charm of Nambu Tekki.
Nambu Tekki products are created by the delicate work of artisans’ hands and years of technique, and are rich in variations of patterns and colors. Therefore, each piece of Nambu Tekki is unique, and while it is a practical item that increases in texture with use, it also has value as a work of art.
Conclusion: The Charm of Nambu Tekki and the Inheritance of Techniques
Nambu Tekki is a representative traditional craft of Japan, created by the natural resources of Iwate Prefecture and the skills of experienced artisans. Its production involves various processes, and artisans’ handwork and skills are required in all aspects, from design, mold creation, casting, to polishing and finishing.
As Nambu Tekki is produced with a lot of effort, it is finished into products that not only have functionality but also beauty and unique texture.
In particular, the patterns and shapes of iron kettles and teapots differ for each product, and traditional patterns such as the “Arare pattern” are applied one by one by hand by artisans. The fact that it increases in texture with use and can be enjoyed as it is nurtured is also a great charm of Nambu Tekki.
