RAW MATERIALS

1) Stone Powder/ Kalnar Mav.

- It is a pop waste sourced from Gujarat and Rajasthan, generated during the
production and finishing of products made out of pop. A dealer in Pondicherry
gets the waste pop blocks in tons, completely sun-dries it because it is wet, gives
it for grinding, and then sells it in packets. The texture is grainy, like suji. Difficult
to source in the rainy season. It is non-bio degradable. They bought it from
Salem, Vadalur and it costs Rs.9-10 per kg.

2) Paper Pulp
- It is a waste from the cotton industry and sourced from a company that makes
cotton boxes. Earlier they gave it for free to clear their waste dumping area. Still,
when pop was banned in making idols for religious festivals (because of the
water pollution), the paper pulp was a good alternative, and in great demand, so
they started selling it at a price. It is bought in Pondicherry for Rs. 30-40 per kg. It
provides flexibility to the dough.

3) Tapioca Flour
- Tapioca Flour is obtained from the starchy vegetable called the cassava root; it is
finely shredded, washed, and dehydrated; the dried pulp is then ground into flour.
It is edible. It gives a smooth texture to the dough. The excellent quality tapioca
flour costs Rs.50/kg and does not stale when stored for an extended time. The
poor quality costs Rs.40/kg and is stale after some days.

4) Copper sulphate
- It is also called mayil thutham because of its turquoise color. Mayil is a peacock
in Tamil. It comes in blocks and is crushed into powder. It is used to prevent
insects and rats from eating tapioca paste and ruining the dolls. It is not harmful
to human beings. It also makes the doll strong and increases its lifespan, but it
forms cracks in the dolls when added in large quantities. For 1kg of tapioca
paste, 20-40 gms of copper sulphate is used.

5) Cement Paper
- It is also a waste paper, thick, making a crunchy sound when crumpled or torn. It
is a packaging material that can be constructed of one or several layers of
high-quality kraft paper, usually produced from virgin fiber. It is used to reinforce
the edges of the dolls and provide strength. 1kg (3-4 sheets) cost about Rs.30.
6) Steel wires/ Metal wires
- Also known as kambi. It is used on delicate portions for strength and joint pieces.
Two types of wires are used- thick is for trisulam(trident), and thin is for
reinforcement.

7) Bamboo / Reed sticks

- It is used as a backbone to provide support to the statue.

8) Paints
- Enamel paints are used because they provide shine—company- Asian or
Rubilex. Rubilex is more expensive and of good quality. They bought it from
Pondicherry and Villianur.

9) Clothes and hard boards are stuffed inside the doll to provide strength, and
everything is covered in oil (oil- ?). Oil is used as a preventive measure to avoid
any damage from water.

10)French Chalk Powder

- It is a waste from the powder company (ponds). It is buffed on the surface where
they work with the layer and also inside the mould. This prevents the dough from
sticking to the mould. It is also used in making sukka which is later used in the
finishing of dolls.

TOOLS AND EQUIPMENTS

1) Dough Maker
- It is a power/electricity-based machine that is used for mixing/making the paper
mache dough. All the parts of the machine, i.e., mixer, bowl engine, etc., all come
from different parts of India and are assembled in Coimbatore. It costs around
Rs.40-50 thousand and can hold up to 20 kgs of dough.

2) Rolling Pin
- Also called uruttu katta. It is made out of wood and is used to make evenly flat
sheets out of dough.
3) Thick Brush/ Paint Brush
- The size of the brush ranges from 0-12. It is used to dust off the mould before
placing the dough/sheet in it and push the dough in the mould for fine
impressions. It is also used to paint the dolls.

4) Knife
- Also called kathi and is used for cutting the excess dough on the mould.

5) Thudupu
- It is one foot long, any random stick of wood weighing 3 kgs used for mixing and
stirring while making tapioca paste.

6) Needles
- They are similar to the ones used to sew sacks, here they are used to make the
holes for attaching hands, heads, etc.

7) Sandpaper
- They get it from Bangalore, 80-100 sheets a roll that costs Rs. 40. It is used in
the finishing stage for smoothening of dolls.

8) Sevarai
- They are of different sizes made of bamboo and are used to shape dolls and add
designs on clothing and stuff. Sometimes artisans make sevarai themselves and
get it finished from a carpenter.

9) Pen caps
- Any pen cap can be used to take circular impressions for design purposes.

10) Spray Gun

- It is used to paint the dolls for a cleaner finish and is also time effective.

PRE- PRODUCTION PROCESS

1) Mould
- Commonly called ‘dye’ by artisans. Also Known as acchu in Tamil. Mainly bought
ready-made, but sometimes artisans make it themselves. Pop, cement, clay, and
coconut fiber are used to make a mould. Earlier it was made using natural clay/
sand from the sea bed, but the mould would shrink by an inch when completely
dried. E.g., 12” of mould shrinks to 11” when dried. Other alternatives included
rubber clay and white clay. Rubber clay was challenging to work with for finer
details, so white clay is used to make mould. Mould dries entirely for 4-5 days or
a week before an imprint can be taken. People from Bangalore design the dolls
and accordingly the moulds are made.

2) Making of Tapioca Paste (Kilangu Mavu)

- In a drum, add 3kgs of tapioca flour and 1½ liters of water to form a paste. Later
add more water to obtain a thin consistency. Boil the same for 1½ hours and stir
every 10-15 mins using a thudupu. In the end, add copper sulphate and mix
properly. It needs a sprinkle of water from time to time to avoid the formation of a
hard, rubber kind of layer.

3) Dough
- Take 2 parts chalk powder(600 gms) and 1 part paper pulp(300 gms) and mix by
rubbing both palms together for 5-10 mins. To this mixture add 200 gms of
tapioca paste and mix into an evenly smooth dough. Making the dough using a
machine is twice as easy as making it using your hands.

4) Chalk powder is tied in a cloth which is then dabbed on the mould before
applying a layer of dough.