RAW MATERIALS

On an average the cost of raw materials used in a day is Rs. 4000.

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 Virudhachalam
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. They source it from Virudhachalam.
One packet contains 50 kg of stone powder and costs Rs. 450-500 including
transportation fees. It is difficult to source during Jan/Feb because of rains and is
usually sourced in april/may. Once they get hold of the product, they get it in bulk,
minimum 50 packets and it is enough for 3-4 months. It is a very important
material in making dolls. It is non-bio degradable. It is white in colour. The texture
is grainy (neither smooth nor rough, like suji). It is easier to mix when grainy.
More dry the powder, the better so, it is both transported and stored both in the
air tight double layered polythene packets to avoid its contact with water. On an
average if 10 people are working, a minimum of 1½ packets is used in a day.

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 sourced from Pondicherry for Rs. 20-30 per
kg. It provides flexibility to the dough. It is a little lumpy and is broken down and
then mixed with stone powder. They usually get ½ ton at a time which will suffice
for 1 year but this also depends on the production rate and the size of the doll.
This time they imported 700 kgs of paper pulp because it was difficult to source it
during covid which stopped the production for 3-4 months. There is a wastage of
approx 50-60 kgs of paper pulp in the making of dolls.

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.70/kg and does not stale when stored for an extended time. The
poor quality costs Rs.50/kg and is stale after some days. 1 bag costs Rs. 2400,
 the price keeps fluctuating because of its high demand. It is directly sourced from
people making the powder in Salem. Gopuram brand tapioca powder is also
used.

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. Any person
using the copper sulphate for long while making the idols, without any proper
precautions, are more likely to get lung disease, the same when used in small
portions and with precautions, then it will not harm. 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. It
is sourced from a waste paper mart. If the budget is good they get it in bulk,
approx 1 ton otherwise are sourced from nearby construction sites. They are not
stored with the moulds because it might spoil the mould. In a day around 25
cement papers are used, and around 40 for larger dolls. The bottom and top part
of the paper is relatively thick and is discarded. Only the side pieces are used.
The paper is torn from the side with the joint to obtain maximum surface area. In
kg of cement paper, nearly 300gms is wasted and earlier was used for the
packaging of the dolls, later they figured it was too stiff for packaging and can
damage the dolls, so they collect all the waste sheets and resell it to the waste
paper mart for Rs.12 a kg.

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. The wires used are 14 and 16 gauge, depending on the
placement of the wire. They get it from the local hardware shop. The wires from
the cycle wheels are also used.

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. Any person using the enamel paint for long while
making the idols, without any proper precautions, are more likely to get lung
disease.
- For a black coloured Ganesha idol 6 liters of black colour and 6 liters of enamel
is used.
- If the idol has more than one colour then primer 1/4th of a litre and white paint
around 6 liters as a base is used. Each colour around 100 ml is used (depends
on the area).

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) , basically 2nd quality unscented
ponds powder. It is extremely soft. It is buffed on the surface of the moulds with
intricate designs for smooth tracing and also used in making the sheets out of
dough. 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. 1kg costs Rs.40 (high
quality hence high price). 1 packet contains 50 kgs of french chalk powder and
6-10 packets are used in a year. It is sourced from Devi and co. in Bangalore.

11) Chalk Powder

- It is slightly yellow in colour. It is used in the finishing of dolls. 1 kg costs Rs. 20. 1
packet weighs 30 kgs, they get 10 to 20 packets at a time. It is sourced from Devi
and co. in Bangalore.

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) Paint Brush
- The size of the brush ranges from 0-12. Size 00 and 000 are also used for
minute details. It is sourced from Devi and co. in Bangalore. They also get it in
Chennai from Shabbir Hussain Traders. Brand- Jaina. 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 buy bamboo, give it to the carpenter and according to the need of the
design the tool is made. The better the bamboo quality, the better the tool. It lasts
for 4 years (depends on the usage). They are of different sizes and made
according to the needs of the artisan 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. In a year a total of 280 sevarais are made. The
carpenter charges Rs. 200-300 for a day for cutting the plywood used in the base
of larger dolls.
9) Pen caps
- Any pen cap can be used to take circular impressions for design purposes.

10) Spray Paint Gun

- For shading AC 30 Art Master is used. It costs Rs. 2740 and lasts for 1½- 2 years
when used regularly (depends on usage). They change the size of the needle
depending on the size of the dolls. It can last for 3-4 years if needles are not
changed.After that it is usable but might affect the quality of shading. 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.