A Fábrica

A Fábrica

BEHIND THE SCENES

“Welcome to our factories. Each piece we craft is a testament to our passion for innovation, quality, and respect for people and the planet, inviting you to enjoy moments of connection around the table while making mindful choices for a brighter future.”

Miguel Casal, Founder | CEO

As a leading Portuguese stoneware manufacturer, we proudly oversee a portfolio of four exceptional factories, nurturing two distinguished brands: COSTA NOVA and Casafina by COSTA NOVA.

At COSTA NOVA, each piece of stoneware begins with a spark of inspiration and a meticulous design process that prioritizes innovation and sustainability. Our talented designers consider every aspect, from form and ergonomics to aesthetics and the product’s life cycle, ensuring minimal environmental impact.

Many hands touch each of our stoneware products. While our four factories are equipped with state-of-the-art technology, the manual process still reigns supreme.

We source raw materials locally from Portugal’s finest natural resources and incorporate recycled elements to enhance our commitment to sustainability.

Our stoneware is crafted from natural clay and mineral-based materials, making it eco-friendly and biodegradable, with a manufacturing process that uses significantly less energy. Additionally, all of our excess clay is reused.

This commitment continues through the casting and molding stages, the decorating and the glazing… where artistry, precision and care are paramount. Even the firing process is significant, as stoneware is single-fired, reducing energy consumption and furthering the commitment to sustainability.

As the clay is shaped and refined, it undergoes a beautiful metamorphosis, evolving from a simple, malleable material into a durable functional piece.

Each moment spent in the factory is a celebration of creation, where we witness the fusion of skill and passion. This immersive environment fosters a deep appreciation for the craftsmanship involved in every piece we produce, turning our work into a shared journey of creativity and dedication.

There is poetry in the stoneware manufacturing process. Each step is magical, transforming raw clay into a solid item that carries with it the artistry and craftsmanship of our artisans.

Our molds are designed and produced internally, allowing for precise control over the form and quality of each stoneware piece. This ensures that each design meets our exacting standards for innovation and aesthetics.

For those of us who work in the factories, the experience of crafting stoneware is truly unique. The texture of the clay between our fingers connects us to the earth and our craft, while the mesmerizing rotation of the jiggering and jollying machines brings the clay to life. The rich aroma of freshly fired ceramics fills the air, a reminder of the transformative power of heat and artistry,

Every day, we work surrounded by materials that inspire our creativity. Within 105,000 m² (1,130,210 sq ft) of covered space in our factories, organization and planning are key factors—and there is certainly no shortage of room for inspiration.

Our factories employ a diverse group of people from different nationalities and cultures. Hundreds of individuals, the majority of whom are women, work in a safe and ethical environment to produce the most beautiful stoneware pieces in the world.

Quality is central to every step of our production process. We handle each piece with great care and attention, minimizing breakages and ensuring excellence.

At Costa Nova, we are dedicated to making stoneware production even more sustainable. Our factories are powered by 1,180 kW of solar panels, harnessing the energy of the sun to reduce our environmental impact. We also operate a closedcircuit system that reuses heat from our kilns, enhancing their efficiency by 15% compared to the most energy-efficient kilns on the market. Furthermore, the heat generated by our kilns is repurposed for our drying processes, significantly reducing the need for additional energy consumption.

Our stoneware is fired at lower temperatures, significantly reducing energy consumption during production. This approach also lowers CO2 emissions, contributing to a more sustainable process.

Sustainable stoneware Sustainable industry

At Costa Nova, sustainability isn’t just a goal—it’s part of our identity. With initiatives like ecogres, our proprietary recycled clay body, we’re turning waste into opportunity, creating beautiful, durable stoneware while paving the way for a more sustainable future.

ECOGRES

From the earth, From the Earth

By carefully considering every stage of the product lifecycle, we create designs that minimize environmental impact while maximizing durability and functionality. Our ecogres collections represent the highest level of this approach, featuring an innovative proprietary recycled clay body crafted from recovered materials within our factories and waste materials from neighboring industries. This process not only reduces waste but also conserves natural resources. Each ecogres piece is thoughtfully designed and crafted to take sustainability in stoneware manufacturing to the next level.

By selecting these thoughtfully crafted pieces, you are not just setting a table; you are making a statement about your commitment to a greener planet. Each meal becomes a celebration of sustainability, a testament to the countless hands that worked with care and consciousness to bring these pieces to life.

Beyond their harmonious and beautiful design, what truly sets our ecogres collections apart is their sustainable craftsmanship.

As manufacturers, we oversee every step of the production process. From the clay to the molding, from forming to decorating, glazing, and firing, all the way to packing and shipping, we ensure the same level of care at every stage.

Eco-design. Waste management. Water treatment. Energy efficiency. Recycled and recyclable packaging.

These sustainable practices are woven into our everyday work, ensuring that each piece we produce is far more than just tableware—it’s a symbol of our dedication and care. Every piece is touched by many hands throughout the manufacturing process, carrying with it not only the thoughtful choice of those who purchase it but also the artistry and passion of its makers.”

The Pearl Collection, crafted from stoneware exclusively in our factories in Portugal, is the epitome of elegant design and durability.

The journey of stoneware plates from clay to table is a blend of artistry, tradition, and innovation. Each plate carries the mark of the artisans who crafted it, making every meal a celebration of their skill and dedication.

As artisans mold and shape each piece of the Marrakesh collection, its ecogres clay transforms into a canvas of sustainability. The journey from the factory to the warmth of our homes is a dance of creation, where every piece crafted tells a story of respect for our planet. In the hands of skilled craftsmen, ecogres becomes more than just clay, and a plate becomes so much more than just a plate; it is a symbol of our commitment to a greener, more beautiful world.

CONTACTS

HEAD OFFICE PORTUGAL

Zona Industrial de Vagos, Lote 78 3840-385 Vagos, Portugal

Phone: +351 234 798 132 E-mail: info@costanova.pt

US OFFICE

301 Fields Lane, Brewster, NY 10509, USA

Phone: (845)277-5700 E-mail: office@costa-nova.com

B2B PLATFORM pro.costanova.pt

SOCIAL MEDIA @costanovatableware @costanovaprofessional

WEBSITE costanova.com costanovaprofessional.com