Clay Pot Factory in Ijok

Ijok in northern Selangor is home to one of the few pottery factories in Malaysia that still uses a wood-fired dragon kiln to produce clay pots and medicine pots – Ng Pottery Enterprise. The TeoChew style of clay pot-making passed down three generations of the Ng family since their ancestors migrated south. From fully manual labour in the early days, to employing machinery and moulds nowadays, human hands remain essential for final touch-ups.

A dragon kiln stands towering at one end of the factory, about 20 metres long and 2.5 metres wide, with two kiln doors and several fire holes (for feeding firewood). Fully loaded, it can hold about 2000 pieces of clay pots and medicine pots. The kiln firing process takes three consecutive days, and requires round-the-clock monitoring, constantly adding firewood and closely observing the fire to maintain the temperature between 1200℃ and 1300℃ to ensure uninterrupted combustion. On day three, the fire is extinguished, and the kiln is left to cool down to room temperature before unloading.

Ng Pottery Enterprise is now run by the third generation, the elder brother Ng Lee Kwong and the younger brother Ng Ah Ming, who grew up playing with clay and inherited the family business. Their grandfather started out manufacturing clay pots, medicine pots, and rubber cups. Their father’s three siblings then branched out into different production lines. Their youngest uncle manufactures and supplies utensils to high-end hotels and restaurants; their second uncle produces everyday items such as piggy banks, kemenyan incense burners, and Indian diya lamps; whereas their father produces household cookware such as clay pots and medicine pots.

Thirty years ago, the Ng brothers took over this substantial clay pot factory from their father. It was the 1990s, and almost every household uses clay pots for cooking; business was booming. At that time, there were numerous clay pot factories throughout Malaysia. Later, with the rising popularity of electric cookers and induction cooktops, clay pots faced obsolescence, and many factories ceased operations. After all, clay pot manufacturing involves hard labour, intricate handiwork, time-consuming production process, and low profits. The two brothers are a good example of teamwork, weathering storms together, never giving up on the family business. Ng Lee Kwong is in charge of production, while Ng Ah Ming is in charge of sales and delivery, handling wholesale orders from Ipoh, Kuala Lumpur, Melaka, Johor, and even exports.

Over the decades since its establishment, the clay pot factory has relocated several times, from its original site in Kepong to Kampung Subang, until finally settled at the current location about 30 years ago. Each move meant a new dragon kiln had to be built. With the passing of the older generation who mastered the craft of kiln-building, the dragon kiln in Ijok may be the last. Year in, year out, the inner walls of the dragon kiln have developed a a glaze-like sheen, yet sharp edges are hidden within the beauty. Thermal shock may cause the kiln bricks to fall off or cave-in, the two brothers had no choice but to figure out how to perform repairs themselves. Since the original Japanese raw bricks have been discontinued, now they can only use building-grade red bricks instead.

Unwilling to see their ancestral craft lost in time, the Ng brothers persisted in running the clay pot factory despite facing numerous challenges. Each clay pot is not only a cookware bearing timeless culinary culture, but also embodies the Ng brothers’ hard work in continuing their family tradition.

【Locality Info】

Ijok is the name of both a town and a Chinese-majority village in Kuala Selangor, Selangor. It is strategically located at the intersection of Federal Route 54, connecting Kuala Lumpur and Batang Berjuntai.

In the early 20th century, Javanese immigrants settled in Ijok to cultivate the land, so most of the Malays in the town have Javanese ancestry. The town’s name is believed to derive from the Javanese word for green, “Ijo” or “Hijau,” symbolizing the lush green rice paddies of the past. Local legend also suggests that the area was named after palm trees called “Ijok” that once grew there.

During the Malayan Emergency in 1948, in response to the activities of the Malayan Communist Party, the British colonial government implemented the Briggs Plan, establishing Kampung Baru Ijok to relocate the Chinese community scattered across Ijok 8th Mile, 28th Mile, and Bukit Padang. Initially, villagers relied on vegetable and taro cultivation for sustenance, but switched to rubber planting in 1951 due to large-scale rubber plantation development by the British colonial government. As rubber profits declined, most villagers converted to oil palm plantations over 20 years ago. In recent years, with the support of the Selangor state government, many small and medium-sized factories have been established in Ijok, gradually transforming it into an industrial zone.

【Clay Pot Info】
Made from all-natural materials, clay pots have a porous nature which enhances food and tea aromas by allowing heat, moisture, and volatile oils to circulate, creating a slow-cooked, complex depth that seals in and rounds out delicate fragrance notes. Therefore, clay pots are widely popular across Malaysia, being the preferred cookware for Indians to cook curry, Malays to cook Tom Yam, and Chinese to cook Bak Kut Teh in.

【Medicine Pot Info】
Although modern people hardly use medicine pots to decoct herbal medicine, there is still a market demand for them — for melting gold. Goldsmiths need to melt gold to create various ornaments. Medicine pots can withstand the high temperatures of metal smelting, are chemically stable, and the side handle design allows for safe and precise pouring of the molten gold. Even if a medicine pot can only be used once, the cost is not too high.

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Producer : Daniel Lim
Cinematographer : Amelia Lim / Michael Lerk
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Copywriter : Pua Hui Wen

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Piggy Bank Factory in Ijok

Clay piggy banks have been widely used since thousands of years ago. They have only one slit for inserting coins, and are broken open to remove them when full. The fact that it has survived to this day shows how important it is to cultivate the habit of saving. In recent years, cashless payments have become increasingly popular, and physical piggy banks are facing elimination, but in Ijok, there is a factory still producing traditional clay piggy banks. The colourful and attractive varieties include animals, gas cylinders, post boxes, and fruits. Each piggy bank produced carries the warmth from the hands of the second-generation owner, Ng Poh Huat, and his wife, Yin Shin Peng. 

The Ng family roots can be traced to Teochew, China. Mr Ng’s grandfather moved to Malaya and made a living with his pottery skills. He first set up a factory in Kepong, but relocated to Kampung Subang to make way for development, yet history repeated itself, the factory thus relocated to its current site in Ijok about 30 years ago. Mr Ng’s father and his two siblings all work in the same industry, each leading a different production line: the eldest makes clay pots, the second makes piggy banks, the youngest makes dining ware. 

47-year-old Mr Ng used to work elsewhere, but later chose to return home and take over the piggy bank factory from his father. The retired senior Mr Ng drops by occasionally to visit and help design piggy bank moulds. Since Madam Yin married into the family, she helped with the operations in the piggy bank factory, learning from scratch, as well as attending courses to upskill. When Mr Ng goes out to make deliveries, she is able to run the factory all by herself. 

Clay piggy banks are made using the slip casting method, which is mixing kaolin clay with water into a mixture and pour into plaster moulds. Plaster moulds absorb water from the mixture, thus forming a layer of clay on the inner walls, taking the shape of the mould. Once the clay has solidified to a certain thickness, excess mixture is poured out, leaving only a small portion, then attach the cover securely and invert the mould, and wait till the next day to unmould. 

With a small knife in hand, Madam Yin pries the plaster mould open, and takes out the piggy bank carefully. She cuts a slit about an inch in size, pats the bottom of the piggy bank to release air, and arranges it onto a wooden plank to air dry and solidify. The next step is refining the outline of the piggy bank, scraping off excess clay, and polish with water to smoothen the surface. After drying to 70-80% dryness, the piggy bank can be loaded into the kiln. 

Nearly a thousand piggy banks of different shapes and sizes are stacked in the kiln, seemingly as easy as a building block game, yet in fact requiring a lot of brainwork and patience. The walls of the kiln are then sealed with bricks, the roof wth zinc sheets, and a fire is kindled to dry the piggy banks over low heat for a day, until they completely dry. Then firewood is gradually added to increase the heat, until the temperature reaches about 1000 degrees Celsius, firing for about five hours before extinguishing, and let the piggy banks cool down, only unloading the kiln on the next day.

A layer of primer is applied to the piggy banks, to make the spray paint colours appear fuller and brighter. Mr Ng exercises precise control over the airbrush, spraying thinly in multiple layers, letting the surface dry before applying the next layer of a different colour to avoid pooling and runs. It takes half a day for the painted piggy banks to dry. Before packaging, Madam Yin adds a finishing touch to the eyes of animal piggy banks.

Clay piggy banks are diverse in style, many details still require great attention and human hands. Before being fired in the kiln, the piggy banks are still clumps of clay, grayish-white in colour, and can be reshaped even if it breaks; after being fired in the kiln, the piggy banks became pottery, yellowish in colour, once broken they must be discarded. The success rate is usually as high as 90%, but if it is unfortunately less than 50%, they had no choice but to suffer the losses.

Traditional piggy banks are pushed into decline due to changes in modern lifestyle and the shift to cashless payment methods. The piggy bank factory also produces goods used in folk religious practices, such as incense burners for worshipping Datuk Kong, and joss paper burners popular in northern Malaysia. Despite facing numerous challenges, Mr Ng and Madam Yin continue to run the traditional piggy bank factory, supporting their family. 

有你 UNI Production
Producer : Daniel Lim
Cinematographer : Amelia Lim / Michael Lerk
Drone : Daniel Lim
Video Editor : Amelia Lim
Copywriter : Pua Hui Wen

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Bespoke Shoemaking in Salak South | The Leather Shoes

In 1974, a twelve-year-old boy from Titi, Negeri Sembilan was recruited by a shoe factory owner, and went to work in Salak South, Kuala Lumpur. He started out as an apprentice, doing odd jobs and running errands for the veteran shoemakers. His honest and unpretentious personality won the favour of one who became his mentor and took him under their wing. He learned through observation, figuring things out on his own, gradually mastering shoemaking skills.

In 1979, a fifteen-year-old girl joined the same shoe factory, sewing shoe uppers at the front while he welt shoes at the back. Her jovial personality caught his eye, and he always sought opportunities to get close to her, eventually they started dating. Even though she shifted to another shoe factory a couple of years later, their relationship was not affected, and they got married in 1984. After their wedding, she went back to work in the same factory as him, for the sake of convenience.

In the fairytale love story of Yap Wee Ming and Wong Mei Foong, there was no glass slipper, instead they make countless men’s leather shoes day in, day out. After decades of hard work, the opportunity for them to run their own business came unexpectedly. In 1991, Wong Mei Foong’s ex-employer sought them out, intending them to take over her shoe factory. After discussion, the duo decided to undertake the venture, and named their business Fullfil Marketing.

Challenges faced by the shoemaking industry became tougher in the 2010s. During the past decades, Yap Wee Ming mentored numerous fellow hometowners and apprentices, however none of them persevered in the industry. After his last employee left, only Master Yap’s lone figure remain stooping at the workbench that used to be shared by four craftsmen. Due to manpower shortage, they were unable to continue supply wholesale, and had to make new attempts, such as collaborating with others and becoming a third-party manufacturer. In 2016, they also ventured into hosting private kitchen.

Crisis turns into opportunity when the connections they built through private kitchen opened new doors in their shoemaking career. In 2017, Yap Wee Ming and Wong Mei Foong officially transformed their business model into bespoke shoemaking, creating the perfect fit for every customer. Bespoke services not only allow customers to choose their favourite styles, colours, and materials. The real test lies in making modifications to compensate for customers’ posture and gait, ensuring comfort while also look appealing and presentable.

To create a pair of shoes from scratch, neither Yap Wee Ming or Wong Mei Foong could do it without the other. He designs the pattern, she cuts the leather and sews the shoe upper, then he welts and handles all the remaining procedures. The duo’s personalities also complement each other; one is steady and reliable, while the other is outgoing and sharp, and they always work together efficiently. He focuses on shoemaking while she liaises with customers.

Embracing the mindset that “50 is still young,” the duo enthusiastically participated in artisan markets all over Malaysia. They also built exposure on social media under the brand name “The Leather Shoes”. Since their being featured in the news, customers from outstation and even abroad flocked to their workshop, and orders kept pouring in. To cater for market demand, they expanded their product range to include women’s leather shoes, handbags, wallets, keychains, and more.

From teenage years to now being over sixty, Yap Wee Ming and Wong Mei Foong have been making shoes and weathered many storms together, perfectly matching the introduction she wrote when they first participated in artisan markets: shoemaking hand-in-hand for life. 

有你 UNI Production
Producer : Daniel Lim
Cinematographer : Amelia Lim / Michael Lerk
Drone : Daniel Lim
Video Editor : Michael Lerk
Copywriter : Pua Hui Wen

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