A Tour of Indian Foundries- Investment Casting

In this post today, I like to discuss a technical subject by standing in the shoes of a traveler. During my student life, I have never been in a race to become a top-scorer. However, it was Professor Mukunda’s enthusiastic teaching method, that ‘Material science and Metallurgy’ has been one subject that I topped the department (I like to show-off a bit, with those dark glasses emoticon). With an in-hand admission letter to one of the top universities to pursue a post-graduation in the subject, the lostlander deviated along the way, only to become a professional ‘Metallurgical Failure Mode Analyst’ much later in her career. If not for Prof.Mukunda, a seed of interest in the subject would have never been sown and I wouldn’t be writing about such an unconventional travel post, it seems.

Metallurgy is a science in which India has mastered from even before the world could imagine. The Vedas have a devoted section to teach these techniques. Prof.Mukunda’s favorite topic was ‘Metal casting with the lost wax technique’. His face beamed in joy every time he mentioned the intricacies that were achieved in the metal art thus created. “No two pieces that are exact replicas of each other can ever be created”, he stressed. We had foundry visits as part of our curriculum but that’s where we could only see sand, centrifugal and other forms of metal casting. Without having easy access, investment casting, also called as the ‘lost wax technique’ of metal casting was only left to our imagination. Many years after my graduation, I have been fortunate that I have been able to visit some of the amazing and traditional foundries in my country that practice the lost wax technique. These places have got them their individual ‘GI’ tags. Here is a walk through my foundry visits which I believe I should share with my fellow readers.

Idols of Swamimalai:

Swamimalai translates to the ‘Hill of the Lord’ that is named after an important temple in Tamil culture dedicated to Lord Murugan. This little town is famous beyond just this holy abode. One doesn’t need explanation at the mention of the bronze idols of the Cholas era. Apart from several of these antiques being prized possessions at museums across the globe, these treasures are among the highly traded commodities in the black market. These are ALL brought to form in Swamimalai. It is believed that the artisans of Swamimalai are a group of skilled men called as the Stapathis who have passed on their heritage of metal idol making, since the 12th century. The precision of composition and the measurements of these metal idols, mostly bronze are followed as per the ‘Agama Shastras’. This holy land of the alchemists was a part of my weeklong backpacking with my brother, back in Year-2015.

Clockwise from top left: 1. Raw material for mould making with the furnace and blower 2. The mould 3. Furnace 4. Metal sheet after moulding ready to be polished

Aranmula Kannadi:

An extremely important part of malayalee culture, this handcrafted mirror is a quintessential part of Kerala. I was told that on the day of ‘Vishu’ festival, after waking up in the morning- he/she should first see themselves in an Aranmula Kannadi placed alongside the ‘Canacona flowers and a lit oil lamp’ before anything else. ‘What is it about a mirror?’ a person unknown to the traditions of this land might ask. ‘These mirrors are not glass!’ These mirrors are super-polished metal surfaces that are capable of reflecting real images. A glass always reflects a secondary image (you can notice that there is a distance from the reflecting surface to the image formed) whereas, the metal surface reflects primary images (There is no additional distance between the object and the image).

Top: The secondary reflection in a glass mirror; Below: The primary reflection in a metal ‘Aranmula Kannadi’ mirror

These manually polished mirrors are created through investment casting whose composition remains to be a secret that is passed down through generations of just 1 family. The small group of these master craftsmen who are protecting their secret recipe of the Malayalee culture all reside around the Aranmula Parthasarthy temple in the state of Pathanamthitta. I had the esteemed opportunity of visiting one of these foundries when I sneaked out after working hours on one of my business trips in Year-2019.

Video of my visit to the mirror making foundry at Aranmula

Dokra art of Bastar:

This non-ferrous metal art is created by the forest dwelling tribes of Chhattisgarh. Historians believe that this art has evolved from what was used by the primitive tribes to create figurines of their local deities for worship and for jewellery purposes. The metals used were earlier collected directly from earth in the mineral rich area of Bastar, then smelted to separate the desired elements and mixed in intended proportions to form the final material for casting. This is an undocumented tribal technique that has been passed down through several centuries. Today, it is widely used for commercial purposes of decoration and gifting. It is now revered as a part of the tribal culture that represents the state of Chhattisgarh. I had an opportunity to visit one of these foundries and observed keenly the lifeless metal take form into art during my family’s five states’ road trip in Year-2020.

Dokra art at various stages of metal casting

Kola masks of Karkala:

Talking about all these foundries, I cannot be leaving my homestate behind. Although the folk art of metal mask making is slowly dying, these masks are an extremely important part of the culture of the Tulunad region. These bell metal masks are used in the spiritual performance of the ‘Bhoota Kola‘. Today, the art is used beyond mask making and can be seen in idols, lamps, bowls, utensils among other things used and sold extensively in Udupi district of Karnataka.

The lamps and idols of Nagamangala:

The contribution of the Hoysalas to the art and heritage of Karnataka cannot be justified with any number of words. Their intricacies and detailing in their work can be seen not only in the stone sculptures of their temples but also in their metal crafts. A few of the practitioners of the Hoysala style of metal casting have saved and passed on their knowledge to a few artisans who have made the town of Nagamangala their home. This thriving art can be seen in the traditional bronze lamps widely used across Karnataka and in the idols of various deities in this region. Although bronze is believed to be a godly material, other metals like tin, copper etc. too are cast into various articles using this technique.

This post is my small attempt towards promoting local art. I look forward to influence at least a few of my readers to learn more about the rich heritage of India and encourage local artisans in various ways possible. Do share your thoughts with me through the comments below.

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Tracing the Cholan trail- Kumbakonam

This was part of a backpacking trip by my brother and me with an original itinerary to cover Bangalore- Kumbakonam – Gangaikondacholapuram – Chidambaram – Pichavaram – Pondicherry – Tiruvannamalai – Bengaluru

Although being located in the same district, soaked in history and RICH architectural heritage from the Chola era, Kumbakonam is a place that is mostly overshadowed by its counterpart at Tanjavur town. Hence, it is a place that is often spoken less about on a typical tourist’s circuit. I was curious to cover this city and absorb as much of it as possible. While I embarked on a weeklong backpacking through some parts of East-coast road, I had enlisted the temples that seemed culturally important and hoped to visit them while I passed through the city of Kumbakonam.

Getting around:

As you may know, most of my trips are by availing public transportation. During this trip, all the places within the city were covered by walk. (you can alternately hire an autorickshaw to show you around and save some time). All other places located on the outskirts were explored through public/ local buses that are very frequent and extremely lighter on the pocket. If you are using this blog as a reference to explore this ancient city of the Cholas, you can plan your commutation accordingly. Places to visit in Kumbakonam city largely comprise of temples and can be broadly grouped into three categories depending on their location and proximity of accessibility.

a. Temples within a cluster within the city (temples 1~5 and 11~12 in my list)
b. Temples within a cluster on the city outskirts (temples 6~8 in my list)
c. Temples located on separate locations on the city outskirts (9~10 and 13~18 in my list)

Accommodation:

It was raining cats and dogs when we alighted at Kumbakonam bus stand in the morning. We had pre-booked a hotel in Kumbakonam city through an online portal. But after reaching the place, we realized that there was a mistake from the portal and the hotel was closed for Deepawali vacation. We sat there and browsed through websites to find alternate accommodation options. Meanwhile, the pounding rain had mellowed down to a drizzle. We finally managed to find a hotel nearby where we dumped all our baggage, freshened up and ventured out to explore. Bonus for the online goof up by the website: We had a room upgrade.

So, here are the places we visited during our short stint of 2 days at this historical city of Kumbakonam in the order of our travel.

Day 1:

1. The Nageswara temple: A sizably big temple dedicated to the Snake king Adishesha who is believed to have offered his prayers to Lord Shiva here. An interesting part in this vast 1000years old temple premise is the kalyana mantap. The Cholas have sculpted this stone structure in the form of a chariot being drawn by life sized elephants and horses with the suspension technique.

The Kalyana mantapa at Nageswaram kovil

2. Sarangampani: We reached this temple that follows the Vaishnavism cult after wading through a flooded road. Notable contributions have been made by Cholas, Vijayanagar, Madurai Nayaks etc. to the overall architecture of this temple. A temple tank is located on the western side of this temple.

The Rajagopuram at the Sarangampani Kovil

3. Someshwar temple: This is located adjacent to the Sarangampani temple. We skipped an exclusive visit to this temple after getting some photos from the outside of the temple. From there, we continued through the busy shopping lanes of the town to reach our next landmark.

4. Adikumbeshwara temple: It is believed that Kumbakonam gets its name from this Shiva temple. Legend has it that lord Brahma’s pot (Kumba) containing nectar of worldly lives was rolled down and stopped at this town after being hit by Shiva’s arrow. The sculptures at the temple are interesting where a 16-pillar hall built by the Vijayanagar kings has all the 27 stars and 12 zodiacs sculpted on a single stone. Also, the piped instruments(nagaswarams) etched out of stone and the cattle-shed are noteworthy. Today, this vast temple premises are also used for commercial purposes with several shops and restaurants setup in this complex.

5. Ramasamy temple: A place dedicated to lord Rama; it is believed to be the only temple which houses the idols of Rama & Sita along with all his brothers inside the sanctum Sanctorum. The entire story of Ramayana has been painted on the corridor walls of this temple. And hence, for someone interested in art and beyond just checking places, it would require at least a day or two to observe the murals here.

Obviously, we did not have the luxury of more than a couple of hours to spend, and hence our visit was limited to just a quick brush up of whatever we could understand of the images there.

The Ramayana painted on the corridor walls of the Ramasami temple

6. Mahamahan tank: We timed our visit to this place around noon, when all temples in South India usually close down. This mythologically important tank is spread across 6 acres and is believed to be created out of the nectar that was spilt from Brahma’s pot.

7. Kashivishwanathar temple: This is located at the entrance of the Mahamahan tank. It is believed that the navakannigas or the 9 maidens of Shiva (Ganga, Yamuna, Saraswathi, Kaveri, Godavari, Narmada, Krishna, Tungabhadra & Sarayu) representing 9 rivers visit and bathe in this tank once in 12 years. A day when lakhs of devotees flock here. It is believed that people who cannot make it to Kailash / Manasa Sarovar visit this temple as an alternative to wash off their sins. Though the temple was closed when we reached there, we were very fortunate to get the prasadam that made a nice filling lunch.

8. Abhimukeshwara temple: Located nearby, on the other side of the tank, we only walked past this place as it too remained closed. From there, we boarded a bus to our next major landmark on my ‘to visit’ list.

9. Airavateshwara temple at Darasuram: We visited this temple, on the outskirts of Kumbakonam (one of the three living Chola temples) when No-one else would! By the time we walked from the bus-stop to the temple, our umbrellas were flipped by the heavy winds and the pounding rain had battered and gotten us drenched till our bone. The entire temple complex was FLOODED (with knee-deep water). It was an insane visit where my brother and I both decided to go ahead, wade through the water, and have the entire place for ourselves. We climbed up a ladder (placed by the temple priest to perform the daily rituals) to reach the temple corridor. It was BEAUTY, up there! Bonus: The sight of the entire temple complex in a reflection in the accumulated water. (I know this photo is not its best, but still the best memory that our mobile phone camera could capture to for our grandkids when we would tell them about this place!).

Airavateshwara temple at Darasuram

After getting some nice shots, we made our way out to the main road to catch a bus to our next destination. The short journey thereon reminded us of Sebastian Vettel cruising on narrow countryside tarmac amid overflowing potholes and LOUD tapangucchi music in the background. With nothing to hold on to during the frequent braking by the driver to stop the bus for passengers to board/alight, got the bus to screeching halts from a revving speed. It was a fun ride that ended in few minutes as we alighted at our next planned landmark.

10. Pateeswaran temple: This is originally a Shiva temple, but the goddess has been given prime importance here. It is said that the Cholas offered prayers to the goddess Patti(daughter), calf of the sacred cow Kamdhenu here before proceeding for any battles during their reign. However, when we arrived here, it remained closed only to open again at 05.00.p.m.

As the rain gods again took over the silent skies, we decided to head back to the city. After reaching Kumbakonam city, we looked out for a place that served the trademark ‘Kumbakonam degree coffee’, our piping hot cuppa filter coffee to warm ourselves to some extent from the chilling rain. It was only 06.00.p.m but dark already. As planned, we set out to find our way through the super crowded street of the city to find the remaining two temples from our list.

The main bazaar street is a state highway- All thanks to the festival of Deepawali, it seemed like the entire district had come down to one street in Kumbakonam for shopping. The street was jam-packed with not even an inch of breathing space. We somehow managed to get out without actually facing a stampede. Albeit the heavy rain, we closed our umbrellas and stood amid the crowd. The crowd pulled us along to reach the exit of the street from where we walked to the next temple on our list.

11. Chakrapani temple: Here, Vishnu is worshipped in his sleeping posture holding his ‘Chakra’ on one finger. We witnessed the last pooja of the day after which we were wondering if we had to continue to the next temple or not since all the nearby temples had started to close down. Anyway, we had a lot of time to kill and walked across to take a chance.

12. Brahma temple: We considered ourselves to be fortunate to have decided to take a chance and arrive here. The temple was still open, and we had made to the last pooja at this temple as well. The priest was ecstatic to greet us who went on narrating us stories from mythology and depicting the importance of this otherwise small temple in Kumbakonam. We were told that it was 1 of the only 2 temples in all of Tamil Nadu that are dedicated to Lord Brahma. We were happy to savor the prasadam, which was very unexpected.

We then had a sumptuous supper at a restaurant before we called it a day. It took the same amount of pain to cross the crowded bazaar street to reach back to the hotel and catch some good night’s sleep.

Day 2:

On the following morning, we were early risers to catch up with our planned itinerary. We boarded a 07.00.a.m. bus to our first destination of the day, situated on a small hillock on the outskirts of Kumbakonam.

13. Swamimalai: Abode of one of the six important murugan temples in Tamil Nadu, Swamimalai is also an important destination of idol making in India. A limited number of artisans who all live in clusters around the temple here, have carried along a science and art of bronze idol making from the Chola period. The technology used in the ‘lost wax method’ of metal casting is practiced as per the Vedas and is something that needs a more elaborate citation, in another post.

After offering our prayers, we decided to head back to the city to get buses to the other places on our list.

Swami Malai- One of the six holy shrines of lord Murugan

Meanwhile, we couldn’t locate any restaurant that was open for breakfast even at 08.00.a.m. Hence, we decided to have lunch once and for all at wherever we would reach. If one had the convenience of an own transportation, there are several other ancient temples that I would recommend for visiting. It would be ideal to have an additional day in hand and make Kumbakonam the central place as all these recommended places are located in different directions, forming somewhat a radius around this town. Local buses are available from Kumbakonam to each of these places, but it would be very time consuming to come back to Kumbakonam to change a bus to every time. Hence, we decided to skip the below places and head to our last major landmark.

14. Uppiliappan

15. Thirubuvanam

16. Thiruvalanchizi

17. Thiruvidaimaruthur etc.

18. The Brihadeeshwara temple at Gangaikondacholapuram: We reached this yet another magnanimous temple after changing two buses (A change of bus at Kork road / GK cross). The biggest (of the three-great living Chola temples enlisted by UNESCO), this structure stood right adjacent to the national highway enchanting every tourist with all its might. The 3 living temples are together called so because the prayers, festivities followed thousands of years ago, during the Chola period are still being followed religiously till date and have stood as true testimony of time and Tamil culture.

The Brihadeeshwara temple at Gangaikonda Cholapuram

From here, we continued our backpacking into another territory within Tamil Nadu. From Tanjavur district, we were thereon heading towards Chidambaram via Pichavaram. Backpacking trips and road trips always carry elements of surprise and they are supposed to be like that. They can never be planned precisely. These trips always carry scope for making impromptu changes in the itinerary and taking on new adventures. That’s what was awaiting us on the next leg of this weeklong trip, far away in the southern-most state of India. Click here to read more on my journey to Chidambaram.

Madurai (Part 2) – Centre of arts and culture

There is no existence of a place without the people, and with civilization exists its culture. Madurai has its own share. My previous post (Madurai Part 1) was exclusively about the architectural landmarks spread across the city. But it would be injustice if the other things associated with this amazing city goes without a mention. Of course, the write-up could run into books if I had to write about each of them. And it isn’t necessary that everyone travelling is a pilgrim or a history buff or an architecture enthusiast. Hence, here’s an attempt to throw light on other aspects that any visitor to Madurai can expect. This is not a detailed one, but I touch upon various dimensions that you can theme your trip around Madurai. Do let me know if this post helps or if there is any other dimension I missed. Here goes my list.

Art:

• Sculptures: adorning every temple wall, pillar and their towers are a marvel in itself.
• Carpentry: Several wooden vahanas used to carry the idols of the various deities in the temple are something that need the attention of art afficionados.
• Handicrafts: Various accessories used for decorating Devi idols, made of delicate sequins, etc. are sold in several stall inside the large corridors of the Meenakshi temple.
• Mural paintings: This needs no introduction, the famous Madurai paintings are a gift of the Pandyan era, adorning the temple walls.

Clockwise from top left: 1.The sculptures on the western tower of the Meenakshi temple; 2.One of the mural paintings from the temple walls; 3.The wooden carriages for the temple idols; 4: Handicrafts from the temple stalls

Food:

Listing just a fixed menu while in Madurai would just be an understatement. If you are a foodie, Madurai would need two full days to explore its culinary delights alone. It is famous for both vegetarian and non-vegetarian specialties. I’d probably write a separate post about it sometime later. But this list is the list that we had when my family visited. But believe me- it is BEYOND!

• Breakfast – Idly & Sambar, Pongal + a cup of filter coffee
  11.00.a.m – Jigarthanda (it’s more like a combination of falooda & kulfi)
• Lunch- Puliyogare @ the temple store, curd rice, Sambar rice
  4.00.p.m.- Karupatti (palm sugar) coffee
• Dinner- Anything after 7.00.p.m is called meals. Must try is the ghee roast & rava Masala dosa

Costume:

• Sarees for women & Dhotis for men.
• Madurai cotton sarees with simple prints and zari borders with temple designs are popular.

Jewellery:

Among the locals- particularly those belonging to the Thevar cast, it is believed that women are prettier with bigger earlobes. Hence, the girl child born in this community is made to wear a traditional earring called the ‘Thandatti’ when she is young. The thandatti is said to evoke the 3 levels of our world: terrestrial, astral and divine and these levels are associated with Mandala. Each piece of this weighs 27gms and is made of gold and this piece of jewelry is specific to Madurai.

A Thevar woman wearing the traditional Thandatti earring

Shopping:

Shopping at Madurai is all about wholesale vendors and there are specified streets for each of them.

• Cotton sarees/ dress materials: Shops are all around the temple complex
• Steel utensils: Plastic beads & girls’ accessories, gold plated imitation jewelry to name a few.
• Pooja related accessories & crafts: Particularly inside Pudumandapam (1000 years old market)
• Farm produce: Varieties of plantains / bananas and green groceries among the others.

A brief intro to a city full of life and activities. Justice yet to be done. Signing off with a hope that it has helped someone somewhere in some form who is seeking for some info on this Pandyan city….