Copying the greatest art the old-fashioned way in Berlin

For a long time plaster casts — exact copies — of artworks were the only way for many people to see and experience art of different cultures. Museums, libraries and private collectors proudly displayed these treasures, often ancient Greek sculptures. Today such collections are rare, nonetheless Berlin's Gipsformerei is stills busy using historic production methods and keeping an old craft alive.

During the past two centuries, the manufactory has mostly used a plaster made from alabaster found in the Harz region of Germany. They call it the "white gemstone" because it gives the best results and "doesn't lie," according to boss Miguel Helfrich. But they can also use other more weather-resistant materials or create molds that a bronze manufactory can use to make a metal copy.

In all, the workshop has molds for around 7,000 different pieces, everything from the miniscule to oversized equestrian statues and the entire Pergamon frieze. For many pieces it also has "master casts." Additionally there are around 3,000 casts that have been painted to reflect the original, no matter what material. To preserve the colors, these special painted models rarely ever see the light.

Today the manufactory employs 26 people, 18 of which work in the studio. There are three painters and a metal fitter who creates the metal skeletons that hold together bigger pieces. The workspaces are full of tools, molds and half-finished works. Along the wall are two bins full of the main ingredient for their work — alabaster plaster. Everything is very tidy and seems to have its own place.

For most of the smaller items in the workshop's catalog they have a set list price. For more complicated orders, however, a price estimate must be requested. Some of the objects have not been created in the last century and all the pieces first need to be found and assessed. The workshop is overflowing with molds — old and new — held together by string. Until today, nothing has ever gone missing.

After getting an order, a master plasterer finds the original molds. Most of them are made of thick plaster themselves, some are silicone. After cleaning and reassembling the mold, liquid plaster is poured in and left to dry. Then it is taken out of the mold and any seams are sanded down. It is a very specialized job, and everyone who comes to the Gipsformerei has to learn on the job.

Plaster replicas are a crisp white. Customers can have them like this, or painted to look like the original no matter what material — wood, marble, ivory or clay. Half of the molds in the collection are of objects in Berlin museums. Unsurprisingly the manufactory is part of the Berlin State Museums. Though not expected to make huge profits, in a good year it can bring in around €1 million.

The painting is done by a small group of master painters. Here they replicate a piece found in Thebes that is from 2,000 BC. The completed hippo looks exactly like the original, costs €590 ($650) and is ready for its new home. Later this month the plaster cast workshop is getting its very first exhibition in Berlin's newly opened James Simon Gallery designed by David Chipperfield.