We remain committed to growth through innovation and technological advances in the manufacture of our architectural terra cotta.


Our professional affiliations with industry experts include The Center for Advanced Ceramic Technology (CACT) Alfred University, Architectural Testing Inc. (ATI), University at Buffalo Instrumentation Center and The Center for Industrial Effectiveness (TCIE) a part of the School of Engineering and Applied Sciences. These technology/testing based affiliations are complimented by several academic collaborations like our most recent Digital Capture and Reproduction initiative with the University at Buffalo School of Architecture. This technological innovation, like so many in the past, contributes positively to product output and quality, ergonomic work conditions, and adherence to specifications and industry standards.


Product output and quality contributions begin right from the start. During site survey, blocks marked for replacement are photographically documented. From these photos, using specific software packages, 3D models of the blocks marked for replacement are electronically generated and can be manipulated to produce shop drawings for architect/owner review and approval.

Once approved, these 3D electronic models are used to generate laser cut profiles or mill models and molds for replacement blocks. Time is saved during site survey, shop drawing production, and model/mold fabrication. Our expert staff moves less product, thereby reducing physical requirements of their workday and frees them to focus on a greater number of project specific requests. The accuracy of digital capture and laser cutting increases quality, predictability and consistency of replacement block fabrication.


The research and development of glaze and through-body clay color formulation proceeds concurrent with site survey work and digital model creation. Physical control samples are studied to formulate glaze and clay recipes. Once a match has been achieved, it is submitted to the architect/owner for review and approval. For single color samples, the acceptable color and range are scanned into a Spectrophotometer to set the acceptable color range for that project. Use of this high-tech color sensing device ensures that the product shipped to the site is consistent with the approved color sample.


Throughout each stage of the manufacturing process, Boston Valley incorporates our custom designed tracking system. This system assigns a unique identifier to each sample received from the building and associates it with replacement units shown on the shop, setting, section and detail drawings generated by our skilled design and drafting departments. Our bar-coded tracking system tool provides production schedule accountability, product delivery updates for contractors to coordinate equipment and labor need at the project site, and a unified method for monitoring project status from material supply award through final shipment and project close out.

From individual blocks to our expansive manufacturing facility in Orchard Park, New York, Boston Valley Terra Cotta employs the latest technology, quality control services and innovative tools to ensure product quality, consistency and production schedule accuracy. We understand that our clients have demanding schedules and utilize those tools available to us to make their work at the project site easier.