Cast Iron Pans: From Sand To Skillet

Cast iron pans are made by pouring molten metal into a sand mould. This manufacturing process originated in China in the 6th century BCE and has barely changed since. The only major difference in modern manufacturing is that machines are used to automate the work of pouring the molten metal into the moulds.

The manufacturing process

Once the iron is molten, it is poured into a mould. Traditionally, this mould is made of sand, and the pan is left to cool before the mould is broken apart to reveal the pan. Modern manufacturing automates this process, with machines handling the pouring of the molten metal. The metal can reach temperatures of over 2,500°F (1371°C) during fabrication, so extreme care must be taken.

The final step is to remove the pan from the mould. With the traditional sand mould, the mould is broken apart to reveal the pan, which emerges in one piece, handle included.

The affordability and durability of cast iron

Cast iron has been a popular material for cookware for centuries due to its affordability and durability. Its manufacturing process, which originated in China in the 6th century BCE, has barely changed. Cast iron skillets are made by pouring molten metal into a sand mould, which is then broken apart to reveal the pan.

Cast iron is composed mainly of iron, carbon, and silicon, with a higher carbon content than metal or wrought iron. This high carbon content gives cast iron its distinctive properties, such as its hardness and resistance to surface wear. This makes it ideal for applications where strength and longevity are required, such as cookware, pipelines, and engine blocks.

The durability of cast iron is well-known, with many people still using cast-iron pans that have been passed down through their families for generations. Cast iron is easily restored and, with proper care, can last for decades. Its longevity is due in part to its resistance to corrosion, as the carbon content forms an iron carbide coating that protects against rust and degradation.

In addition to its durability, cast iron is also affordable. The manufacturing process is simple and cost-effective, making cast iron a popular choice for various applications, including smaller pipes, guttering pipes, and stove/grill plates.

However, cast iron does have some drawbacks. Its hardness makes it fragile and prone to fracture under pressure. It is also susceptible to corrosion, which can lead to rust and degradation over time if not properly maintained. Despite these limitations, cast iron remains a popular and affordable choice for cookware and other applications due to its strength and longevity.

The modern manufacturing process

The manufacturing process for cast iron pans has changed very little since its inception in the 6th century BCE. The modern manufacturing process for cast iron pans involves pouring molten metal into a sand mould. The pan, including the handle, emerges in one piece when the mould is broken after cooling. The main difference in modern manufacturing is the use of machines to automate the process of pouring the molten metal, which can reach temperatures of over 2,500 degrees Fahrenheit.

On a small scale, cast iron pans can be made by obtaining scrap cast iron from a scrapyard, melting it down in a foundry furnace, and pouring it into a sand mould. This process requires careful control of temperatures, chemistry, and inoculation practices to ensure the final product is safe for cookware.

On a larger scale, a cupola furnace can be used to produce cast iron pans in batches of a few hundred pounds. This involves mixing scrap steel, pig iron, and coke or charcoal with a large supply of air. Once the furnace is filled, a plug at the bottom is cracked open, and the cast iron flows out. This is a complex process that requires several people to operate.

The molten cast iron must then be carefully manipulated and poured into the mould. This typically requires a team of two people or a custom-built pouring mechanism to handle the weight and avoid injury.

In recent years, there has been a resurgence in the popularity of cast iron pans due to concerns about the environmental and health impacts of non-stick coatings on alternative cookware. This has led to a new wave of American companies producing artisanal batches of cast iron cookware and experimenting with innovative design tweaks to modernise the classic design.

The history of cast iron pans

In the 18th and 19th centuries, cast iron cookware experienced a boom in popularity. Cast iron pots and pans were so valuable that Adam Smith claimed they were worth more than gold in his book, "The Wealth of Nations." During this time, cast iron cookware was produced by companies such as Griswold (founded in 1865), Wagner (founded in 1891), and Blacklock Foundry (founded in 1896).

In the early 20th century, cast iron began to lose its dominance as aluminium became a cheaper and more widely available alternative. The invention of non-stick coatings in the late 20th century further contributed to the decline of cast iron cookware, as health and environmental concerns emerged about the effects of chemical coatings.

However, in recent years, cast iron cookware has seen a resurgence in popularity. Health concerns about other types of cookware, the durability of cast iron, and its visual appeal have all contributed to its comeback. Cast iron cookware is now sought after by antique collectors and dealers and is once again being produced by a new wave of American companies, bringing this timeless pan firmly into the 21st century.

The benefits of cast iron pans

Cast iron pans have been used for centuries and, despite a brief hiatus in the early 20th century, they are still a popular choice for cooks today. Here are some of the benefits of cast iron pans:

Durability

Cast iron pans are made to last a lifetime. They are incredibly tough and can handle high temperatures, making them ideal for all kinds of culinary adventures.

Non-stick

Cast iron pans have a naturally non-stick finish when they are properly seasoned. This means that food will not stick to the surface, making it easier to cook and clean.

Even heating

Cast iron has a higher specific heat than stainless steel, and while aluminium has a higher specific heat, cast iron has a higher thermal mass due to its greater density. This means that cast iron pans offer an even heating area, making them perfect for cooking things like cornbread or searing large chunks of protein.

Versatility

Cast iron pans can be used on any heat source, including kitchen stovetops, outdoor grills, and open campfires. They can also be used to cook a wide variety of dishes, from fried eggs and bacon to juicy steaks, roast chicken, and vegetables.

Health benefits

Cast iron pans can add iron to your diet, which is beneficial for people with anaemia or low iron levels. They are also a healthier alternative to non-stick pans, which can release toxic fumes at high temperatures.

Affordability

Cast iron pans are typically a fraction of the cost of other cookware with similar quality and material. They are a great affordable option for those looking for durable and versatile cookware.

Frequently asked questions