Ella Walter
Lodge Manufacturing Company is an American manufacturer of cast-iron cookware based in South Pittsburg, Tennessee. The company was founded in 1896 by Joseph Lodge and has been making cast iron products for over a century. Lodge pans are made from a mixture of pig iron, recycled cast iron, and recycled scrap steel that are melted into molten cast iron in a 2800°F furnace. Vermiculite is then added as a bonding agent to remove impurities. The molten cast iron is then poured into molds to create each piece of cast iron, which is then shot-blasted with a fine steel shot to remove any residual molding sand before being ground, polished, rinsed, and hung to dry. In 2002, Lodge became the first cast-iron cookware manufacturer to season their products, and the company continues to innovate with new product lines to meet additional cooking needs.
| Characteristics | Values |
|---|---|
| Materials | Pig iron, recycled cast iron, recycled scrap steel, vermiculite |
| Melting point | 2800°F |
| Time taken to melt | 15 minutes |
| Molding process | Automated |
| Machinery | Disamatic molding machines |
| Number of molds made per hour | 350-400 |
| Weight of iron product shipped per week | 1 million pounds |
| Manufacturing location | South Pittsburg, Tennessee |
| Manufacturing process | Hands-on, controlled by workers |
| Seasoning | Factory seasoned with soybean oil |
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What You'll Learn
Lodge's manufacturing process
Lodge Manufacturing Company is an American manufacturer of cast-iron cookware based in South Pittsburg, Tennessee. The company was founded in 1896 by Joseph Lodge, who revived an abandoned railroad foundry and began producing high-quality cast-iron home goods. Lodge is one of America's oldest cookware companies in continuous operation and is still owned and managed by the Lodge family.
The manufacturing process at Lodge involves a mixture of pig iron, recycled cast iron, and recycled scrap steel that are melted into molten cast iron in a 2800°F furnace. Vermiculite is added as a bonding agent to remove impurities. The molten cast iron is then poured between two sand molds to create each piece of cookware. The formed cookware is shaken and tumbled to remove the molding sand and is then shot-blasted with a fine steel shot to remove any residual sand. After this, the cookware is ground, polished, rinsed, and hung to dry with a steam dryer.
In the past, Lodge used a hand-pouring operation, but in 1950, the company converted to an automated molding process, improving safety for workers. In 1965, Lodge became the first American company to use a Disamatic, a Danish molding machine that fully automated the casting process and greatly improved production. Today, Lodge operates five Disamatic molding machines, each capable of making 350-400 molds per hour. Lodge ships an average of one million pounds of iron products each week, all melted, poured, molded, finished, and packaged in South Pittsburg.
Lodge has also implemented eco-friendly options in its manufacturing process, such as replacing coal-fired cupola furnaces with an electro-magnetic induction melting system. The company has improved its foundry to minimise waste, recycling sand, steel shot, and any lesser-quality products. Lodge was the first cast-iron cookware manufacturer to season their products in the foundry in 2002, spraying the cookware with soybean oil and baking it at a high temperature before boxing. This process creates a non-stick coating and makes the cast iron ready for use, unlike traditional unseasoned cast iron, which required a time-consuming preparation process at home.
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Materials used
Lodge Manufacturing is an American company that has been making cast iron pans and other cookware for over a century. The company was founded by Joseph Lodge in 1896 and has been based in South Pittsburg, Tennessee, ever since. Lodge pans are made from cast iron, which is a mixture of pig iron, recycled cast iron, and recycled scrap steel. This mixture is melted into molten cast iron in a 2800°F furnace, with vermiculite added as a bonding agent to remove impurities.
The molten cast iron is then poured into molds to create each piece of cookware. Lodge operates five Disamatic molding machines, each capable of making 350-400 molds per hour. After the cast iron is molded, the formed cookware is shaken and tumbled to remove any residual molding sand. It is then shot-blasted with a fine steel shot to ensure that all the sand is removed. The cookware is then ground, polished, rinsed, and hung to dry with a steam dryer.
Before boxing, the cast iron cookware is sprayed with soybean oil and baked at a high temperature, creating a non-stick coating. This process, known as seasoning, was introduced by Lodge in 2002 and has since become an industry standard. Lodge was also the first company to use a Disamatic molding machine, which fully automated the casting process and greatly improved production capabilities.
In addition to their classic cast iron line, Lodge has expanded its product offerings to include enameled cast iron, seasoned carbon steel, and heat-enhanced cast iron. Enameled cast iron is made of traditional cast iron but is coated in enamel, resulting in vibrant, eye-catching hues. Heat-enhanced cast iron is dishwasher-safe, making it a popular choice for commercial eateries. Lodge's carbon steel line was introduced in 2013, providing high-quality carbon steel cookware to match the standards of European manufacturers.
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Melting and molding
Lodge Manufacturing is an American company that has been making cast iron cookware since 1896. The company was founded by Joseph Lodge, who built the Lodge family home in 1877 and opened the Blacklock Foundry in 1896. Lodge pans are made through a melting and molding process that has been refined over the years.
The first step in the manufacturing process involves melting a mixture of pig iron, recycled cast iron, and recycled scrap steel into molten cast iron. This mixture is heated to extremely high temperatures of around 2800°F, taking approximately 15 minutes to melt. Vermiculite is added as a bonding agent to remove any impurities.
Once the molten cast iron is ready, it is poured into molds to create each piece of cookware. Lodge utilizes Disamatic molding machines, which are fully automated and have significantly improved production capabilities. Each machine can produce 350-400 molds per hour. The formed cookware is then shaken, tumbled, and shot-blasted to remove any residual molding sand before being ground, polished, rinsed, and dried.
Lodge has a long history of innovation in the molding and casting process. In the 1950s, the company transitioned from a hand-pour operation to an automated molding process, improving workplace safety. In 1965, Lodge became the first American company to adopt the Disamatic molding machine, originally used during World War II.
The company continues to embrace technology while maintaining a hands-on approach. Workers directly control the machinery and monitor metal chemistry and other critical aspects during melting and throughout the production process. Lodge has also implemented eco-friendly initiatives, such as replacing coal-fired cupola furnaces with an electromagnetic induction melting system.
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Finishing and packaging
Before boxing, the Lodge cookware is sprayed with soybean oil and baked at a high temperature. This process seasons the cast iron, creating a natural non-stick coating. Lodge was the first cast-iron cookware manufacturer to season their products in the foundry, an industry first that occurred in 2002. This eliminated the need for consumers to wash off wax and season their pans before use.
The finished products are then packaged and shipped. Lodge operates five Disamatic moulding machines, capable of making 350-400 moulds an hour. The company ships an average of one million pounds of iron products each week, all finished and packaged in South Pittsburg, Tennessee, where the company has been based for over 120 years.
Lodge pans are packaged in boxes with labels that indicate eye size rather than skillet size. For instance, L10SK3 is a 12-inch skillet, not a 10-inch, because the numbers are from the days when cookware was sized to fit on the numbered eyes of a wood stove.
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History of the company
Lodge Manufacturing Company is an American manufacturer of cast-iron cookware based in South Pittsburg, Tennessee. The company was founded in 1896 by Joseph Lodge, who settled in South Pittsburg with his wife in the 1870s. Joseph travelled the US and worked on the railroads in Cuba before returning to Tennessee and building the Lodge family home in 1877.
In 1896, Joseph opened the Blacklock Foundry, which unfortunately burned down in 1910. When Joseph rebuilt the foundry, he renamed the company Lodge Manufacturing. The company has been in business for over a century, producing cast iron products for home and commercial chefs. Lodge is the oldest manufacturer of cast iron cookware remaining in the United States and is still owned and managed by the descendants of the Lodge family.
In the 1950s, Lodge converted from a hand-pour operation to an automated molding process, improving safety for foundry workers. In 1965, Lodge became the first American company to use a Disamatic, a Danish molding machine used during World War II. This innovative machinery fully automated the casting process and significantly improved production. During the 1970s, the foundry underwent renovations, and in 1973, Lodge's iconic logo was created.
In 2002, Lodge introduced seasoned cast iron cookware, an industry first. Prior to this, cast iron was sold unseasoned with a thin layer of wax to prevent rust. Lodge's "aha!" moment came when they launched factory-seasoned cast iron, which is sprayed with soybean oil and baked at a high temperature before being boxed. In the same year, Lodge also introduced its first carbon steel cookware line. In 2005, the company launched a line of enameled cast-iron cookware to match the quality of European manufacturers. Lodge continues to expand its product lines to meet additional cooking needs, offering grills, griddles, Dutch ovens, tableware, baking pans, and more.
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Frequently asked questions
Lodge pans are made of cast iron, a mixture of pig iron, recycled cast iron, and recycled scrap steel.
Lodge pans are made by melting a mixture of pig iron, recycled cast iron, and recycled scrap steel into molten cast iron. Vermiculite is then added as a bonding agent to remove impurities. The molten cast iron is then poured between two sand molds to create each piece of cast iron. The formed cookware is then shaken and tumbled to remove the molding sand.
Lodge pans are made in South Pittsburg, Tennessee, USA, where the company was founded in 1896.
