Forging Iron Pans: A Step-By-Step Guide

Cast iron pans are made by melting blocks of iron and steel together in a factory. Chemicals are then added to the mixture to raise its carbon levels. The molten metal is then poured into a mould made of sand, water and powdered clay. Once the cast iron pot or pan is cool, the sand mould is broken and the cookware is released. Workers then smooth each piece before it's ready to be sold.

Iron pans are made by pouring molten iron into a sand mould

To make an iron pan, moulds are first made out of fine, pliable sand that is compressed in massive machines. Molten iron is then poured into these moulds. Once the iron has been poured and cooled, the sand moulds are placed into a shake-out machine that shakes the sand away from the pan. The pans are then put on a giant conveyor belt to be sorted and inspected. If any pans are not up to standard, they are thrown back into the original scrap heap to be melted down and remade.

The process for making iron pans by hand is very similar, just on a much smaller and more hands-on scale.

Most modern iron pans are made using this method, though some are also made by pounding sheets of metal into shape, or by spinning iron on a lathe.

The sand is compressed in a machine and the iron is cooled

The process of making an iron pan starts with molten iron being poured into pre-shaped pan moulds. The sand is compressed in a machine, and the iron is cooled. This is followed by a process called 'seasoning', which is done to protect the iron from rusting and to create a non-stick surface for cooking. Seasoning involves applying a layer of animal fat or vegetable oil to the pan's surface and cooking it on. This process is repeated multiple times to build up a layer of polymerised fat, also known as a 'patina', which fills in the pores of the iron and creates a non-stick coating.

The process of making an iron pan begins with molten iron, which is poured into pre-shaped pan moulds. The exact shape of the mould depends on the type of iron pan being made – for example, a skillet will have a thicker body and shorter handles, while a frying pan will be thinner and have longer handles. Once the molten iron has been poured into the moulds, the sand is compressed in a machine. This removes any air bubbles and ensures that the iron takes on the shape of the mould. After the iron has cooled, it is removed from the mould and is ready to be seasoned.

Seasoning is a crucial step in the process of making an iron pan. It serves two main purposes: protecting the iron from rust and creating a non-stick surface for cooking. The first step in seasoning is to apply a layer of animal fat or vegetable oil to the surface of the pan. This can be done using a cloth or brush, and it is important to ensure that the entire surface is coated, including the handles and exterior. The pan is then placed in an oven and baked at a high temperature, typically between 250°C and 475°C. This process is repeated multiple times, with the number of repetitions depending on the desired level of seasoning. A well-seasoned pan will have a deep black colour and a non-stick surface.

The final step in the process is to cool the pan. This is done to allow the seasoning to set and create a durable, non-stick surface. Once the pan has cooled, it is ready to be used for cooking. A properly seasoned iron pan will have a shiny, glass-smooth surface that is prized by professional chefs and home cooks alike for its superior cooking performance.

The pans are sorted and inspected on a conveyor belt

Once the iron pans have been moulded and cooled, they are placed on a conveyor belt to be sorted and inspected. This is the final stage of the manufacturing process, where quality control ensures that any sub-standard pans are rejected and sent back to the start of the production line to be melted down and remade.

The conveyor belt moves the pans along a production line, where workers can inspect the pans for any faults. Pans are checked for chips, cracks, or other imperfections that would render them unfit for sale. This stage is vital to ensuring that only the highest-quality pans are sent out to retailers and customers.

The pans are sorted according to their condition, with any defective pans being removed from the line. The remaining pans will be packaged and shipped to stores, where consumers can purchase them. This process ensures that only the best products reach the market and helps to maintain the reputation of the manufacturer.

The sorting and inspection process is a meticulous one, requiring a keen eye for detail and a thorough understanding of the product. Each pan is individually assessed to ensure it meets the required standards. This stage of production is just as important as the casting and moulding processes, as it ensures customer satisfaction and helps to build brand loyalty.

Iron pans are heavy and durable

Iron pans are valued for their durability and heat retention. They are made from cast iron, which is a combination of iron and carbon. Cast iron is tough and long-lasting, and its ability to withstand high temperatures makes it ideal for searing and frying.

The process of making iron pans involves pouring molten iron into pre-shaped pan moulds. This method has been used for centuries, and its longevity is a testament to the durability of the material. Iron pans are typically thicker than similar-sized pans made from other materials, contributing to their weight and durability.

The weight of an iron pan is a sign of its robust construction. Its weight also indicates that it can retain more heat than other pans. The heavier the pan, the more heat it can store, and the longer it can retain that heat. This makes iron pans ideal for cooking methods that require high and consistent heat, such as searing and frying.

Iron pans are also valued for their ability to develop a non-stick surface over time. This is achieved through a process called seasoning, where oil is polymerised onto the surface of the pan, creating a slick, hardened coating. A well-seasoned iron pan will be almost non-stick and will also be protected from rust.

Overall, iron pans are heavy and durable due to the properties of cast iron, the thickness of the pans, and the development of a non-stick surface through seasoning. These characteristics make iron pans a popular and long-lasting choice for cooks.

They are also non-stick when properly seasoned

Cast iron pans are known for their heat retention, durability, and non-stick cooking when properly seasoned. Seasoning is a process by which a layer of animal fat or vegetable oil is applied and cooked onto the pan. This layer protects the cookware from rusting, provides a non-stick surface for cooking, and reduces food interaction with the iron of the pan.

The process of seasoning involves rubbing the pan with oil and heating it repeatedly. This causes the oil to break down into a plastic-like substance that bonds to the surface of the metal, creating a non-stick coating. The more layers of seasoning that are built up, the smoother and more non-stick the pan becomes.

It is important to note that cast iron pans should not be soaked in water or left wet, as this can lead to rust. Properly drying and re-seasoning the pan after each use will help maintain its non-stick properties.

In addition to the non-stick benefits, seasoning also helps to protect the pan from rust and can improve its heat retention. A well-seasoned cast iron pan can last for decades and even centuries, making it a valuable addition to any kitchen.

While modern cast iron pans often come pre-seasoned, it is recommended to season them again before first use to kickstart the patina and make clean-up easier. Regular use of the pan will also help to build up the seasoning and improve its non-stick properties over time.

Frequently asked questions