The Art Of Crafting Lodge Cast Iron Pans: A Step-By-Step Guide

Lodge Cast Iron is the oldest and longest-running cast iron manufacturer in the United States. The company has been creating cast iron cookware in South Pittsburg, Tennessee since 1896. Lodge's cast iron pans are made through an ancient process called sand moulding, which involves pouring a mixture of molten pig iron, steel and other ingredients into a mould made of sand. The brand offers a wide range of cast iron pans, from skillets to Dutch ovens, in various sizes and colours. Lodge's cast iron pans are known for their durability, versatility and excellent heat retention. They can be used on the stovetop, in the oven, on the grill, and even over a campfire, making them a kitchen essential for many cooks.

The benefits of cast iron

Cast iron is a popular choice for both home and professional chefs due to its durability, heat retention, and versatility. Here are some key benefits of cast iron cookware:

Durability

Cast iron is renowned for its durability and longevity. With proper care, cast iron cookware can last for generations. Its legendary durability means it is virtually indestructible and easily restored if mistreated. Many people still use cast iron pans that have been passed down through their families.

Heat Retention

Cast iron has excellent heat retention properties. Once heated, it stays hot, helping to keep food warm. This makes it ideal for high-heat cooking techniques like searing steaks, grilling sandwiches, or baking bread. Cast iron's heat retention also contributes to even heating and cooking, ensuring your food is cooked evenly.

Versatility

Cast iron cookware is incredibly versatile. It can be used on various heat sources, including gas, electric, or induction stovetops, outdoor grills, and open campfires. It can also be placed directly into the oven. Cast iron's versatility extends to the types of dishes you can cook with it, from juicy steaks to gooey chocolate chip cookies.

Non-Stick Surface

When properly seasoned, cast iron develops a natural, slick patina called seasoning, which releases food easily. This non-stick coating can be reapplied through the seasoning process, making cast iron incredibly versatile and minimizing the need for additional oils or butter during cooking.

Health Benefits

Cooking with cast iron can add iron to your food, which is beneficial for those suffering from iron deficiency. Additionally, cast iron's non-stick surface allows you to cook with less oil, promoting healthier cooking options.

Affordability

Cast iron cookware is often sold at affordable prices and, due to its durability, can be considered a long-lasting investment. It is typically a fraction of the cost of similar cookware materials, making it an excellent option for those looking for quality without breaking the bank.

How to care for your Lodge cast iron pan

Lodge cast iron pans are a great addition to your kitchen and, with the right care, can last for generations. Here are some detailed instructions on how to care for your Lodge cast iron pan to keep it in top condition:

Washing and Drying:

First, it is important to note that you should always wash your Lodge cast iron pan by hand. Using a dishwasher will remove the seasoning and likely cause rust. Use hot water and a small amount of mild detergent or soap. You can use a nylon scrubbing brush or a pan scraper to remove any stuck-on food residue. Ensure you dry the pan promptly and thoroughly with a lint-free cloth or paper towel. If you notice black residue on your towel, don't worry, it is just the seasoning coming off, which is perfectly normal.

Re-seasoning:

To maintain the seasoning, rub a light layer of cooking oil or seasoning spray onto the surface of the pan after drying. Use a paper towel to wipe the surface until no oil residue remains. You can also season your pan in the oven a few times a year to strengthen the bond of the seasoning to the iron. To do this, apply a thin layer of cooking oil to the pan, place it upside down on the top rack of the oven, and bake at 450-500 degrees Fahrenheit for one hour.

Removing Rust:

If your pan develops rust, don't panic. Simply scour the rusty pan with warm, soapy water and steel wool. Rinse and dry the pan thoroughly, then apply a thin layer of cooking oil before baking it in the oven as described above.

Troubleshooting:

If you are experiencing issues with rust, flaking, odours, or tough, stuck-on messes, Lodge provides comprehensive guides and tips on their website to help you resolve these issues and maintain your cast iron pan.

The history of Lodge cast iron

In 1910, the Blacklock Foundry burned down, but Joseph Lodge was determined to keep his business going. Just three months later, he reopened the company as Lodge Cast Iron, a few blocks away from the original foundry's location. During the Great Depression in the 1930s, the Lodge family struggled to keep the business afloat. They produced and sold novelty items such as cast iron garden gnomes and animals to stay afloat.

In the 1950s, Lodge began to convert its foundry from a hand-pour operation to an automated molding process, which improved safety and efficiency. In the 1970s, the company faced another challenge during a period of tough economic conditions. William Leslie Kellermann, Joseph Lodge's grandson, led the effort to reconstruct the foundry, allowing the company to bring employees back to full workweeks.

In 1994, Lodge was recognised for its commitment to technology and conservation, receiving the Tennessee Governor's Award for Excellence in Hazardous Waste Reduction. The company continued to innovate, and in 2002, it became the first to debut seasoned cast iron, which has since become the industry standard. Lodge introduced its seasoned carbon steel cookware line in 2013, appealing to both professional chefs and outdoors enthusiasts.

Lodge Cast Iron has a rich history spanning over 125 years, adapting to challenges and innovations while remaining true to its roots in South Pittsburg, Tennessee.

The Lodge cast iron manufacturing process

The Lodge Manufacturing Company has been making cast iron products since 1896, when it was known as Blacklock Foundry. The company's founder, Joseph Lodge, began by manufacturing sad irons, tea kettles, kitchen sinks, and cast-iron cookware in South Pittsburg, Tennessee.

Lodge creates its diverse line of cast-iron cookware through an ancient process called sand moulding. This process involves pouring a proprietary mix of molten pig iron, steel, and other ingredients into a mould made of sand. Since sand melts at a higher temperature than iron, the mould holds its shape. Once the cast iron has cooled, the sand mould is broken, leaving behind a brand new piece of cast-iron cookware.

To make their cookware, Lodge first starts with a pattern. They use a Disamatic moulding machine to press a mixture of sand, water, and clay against the pattern to create moulds. Each machine can make 350-400 moulds an hour. Once the sand mould is created and the molten iron hits the right temperature, the liquified metal is poured into the mould.

When the cast iron has cooled, the castings move along a vibratory conveyor to shake off the moulding sand, which is then recycled. The cast iron then enters a rotating drum, filled with iron media, which is specifically engineered to break up the sand and scrub it from the casting surface. The media is continuously recycled. The cookware is then cleaned with fine steel shot and blasted from all sides inside the machine. Next, the cookware will fall into a bath of stainless steel media, soap, and water to enhance the finish. The stainless steel media is designed to come into complete contact with every inch of the skillet for a deep clean.

Once the cast iron is completely cleaned, it is hung on a conveyor to be seasoned. First, they go through a hot rinse and hot air blow-off. The cookware is then sprayed with vegetable oil and baked at a high temperature, creating a natural, easy-release finish that improves with use. Lodge debuted this seasoned cast-iron cookware in 2002—an industry first.

Lodge cast iron design features

Lodge cast iron pans are designed with versatility in mind. They can be used on a variety of heat sources, including stovetops, ovens, grills, and even over a campfire. The brand offers a range of sizes, from small, single-serve skillets to party-size pots and pans, ensuring that you have the perfect piece of cookware for any cooking adventure.

Lodge cast iron pans are known for their durability and heat retention. The pans are made with a mix of molten pig iron, steel, and other ingredients, which are poured into sand molds, creating a high-quality, long-lasting product. The brand's classic cast iron skillets are heavy and have a rustic look, with a slightly rough finish. However, they come pre-seasoned and are very affordable, making them a popular choice for both beginners and experienced cooks.

The Lodge Blacklock Collection is a lightweight line of cast-iron cookware inspired by the brand's original foundry. The pieces in this collection have longer handles, which stay cooler for longer, and unique markings on the bottom for easy identification. The Blacklock Deep Skillet is a versatile option, offering the benefits of a cast-iron skillet with the depth of a Dutch oven.

Lodge also offers a range of enameled cast iron cookware, which is designed with a smooth porcelain surface. This surface is resistant to acidic and alkaline foods and can be used for marinating, cooking, and refrigerating. The USA Enamel series is the latest addition to this collection, featuring a stainless steel knob and handles, and is available in red, white, and blue.

In addition to skillets and Dutch ovens, Lodge offers a variety of other cast iron products, including griddles, grill pans, presses, woks, and bakeware. The brand's grill pans have ribs that allow grease and fat to drain away from food while searing grill marks onto meats, vegetables, and sandwiches. The cast iron griddles have slightly raised edges to contain oil and ingredients, making them perfect for cooking breakfast foods like eggs, sausage, and pancakes.

Frequently asked questions