Revitalizing Vintage: Reseasoning Cast Aluminum Pans

Cast aluminium pans are durable and can last for several lifetimes, but they do need to be seasoned and maintained. Seasoning a cast aluminium pan involves washing it with hot soapy water, drying it, coating it with vegetable oil, and then baking it in the oven for one to two hours. This process helps to create a natural, non-stick coating. It's important to avoid using scouring pads, steel wool, or detergent on cast aluminium, as these can strip away the seasoning. Instead, use a gentle, synthetic scourer and a non-abrasive cleaner or a paste made with baking soda and water. With proper care, a cast aluminium pan can become a well-loved family heirloom.

Cleaning the pan

To clean an old cast aluminium pan, start by preparing a solution of three tablespoons of cream of tartar and four cups of water. Place the pan on the stove and pour the solution inside. Boil the solution on medium-high heat for 15 minutes, then remove the solution and let the pan cool.

If there is still a lot of residue left, or if the pan was too large to soak, gently scrub the pan with a soft-bristled toothbrush or a non-abrasive sponge. Use soft, circular motions to avoid scratching or damaging the surface of the pan.

Alternatively, you can use vinegar or lemon juice to clean the pan. Combine either one part lemon juice with four parts water or equal parts white vinegar and water. Spray the cleaner onto the pan and rub it with a soft cloth. To remove stains and stuck-on food, boil the cleaning solution in the pan.

If your pan has a lot of rust, you can try soaking it in a solution of equal parts vinegar and water. Check on the progress of the pan; the rust may be gone within an hour, but you can soak it for up to eight hours if needed.

Another option is to use a commercial cleaner, such as an oven cleaner or dissolver spray. Apply the cleaner to the pan and let it sit for 30 minutes to an hour. Then, scrub the pan with a non-abrasive pad or a soft-bristled brush.

It is important to note that you should avoid using certain materials when cleaning cast aluminium. Do not use an alkaline product, such as baking soda or ammonia, and do not use steel wool as it can scratch the surface. Instead, use a soft-bristled toothbrush or a non-abrasive scouring pad.

Drying the pan

As soon as you have finished scrubbing and rinsing the pan, use a clean cloth towel to dry it. Make sure to get it completely dry. Any remaining moisture can cause rust, so it is important to be thorough.

Once you have towel-dried the pan, place it on the stove and warm it over medium-low heat. This will help to evaporate any remaining moisture. It is important to do this step immediately after towel-drying, as rust can start to develop very quickly.

While the pan is warming up, prepare your oven by placing a sheet of aluminum foil on the bottom rack. This will catch any drips of oil when you place the pan in the oven to bake later in the process.

Some sources recommend preheating your oven to 500°F (or your oven's highest setting) at this point. Others suggest preheating to 325°F. This lower temperature is still high enough to open up the pores of the cast iron, allowing it to better absorb the oil.

It is important to note that you should not place the pan in the oven until after it has been coated in oil (the next step in the reseasoning process). However, having the oven prepared and ready to go at this stage will help you move through the process more efficiently, reducing the risk of rust developing on the surface of the pan.

By following these steps, you can ensure that your cast-aluminum pan is thoroughly dried and prepared for the next steps in the reseasoning process.

Baking the pan

Once your cast-iron pan is cleaned and dried, it's time to bake it in the oven. Place the pan in the oven and bake for one hour, un-oiled at first. This will allow the pores to open up and better soak in the oil in the next step. Be sure to place a sheet of aluminium foil on the lower shelf to catch any drips. Preheat the oven to 500° F or your highest setting.

After an hour, carefully remove the pan from the oven, using double oven mitts if necessary. Immediately rub a coat of oil all over the pan (inside and out) with a wadded paper towel or cotton cloth; the hot cast iron will absorb the oil into its pores and within minutes you’ll begin noticing a sheen. Keep rubbing oil into the metal until it begins to build up, then use new paper towels to wipe up excess oil until the pan just looks wet. Be very careful to avoid burning yourself. (The oil may smoke, but that’s ok.)

You can use olive oil, lard, or any other oil you want, but try to find a high smoke-point oil if you can. And open the windows; there will be some smoke.

If your pan is in bad condition, you may need to repeat the seasoning method a few times to build up a non-stick base coat. Simply rub oil on the cool pan and bake upside down for one hour at 500° F, letting the pan cool in the oven.

Seasoning the pan with oil

Seasoning a pan is a simple process that helps to prevent food from sticking to the cooking surface. To season new cookware, you just coat it with oil and heat it up. As it heats, the oil fills in any tiny cracks or imperfections in the metal to prevent food from sticking there.

Step 1: Wash the pan

Wash the pan with hot soapy water and scrub off any rust or black buildup with a nylon scrub brush or fine steel wool scrubber. Rinse and dry it thoroughly inside and out.

Step 2: Coat the pan with oil

Coat the inside of the pan with a thin layer of vegetable oil, canola oil, or flaxseed oil. Make sure to cover the inside, outside, and handle. Don't add too much oil—you don't want the pan to be too slippery. Aim for a nice even coating.

Step 3: Place the pan in the oven

Preheat your oven to between 300 and 500 degrees Fahrenheit. Place a sheet of aluminium foil on the lower shelf to catch any drips. Put the pan upside down on the middle rack of the oven to prevent the oil from pooling inside the pan.

Step 4: Bake the pan

Bake the pan for 15 to 20 minutes. For better seasoning, you can repeat the oil coating and baking steps up to three times.

Step 5: Cool the pan

After the designated time has passed, turn off the oven and allow the pan to cool completely. This gradual cooling process helps the oil to polymerize and create a durable non-stick coating on the surface of the pan.

Step 6: Wipe away excess oil

Once the pan has cooled, remove it from the oven and wipe away any excess oil with a paper towel. Your pan is now seasoned and ready for use!

Maintenance tips:

• For long-term care, it is best practice to oil your pan after each use.
• A well-seasoned skillet has a distinct look—it is noticeably dark with a shiny, semi-gloss finish.
• If you rarely use your cast-aluminium skillet, oiling it only two to three times a year will work.
• To clean a seasoned pan, use hot water and a sponge. Never use harsh chemicals or abrasive scouring pads, as these can scrub away the seasoning.
• Store your seasoned pan in a cool, dry place to prevent rust.

Returning the pan to the oven

Once you have cleaned your cast-iron pan, dried it, and applied a coat of oil, it's time to return the pan to the oven to bake.

Place the pan in the oven, upside down, and bake for one hour. This will allow the seasoning to bake into the cast iron, forming a natural, non-stick coating. This process can get a little smoky, so it's a good idea to place a sheet of aluminium foil on the lower shelf of the oven to catch any drips.

After an hour, turn off the oven and leave the pan inside to cool completely. This can take a few hours.

If your pan is in bad condition, you may need to repeat the seasoning process a few times to build up a non-stick base coat. Simply rub oil onto the cool pan and bake it upside down for an hour at 500°F (260°C), allowing the pan to cool in the oven.

Frequently asked questions