Cast Iron Revival: Restoring And Reseasoning Your Grill Pan

Cast iron grill pans are a vital tool to have in your kitchen. With the right care, they can outlast even your most durable non-stick or stainless steel pans. If your cast iron grill pan has developed rust or lost its non-stick surface, it's time to restore and reseason it. This process involves removing any existing rust, thoroughly cleaning the cast iron, and applying a layer of oil or fat to create a protective barrier. By restoring and reseasoning your cast iron grill pan, you can give it a fresh start and improve its performance.

Cleaning a cast iron grill pan with salt and water

To clean a cast iron grill pan with salt and water, start by allowing the pan to cool to the touch, but not completely. Then, generously cover the surface with coarse kosher salt. Next, add a small amount of hot water to the surface so that the salt sticks together to form a paste-like texture. Use a sponge to scrub the salt around the pan, getting in between the ridges and all around the sides. Rinse the pan with hot water to remove the salt and debris, and repeat if necessary.

If you want to avoid using water, you can also clean your cast iron grill pan with salt alone. Simply sprinkle a generous amount of coarse kosher salt on top of the pan and use a folded paper towel to rub the salt into the stuck-on food. Add more salt as needed and continue to scrub the pan with the salt and paper towel. Finally, use a new paper towel to wipe down the pan and dump all residue and salt into the trash.

After cleaning your cast iron grill pan, it's important to season it to protect the surface and prevent rust. To do this, rub a light layer of cooking oil or seasoning spray onto the surface of the pan, making sure to cover the inside, outside, and handle. Use a paper towel to wipe away any excess oil, then place the pan in the oven upside down on the top rack. Place a baking sheet or aluminium foil on the bottom rack to catch any drips, and bake at 450-500°F for one hour. Allow the pan to cool, then repeat the process as necessary to achieve the desired finish.

Removing old seasoning from a cast iron pan

Using a Fire Pit or Wood-Burning Stove

• Build a campfire in an outside fire pit or use a wood-burning stove to create a bed of hot coals.
• Once you have a good amount of coals, bury your cast iron pan, face down, in the hot coals and leave it there for several hours or overnight.
• The next day, remove the pan from the coals and wash it with hot, soapy water. If needed, use steel wool to remove any remaining seasoning, rust, or flakes.

Self-Cleaning Oven Method

• If you don't have access to a fire pit or wood-burning stove, you can use your oven's self-cleaning function. Place the cast iron pan upside down on the middle rack and run the self-cleaning cycle.
• Be warned that this method will produce a lot of smoke and odour, so it's best to do it on a day when you can open the windows for ventilation.
• After the cycle is complete, allow the pan to cool in the oven, then remove it and wash it with hot, soapy water. Use steel wool as needed to remove any stubborn residue.

Lye Bath or Oven Cleaner

• For heavily seasoned cast iron, you can use a lye bath or an oven cleaner like Easy-Off. Caution must be taken when working with lye, so be sure to wear long cuffed chemical-resistant gloves, eye protection, and cover any exposed skin.
• Spray the oven cleaner generously onto the cast iron pan or place the pan in a lye bath.
• Place the pan in a heavy-duty garbage bag and seal it tightly. Leave it for at least 24 hours or up to several days.
• Remove the pan from the bag and scrub it with steel wool or a steel brush. Be careful as the lye-soaked pan can be very slippery.
• Rinse the pan thoroughly and repeat the process if necessary.

Vinegar Soak

• For pans with no remaining seasoning, you can use a vinegar soak to remove rust. Fill a water-tight container with a 50/50 mix of distilled white vinegar and water, ensuring the pan is completely submerged.
• Soak the pan for no more than 30 minutes at a time. Vinegar effectively removes rust but can also eat away at the iron if left too long.
• Remove the pan from the vinegar and scrub it with steel wool and/or a steel brush while rinsing. Repeat the process as needed, but do not exceed 30 minutes per soak.
• Thoroughly rinse and dry the pan once the rust has been removed.

Electrolysis

• Electrolysis is another method to remove both seasoning and rust simultaneously. This method requires a battery charger and a steel plate.
• Connect the positive clamp to the steel plate and the negative clamp to the cast iron pan. Ensure that the pan and steel plate are completely submerged in the water and do not touch each other.
• Turn on the battery charger and let it run overnight. The solution will produce a cloudy stream of bubbles, indicating that the process is working.
• Once complete, remove the pan and scrub off any remaining residue with steel wool or a steel brush.

Removing rust from a cast iron pan

Step 1: Remove Rust

If your pan has minor surface rust, use a scouring pad or kitchen towel to rub about 1/3 cup of kosher salt into the pan until the rust spots disappear. For more serious cases of rust, start by soaking the pan in a vinegar solution. Create a mixture of equal parts water and distilled white vinegar in a bucket or deep foil pan, ensuring the entire pan is submerged. Check the pan every 15 minutes and remove it from the solution once the rust easily flakes away. This can take anywhere from one to eight hours, so keep a close eye on it to avoid over-soaking.

Step 2: Scrub and Wash the Pan

After removing the rust, wash the pan with mild dish soap and warm water. Use a mildly abrasive sponge or scrub pad to clean away any lingering rust. Be sure to use warm water to prevent the pan from warping or cracking. Dry the pan immediately and thoroughly with a kitchen or paper towel. You can also place it on the stovetop over low heat for a few minutes to ensure it is completely dry.

Step 3: Re-season the Pan

To restore the protective layer, you will need to re-season the pan. Preheat the oven to 450-500°F. Using a cloth, wipe a thin layer of cooking oil with a high smoke point, such as vegetable oil, all over the pan, including the inside, outside, and handle. Buff any excess oil, and place the pan upside down in the oven, with aluminum foil or a baking sheet on the bottom rack to catch any drips. Turn off the heat after an hour and let the pan cool in the oven.

Maintenance Tips:

• Always ensure your cast iron pan is completely dry before putting it away.
• Store it in a low-humidity environment.
• If stacking multiple pans, separate them with paper towels or breathable pan separators to prevent moisture buildup.
• Regularly oil your pan after each use or a few times a year if you use it infrequently.
• Repeat the complete seasoning process once or twice a year for regular upkeep.

By following these steps, you can effectively remove rust from your cast iron pan and restore it to its former glory!

Oiling a cast iron pan

Step 1: Wash and Dry Your Pan

Start by giving your cast iron pan a good scrub with warm, soapy water. You can use a small amount of soap or a mild detergent to clean the pan. If there is stuck-on food residue, you can use a pan scraper or a nylon brush to remove it. Rinse the pan thoroughly with warm water to remove any soap residue. Once rinsed, dry the pan promptly and thoroughly using a lint-free cloth or a paper towel. You can also place the pan on a stovetop flame for a few minutes to ensure that any remaining moisture is completely evaporated.

Step 2: Apply a Thin Layer of Oil

The next step is to apply a thin and even layer of cooking oil to the pan's surface. Use an oil with a high smoke point, such as vegetable oil, canola oil, safflower oil, or melted shortening. Avoid using too much oil, as it can make the pan sticky. The goal is to create a nice, even coating on the entire pan, including the handle and the outside. Use a paper towel to wipe the surface until no oil residue remains and the pan no longer looks greasy.

Step 3: Heat the Pan in the Oven

Preheat your oven to a temperature between 450°F and 500°F (230°C to 260°C). Place the oiled pan upside down on the top rack of the oven. Place a large baking sheet or a piece of aluminum foil on the bottom rack to catch any excess oil that may drip from the pan. Leave the pan in the oven for about an hour. The oil will undergo a process called polymerization, where it carbonizes and forms a hard, protective coating on the pan.

Step 4: Repeat the Process

You may need to repeat the oiling and heating process three to four times to build up a good initial layer of seasoning. After each round of seasoning, allow the pan to cool down completely before applying another layer of oil. Once you have completed the desired number of seasoning sessions, your cast iron pan will be ready for cooking!

Maintenance

To maintain the seasoning on your cast iron pan, it is recommended to oil it after each use. Simply rub a light layer of cooking oil onto the surface and wipe away any excess with a paper towel. Additionally, avoid using soap or abrasive scrubbers during routine cleaning, as they can strip away the seasoning. Instead, opt for a soft sponge, hot water, and a mild detergent if needed. Always dry the pan thoroughly after washing and apply a thin layer of oil to prevent rusting.

Heating a cast iron pan in the oven

To heat your cast iron pan in the oven, start by preheating your oven to a high temperature, somewhere between 350°F and 500°F. The high heat allows the oil to break down and bond with the cast iron. Place the oiled pan upside down on the middle rack of the oven. This prevents the oil from pooling inside the pan. Place a sheet of aluminium foil on the lower rack to catch any drips.

Leave the pan in the oven for around 30 minutes to an hour. The oil will polymerize and form the first of several hard, plastic-like coatings. You may need to repeat this process three to four times to achieve the right finish. When you are happy with the finish, turn off the oven and leave the pan inside to cool completely.

Once the pan is cool, wipe away any excess oil with a paper towel. When it's time to cook with your newly seasoned pan, wash it with hot water (no soap) and dry it thoroughly after each use.

Frequently asked questions