Tillie Doyle
Lodge Manufacturing Company is an American manufacturer of cast-iron cookware based in South Pittsburg, Tennessee. Founded in 1896 by Joseph Lodge, Lodge Manufacturing is one of the oldest cookware companies in continuous operation in the United States. The company has been in business for over a century and is well-known for its classic, long-lasting skillets and other cast-iron products. With a combination of old-school techniques and new technology, Lodge creates reasonably priced cookware that is designed to last a lifetime.
| Characteristics | Values |
|---|---|
| Location | South Pittsburg, Tennessee |
| Year of establishment | 1896 |
| Founder | Joseph Lodge |
| Current owners | Descendants of the Lodge family |
| Number of employees | 480 |
| Metal melting temperature | 2,800 degrees Fahrenheit |
| Metal pouring temperature | 2,500 degrees Fahrenheit |
| Molding machines | 5 Disamatic molding machines |
| Molds made per hour | 350-400 |
| Metal mixture | Pig iron, recycled cast iron, and recycled scrap steel |
| Bonding agent | Vermiculite |
| Foundry | Opened a second foundry in 2017 |
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What You'll Learn
- Lodge Manufacturing Company: founded in 1896 by Joseph Lodge in South Pittsburg, Tennessee
- The manufacturing process: a combination of hands-on work and machinery
- Ingredients: pig iron, recycled cast iron, and recycled scrap steel
- Moulding: Lodge operates five Disamatic moulding machines
- Seasoning: Lodge was the first cast-iron cookware manufacturer to season their products
Lodge Manufacturing Company: founded in 1896 by Joseph Lodge in South Pittsburg, Tennessee
The Lodge Manufacturing Company was founded in 1896 by Joseph Lodge, a native of England, in South Pittsburg, Tennessee. Joseph Lodge settled in South Pittsburg, a small town of 3,000 people, with his wife. Joseph built the Lodge family home in 1877 and then opened his first foundry in 1896, named the Blacklock Foundry. This foundry burned down in 1910, and when Joseph Lodge rebuilt it, he renamed the company Lodge Manufacturing. The company has been in business for over 120 years and is the oldest manufacturer of cast-iron cookware in the United States.
Lodge Manufacturing is one of America's oldest cookware companies in continuous operation and is still owned and managed by the descendants of the Lodge family. Two fourth-generation family members run the company, which is the largest employer in its county. Lodge sells over 140 items, including skillets, Dutch ovens, and a variety of cookware and decorative items. The company employs 480 people and combines old-school techniques with new technology to create reasonably priced, top-quality, long-lasting cookware. Lodge operates five Disamatic moulding machines, each capable of making 350-400 moulds an hour, and ships an average of one million pounds of iron product each week.
Lodge's manufacturing process is unique in that it employs a hands-on approach, with machinery controlled directly by workers rather than being computer-automated. The metal chemistry and other aspects of the production process are monitored by workers during melting and throughout the rest of the process. Lodge has also implemented eco-friendly options, such as replacing coal-fired cupola furnaces with an electro-magnetic induction melting system, and has improved the foundry to yield little to no waste by 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, and in 2005, they introduced a line of enameled cast-iron cookware to match the ability of European manufacturers.
Lodge's cast-iron products are made from a mixture of pig iron, recycled cast iron, and recycled scrap steel that is melted into molten cast iron at 2,800 degrees Fahrenheit. Vermiculite is added as a bonding agent to remove impurities. The molten cast iron is then poured into sand case moulds made of sand, clay, and water. The formed cookware is shaken, tumbled, shot-blasted, ground, polished, rinsed, and hung to dry. In the final step of the finishing process, the cookware is sprayed with soybean oil, baked at a high temperature, and then packaged. Lodge's products are sold in big-box stores like Target and Walmart, as well as high-end independent gourmet stores, and are shipped to 3,000 dealers in the United States and distributors in over 80 countries.
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The manufacturing process: a combination of hands-on work and machinery
The manufacturing process of Lodge pans combines hands-on work and machinery, with the latter being directly controlled by workers rather than computer-automated. Lodge operates five Disamatic molding machines, each capable of making 350-400 moulds per hour.
The manufacturing process begins with a mixture of pig iron, recycled cast iron, and recycled scrap steel, which are melted into molten cast iron in a 2,800°F furnace. Vermiculite is added as a bonding agent to remove impurities. The molten cast iron is then poured into sand moulds, creating each piece of cast iron. The formed cookware is shaken and tumbled to remove the moulding sand, and it is then shot-blasted with a fine steel shot to remove any residual sand. The cookware is then ground, polished, rinsed, and hung to dry with a steam dryer.
In the past, Lodge used a hand-pouring operation, where employees were compensated by the number of moulds poured daily, as indicated by unique symbols or numbers on the bottom of the cookware. Today, the company has an automated molding process, which has improved safety and production capabilities. Lodge has also implemented eco-friendly options, such as replacing coal-fired cupola furnaces with an electro-magnetic induction melting system, and recycling sand, steel shot, and any lesser-quality products.
The final step in the finishing process before packaging is seasoning the cookware. Lodge was the first cast-iron cookware manufacturer to season their products in the foundry, spraying them with soybean oil and baking them at a high temperature. This replaces the traditional method of using lard or fat and baking at a very high temperature. Lodge's seasoned cast iron cookware was debuted in 2002, and it has since become an industry standard.
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Ingredients: pig iron, recycled cast iron, and recycled scrap steel
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 opened his first foundry in South Pittsburg, a town of 3,000 residents located alongside the Cumberland Plateau of the Appalachian Mountains. Lodge skillets are made from a mixture of pig iron, recycled cast iron, and recycled scrap steel.
The manufacturing process begins by melting these materials into molten cast iron in a 2,800°F furnace. It takes around 15 minutes to melt a 2,000-pound mixture of these ingredients. Vermiculite is then added as a bonding agent to remove impurities. The molten cast iron is poured into sand molds to create each piece of cookware. The formed cookware is then shaken and tumbled to remove the molding sand. It is then shot-blasted with a fine steel shot to remove any remaining sand, before being ground, polished, rinsed, and hung to dry with a steam dryer.
Lodge skillets are known for their durability and longevity, with the coating improving over time and use. The company employs a combination of hands-on processes and technology to create its cookware. While machinery is controlled directly by workers, Lodge has also implemented eco-friendly options, such as replacing coal-fired cupola furnaces with an electro-magnetic induction melting system. The foundry was renovated in the 1970s with steel columns, a new roof, and an updated exterior.
Lodge skillets are reasonably priced and widely available in the United States and internationally. The company employs 480 people and is the largest employer in its county. Lodge remains a family-owned business, with two fourth-generation family members still running the company.
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Moulding: Lodge operates five Disamatic moulding machines
Lodge has been manufacturing cast iron cookware in South Pittsburg, Tennessee, since 1896. The company was founded by Joseph Lodge, and it has stayed in the family ever since. Lodge is the largest employer in its county and is the oldest manufacturer of cast iron cookware in the United States.
Lodge's manufacturing process is unique in that it employs a hands-on approach with machinery that is controlled directly by workers rather than being computer-automated. The company has also implemented eco-friendly options, such as replacing coal-fired cupola furnaces with an electro-magnetic induction melting system. Lodge's foundry was converted from a hand-pour operation to an automated moulding process in 1950, creating a safer working environment for its employees.
In 1965, Lodge became the first American company to use a Disamatic moulding machine. This Danish invention was used for manufacturing during World War II. The Disamatic fully automated the casting process and significantly improved Lodge's production capabilities. Lodge currently operates five Disamatic moulding machines, each capable of making 350-400 moulds per hour. The Disamatic consists of a moulding machine and a mould-transporting conveyor. A moulding sand mixture, typically green sand or bentonite, is blown into a rectangular steel chamber using compressed air. The sand is then squeezed between two patterns at the ends of the chamber. After this, one of the chamber plates opens, and the opposite plate pushes the finished mould onto the conveyor. The cycle repeats, creating a chain of finished moulds that butt up against each other on the conveyor. These moulds are then filled with molten metal and placed on a cooling conveyor.
Lodge ships an average of one million pounds of iron products each week, all melted, poured, moulded, finished, and packaged in South Pittsburg, Tennessee.
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Seasoning: Lodge was the first cast-iron cookware manufacturer to season their products
Lodge Manufacturing, the oldest manufacturer of cast-iron cookware in the United States, has been in business since 1896. The company was founded by Joseph Lodge and has been crafting cast iron cookware in South Pittsburg, Tennessee, for over 120 years. Lodge operates a total of five Disamatic moulding machines, each capable of making 350-400 moulds an hour. They ship an average of one million pounds of iron products each week, all melted, poured, moulded, finished, and packaged in Tennessee.
Lodge was the first cast-iron cookware manufacturer to season their products. In 2002, Lodge debuted seasoned cast-iron cookware, an industry first. Before this, cast iron was sold unseasoned, with a thin layer of carnauba bean wax to prevent rust during storage and merchandising. This water-soluble wax had to be washed off at home, and the cookware had to be oiled and baked in the oven before use. Lodge's "aha!" moment, according to Public Relations and Advertising Manager Mark Kelly, was when they launched their factory-seasoned cast iron. Now, in the final step of the finishing process before boxing, Lodge cookware is sprayed with soybean oil and baked at a high temperature. This creates a smooth, hard protective coating that seals out moisture and prevents rust, keeping the pan in good condition for years. Lodge recommends giving new cookware a quick rinse, drying it thoroughly, and adding a light coat of cooking oil for its first use.
Lodge cast-iron cookware is made with a mixture of pig iron, recycled cast iron, and recycled scrap steel that is melted into molten cast iron. Vermiculite is added as a bonding agent to remove impurities. The molten cast iron is then poured between two sand moulds to create each piece of cast iron. The formed cookware is shaken and tumbled to remove the moulding sand, and it is then shot-blasted with a fine steel shot to remove any residual sand. It is then ground, polished, rinsed, and hung to dry with a steam dryer. Lodge has a hands-on manufacturing process, with machinery that is controlled directly by workers rather than being computer-automated. Lodge has also implemented eco-friendly options, such as replacing coal-fired cupola furnaces with an electro-magnetic induction melting system.
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Frequently asked questions
Lodge pans are made in South Pittsburg, Tennessee. The company was founded in the town in 1896 by Joseph Lodge and has been in the Lodge family ever since.
Lodge pans are made from cast iron. The company uses a mixture of pig iron, recycled cast iron, and recycled scrap steel melted into molten cast iron at 2,800°F. Vermiculite is then added as a bonding agent to remove impurities.
Lodge pans are made by pouring the molten cast iron into sand molds. The formed cookware is then shaken, tumbled, shot-blasted, ground, polished, rinsed, and hung to dry. Lodge uses a combination of old-school techniques and new technology to create its pans.
Lodge pans are available at retailers like Target and Walmart, as well as high-end independent gourmet stores like Williams Sonoma. They can also be purchased online through Amazon and other merchants.
