Do you know how the iron pan is made? We will visit the Lodge Cast Iron factory located in the United States.
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It is recognized as the oldest manufacturer of cast iron pots, pans and other cookware in the United States.
The raw material is composed of iron, recycled steel, and a sand composition for the lost mold.
Materials are loaded using a powerful electromagnet, capable of transporting up to 5,000 kilograms of metal.
The material passes through a vibrating belt until it reaches the feeding chamber. They are weighed according to product specifications. Other material metal alloys are added to complete its composition.
Once the raw material is set, the metals are placed in the oven for their melting. The temperature reaches 1,500 degrees Celsius, where it can melt 10,000 kilograms of metal. It takes 45 minutes for these 10 tons to turn into liquid.
In the melting of iron, the impurities are less dense, and stay on the surface. And they are removed by the operator with the help of the shovel.
Then a small sample of the solution is taken. Spectrometer equipment is used to measure the chemical composition of each sample.
During the melting of the metal, the operator prepares a quantity of silica that will also be added in the process. It must be placed at the right time, so as not to harm the material.
And before leaving for molding, the operator checks that the temperature is correct.
Yet another operator adds more components to the molten metal. They are mixed and some more impurities are removed.
Now the metal is transferred to the molding machine. But before the mold, we still need to make the model.
In this process, the model is made with different types of metal, and will be used as a base for a sand mold. Cast iron is poured into this mould, and as the melting temperature of the sand is much higher than that of the metal, the iron piece takes on its shape. This process is known as "lost mold",
Upstairs is where the sand, water and clay from the sand mold are mixed. The prepared sand is transported through the conveyor and poured into a funnel.
It is in the funnel that the sand is molded with the model of the pot. The technician has full control over the process, from belt speed to mold filling by cast iron.
And then the liquid iron is put into the sand mold, where it will replace the model.
The entire set is transported by the vibrating belt. This vibration separates the sand from the pan. The sand is reused.
The iron pan is placed in the rotating drum, where the grinding takes place.
The pans remain on the conveyor belt to remove burrs.
In the finishing sector, the operator separates the pans for the fine blasting machine. Which makes the pan shiny. Inside the machine, the part is blasted on all sides.
To complete the cleaning, the products are transported to tanks with water, soap and small steel balls.
Once cleaned, the pans go through a tempering or curing system.
First, the pans are ventilated with hot air. So all water and soap are removed.
A spray with a type of oil is applied to the pans. And then they are passed through a very high temperature oven.
After the oven, the pans go through another cooling system to allow their handling.
The packaging sector gives a final check on the quality of the pans before packaging.
#manufacture
00:00 Cast iron pot factory
00:39 Raw material
02:04 Melting of materials
04:26 Model molding
06:46 Cast iron dump
07:06 Vibration mat
08:15 Finishing
09:53 Cure cast iron pans
10:45 Packing
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