Lodge Cast Iron 2012 - GoExpo
Lodge Cast Iron 2012 - GoExpo
Lodge Cast Iron 2012 - GoExpo
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outdoor retailer<br />
summer show <strong>2012</strong><br />
For more information contact: Mark H. Kelly<br />
office 423-837-7181<br />
cell 423-645-5511<br />
mkelly@lodgemfg.com
<strong>2012</strong> BACKPACKER MAGAZINE EDITOR’S CHOICE AWARD<br />
<strong>Lodge</strong> Manufacturing Company<br />
is honored to be a recipient of<br />
a <strong>2012</strong> Backpacker magazine<br />
Editor’s Choice Award for our Camp<br />
Dutch Ovens, the most prestigious<br />
award in the outdoor industry.<br />
Backpacker magazine Editors’<br />
Choice Award is given annually to<br />
products in recognition of their<br />
outstanding innovation in design,<br />
materials and/or performance.<br />
The <strong>Lodge</strong> Camp Dutch Oven was<br />
one of only 13 innovative products<br />
that are honored with a <strong>2012</strong><br />
Backpacker Editors’ Choice Award.<br />
The sole domestic manufacturer<br />
of <strong>Cast</strong> <strong>Iron</strong> Cookware, <strong>Lodge</strong><br />
produces eight different sizes of<br />
Camp Dutch Ovens – from 1-qt to<br />
12-qt – with the 6-qt, 12-inch Camp<br />
Dutch the most popular. <strong>Lodge</strong><br />
Camp Dutch Ovens are revered<br />
for the versatility, allowing camp<br />
cooks the ability to use numerous<br />
cooking techniques to prepare a<br />
wide array of recipes.<br />
Since their inception, the<br />
Backpacker Editors’ Choice<br />
Awards have come to be regarded<br />
as the most sought-after award<br />
for outdoor equipment and<br />
apparel found in the industry. The<br />
impeccable outdoor credentials<br />
and rigorous field-testing<br />
standards of the Backpacker staff<br />
guarantee that these awards are<br />
an undisputed mark of quality<br />
for the companies and products<br />
selected.
SOUTH PITTSBURG, TN – <strong>Lodge</strong>, America’s Original Cookware Company, is<br />
featuring several new products at the International Housewares Show, March<br />
10-13, at Chicago’s McCormick Place. The 116-year-old manufacturing company’s<br />
booth is S3218.<br />
Founded by Joseph <strong>Lodge</strong> in 1896, <strong>Lodge</strong> Manufacturing Company is the sole<br />
US manufacturer of cast iron cookware and the oldest family-owned cookware<br />
company in the country. For more information on <strong>Lodge</strong>, visit www.lodgemfg.com.<br />
LODGE SEASONED CARBON STEEL<br />
An industry first, the seasoned skillets (at left)<br />
are available in 8” (CRS8) $40, 10” (CRS10)<br />
$45 and 12” (CRS12) $50. The 15” carbon steel<br />
skillet (below) features two loop handles<br />
(CRS15) $90, available 4th quarter.<br />
Made in the USA.<br />
NEW PACKAGING<br />
<strong>Lodge</strong> Manufacturing Company is<br />
introducing new packaging and<br />
labeling for our foundry seasoned cast<br />
iron cookware and Enamel Coated <strong>Cast</strong><br />
<strong>Iron</strong> cookware. The designs enhance<br />
our 116-year history as an American<br />
cookware manufacturer while also<br />
targeting growing market segments,<br />
including millennials.<br />
LODGE ACCESSORIES<br />
Yellow and Orange silicone handle holders are<br />
added to our wildly popular line of silicone kitchen<br />
accessories. Yellow (ASHH21) and Orange (ASHH61)<br />
Imported. $6. Yellow Pot Holder (AS6S21).<br />
Imported. $5.<br />
Yellow Silicone egg ring. Imported. (ASER). $3.75<br />
Following up on the success of our pan scraper<br />
(SCRAPERPK), <strong>Lodge</strong> introduces our Grill Pan<br />
Scraper. 2-pack of red and black. Imported.<br />
(SCRAPERGPK) $5<br />
Parchment Dutch Oven liners. 8 liners per box. Made<br />
in the USA. (A5DOL) $8<br />
<strong>Lodge</strong> enamel stainless steel knob 2” dia., includes<br />
stainless steel screw. Oven safe to 450°F. Imported.<br />
(ECSSK) $8<br />
Visit www.lodgemfg.com for pictures of new items.
lodge manufacturing company<br />
INFORMATION<br />
<strong>Lodge</strong> Manufacturing is the sole <strong>Cast</strong> <strong>Iron</strong> Cookware manufacturer in the United States<br />
• <strong>Lodge</strong> is the oldest family-owned cookware company in America, founded by<br />
Joseph <strong>Lodge</strong> in 1896<br />
• Today’s management team includes fourth generation descendants—CEO and Chairman Bob<br />
Kellermann and COO and President Henry <strong>Lodge</strong>.<br />
<strong>Lodge</strong> produces the highest quality <strong>Cast</strong> <strong>Iron</strong> Cookware in the world<br />
• Over 120 items of foundry seasoned cookware, representing the most extensive selection<br />
on the market<br />
• <strong>Lodge</strong> Signature Series: Seasoned <strong>Cast</strong> <strong>Iron</strong> with Stainless Handles<br />
<strong>Lodge</strong> Enamel: Imported Enamel Coated <strong>Cast</strong> <strong>Iron</strong><br />
• Dutch Ovens, Covered Casseroles, Grill Pans, Skillets, Panini Presses, Apples and oval,<br />
uncovered casseroles and Tea Kettles (new for <strong>2012</strong>)<br />
<strong>Lodge</strong> Seasoned Carbon Steel: Made in USA<br />
• An industry first, our Seasoned Carbon Steel Skillets are available in 8, 10 and 12 inches.<br />
<strong>Lodge</strong> Elements: 8 piece imported set of stainless steel cookware and USA made 10 ¼ inch<br />
<strong>Cast</strong> <strong>Iron</strong> Skillet.<br />
<strong>Lodge</strong> Press and more<br />
• <strong>Lodge</strong> Press has nine cookbooks on the preparation of food with <strong>Cast</strong> <strong>Iron</strong> Cookware<br />
• Accessory items for the culinary and outdoor markets<br />
Where to find <strong>Lodge</strong> cookware and accessories:<br />
• A wide variety of retail venues: Discounters/Mass Merchants (Wal-Mart and Target;<br />
Gourmet (Williams-Sonoma, Sur La Table, Independents); Big Box Specialty Stores (Crate &<br />
Barrel); Sporting Goods (Bass Pro Shop, Cabela’s, Sportsman’s Warehouse,<br />
Dick’s, Gander Mountain, Academy); Hardware (Ace, True Value,<br />
Independents); Tractor Supply, Mast General; Internet<br />
Retailers (Amazon.com, Overstock.com, Cooking.com,<br />
FoodNetwork.com, <strong>Lodge</strong>mfg.com and others).<br />
• <strong>Lodge</strong> Factory Stores: South Pittsburg, TN;<br />
Sevierville, TN; Commerce, GA;<br />
and Myrtle Beach, SC.<br />
• Call <strong>Lodge</strong> Customer Service at<br />
423-837-7181 for local dealer<br />
information.
how green is<br />
OUR FOUNDRY?<br />
LODGE CAST IRON COOKWARE’S SOCIAL RESPONSIBILITY SUCCESS STORIES<br />
Zero hazardous waste stream foundry<br />
Recycling Program, 2011 results: Cardboard – 78.05 tons; Foundry Sand<br />
Beneficial Reuse 270 tons; bushing steel – 4,822 tons; Metal scrap – 399<br />
tons; Batteries – 134 pounds; Seasoning Oil – 960 gallons, saving $5,300<br />
in purchase of new oil; Used Oil sales – 500 gallons of used motor oil.<br />
2010: <strong>Lodge</strong> <strong>Cast</strong> <strong>Iron</strong> begins use of a Zaptruck, a zero emission<br />
two-seat utility vehicle with a 1,600-pound capacity flatbed. Zaptruck is<br />
used to deliver items from the <strong>Lodge</strong> receiving department throughout<br />
our foundry and office campus. Using a quiet, 72 Volt AC motor, the<br />
Zaptruck is recharged by electrical outlet.<br />
• Alternative fuels used in 2011: Propane – 4,555 gallons for 2<br />
propane lift trucks and 2 propane sweepers. <strong>Lodge</strong> has 11 battery<br />
powered lifts, 5 pallet jacks, 3 man-lifts.<br />
2010: <strong>Lodge</strong> donates 6,000 Cubic Yards of Used Foundry Sand to the<br />
city of New Hope, TN for filling pond. The beneficial use of foundry sand<br />
policy was developed in 1996 (see item below).<br />
2008 Tennessee Pollution Prevention Partnership Success Story:<br />
Engineering Manager Keith Nunley designed a vegetable oil recycler for<br />
foundry seasoning process. Result is clean and reusable oil that can be<br />
re-introduced into seasoning system, and can also be used as biodiesel<br />
generator. In 2008, the system saved 1,170 gallons of vegetable oil from<br />
disposal, and reduced purchases of new oil.<br />
Conversion to recycled and biodegradable packing materials<br />
• 2008: replaced foam packing inserts for paper inserts, with over<br />
1 million inserts made of sustainable material used annually.<br />
• 2009: <strong>Lodge</strong> began using brown paper, corrugate packing<br />
material instead of plastic bubble wrap and Styrofoam peanuts<br />
<strong>Lodge</strong> Manufacturing received the 1994 Governor’s Award for<br />
Excellence in Hazardous Waste Reduction: In 1991, <strong>Lodge</strong> President<br />
Henry <strong>Lodge</strong> replaced the cupola melting system with more<br />
environmentally friendly induction melt system. The result was that<br />
<strong>Lodge</strong> Manufacturing changed its status as a Large Quantity Generator<br />
of Hazardous Waste to Small Quantity Generator.
HOW GREEN IS OUR FOUNDRY? (continued)<br />
Establishment of Beneficial Use of Foundry Sand: <strong>Lodge</strong> Manufacturing, the American<br />
Foundry Society (AFS), and the Environmental Committee of the AFS worked with the Tennessee<br />
Department of Environment and Conservation’s Division of Solid Waste to request and help draft<br />
a beneficial use policy for non-hazardous foundry sand. The policy was adopted in April 1996 and<br />
is an example of industry and government working together for the good of the environment.<br />
Beneficial Reuse of Foundry Sand/Marion County Landfill: <strong>Lodge</strong> Manufacturing coordinated<br />
with Marion County government to have 9,225 cubic yards of foundry sand to create the required<br />
12-inch protective cover over the liner in the first phase of two new units. Completed in March<br />
2003, the County saved $191,311.75 by using the sand.<br />
Settling Ponds Support Plant & Animal Life: A stream flows from South Pittsburg Mountain<br />
through the <strong>Lodge</strong> foundry and into the Lake Guntersville Reservoir Watershed. Working to<br />
enhance the stream’s water, <strong>Lodge</strong> constructed three storm water settling ponds to support<br />
plant and animal life. Water lilies, cattails and fish have been introduced to the ponds and are<br />
thriving. Water quality is now above requirements.<br />
Planting Trees for Site Beautification & Ozone Attainment: A total of 121 trees have been<br />
planted on the <strong>Lodge</strong> Manufacturing campus to help improve air quality and beautification. The<br />
establishment of 1.4 acres of trees is equivalent to removing one motor vehicle from the highway.
<strong>Lodge</strong> Manufacturing Company<br />
PO Box 380<br />
South Pittsburg, TN 37380<br />
P 423 837-7181<br />
F 423 837-8279<br />
info@lodgemfg.com<br />
www.lodgemfg.com<br />
For Immediate Release<br />
Contact: Mark H. Kelly<br />
<strong>Lodge</strong> Manufacturing Company<br />
423-837-7181<br />
mkelly@lodgemfg.com<br />
<strong>Lodge</strong> Accepts, Exceeds ENERGY STAR Challenge<br />
SOUTH PITTSBURG, TN – In a positive step toward energy efficiency and fighting climate change, <strong>Lodge</strong><br />
Manufacturing Company has taken the U.S. Environmental Agency’s (EPA) ENERGY STAR Challenge.<br />
The Energy Star Challenge calls for energy efficiency improvement of at least 10% for more<br />
than 5 million commercial/industrial buildings in the United States. Energy is often generated<br />
by burning fossil fuels, which emits greenhouse gases that contribute to climate change, and<br />
commercial/industrial buildings are responsible for 45% of U.S. greenhouse gas emissions.<br />
Using energy more efficiently will help reduce the country’s carbon footprint and save money.<br />
“Not only has <strong>Lodge</strong> accepted the Energy Star Challenge, we met our five-year goal in<br />
one year,” says <strong>Lodge</strong> Engineering Manager, Keith Nunley. “By working with all of the<br />
departments in our foundry, we are able to monitor energy usage more efficiently and reduce<br />
the amount of energy consumed.<br />
“We continue to improve every facet of monitoring and consumption of energy, and we will<br />
meet our goals for 2011.”<br />
EPA estimates that if the energy efficiency of commercial/industrial buildings in the U.S.<br />
improved 10%, Americans would reduce greenhouse gas emissions equal to those from about<br />
30 million vehicles while saving about $20 billion on annual utility bills.<br />
The 116-year-old family-owned company is the only manufacturer in the state of Tennessee to<br />
meet its goal and be recognized by the EPA for its efforts.<br />
Additionally, the reduction of energy usage by <strong>Lodge</strong> is equivalent to:<br />
• Eliminating the production of 2,500 metric tons of Co2, or removing 600 cars off of streets<br />
• Removing 292 homes from the electrical grid<br />
• Adding 728 acres of sequestered forests<br />
ENERGY STAR was introduced by EPA in 1992 as a voluntary, market-based partnership to reduce<br />
greenhouse gas emissions through energy efficiency. Today, the ENERGY STAR label can be<br />
found on more than 60 different kinds of products as well as new homes and commercial and<br />
industrial buildings that meet strict energy-efficiency specifications set by the EPA. In 2010,<br />
Americans saved $18 billion on their energy bills while reducing greenhouse gas emissions<br />
equivalent to 34 million vehicles.
Screen capture<br />
from the demand<br />
monitoring system<br />
that <strong>Lodge</strong> uses to<br />
meet the Energy<br />
Star ® Challenge.
foundry<br />
tour<br />
introduction<br />
Welcome to the <strong>Lodge</strong> <strong>Cast</strong> <strong>Iron</strong> Cookware Foundry in South Pittsburg, Tennessee. Founded in 1896 by Joseph <strong>Lodge</strong>, we’re the sole<br />
domestic manufacturer of cast iron cookware, and the oldest family-owned cookware company in the country.<br />
Unlike other cookware, cast iron gets better with constant use.<br />
But before you start cooking, we’ve got a lot of hard work to do.
ingredients<br />
The main ingredients for cast iron cookware are pig iron, stamped steel, carbon and silicon, primarily derived from three things.<br />
First we have pig iron, the result of smelting of iron ore. Our next ingredient is recycled scrap steel from other manufacturers.<br />
The last ingredient is recycled cast iron. Any cast iron that doesn’t meet our quality standards is returned to be melted again.
These raw materials are mixed according to a specific recipe to obtain a 2,000-pound charge. The materials are then transferred<br />
into a 600°F pre-heater, which removes any oil or water.<br />
melting<br />
This is an electric induction furnace. It has a four-ton capacity. The raw materials are transferred to the furnace,<br />
then melted at 2,800°F. It takes 15 minutes to melt the 2,000-pound charge into molten metal.
At this point we take a sample and, depending on an analysis of the sample, workers add measured amounts of alloys to create the<br />
proper metal chemistry.<br />
When the molten metal achieves the desired temperature and composition, it is poured into a transfer ladle.
We’re almost ready for the molds; however, when the 2,000 pounds of molten metal meets oxygen, impurities, referred to as<br />
oxides or slag, forms. We add a binding agent, called vermiculite, that holds together all of the impurities in the metal mixture.<br />
The slag is then removed.<br />
molding<br />
<strong>Lodge</strong> has two production lines. Depending on the patterns used, we can produce between 400 and 1,600 pieces<br />
of cookware an hour. This is a steel tool for making cast iron cookware. <strong>Lodge</strong> has tooling for all of our Skillets, Dutch Ovens,<br />
Griddles and other items.
An employee inserts a new pattern into the Disamatic, the machine that makes our sand molds. There are two halves to the pattern.<br />
When these two halves come together we will pour our metal mixture in between them.<br />
<strong>Lodge</strong> uses sand molds, a middle age technology. Sand molding remains the best and most practical way to produce cast iron.<br />
Molten iron is so hot it would melt almost any other material. But the sand can hold its own against the heat.<br />
This is how it works. Compressed air forces moist sand into a pattern that is squeezed at 700 to 1000 pounds per square inch to<br />
form the exact contour of our skillet. Exact reverse impressions of both sides of the pan are formed in the cavity in the sand. The<br />
molten iron fills the cavity, creating our cookware.<br />
In pouring our molds, the liquid metal must be between 2,480 and 2,520 degrees. This temperature produces the best finish<br />
for the castings. Following the shake off, the sand is captured, cooled and recycled.<br />
sand removal<br />
From here our cookware begins its cleaning process. After the molten metal is poured into the sand mold, the cookware moves<br />
along a vibrating conveyer belt to shake off the molding sand.<br />
The cookware is then transferred to a large rotating drum, where the cookware tumbles in a bed of iron media, which removes<br />
much of the remaining sand.
shot blasting<br />
Next we blast the cookware with fine steel shot to remove any remaining residual sand. It is a very effective way to remove sand<br />
and efficient because the steel shot is recycled.
Grinding removes any sharp edges or burrs and insures a smooth surface before the final step in the cleaning process.<br />
polishing<br />
Here the pots and pans swirl in a bath of steel media along with soap and water for a power scrubbing that enhances the<br />
surface finish. At the end of this step our cast iron is hung out to dry insuring that it is ready for the next process, seasoning.<br />
seasoning<br />
A critical step in making <strong>Lodge</strong> cast iron is seasoning. Vegetable oil is applied with electro static spray guns creating a uniform<br />
coating with charged oil particles. The positively charged oil atoms bond with the negatively charged iron atoms in the pan,<br />
creating a barrier between food and the pan without the need for a synthetic surface. The result is a natural easy-release surface<br />
that improves with continued use.<br />
baking<br />
From here the skillets travel to an oven, where they are baked at a high temperature. This transforms the oil into the black patina
providing your <strong>Lodge</strong> <strong>Cast</strong> <strong>Iron</strong> Cookware its distinctive look.<br />
packing<br />
What started out as raw materials and then became molten metal is now cool and is shipped to over 3,000 dealers throughout<br />
the United States and internationally.<br />
Lasting generations, the cookware will be sold to home cooks, restaurants and camp cooks.