Lodge Cast Iron 2012 - GoExpo

outdoor retailer
summer show 2012
For more information contact: Mark H. Kelly
office 423-837-7181
cell 423-645-5511
mkelly@lodgemfg.com

2012 BACKPACKER MAGAZINE EDITOR’S CHOICE AWARD
Lodge Manufacturing Company
is honored to be a recipient of
a 2012 Backpacker magazine
Editor’s Choice Award for our Camp
Dutch Ovens, the most prestigious
award in the outdoor industry.
Backpacker magazine Editors’
Choice Award is given annually to
products in recognition of their
outstanding innovation in design,
materials and/or performance.
The Lodge Camp Dutch Oven was
one of only 13 innovative products
that are honored with a 2012
Backpacker Editors’ Choice Award.
The sole domestic manufacturer
of Cast Iron Cookware, Lodge
produces eight different sizes of
Camp Dutch Ovens – from 1-qt to
12-qt – with the 6-qt, 12-inch Camp
Dutch the most popular. Lodge
Camp Dutch Ovens are revered
for the versatility, allowing camp
cooks the ability to use numerous
cooking techniques to prepare a
wide array of recipes.
Since their inception, the
Backpacker Editors’ Choice
Awards have come to be regarded
as the most sought-after award
for outdoor equipment and
apparel found in the industry. The
impeccable outdoor credentials
and rigorous field-testing
standards of the Backpacker staff
guarantee that these awards are
an undisputed mark of quality
for the companies and products
selected.

SOUTH PITTSBURG, TN – Lodge, America’s Original Cookware Company, is
featuring several new products at the International Housewares Show, March
10-13, at Chicago’s McCormick Place. The 116-year-old manufacturing company’s
booth is S3218.
Founded by Joseph Lodge in 1896, Lodge Manufacturing Company is the sole
US manufacturer of cast iron cookware and the oldest family-owned cookware
company in the country. For more information on Lodge, visit www.lodgemfg.com.
LODGE SEASONED CARBON STEEL
An industry first, the seasoned skillets (at left)
are available in 8” (CRS8) $40, 10” (CRS10)
$45 and 12” (CRS12) $50. The 15” carbon steel
skillet (below) features two loop handles
(CRS15) $90, available 4th quarter.
Made in the USA.
NEW PACKAGING
Lodge Manufacturing Company is
introducing new packaging and
labeling for our foundry seasoned cast
iron cookware and Enamel Coated Cast
Iron cookware. The designs enhance
our 116-year history as an American
cookware manufacturer while also
targeting growing market segments,
including millennials.
LODGE ACCESSORIES
Yellow and Orange silicone handle holders are
added to our wildly popular line of silicone kitchen
accessories. Yellow (ASHH21) and Orange (ASHH61)
Imported. $6. Yellow Pot Holder (AS6S21).
Imported. $5.
Yellow Silicone egg ring. Imported. (ASER). $3.75
Following up on the success of our pan scraper
(SCRAPERPK), Lodge introduces our Grill Pan
Scraper. 2-pack of red and black. Imported.
(SCRAPERGPK) $5
Parchment Dutch Oven liners. 8 liners per box. Made
in the USA. (A5DOL) $8
Lodge enamel stainless steel knob 2” dia., includes
stainless steel screw. Oven safe to 450°F. Imported.
(ECSSK) $8
Visit www.lodgemfg.com for pictures of new items.

lodge manufacturing company
INFORMATION
Lodge Manufacturing is the sole Cast Iron Cookware manufacturer in the United States
• Lodge is the oldest family-owned cookware company in America, founded by
Joseph Lodge in 1896
• Today’s management team includes fourth generation descendants—CEO and Chairman Bob
Kellermann and COO and President Henry Lodge.
Lodge produces the highest quality Cast Iron Cookware in the world
• Over 120 items of foundry seasoned cookware, representing the most extensive selection
on the market
• Lodge Signature Series: Seasoned Cast Iron with Stainless Handles
Lodge Enamel: Imported Enamel Coated Cast Iron
• Dutch Ovens, Covered Casseroles, Grill Pans, Skillets, Panini Presses, Apples and oval,
uncovered casseroles and Tea Kettles (new for 2012)
Lodge Seasoned Carbon Steel: Made in USA
• An industry first, our Seasoned Carbon Steel Skillets are available in 8, 10 and 12 inches.
Lodge Elements: 8 piece imported set of stainless steel cookware and USA made 10 ¼ inch
Cast Iron Skillet.
Lodge Press and more
• Lodge Press has nine cookbooks on the preparation of food with Cast Iron Cookware
• Accessory items for the culinary and outdoor markets
Where to find Lodge cookware and accessories:
• A wide variety of retail venues: Discounters/Mass Merchants (Wal-Mart and Target;
Gourmet (Williams-Sonoma, Sur La Table, Independents); Big Box Specialty Stores (Crate &
Barrel); Sporting Goods (Bass Pro Shop, Cabela’s, Sportsman’s Warehouse,
Dick’s, Gander Mountain, Academy); Hardware (Ace, True Value,
Independents); Tractor Supply, Mast General; Internet
Retailers (Amazon.com, Overstock.com, Cooking.com,
FoodNetwork.com, Lodgemfg.com and others).
• Lodge Factory Stores: South Pittsburg, TN;
Sevierville, TN; Commerce, GA;
and Myrtle Beach, SC.
• Call Lodge Customer Service at
423-837-7181 for local dealer
information.

how green is
OUR FOUNDRY?
LODGE CAST IRON COOKWARE’S SOCIAL RESPONSIBILITY SUCCESS STORIES
Zero hazardous waste stream foundry
Recycling Program, 2011 results: Cardboard – 78.05 tons; Foundry Sand
Beneficial Reuse 270 tons; bushing steel – 4,822 tons; Metal scrap – 399
tons; Batteries – 134 pounds; Seasoning Oil – 960 gallons, saving $5,300
in purchase of new oil; Used Oil sales – 500 gallons of used motor oil.
2010: Lodge Cast Iron begins use of a Zaptruck, a zero emission
two-seat utility vehicle with a 1,600-pound capacity flatbed. Zaptruck is
used to deliver items from the Lodge receiving department throughout
our foundry and office campus. Using a quiet, 72 Volt AC motor, the
Zaptruck is recharged by electrical outlet.
• Alternative fuels used in 2011: Propane – 4,555 gallons for 2
propane lift trucks and 2 propane sweepers. Lodge has 11 battery
powered lifts, 5 pallet jacks, 3 man-lifts.
2010: Lodge donates 6,000 Cubic Yards of Used Foundry Sand to the
city of New Hope, TN for filling pond. The beneficial use of foundry sand
policy was developed in 1996 (see item below).
2008 Tennessee Pollution Prevention Partnership Success Story:
Engineering Manager Keith Nunley designed a vegetable oil recycler for
foundry seasoning process. Result is clean and reusable oil that can be
re-introduced into seasoning system, and can also be used as biodiesel
generator. In 2008, the system saved 1,170 gallons of vegetable oil from
disposal, and reduced purchases of new oil.
Conversion to recycled and biodegradable packing materials
• 2008: replaced foam packing inserts for paper inserts, with over
1 million inserts made of sustainable material used annually.
• 2009: Lodge began using brown paper, corrugate packing
material instead of plastic bubble wrap and Styrofoam peanuts
Lodge Manufacturing received the 1994 Governor’s Award for
Excellence in Hazardous Waste Reduction: In 1991, Lodge President
Henry Lodge replaced the cupola melting system with more
environmentally friendly induction melt system. The result was that
Lodge Manufacturing changed its status as a Large Quantity Generator
of Hazardous Waste to Small Quantity Generator.

HOW GREEN IS OUR FOUNDRY? (continued)
Establishment of Beneficial Use of Foundry Sand: Lodge Manufacturing, the American
Foundry Society (AFS), and the Environmental Committee of the AFS worked with the Tennessee
Department of Environment and Conservation’s Division of Solid Waste to request and help draft
a beneficial use policy for non-hazardous foundry sand. The policy was adopted in April 1996 and
is an example of industry and government working together for the good of the environment.
Beneficial Reuse of Foundry Sand/Marion County Landfill: Lodge Manufacturing coordinated
with Marion County government to have 9,225 cubic yards of foundry sand to create the required
12-inch protective cover over the liner in the first phase of two new units. Completed in March
2003, the County saved $191,311.75 by using the sand.
Settling Ponds Support Plant & Animal Life: A stream flows from South Pittsburg Mountain
through the Lodge foundry and into the Lake Guntersville Reservoir Watershed. Working to
enhance the stream’s water, Lodge constructed three storm water settling ponds to support
plant and animal life. Water lilies, cattails and fish have been introduced to the ponds and are
thriving. Water quality is now above requirements.
Planting Trees for Site Beautification & Ozone Attainment: A total of 121 trees have been
planted on the Lodge Manufacturing campus to help improve air quality and beautification. The
establishment of 1.4 acres of trees is equivalent to removing one motor vehicle from the highway.

Lodge Manufacturing Company
PO Box 380
South Pittsburg, TN 37380
P 423 837-7181
F 423 837-8279
info@lodgemfg.com
www.lodgemfg.com
For Immediate Release
Contact: Mark H. Kelly
Lodge Manufacturing Company
423-837-7181
mkelly@lodgemfg.com
Lodge Accepts, Exceeds ENERGY STAR Challenge
SOUTH PITTSBURG, TN – In a positive step toward energy efficiency and fighting climate change, Lodge
Manufacturing Company has taken the U.S. Environmental Agency’s (EPA) ENERGY STAR Challenge.
The Energy Star Challenge calls for energy efficiency improvement of at least 10% for more
than 5 million commercial/industrial buildings in the United States. Energy is often generated
by burning fossil fuels, which emits greenhouse gases that contribute to climate change, and
commercial/industrial buildings are responsible for 45% of U.S. greenhouse gas emissions.
Using energy more efficiently will help reduce the country’s carbon footprint and save money.
“Not only has Lodge accepted the Energy Star Challenge, we met our five-year goal in
one year,” says Lodge Engineering Manager, Keith Nunley. “By working with all of the
departments in our foundry, we are able to monitor energy usage more efficiently and reduce
the amount of energy consumed.
“We continue to improve every facet of monitoring and consumption of energy, and we will
meet our goals for 2011.”
EPA estimates that if the energy efficiency of commercial/industrial buildings in the U.S.
improved 10%, Americans would reduce greenhouse gas emissions equal to those from about
30 million vehicles while saving about $20 billion on annual utility bills.
The 116-year-old family-owned company is the only manufacturer in the state of Tennessee to
meet its goal and be recognized by the EPA for its efforts.
Additionally, the reduction of energy usage by Lodge is equivalent to:
• Eliminating the production of 2,500 metric tons of Co2, or removing 600 cars off of streets
• Removing 292 homes from the electrical grid
• Adding 728 acres of sequestered forests
ENERGY STAR was introduced by EPA in 1992 as a voluntary, market-based partnership to reduce
greenhouse gas emissions through energy efficiency. Today, the ENERGY STAR label can be
found on more than 60 different kinds of products as well as new homes and commercial and
industrial buildings that meet strict energy-efficiency specifications set by the EPA. In 2010,
Americans saved $18 billion on their energy bills while reducing greenhouse gas emissions
equivalent to 34 million vehicles.

Screen capture
from the demand
monitoring system
that Lodge uses to
meet the Energy
Star ® Challenge.

foundry
tour
introduction
Welcome to the Lodge Cast Iron Cookware Foundry in South Pittsburg, Tennessee. Founded in 1896 by Joseph Lodge, we’re the sole
domestic manufacturer of cast iron cookware, and the oldest family-owned cookware company in the country.
Unlike other cookware, cast iron gets better with constant use.
But before you start cooking, we’ve got a lot of hard work to do.

ingredients
The main ingredients for cast iron cookware are pig iron, stamped steel, carbon and silicon, primarily derived from three things.
First we have pig iron, the result of smelting of iron ore. Our next ingredient is recycled scrap steel from other manufacturers.
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
into a 600°F pre-heater, which removes any oil or water.
melting
This is an electric induction furnace. It has a four-ton capacity. The raw materials are transferred to the furnace,
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
proper metal chemistry.
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
oxides or slag, forms. We add a binding agent, called vermiculite, that holds together all of the impurities in the metal mixture.
The slag is then removed.
molding
Lodge has two production lines. Depending on the patterns used, we can produce between 400 and 1,600 pieces
of cookware an hour. This is a steel tool for making cast iron cookware. Lodge has tooling for all of our Skillets, Dutch Ovens,
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.
When these two halves come together we will pour our metal mixture in between them.
Lodge uses sand molds, a middle age technology. Sand molding remains the best and most practical way to produce cast iron.
Molten iron is so hot it would melt almost any other material. But the sand can hold its own against the heat.
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
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
molten iron fills the cavity, creating our cookware.
In pouring our molds, the liquid metal must be between 2,480 and 2,520 degrees. This temperature produces the best finish
for the castings. Following the shake off, the sand is captured, cooled and recycled.
sand removal
From here our cookware begins its cleaning process. After the molten metal is poured into the sand mold, the cookware moves
along a vibrating conveyer belt to shake off the molding sand.
The cookware is then transferred to a large rotating drum, where the cookware tumbles in a bed of iron media, which removes
much of the remaining sand.

shot blasting
Next we blast the cookware with fine steel shot to remove any remaining residual sand. It is a very effective way to remove sand
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.
polishing
Here the pots and pans swirl in a bath of steel media along with soap and water for a power scrubbing that enhances the
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.
seasoning
A critical step in making Lodge cast iron is seasoning. Vegetable oil is applied with electro static spray guns creating a uniform
coating with charged oil particles. The positively charged oil atoms bond with the negatively charged iron atoms in the pan,
creating a barrier between food and the pan without the need for a synthetic surface. The result is a natural easy-release surface
that improves with continued use.
baking
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 Lodge Cast Iron Cookware its distinctive look.
packing
What started out as raw materials and then became molten metal is now cool and is shipped to over 3,000 dealers throughout
the United States and internationally.
Lasting generations, the cookware will be sold to home cooks, restaurants and camp cooks.