Caraway has made a name for itself in recent years as a maker of beautiful, high-quality ceramic cookware. If you’ve seen photos of Caraway pans online or in stores, you may have wondered, how are these pans constructed. As a newer cookware brand, Caraway wasn’t content to follow traditional manufacturing methods. Instead, they developed an innovative process to create their signature cookware.
In this post, we’ll take a deep dive into how Caraway pots and pans are crafted. Here are the key steps:
Table of Contents
Sourcing the Right Materials
The quality construction of Caraway cookware starts with sourcing the right materials. Each pan uses a specific combination of metals and coatings:
Caraway uses a heavy-gauge aluminium core in the base of each pan. Aluminum is valued for its quick, even heating, which prevents hot spots while cooking. Caraway tested over 50 aluminium alloys to find the one that optimizes both durability and conductivity.
The proprietary ceramic coating was developed just for Caraway after extensive R&D. It contains no toxic chemicals and provides superior food release compared to traditional non-stick. The coating also allows for metal utensil use.
The pan rims and handles are made from stainless steel, which provides sturdiness and allows for a beautiful hammered finish. Caraway uses 18/10 stainless steel.
The lids are constructed from tempered glass to allow monitoring of food while cooking. The glass is thermal shock resistant.
In addition to rigorous material testing, Caraway insists on ethically sourced components. They require third-party audits for all suppliers.
Forging the Aluminum Core
The aluminium core gives Caraway pans their excellent heat distribution. To construct this base, solid aluminium discs are first cut to size. These discs then go through an advanced forging process.
The aluminium is stamped at pressures over 2,000 tons using a mechanized press. This compacting process thickens the aluminium by up to 30%. The end result is a heavier gauge, more durable aluminium core.
Forging also enhances the aluminium’s conductive properties by realigning the internal grain structure. This leads to superior heating and eliminates hot spots.
Coating and Curing
Once forged, the aluminium pans move to the coating stage. The proprietary ceramic non-stick formula is applied using a patented rotating process. This achieves a seamlessly uniform ceramic coating from edge to edge.
The pans then go through a curing process under intense heat. They are brought to temperatures over 700°F to bond the ceramic firmly to the forged aluminium. This process creates a smooth, durable cooking surface.
Adding Finishing Touches
With the ceramic coating cured, the pans move to finish. Here, the stainless steel handles and rims are welded on securely. Caraway takes pride in the wide, sloped rims they construct, which are more durable than rolled rims.
The tempered glass lids are also attached during finishing. They are equipped with a hole for steam release while securing food flavours and nutrients.
At each manufacturing station, the cookware is polished and brushed to attain a bright, flawless look. The signature hammered finish is also applied to the handles and rims.
Rigorous Quality Control
Before shipment, each Caraway pan goes through extensive quality control checks. Caraway staff examines them for proper handle alignment, non-stick performance, and aesthetic aspects. Pans are thoroughly cooked in to verify the non-stick coating readiness.
Caraway’s strict standards mean that less than 7% of pans produced actually make it to customers. But this ensures every shipped pan meets the highest quality benchmarks.
Customers can feel confident that their Caraway cookware underwent meticulous construction and inspection. Caraway also individually examines returned pans to improve their manufacturing. This commitment to excellence is why every pan is backed by a lifetime warranty.
After passing quality control, the Caraway cookware is packaged in their signature boxes. The minimalist, eco-friendly boxes reflect the brand’s modern aesthetic. Caraway also includes helpful resources with each cookware set, like recipes and care instructions.
The innovation continues even after purchase through Caraway’s free recycling program for their pots and pans. They also offer replacement components like lids and handles if needed.
Caraway’s Innovative Manufacturing Legacy
As you can see, Caraway creates much more than just attractive ceramic cookware. Through rigorous materials testing, advanced forging, and over 700 custom parts, they have engineered high-performing pans suited for all cooking needs.
Caraway continues to grow as a company, but its commitment to thoughtful design and production remains. Their pans are crafted to last a lifetime and provide home chefs with the best possible cooking experience.
Also read, What Makes Caraway Cookware Unique
So next time you’re searing a steak or simmering a sauce in your Caraway cookware, take a moment to appreciate the manufacturing story behind these remarkable pans. The world-class team of designers, engineers, and craftspeople who make Caraway are reinventing non-toxic cookware.