Ethiopian Technical University

Faculty of Mechanical Technology,

Department of Manufacturing Technology

Course Title: Production Planning and

Control (MAT 615)
Individual Assignment for Manufacturing Technology MSc
Class of 2020/21 G.C
2nd Year Students –Section – I

ASSIGNMENT: One and Two

SUBMITTED BY:

No Name ID No
1 Kedir Yimer Ebrie MTR/615/13

SUBMITTED TO: Dr. Sujit Singh (PhD)

Jan 20, 2022

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Addis Ababa Ethiopia

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INTRODUCTION
Cookwares and bakewares are food preparation equipment, such as cooking pots, pans,
baking sheets etc. used in kitchens. Cookware is used on a stove or range cooktop, while
bakeware is used in an oven. Some utensils are considered both cookware and bakeware.
There is a great variety of cookware and bakeware in shape, material, and inside surface.
Some materials conduct heat well; some retain heat well. Some surfaces are non-stick; some
require seasoning. Some pots and their lids have handles or knobs made of low thermal
conductance materials such as bakelite, plastic or wood, which make them easy to pick up
without oven gloves.
A good cooking pot design has an "overcook edge" which is what the lid lies on. The lid has
a dripping edge that prevents condensation fluid from dripping off when handling the lid
(taking it off and holding it 45°) or putting it down.
Producing of a cookingdish isn’t something typically build simply; it needs a well-equipped
metal shop to do the job and do it right. [Torbjörn Åhman] has just that, however, and set
about forging a stout-looking skillet from scratch.
The build starts with a round disc of steel serving as a blank for the project. The blank is spun
up and the outer perimeter ground down thinner with an angle grinder in what looks like a
moderately sketchy operation. A forge is then used to heat the blank so that it can be shaped
into a pan using a hammer. Slowly, as the metal is beaten one way and then to other, the
skillet begins to form. A belt sander takes off high points on the outside, and a torch is then
used to square up the base of the pan so it sits nicely. Finally a handle attached with some
stout rivets, and the newly formed piece of cookware gets a seasoning with sunflower oil.
The project shows just how many special skills are required to make even a simple cooking
dish by hand.

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Various commercial baking pans

Types of Cookware materials

The size and shape of a cooking vessel is typically determined by how it will be used.
Intention, application, technique and configuration also have a bearing on whether a cooking
vessel is referred to as a pot or a pan. Generally within the classic batterie de cuisine a vessel
designated "pot" is round, has "ear" handles in diagonal opposition, with a relatively high
height to cooking surface ratio, and is intended for liquid cooking such as stewing, stocking,
brewing or boiling. Vessels with a long handle or ear handles, a relatively low height to
cooking surface ratio, used for frying, searing, reductions, braising and oven work take the
designation "pan". Additionally, while pots are round, pans may be round, oval, squared, or
irregularly shaped.
Metal
Metal pots are made from a narrow range of metals because pots and pans need to conduct
heat well, but also need to be chemically unreactive so that they do not alter the flavor of the
food. Most materials that are conductive enough to heat evenly are too reactive to use in food
preparation. In some cases (copper pots, for example), a pot may be made out of a more
reactive metal, and then tinned or clad with another.

Stainless steel

Fig: 7, Stainless steel

Stainless steel is an iron alloy containing a minimum of 11.5% chromium. Blends containing
18% chromium with either 8% nickel, called 18/8, or with 10% nickel, called 18/10, are

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commonly used for kitchen cookware. Stainless steel's virtues are resistance to corrosion,
non-reactivity with either alkaline or acidic foods, and resistance to scratching and denting.
Stainless steel's drawbacks for cooking use are that it is a relatively poor heat conductor and
its non-magnetic property, although recent developments have allowed the production of
magnetic 18/10 alloys, which thereby provides compatibility with induction cooktops, which
require magnetic cookware.[citation needed]

Since the material does not adequately spread the heat itself, stainless steel cookware is
generally made as a cladding of stainless steel on both sides of an aluminum or copper core to
conduct the heat across all sides, thereby reducing "hot spots", or with a disk of copper or
aluminum on just the base to conduct the heat across the base, with possible "hot spots" at the
sides. In so-called "tri-ply" cookware, the central aluminum layer is obviously non-magnetic,
and the interior 18/10 layer need not be magnetic, but the exterior layer at the base must be
magnetic to be compatible with induction cooktops. Stainless steel does not require seasoning
to protect the surface from rust, but may be seasoned to provide a non-stick surface.
Carbon steel

Fig: 8, Carbon steel

Carbon-steel cookware can be rolled or hammered into relatively thin sheets of dense
material, which provides robust strength and improved heat distribution. Carbon steel
accommodates high, dry heat for such operations as dry searing. Carbon steel does not
conduct heat efficiently, but this may be an advantage for larger vessels, such as woks and
paella pans, where one portion of the pan is intentionally kept at a different temperature than
the rest. Like cast iron, carbon steel must be seasoned before use, usually by rubbing a fat or
oil on the cooking surface and heating the cookware on the stovetop or in the oven. With
proper use and care, seasoning oils polymerize on carbon steel to form a low track surface,
well-suited to browning, maillard reactions and easy release of fried foods. Carbon steel will

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easily rust if not seasoned and should be stored seasoned to avoid rusting. Carbon steel is
traditionally used for crêpe and fry pans, as well as woks.
Clad aluminium or copper
Cladding is a technique for fabricating pans with a layer of efficient heat conducting material,
such as copper or aluminum, covered on the cooking surface by a non-reactive material such
as stainless steel, and often covered on the exterior aspect of the pan ("dual-clad") as well.
Some pans feature a copper or aluminum interface layer that extends over the entire pan
rather than just a heat-distributing disk on the base. Generally, the thicker the interface layer,
especially in the base of the pan, the more improved the heat distribution. Claims of thermal
efficiency improvements are, however, controversial, owing in particular to the limiting and
heat-banking effect of stainless steel on thermal flows.
Aluminum is typically clad on both the inside and the exterior pan surfaces, providing both a
stainless cooking surface and a stainless surface to contact the cooktop. Copper of various
thicknesses is often clad on its interior surface only, leaving the more attractive copper
exposed on the outside of the pan (see Copper above).
Some cookware use a dual-clad process, with a thin stainless layer on the cooking surface, a
thick core of aluminum to provide structure and improved heat diffusion, and a foil layer of
copper on the exterior to provide the "look" of a copper pot at a lower price.[16]
Coatings
Enamel
Enameled cast iron cooking vessels are made of cast iron covered with a porcelain surface.
This creates a piece that has the heat distribution and retention properties of cast iron
combined with a non-reactive, low-stick surface.
The enamel over steel technique creates a piece that has the heat distribution of carbon steel
and a non-reactive, low-stick surface. Such pots are much lighter than most other pots of
similar size, are cheaper to make than stainless steel pots, and do not have the rust and
reactivity issues of cast iron or carbon steel.[citation needed] Enamel over steel is ideal for large
stockpots and for other large pans used mostly for water-based cooking. Because of its light
weight and easy cleanup, enamel over steel is also popular for cookware used while camping.
Seasoning

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Fig: 9. Cast-iron skillets, before seasoning (left) and after several years of use (right)

Fig: Commercial waffle iron requiring seasoning

Seasoning is the process of treating the surface of a cooking vessel with a dry, hard, smooth,
hydrophobic coating formed from polymerized fat or oil. When seasoned surfaces are used
for cookery in conjunction with oil or fat a stick-resistant effect is produced.
Some form of post-manufacturing treatment or end-user seasoning is mandatory on cast-iron
cookware, which rusts rapidly when heated in the presence of available oxygen, notably from
water, even small quantities such as drippings from dry meat. Food tends to stick to
unseasoned iron and carbon steel cookware, both of which are seasoned for this reason as
well.
Other cookware surfaces such as stainless steel or cast aluminium do not require as much
protection from corrosion but seasoning is still very often employed by professional chefs to
avoid sticking.
Seasoning of other cookware surfaces is generally discouraged. Non-stick enamels often
crack under heat stress, and non-stick polymers (such as Teflon) degrade at high heat so
neither type of surface should be seasoned.

The raw materials for cookware

Over the ages, humankind has used many different materials for cookware. Each
material has different requirements and properties. Apart from clay vessels, copper kettles or
uncoated aluminium cookware, above all cast steel pots and pans have been used in more
recent human history. Ever higher requirements relating to cooking and cleaning triggered the
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development of stainless steel, aluminium and cast aluminium cookware as well as non-stick
coatings. Today, BERNDES focuses on cookware made of stainless steel, aluminium and
cast aluminium.
Stainless steel
The starting point for stainless steel products is a stainless steel blank (flat disc). This is
greased, placed in a hydraulic drawing press and shaped over a so-called deep-drawing die.
Next, the edge of the raw body is punched so that the finished cookware has a clean pouring
edge. For better heat conduction, stainless steel bodies are fitted with a capsule base.
Aluminium is integrated in the capsule base to optimise the absorption and transfer of heat.

Aluminium
A circular aluminium disc (blank) is used for the pan or frying pan. BERNDES uses
discs between 3 and 5 mm thick. We use two different production methods and exclusively
process aluminium alloys approved for contact with food.
Deep-drawing
Similar to stainless steel processing, the aluminium blank is greased and placed into a
hydraulic drawing press where it is shaped over a deep-drawing die. Depending on the
product size and blank thickness, a weight of up to 200 tons is applied for this forming
process. The advantage of deep-drawn parts is an even thickness of base and walls. This
ensures good heat conductivity.

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Forging
Each pan starts its journey as a flat, circular steel disc. The disc is pressed between a larger
outer ring and a smaller inner die. This process raises the side walls and gives the steel a
basic and rough pan shape. 
Following the press, the blank is placed in the forge and heated to a glowing red. Blacksmiths
continue to shape the sidewalls with precise and rhythmic blows on the anvil. 
When the side walls are of even height and pitch the pan returns to the press where the base is
flattened under fifteen tons of pressure. Fine adjustments are made with a lever and hammer
blows.

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Fig: Forging process of cooking dish

Assembly
Once the pan base has cooled, it is passed along to clean-up and assembly. The sharp edges
of each pan are taken down with grinders and smoothed to an even radius. 
Handles are shaped on the anvil and hammered to match the curvature of the pan's sidewall. 
Holes are drilled and the handles are riveted in place. 

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Fig: Assembling Process of the cooking dish

Clean Up & Seasoning

After the pan is fully assembled, it is placed in the sand blasting cabinet. Aluminum-oxide
combined with high-pressure air blasts the surface of the metal removing mill scale and
surface imperfections. A wire-brush then polishes the surface, restoring the surface to an even
and smooth finish. At this stage the steel is very reactive to moisture and oxygen. Left in this
state the steel will begin to rust. To create a protective barrier the pans are placed in a kiln
and baked at high temps for forty minutes.

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Under this high temperature, the steel reacts and builds a layer of iron-oxide on its surface.
This reaction produces the familiar blue-ish black tones of the final product. While the pans
are still hot, coconut oil is applied and allowed to pull into the pores of the metal as it cools. 

Fig: Cleaning up and seasoning of cooking dish

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COOKWARE TO AVOID
TEFLON
PFOA (Perfluorooctanoic acid) is the compound that is used to manufacture non-stick
coatings. It is linked to thyroid damage and is a likely human carcinogen. PFOA’s build up in
your body and are difficult to eliminate once they are absorbed.
High-temperature cooking with Teflon cookware can induce a “Teflon flu” in which
you experience flu-like symptoms several hours after inhaling toxic Teflon fumes – yuck.
ALUMINUM
There are 2 types of aluminum cookware: non-anodized aluminum and anodized
aluminum. Anodized aluminum has been sealed with a coating to make it denser, harder,
non-reactive and non-stick. Most cookware today is made of anodized aluminum. The
problem with the newer anodized pots and pans, is that they have a non-stick coating applied
to them, which has it’s own health dangers.
Old aluminum pots and pans are often made of non-anodized aluminum. These can
leach aluminum particles into the food. They react with acidic foods that are cooked in them
and give them an unpleasant taste. Non-anodized aluminum pots are usually heavy, with an
appearance of having been pressed from a single piece of thick metal. The inside and outside
are the same color.
Hard anodized aluminum is said to be a safe cookware, and it can be, if it is not
scratched at all. Once it has become scratched, it can leak aluminum into your food. Also, if a
non-stick coating is applied, you will be exposed to those chemicals as well. We all know
how easy it is to accidentally scratch a pot or pan, so why even bother investing in aluminum
cookware then?
COPPER
Copper responds to heat very quickly. It heats well and evenly, then loses heat rapidly
when the temperature is turned down. It is more reactive than cast-iron or aluminum and is
often sold “tinned”, or mixed with another metal such as stainless steel to prevent copper

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leaching into food. Large amounts of copper ingestion can cause nausea, vomiting, and
diarrhea.
Coatings on copper cookware can break down over time, exposing the copper to food.
Old copper cookware often has tin or nickel coatings and should not be used for cooking.
Copper is often used as a base to help stainless steel cookware conduct heat better, and
as long as the copper is not coming in contact with the food, it is safe.

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