The manufacturing of the original STAUB cocotte is something special—and something personal. Every cocotte is one of a kind and hand finished. And we would like to introduce you to some of the people who make our famous cocottes.
The manufacturing process of cast iron is traditional craftsmanship. It all starts with high quality raw materials and people like Bernard. For over 35 years now he has been responsible for melting those materials. In the melting furnace the liquid cast iron is going to melt down from 1600 °C (2912 °F). The most important part is the recipe of the materials and the additives.
Meet Daniel. His workspace is our workshop. He is responsible for the building of the casting molds that are used as negatives for the final sand molds. For best results you need the absolute precision that only comes from a combination of technique and craftsmanship. The better the aluminum mold, the better the sand form that is used for the molten iron - and the better the final product.
Molten iron produces a one-of-a-kind structure. Every piece varies in form and color, which makes them really unique. Every sand mold is only used once and then gets destroyed. We like how every mold is made for just one cocotte. That truly makes each STAUB cast iron product a unique piece.
It may sound sentimental, but we like to say that a cocotte is not made—it’s born. People like Benjamin start removing the molding sand, and, after precise deburring, the excess material and any unevenness gets removed. For the next step Benjamin has lots of little helpers: by shot blasting with millions of metal particles that clean and finish the surface. Then, the cocotte is ready for the final step – the enameling.
First things first. Jean-Yves’ job starts with the primer coat. Then he enamels the inside of the cast iron cookware with a matte black finish. In total, he is using two to three internal and external layers of enameling. The high-quality enamel offers improved resistance to thermal shocks and scratching. The final stage is the firing at 800 °C (1472 °F) for 30 minutes. Now it’s time to color things up with the external coating. The special Majolica enameling technique gives the colors brilliance, depth and intense shades by using three enamel layers. With this unique look the cocotte can beautifully transition from kitchen to table.
During the production process each item is inspected visually or technically 100 times. We have really high quality standards and that’s why we subject each single product to a strict check. Selected employees like Lydie proudly stand by this quality. So if you see the name “Lydie“ on the seal, you know that Lydie herself approved the cocotte.
THE MOST IMPORTANT PERSON
Why such a big effort you may ask? Well, the answer is easy: because of you. You are the one person that will create amazing meals with our products. Whatever dishes you prepare in the STAUB cocotte, you can rely on a tasty and healthy result. You’re sure to delight your family and friends with everything you serve. Bon Appétit.