The All Clad Manufacturing Process: An Inside Look

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Some of the common questions that I’ve seen regarding All Clad include “What is the All Clad manufacturing process for its cookware?”, “What is All Clad cookware?”, and “Where is All Clad made?”. I’m going to answer these questions in this article and provide a video at the end so that you can see for yourself.

First of all, All Clad cookware is made in Canonsburg, Pennsylvania in the good ole U.S. of A. This town is located near Pittsburgh in southwest, PA. Now, I had heard that at one time, All Clad used to outsource manufacturing of its cookware lids to China, but brought this back to the U.S. because of quality issues. But I don’t know for certain. I know that everything else is produced in the U.S.

Second, in answer to the question, “What is All Clad cookware?”, I’ll give you a short direct response. All Clad manufactures professional grade cookware. What makes them unique is that they were the first company to manufacture pots and pans that consisted of multiple layers of metal that went all the way up the sides of the cookware.

Until All Clad came along some companies would attach a disc to the bottom of cookware to distribute heat. Depending on which All Clad product you purchase, the cookware could consist of 3 or 5 layers of metal. The metals used in the manufacturing process are stainless steel, copper, and aluminum (standard, brushed, and anodized).

Third, the answer to the question, “What is the All Clad manufacturing process for its cookware?”, is a bit more involved. Luckily, the process was featured on the Travel Channel. In the video below, host George Motz takes a fascinating tour (at least to me) of the Canonsburg facility to see how the king of cookware is made. As you’ll see, the All Clad manufacturing process is all about precision, quality, and attention to detail.

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All Clad Manufacturing Process For Cookware: 4 Key Steps

1. Cladding

all clad manufacturingThis is the process of combining sheets of highly durable stainless steel with sheets of highly conductible aluminum and sometimes copper. This combination results in pots and pans that will have great heat distribution and last for many years. The plys or layers of metal sheets that are “clad” together depends on the line of cookware being made. As previously mentioned, there could be 3 or 5 layers.

All Clad manufacturing starts by stacking the desired layers of metal on top of one another, like cards. The stack is then rolled into an oven that is heated to nearly 1000 degrees Fahrenheit. From there it is routed through a process called “roll bonding”. This is where the metal stack is passed between a series of rollers under enormously high pressure. Reminds me of making pasta and how it’s continually cranked through rollers to get it thin.

Anyway, the end result is a fused rectangular metal sheet that you can’t tell was once a multi-layer stack. The cladded metal sheets are then carried to a cutting machine. This machine cuts out four circular discs from each sheet. The discs are then sent to the Forming department.

2. Forming

In the step, the Forming machine operator programs in the desired pot or pan to be made. Then, each flat rectangular disc (called a blank) is placed in the Forming machine under 160 tons of pressure. The machine reshapes the disc as instructed.

Now it’s time for Finishing.

3. Finishing

When the pots and pans reach the Finishing department, they look dingy and don’t have any handles. In this department, the raw pots and pans are loaded into a grinding sander machine. Their insides are sanded to a beautiful lustrous shine.

Afterwards, the unfinished cookware is sent through an industrial strength washer to remove any oils. Then a quality control technician inspects them. Next, they receive some industrial buffing all over until there is a mirror-like shine. The final step in this process is to have the laser engraving machine add the All Clad logo and other details to the bottoms.

All that’s left to do now is to add the pre-made handles.

4. Handle Riveting

Attaching the handles to the unfinished cookware is more about accuracy than anything else. One mistake and the pan is trashed. Since the handles are riveted onto the cookware, it’s important that the rivets be perfectly aligned when the rivet compression machine seals the handle in place.

If all goes well, the pot or pan is ready to be packaged and shipped to retailers.

All Clad Manufacturing Process: Fascinating Video

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