Ironman: Artisan-Made Skillets from Upstate New York

The Skillet Behind the “Ironman” Headline: Borough Furnace

Remodelista’s spotlight centers on Borough Furnace, a New York maker that started with a simple, slightly wild idea:
produce small-batch cast-iron skillets in the U.S. using recycled metal, and do it with a level of finishing you’d normally associate with
vintage pans (the kind people whisper about at flea markets).

The company was founded by cousins John Truex and Jason Connelly (with the project gaining early traction through a
Kickstarter campaign). Remodelista describes their early approach as both pragmatic and poetic: build a tool meant to last, and make the
process as resource-conscious as possible.

The most memorable detail is their custom melting setup: a barrel-sized furnace nicknamed the Skilletronbecause if you
can’t name your furnace like it’s about to fight a villain, what are you even doing? The premise is straightforward: melt scrap iron and
pour it into sand molds to make cookware that’s equal parts utility and sculpture.

Remodelista also notes the brand’s positioning from the start: these are investment skillets, not “grab one on aisle seven” pans. Early
pricing reflected that, with models like a frying skillet and a braising skillet in the several-hundred-dollar rangemore design object than
impulse buy.

What Makes an Artisan Cast-Iron Skillet Different?

A cast-iron skillet can be a $20 workhorse or a $300 showpiece. Both can make cornbread. The difference is in how they feel,
how they finish, and how intentionally they’re made.

1) The surface: from “pebbly” to “buttery”

Many mass-market cast-iron pans have a slightly pebbled texture from sand casting. It’s not “bad”it’s just the texture you get when you
make a lot of pans efficiently. Artisan brands often spend more time on finishing: sanding, polishing, or otherwise refining the cooking
surface so it’s smoother in the hand and easier to build a consistent seasoning layer over time.

Smoothness is not magic nonstick, but it can make early cooking feel friendlierespecially for delicate foods like eggs or fish. Think of it
like the difference between writing on notebook paper and writing on a fancy card stock: both work, but one feels like you’re trying harder.

2) The design details: handles, walls, pour spouts, and balance

Artisan cookware makers tend to obsess over geometry. Small changesslightly flared sidewalls, a helper handle that actually helps, a rim
that pours without dribbling down the outside like a toddler with juicemake the pan more usable day-to-day.

Balance matters, too. A skillet that feels good lifting from stove to oven is a skillet you’ll use more often. And frequency of use is the
real secret sauce of cast iron: the more you cook, the better the seasoning gets.

3) The story and transparency: you know what it is and where it came from

With premium, small-batch cast iron, you’re often buying a manufacturing philosophy: where the iron is sourced, how it’s melted, how the
surface is finished, and how it’s seasoned. That transparency is part of the appealespecially if you’re the kind of person who reads
ingredient labels on olive oil and also feels suspicious of anything labeled “natural-ish.”

Sustainability That’s Not Just Marketing Copy

Remodelista highlights Borough Furnace’s resource-minded angle: the company focuses on recycled iron as input material and
built its own furnace to melt scrap efficiently. The brand’s narrative leans heavily into minimizing waste and treating cookware as a
long-life object rather than a disposable “kitchen accessory.”

This matters because cast iron is, fundamentally, a “buy it once” category. Unlike coated nonstick, there’s no surface designed to wear out.
A cast-iron skillet can look a little rough after a hard season of cooking, but it’s almost always recoverable with cleaning, drying, and
reseasoning.

If you like the idea of sustainable cooking gear, cast iron is one of the few places where the sustainability pitch is genuinely baked in:
it’s durable, repairable, and gets better with use. The most eco-friendly skillet is the one you stop replacing.

How These Skillets Are Made: A Quick Tour of the Process

“Handmade” gets used loosely online, so let’s be specific. The artisan cast-iron process (as shown in behind-the-scenes coverage of Borough
Furnace’s shop) typically involves:

• Designing the pan (often digitally first), then creating a pattern used to form the mold.
• Packing a sand mold around the patternsand casting is classic for a reason: it’s adaptable and precise.
• Melting iron in a furnace, then pouring the molten metal into molds.
• Cooling, “shakeout,” and cleanupbreaking away the sand mold and refining the casting.
• Finishing the surface by sanding or texturing so it’s ready for seasoning and cooking.
• Seasoning (or enameling for certain pieces), creating that protective layer that helps resist rust and improves release.

The point isn’t that this is mystical; it’s that it’s labor-intensive. Time and attention are the premium ingredients. You’re paying for the
hours you don’t want to spend standing next to a furnace named Skilletron.

Seasoning, Decoded: The “Nonstick” Layer That Isn’t Oil

Let’s clear up the biggest cast-iron misconception: seasoning is not a sticky layer of old grease. Seasoning is polymerized oil
oil that has transformed under heat into a hardened, bonded layer on the iron. That layer helps protect against rust and improves food
release. It’s why a well-loved skillet can fry an egg without drama (and without the pan tasting like last week’s salmon).

This is also why modern guidance from major cooking authorities has shifted: a bit of dish soap won’t “strip” seasoning the way people fear,
because you’re not washing away liquid oilyou’re cleaning a bonded surface. The bigger enemy is leaving cast iron wet or letting it soak.
Water + time = rust’s favorite hobby.

Why flaxseed oil shows up in artisan cast iron

Remodelista notes Borough Furnace skillets were preseasoned with flaxseed oil, and the company’s care guidance includes
oven-seasoning steps built around it. Flaxseed oil is high in polyunsaturated fats, which can polymerize into a hard film. Some cooks love it
for building a base layer; others prefer more forgiving oils (like canola or vegetable oil) because extremely hard films can sometimes chip
if applied too thickly or baked unevenly. The practical takeaway: whatever oil you use, thin coats and proper heat beat
expensive bottles every time.

Care and Feeding of Your “Ironman” Skillet

If cast iron had a personal trainer, it would shout one instruction all day: dry it completely. Everything else is optional
flair.

Daily cleanup (the realistic version)

• Wash: Warm water, a brush or sponge, and (yes) a little mild soap if needed.
• Dry: Immediately, and thoroughly. If you’re nervous, warm it briefly on the stove to evaporate moisture.
• Oil (optional but helpful): A tiny rub of oil can keep the surface protected, especially in humid kitchens.

Borough Furnace notes that a new, preseasoned skillet may feel a bit stickier in the first few uses than you expect. That’s normal. Their
advicealso echoed by many cast-iron expertsis to preheat the pan and warm your oil before adding food. Think of preheating
as the difference between “chef” and “why is my chicken glued to this pan.”

Oven reseasoning (when the pan needs a reset)

If your skillet looks dull, sticky, or starts grabbing food like it’s clingy, oven seasoning can help. The universal rules:
clean first, apply a very thin layer of oil (wipe most of it back off), and bake hot enough to polymerize.
Many manufacturers recommend 450–500°F for about an hour, with the pan upside down so oil doesn’t pool.

Pro tip: if you’re getting a sticky finish, it’s usually because the oil layer was too thick or the bake wasn’t long enough. Cast iron is
forgiving, but it is not impressed by puddles.

Cooking Performance: Where Premium Cast Iron Actually Shines

Cast iron’s superpower is heat retention. Once it’s hot, it stays hot, which is exactly what you want for deep browning and crisp edges.
The “gotcha” is that cast iron doesn’t spread heat as quickly as some materials, so it benefits from patient preheatingespecially on burners
smaller than the pan.

Best uses (a love letter in bullet points)

• Searing: steaks, chops, burgers, cauliflower “steaks,” anything that deserves a crust.
• Shallow frying: chicken cutlets, latkes, fried eggs, crispy tofustable heat helps keep oil temps consistent.
• Oven-to-table: skillet cornbread, Dutch babies, baked pastas, pan pizza, cobblers.
• One-pan meals: chicken thighs with vegetables, sausage and peppers, or “what’s in the fridge” hash.

What to avoid early on

Highly acidic, long-simmered dishes (think tomato sauces that bubble for hours) can be rough on a newer seasoning layer. Once your skillet has
a well-established patina, occasional acidity is fine; early on, it’s smarter to keep the pan in its comfort zone and build seasoning
through regular cooking with fats.

Is It Worth It? A Practical Value Check

A premium artisan skillet costs more because it takes more time: more finishing, more hands-on work, more careful production. But value isn’t
only about whether it can cook; it’s about whether it makes you want to cook.

Premium makes sense if…

• You cook often and want one pan that can handle most tasks.
• You care about U.S.-made manufacturing and material sourcing.
• You love objects that are functional and beautiful enough to leave out on the stove.
• You want smoother finishing, thoughtful ergonomics, and long-term durability.

Classic cast iron is plenty if…

• You’re new to cast iron and want to learn without stress.
• You prefer a lighter upfront investment (financially and emotionally).
• You’re happy to let seasoning build slowly and don’t mind a rougher surface at first.

Here’s the honest truth: you can make incredible food with any solid cast-iron skillet. The artisan difference is about the experiencehow
it feels, how it looks, and how connected you feel to the thing you’re cooking with.

Buying Tips: Choosing the Right Size (and Avoiding Regret)

If you’re shopping “Ironman”-style cast iron, don’t just buy the prettiest pan and call it destiny. Buy the pan you’ll actually lift, wash,
and use on a random Wednesday.

Quick sizing guide

• 10–10.5 inches: the everyday sweet spot for most home cooks (eggs, chicken thighs, cornbread).
• 12 inches: great for families and big batches, but heavier and more awkward in small sinks.
• Braising/skillet hybrids: taller sides are excellent for shallow braises, pan sauces, and sautéing without launching food.

What to look for in artisan cast iron

• Handle comfort: a usable grip matters more than aesthetics once the pan is screaming hot.
• Helper handle: genuinely helpful on larger pans.
• Surface finish: smoother can feel friendlier, but seasoning and technique still matter most.
• Clear care instructions: good makers teach you how to succeed, not just how to buy.

Experience Notes (500+ Words): What Living with an Upstate New York “Ironman” Skillet Feels Like

Because I can’t stand in your kitchen and watch you cook (and you probably prefer it that way), the next best thing is to describe the
experience patterns that show up again and again with artisan cast ironespecially skillets like the ones Remodelista featured. Call this the
“day-in-the-life” section: what you can expect emotionally, practically, and deliciously.

The first week: a tiny learning curve and a big payoff

The first few cooks are usually where people decide cast iron is either a soulmate or a chaotic roommate. Borough Furnace itself notes that
a preseasoned skillet may stick a bit more at first than “typical,” and that’s incredibly normal with any new cast iron: your seasoning base
exists, but it hasn’t been reinforced by dozens of meals yet. In real life, that means your inaugural egg may cling a little, and your first
chicken thigh might need a gentle nudge with a spatula.

The fix is not panic. It’s preheating and patience. Many experienced cooks treat preheating like a ritual:
warm the pan empty, add oil only after the pan is evenly hot, and let the oil shimmer before food goes in. When you do this, the pan’s
behavior changes dramaticallyless sticking, better browning, and more confidence. It’s not superstition; it’s physics and good technique.

The “seasoning glow-up”: when the pan starts feeling like yours

A premium artisan skillet often has a smoother feel and a more refined silhouette, so it looks impressive on day one. But the real
transformation is the surface you build through use. Over time, the color deepens and becomes more uniform. You might notice patchiness
earlyslightly lighter areas, darker swirls, spots that look “less Instagram”and that’s fine. Seasoning builds in micro-layers. It’s more
like a coral reef than a coat of paint.

There’s also a psychological shift that happens. The skillet stops feeling precious and starts feeling dependable. At first you might handle
it like a museum object (“No metal utensils! Don’t breathe near it!”). Eventually you realize modern cast iron can handle a metal spatula,
and a quick wash with mild soap isn’t a crime. The pan gets easier precisely because you stop being afraid of it.

Your “starter recipes”: what people cook to build confidence

Many cooks break in artisan cast iron with fat-friendly foods that encourage seasoning: bacon (obvious), smash burgers (satisfying), cornbread
(the crisp edge flex), and shallow-fried chicken cutlets (the “I am a competent adult” milestone). Searing steak is another classic because
the pan’s heat retention creates that dramatic crust that makes you feel like you should have a restaurant playlist going in the background.

Eggs are the final bossnot because cast iron can’t do eggs, but because eggs punish rushed preheating and under-oiled surfaces. Once you
master eggs in cast iron, you develop the quiet swagger of someone who knows where the good spatula is.

The real everyday rhythm: wash, dry, done

The happiest cast-iron owners aren’t the ones doing complicated ceremonies after every meal. They’re the ones with a simple routine:
wash briefly, dry immediately, and give the pan a tiny wipe of oil if the kitchen is humid or the pan looks thirsty. That’s it. The skillet
doesn’t need to be worshipped. It needs to be used.

Why people fall for artisan cast iron anyway

Beyond performance, artisan cast iron scratches a particular itch: it’s a tool with a visible point of view. A Borough Furnace-style skillet
isn’t trying to disappear into your cabinet. It’s meant to be seen, used, and kept. You’re not just buying a pan; you’re buying the
motivation to cook something worth putting in it. And if that means your Tuesday dinner gets a little crispier and your kitchen feels a
little more intentional, that’s a surprisingly good return on investment.

Conclusion

Remodelista’s “Ironman” feature isn’t really about cookwareit’s about the pleasure of owning something made with intention. Borough Furnace’s
Upstate New York cast iron is a reminder that a skillet can be practical, durable, and genuinely beautiful. Whether you choose artisan cast
iron for the sustainability story, the design details, or the feel of a pan that improves with every meal, the best outcome is simple:
you cook more, you cook better, and your food gets the kind of crust that makes you want to brag (politely).