You've probably never thought how complicated is to make a good non-stick pan! And surely you did not ever wonder how the pots are made​​.

Do you know how an aluminum disk is transformed into a non-stick surface on which a fried egg slips away?

 

But let's go step by step and analyze each part of the cookware shell!

 

First of all, why to make pans with PTFE coated aluminum disks?

Because they are economical, safe, environmentally friendly, no waste, because it is the easiest way to make safe and sustainable pots. We provide a disc, then the customer press it, trim it, applies the handle and the pan is complete!

Making pots in this way is easy and does not require large investments.

 

Why to use aluminum??

Because it is the best material for making pots! Because it is non-toxic, lightweight, eco-friendly, durable, with high formability and easy to work.

How to do the discs?

The raw material into ingots, versatile and fully recyclable, arrives to furnaces in foundry casting plates. Lamination is a process that leads the preform to the size required by the market. The heat treatment procedure is the one which gives the mechanical characteristics required for the workability during finishing. The latter includes degreasing, washing, cutting and shearing. This phase is crucial in order to allow the PTFE to adhere perfectly to the surface of the aluminum. The laboratories monitor in real time the flatness, thickness, mechanical and physical characteristics of the disc.

 

 

What is PTFE?

PTFE is polytetrafluoroethylene that is the polymer of tetrafluoroethylene. It is a substance smooth to touch and resistant to high temperatures (over 200° C), used in the houseware industry to coat internal surfaces of cookware which requires an excellent non-stick property (imagine that is the material with the lowest known coefficient of friction in the world!) and good chemical inertness.

Gruppo Viva uses only Greblon of Weilburger, a PTFE in which other specific components are added to the polymer like stabilizers and fluidizers in order to improve the possibilities of application.

 

 

Why the PTFE?

Because the PTFE features an interesting series of unique characteristics that make it irreplaceable for the healthy cooking of food and these remain unaltered in a range of temperatures between -80 ° C and 250 ° C (well beyond the temperatures normally used on cookers).

Having a complete chemical inertness, PTFE is not attacked by almost all chemical compounds and anyway by no ingredient normally used in the kitchen. It has excellent resistance to fire (does not propagate the flame), excellent surface smoothness (the coefficient of friction is the lowest among the industrial products) and outstanding non-stick properties. There is enough in this regard to think that the surface is not bondable and there is no adhesive - including those produced so far - capable of pasting the PTFE.

Also - out of sheer curiosity - PTFE has complete insolubility in water (and in any organic solvent), has excellent dielectric features, is hydrophobic and oil repellent.

We have never sold PTFE containing PFOA, well before it was banned in the U.S., because the health of consumers is the most important thing for Gruppo Viva.

 

 

 

How to paint a disc?

The application of the PTFE is through spreading with rollers on the previously treated aluminum surface. After coating the discs are placed in drying furnace at high temperature in order to facilitate the polymerization and to adhere the film of PTFE to the metal.

The production of aluminum cookware discs is divided into three main phases:

- The pre-treatment of the surface of the disc by sanding

- The non-stick coating of the inner part

- The painting, and eventually the decoration, of the exterior.

The first treatment consists in the mechanical brushing of the disc in order to create a matt surface that holds the applied coating. The painting is done by rolling the pieces in to subsequent five reels (primer, mid, top, surface, and finally eventually polychrome). The varnishes used are water-based and completely suitable for contact with foodstuffs.

The most requested colors for the inner part of the disk are usually all shades of gray, from pearl till anthracite or even the “British black” (could be more or less metallic according to the customer's needs). Ultimately our customers prefer even more fancy colors as whites, creams, the colors of earthenware and those of fashion.

The painting on the outer part, always carried out by roller coating the discs, employs polyester coatings in the most varied shades customized according to the customer's favorite colors. The latest trends in household see our customers personalize the outside surface with any type of decoration: in addition to traditional screen printing, even with multiple colors, we can apply PhotoPaint coating of the latest technology, which can faithfully reproduce vivid colors photos.

All stages of production are environmentally friendly; great attention is mainly spent to emissions that are filtered and purified before being remitted in the environment. Varnishes are reintroduced into the production. All waste is outsourced to companies specialized in the disposal and / or treatment. Particular attention is spent to ensure that all operators enjoy healthy working conditions, both safe and enjoyable. The surface of all discs sold by Viva Group has never undergone chemical treatment, because for us the health of our employees is a priority.

 

The discs coated on both sides are constantly undergoing tests (both random and systematic) in order to verify the correspondence of the product to strict technical parameters, the full compliance with the current legislation (as well as the one of the country of destination) in the field of non-stick paints and food contact. A particular attention is given by the technicians to the results of sintering and adhesion of the coating, the non-stick properties, the resistance to abrasion, to wear and to acids.

Once out of the production chain, aluminum discs or rectangles are ready for molding and finishing. For some special forms, customers of certain parts of the world instructed Gruppo Viva of drawing the cookware shell without positioning any handle (operation that will be done at destination). The special characteristic of elasticity of our paints makes possible the perfect modeling of the coating to the part without the aid of lubricants, oils, soaps and greases.

Our special packaging eliminate all risks of damage or scratches on the disc, especially the non-stick surfaces: a considerable saving in terms of final output

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