Charcoal Making with Robert Sowter
Charcoal making is a very physical and time consuming project,which from beginning to end will last at least three days, with some or all of the helpers camping out to keep an eye on the metal kiln and its precious contents.
True and in tune with nature Charcoal producers are NOT woodland destroyers,as some of today's general public seem to incorrectly see us in the UK.
The wood collier, to give us our correct title, assists nature by bringing light,warmth and new life to an area of forest,called a coupe or cant,by harvesting over stood hazel or other broad leaved coppiced species,plus thinnings,wind blown or even diseased trees during the winter months.
This is the best time of the year, for her leaves have fallen from the Deciduous species in the autumn and the bulk of her energy is now being stored back in the root system,which results in minimal stress being inflicted on the tree or shrub and allowing maximum regrowth the following spring.
We normally leave the small twiggy brash on site to rot down, which attracts fungi,bugs and beetles etc., this in turn will kick start a brand new healthy life cycle of flora and fauna to that section,whilst we are producing quality by products from the timber in the meantime.
In Croydon I produce charcoal between May and September,using the above thick material harvested from the previous winter months crop that were cut to cord wood lengths and left to season,that is to allow the timber to weather dry, reducing the water content naturally by about 20%.
The making of charcoal dates back to before the Roman era, although it was they who refined the art and expanded it in general.
The original method for hundreds of years was to construct an earth kiln over the top of the standing timber to be charred, hence it being called char-coal.
Stacked Timber - Before bracken/grass sods and earth are applied.
Photos taken at Weald and Downlands Museum
This way of making charcoal was still going on as late as the 1930s, when at around the same time the larger metal kilns really came into there own,as less flair ups and contamination from the soil made the production more attractive and efficient, yet even these metal versions had been going since the early 1800s!
Both methods have the same basis of charcoal creation,and that is to control the temperature, by regulating the air flow being drawn into and around the timbers in a confined space,and then to close it down at the right moment!
Kiln Kit / Levelling the Kiln on bricks and flues.
In Croydon we use the metal kiln method, which Homebase.D.I.Y. kindly sponsored the purchase of, for the Councils Woodland Community projects within the Borough, which we borrow and demonstrate with,at different locations,when invited.
It is 7 feet in diameter and 3 feet high and holds approx one and a half tonnes of timber, from which on average we bag up some 200kg of first class BBQ Lumpwood,also bags of charcoal finds,which fall through the griddle mesh and is an excellent soil conditioner.
With our size of kiln, cooking (Charring) time is approximately twenty (20) hours (depending on location and weather conditions) with a chimney/flue change round after ten (10). i.e. Changing the four (4) inlets to outlets (Chimneys) and vice versa.
We have eight flues in total, but only four are in operation at any one time, drawing in that controlled (Baffaling down) air flow,and the other four are letting out the moisture (chimney), with most of the small amounts of heavy black tar/Bitumen elements collected in the flues or in the chimneys themselves.
Splitting the logs / Logs loaded Starting to draw.
Thus by maintaining that even distribution of heat in the kiln, we gain a maximum charcoal return on all our hard work. High grade charcoal we produce is 95% carbon.
If we did not change the chimneys round we would end up with ash in some quarters and browning's (Timber with only up to 50% water removed) in the others,and a very poor if any charcoal return!
Smoke Check - Thick white, Kiln in full draw / Thin whispey blue, Ready to close.
When the smoke has turned from a thick white to a whispey see through blue we close the kiln down stopping ALL air flow so it snuffs out the hot embers.
Then over the following 24hrs the kiln cools down naturally.
When every part of the kiln is cold to the touch all over, we open. If it was opened too soon,a rush of air would re-ignite any hot embers ,and all would go up in flame!
Admiring their Lumpwood Charcoal / Griddle and Grading shoot.
As a rule of thumb, for every five tonnes of timber , you will get one tonne of charcoal back.
English lumpwood achieves a higher temperature quickly,so not a lot is needed compared to those bags that are imported,from around the world and you could be cooking on our Croydon Charcoal for example within 20 minutes of starting the Barbecue, allowing you to enjoy the natural flavours of your food for the first time, whilst experiencing the unique woodland aroma as the embers glow.
Local / Global (Marked in Red we import from).
The UK on average consumes some 60,000 tonnes of charcoal each year mainly for the barbecue market of which 95% is imported, from as far away as South Africa,South America and China.
Why do we waste precious power, fuelling ships to transport other countries carbon (who need it more themselves) to this country, when we can produce a superior product from our own broadleaved neglected woodlands?
Personally this is the ultimate Carbon Footprint.
All sales are put back into Croydon Charcoal to cover future operational costs.
There is a lot to the art of charcoal making, so if you want to know more and support and maintain your healthy woodlands in Croydon, why not come along see how its done first hand, join in and even buy a bag or two!
In 2002 there were only 300 charcoal makers left in the UK!