The Making of Charcoal

Production of Charcoal is one that transform raw logs into black coloured coal-like materials after disposing off the moisture and organic substances within. The remnants solid will retain the heat giving combustible materials.

This done by a process of heating up the kiln. The retained heat will "bake" the wet logs without bursting into flames.

This is one of the few kilns, usually 3/4 of them, sheltered inside an enclosed factory! The kiln are semi-hemispherical dome - 50 feet high at the apex. The conical entrance can be dismantled and rebuilt as part of the production process.

The barks with virtually no solid were disposed off before the trunks go in for "baking" . Reason- moisture content in them is high and they generate exceptionally larger amount of smoke.

Each log about 6 feet long are individually loaded and stacked very close, 2 logs high.

Imagine the kiln is still warm and tedious hours of stacking up to fill the whole kiln. It takes 2 persons about 2/3 days to load one kiln

Beside being warm, stuffy and suffocating, the attendant must also have the physical strength and endurance to complete his quotas!

The entrance is walled up with bricks and the seams carefully sealed with clay.

A small orifice adequate to accommodate a few firewood is the beginning of the "firing" up process. This step is done to parch the wet log and prepare them for the next step. Depending on the load in the kiln, the process varies between 8-12 days!

What devices are used to signal the production progress and consistency of quality?

Small chimmies strategically located along the lower rim of the kiln allow smokes from each sector to be emitted. The temperature of the discharged smoke to an experienced palm, will denote the environment within the kiln!

Finally, when the drying process had reached its peak, the feeding of the flame cease, the wood in the kiln enters its smoldering stage. In local term- small fire!

This slow process will take 8-12 days!

Now a look into at the veteran who perform such arduous tasks. They may be coated with a layer of dark dust, but shy away from the sun.