How Butcher Block Is Made

How Butcher Block Is Made

A few years ago, when I started working for ButcherBlockCo., I had the privilege of touring the John Boos & Co. butcher block manufacturing facility in Effingham, Illinois. Seeing the process of how butcher block is made from start to finish was enlightening.  It felt a lot like making furniture by hand in a workshop, but on a much larger scale.

The process seems to be a wonderful balance of technology and science with craftsmanship and artistry, all working together to make these beautiful pieces of butcher block furniture come to life.

Here is my summary of How Butcher Block Is Made:

Harvesting Wood
Before the wood ever arrives at the manufacturing plant, individual trees are selected for harvest, encouraging forests to renew and regenerate themselves naturally. At the lumber mill, trees are cut into lumber for purchase and distribution. John Boos only buys wood from suppliers who are members of the National Hardwood Lumber Association, guaranteeing they practice responsible reforestation.
Drying Wood
When lumber arrives at the John Boos facility it is staged in their lumber yard.  Lumber is sorted, piece by piece, to gauge its grade using a “grader’s stick” to approve each board for processing. After lumber is inspected and graded it “rests” in an outdoor staging area for a few weeks as part of the first steps in the drying process.  Step two of the drying process is to transfer the lumber to gigantic, wood-fired kilns where it is dried for 18 to 28 days. The enormous kilns used to dry the lumber are heated by a boiler, which is fueled by sawdust and wood scraps generated during the process of making butcher block. After nearly a month of drying in the kiln, the cured lumber enters the start of the production process.
Production Process
All the lumber coming into the manufacturing plant is first planed and sanded to get a very flat and smooth work surface. Then it is immediately run through a glue line rip saw cutting the wood into 1.75 inch rails. Each wood rail is inspected and marked for defects using fluorescent markers, which are read by a computer to eliminate defective sections. Final rails are then sorted by grade, separating the premium rails to be used for kitchen countertops and high quality butcher block surfaces from the lower grade rails to be used for industrial countertops.
To make blended-grain butcher blocks, rails of varying length are finger jointed together, then laminated and glued side by side, hiding all finger joints. To make edge-grain butcher blocks, rails of the same length are laminated and glued together side by side, forming what then looks like a solid piece of butcher block wood. End-grain butcher block is characterized by its checkerboard appearance. This block starts with laminated edge-grain boards, that are glued and stacked on top of each other, then placed in a gigantic vice called a screw press, squeezing the wood and glue together. After drying, the block is set on end and the “ends” of the rails become the butcher block cutting surface, hence the term “end-grain.”
Finishing
All butcher block, be it blended, edge or end-grain, is then sanded down with 200 grit to provide a silky smooth cutting surface. It is then made into Boos Blocks, cutting boards, butcher block table tops, standard and custom countertops, etc.  Finally, all butcher block is finished with a treatment of food-safe mineral oil or board cream before it is allowed to leave the plant. It is packaged with care and shipped to consumers, restaurants and retailers all across the US.
Having seen how butcher block is made makes me appreciate all of the effort that has gone into what appears to be a relatively simple piece of wood.  I know I take great pride in displaying and using my John Boos butcher block every day!
Get Organized and Stay That Way!

Get Organized and Stay That Way!

Now that you’re used to the idea of it being 2014 (I’m just assuming you’re not still writing “2013” on everything like I am), it’s time to start making good on those resolutions!

Now is a great time to get your kitchen organized in a way that makes sense for your life.

While the aesthetic of an organized kitchen is highly desirable, don’t just focus on putting things away to make the space look nicer – the key to staying organized is to set up a system that is logical, one that will be easy to maintain and will help your kitchen be more functional. We’ve been keeping track of our top sellers and best storage solutions to help you get your kitchen in tip-top shape.
Our best-selling butcher block table of the year is the John Boos Classic Country Work Table. This customizable table ranges in sizes from 36”x24” up to 60”x36”, comes in a variety of colors, and offers optional drawers, baskets, and shelves to meet your needs. This is a beautiful solution to the everyday cook’s organizational dilemmas. No wonder it was our top seller!

classic-country-kitchen-island-white organized

So many options to cater to your tastes

If you love to bake as much as you love to cook, check out the Pro Chef Prep Station, which comes with a granite inset for rolling out dough. This unique work center comes with wire baskets for stowing produce or towels, a slatted shelf for your mixing bowls and canisters, and a side rack for spices and utensils. A stainless steel pan is placed under a cut-out in the butcher block surface to catch scraps, juices, and waste for easy clean-up. This versatile workstation also features a large utility drawer with built-in knife storage.

Organized Pro Chef Prep Station

Look at all that storage!

Are you always trying out new recipes and staying on the cutting edge of technology? Well, John Boos has created the perfect addition for your kitchen: the iBlock. Available in Maple, Walnut, and Cherry, this handy little guy doubles as a cutting board and tablet holder. The iBlock comes with protective sleeves so you don’t get your tablet messy while you whisk and watch cooking shows at the same time!

iblock-cutting-board-with-stand

Keep your tablet handy without worrying about the mess

If entertaining or wine-and-cheese nights are more your style, Catskill Craftsmen has created the ultimate kitchen helper for you – the Portable Wine Island. This lovely cart can store 15 bottles of the good stuff and has a stemware rack for glasses up to 8” tall. This hardwood island also features an enclosed cabinet with an adjustable shelf, ample storage in a utility drawer, and two towel bars. The best part may just be the locking casters, though. You can prep all your hors d’oeuvres in the kitchen then roll the whole cart out for service in the dining room or on the patio.

Organized Wine Island

Entertain with ease with the Portable Wine Island

Now that we’ve introduced you to some of our most popular and helpful products, it’s time to get into gear and get your kitchen ready for a new year full of cooking, baking, experimenting, and entertaining! What has been the best addition to your kitchen? Do you have plans to get organized for the new year?

Cutting Boards: A Collection to Handle Any Occasion

Cutting Boards: A Collection to Handle Any Occasion

Okay, let’s talk cutting boards! Having a good collection of cutting boards is something I think is essential. There is a reason there are so many different styles available – each type accomplishes a different goal. Depending on your level/style of cooking and entertaining, here is a list of some of the most commonly used and needed cutting boards.

End-grain-round-cutting-board

The All-purpose Chopping Block:  A nice, hefty, End Grain countertop block is super handy,since it is ready when you need it, and will look beautiful in your kitchen.  Not only are these blocks incredibly durable, the End Grain style is easier on your knives than other cutting surfaces, so it just makes sense to do the bulk of your chopping on one. End Grain blocks are available in a variety of sizes/woods/prices, one of which is sure to fit into your kitchen. They are also incredibly beautiful, and make a great serving surface on a buffet.NSF-Approved-Cutting-Board

The Lightweight Reversible Board: Sometimes it doesn’t make sense to use your big chopping block, and you need a board you can pull out easily and that won’t take up much storage space.  Enter the reversible cutting board: a lightweight edge grain board that can be used on both sides, and easily cleaned and stowed away for next time. This is the board you are going to pull out when you just need to slice up an apple or chop some parsley or other highly pigmented food. The big chopping block is unnecessary for such a small job, and the cleanup on a smaller board is much simpler. While you don’t want to leave this board soaking, you do have the option to scrub it down well after you make all those nice green stains. Also, since this one isn’t going to be out on the counter all the time, who really cares if it has a green spot?Carving-board

The Carving Board: Carving boards come in a variety of sizes and styles, and the one you choose will depend on how you intend to use it and where you intend to keep it. If you are like me and only use a carving board twice a year, you can get away with a thin, relatively inexpensive, standard board with a juice groove, like this one. If you are a die-hard BBQ-er, you will benefit from a bit more heft in a board that can take a bit of a beating and is easily transported, like this board with handles and a juice groove. Now, if you’re really serious about this roasting and carving stuff, this cutting board with carving spikes and a groove tree is pretty much a no-brainer. The spikes hold the meat in place while you carve away, and the groove tree directs juices into a reservoir so you can easily whip up some gravy or au jus.  If you want something that is both functional and stunningly beautiful, check out these End Grain boards with stainless steel feet; they are sure to wow at your dinner table.server-boards

Serving Boards and Blocks: There are so many fun and unique serving boards available these days! From contemporary to whimsical, and everything in between, we’ve got you covered no matter the occasion! Whether you are hosting an elegant dinner party or a potluck lunch, wooden serving boards will bring warmth and function to your table.

With the holidays quickly approaching, now is a great time to add some interesting cutting boards to your collection. They make great gifts, too!

The Mini-Boos Block and cheese hatchet set is a perfect housewarming or hostess gift and looks fantastic on any table.Mini-Boos-Butcher-Block

Butcher Block Countertops – How to choose the right one for your kitchen.

Butcher Block Countertops – How to choose the right one for your kitchen.

Perhaps this summer you’re considering a kitchen remodel and upgrading your kitchen countertops or island top.  There are a number of different countertop materials to choose from, each with its own unique benefit. Butcher block countertops are timeless, having been around for generations and remaining extremely popular today.  Many people migrate to the natural wood grain of butcher block because it fits any kitchen décor style, be it traditional, contemporary, or eclectic.  Butcher block is often chosen for kitchen island tops because of its durability and versatility, doubling as both a chopping surface and serving table. Choosing  butcher block countertops can be daunting and involves a significant investment.  But here are some considerations to help make the process easy! 

Perfect butcher block countertops fit your kitchen décor, your space, and your budget. 

butcher-block-countertops-choose-a-wood-species

Think about how light/dark and cool/warm you want your kitchen to look.

  • Hard Rock Maple is very light in color and uniform in appearance.  It can help brighten a kitchen and make it feel light, airy and cool.
  • Red Oak is of medium tone, with a golden, red tint.  It falls in the middle of the wood species selection with regard to light/dark or warm/cool.
  • American Cherry has a warm, red tint and can add both color and warmth to a kitchen.
  • Black Walnut is naturally a chocolate brown color, and can help darken a kitchen or visually warm a kitchen with its rich tone.
You can match, or you can complement other wood grain in your kitchen.
  • Matching the color of an existing wood can be difficult since many woods darken with age.  But matching a species and a grain pattern is much easier.  If you have Maple cabinets now, you can consider Maple countertops as a nice match.
  • Often it is more interesting to mix and match woods.   Differences in textures and colors, in moderation, can work nicely together.  It is easy to complement woods, especially when they are separated, like a wood floor and wood countertop. Or kitchen cabinets and counter tops separated by a tile backsplash.  Just be mindful;  make it look well thought-out, not like an add-on.
butcher-block-countertops-choose-a-grain-style

Three grain-style choices for butcher block countertops: Blended Grain, Edge Grain and End Grain.

  • Blended Grain will give a wide variety of color and grain pattern.  Rails of varying lengths are finger-jointed together showing much visual texture.  Blended grain  can look “busy” so it is  awesome when paired with a simple kitchen design, regardless of your decorating style.  It is the most affordable grain style.
  • Edge Grain is the end result when full-length rails are bonded side by side giving the appearance of a solid tabletop.  There is some  color and grain variation, therefore it is well suited for matching with other woods or natural stone surfaces in your kitchen.  Edge grain is moderately priced.
  • End Grain countertops provide lots of color and texture variation within the checkerboard pattern.  It has a very upscale appearance and is pricier, but it is the traditional butcher block look that shouts professional gourmet chef!
Your final considerations are a bit easier and they include your DIMENSIONS and FINISHING TOUCHES.  Choose your butcher block countertops now!
Kitchen Fitness: Use it or Lose it!

Kitchen Fitness: Use it or Lose it!

Having grown up in a gourmet kitchen store, I have a fabulous collection of kitchen essentials. Unfortunately, I have a mass of non-essentials, too! I need to focus on my kitchen fitness!! Honestly, who really needs six whisks of the same style?

The new year brought a new home with a smaller kitchen and, let me tell you, this kitchenware collector did not adjust well! For a solid month we lived with pans literally stacked on the floor, utensils pouring out of boxes, and a butcher block table so overloaded with stuff I couldn’t even use it! After stubbing my toe on a cast iron skillet for the 27th time, I’d had enough. I painstakingly went through every piece of cookware, bakeware, gadgetry, and appliance and whittled my way down to a manageably fit kitchen.

A few of the more ridiculous things I ousted:

  • Five whisks (kept four!)
  • Three 8” fry pans. THREE!!
  • Two nasty 12” skillets
  • Two garlic presses
  • A brand new ravioli rolling pin (why??)
  • Two identical carrot ribboning tools (why I even had one is beyond me)

A few things I can’t live without:

  • Counter-space-hogging espresso machine
  • Super quality cookware and knives
  • Silicone spatulas (colorful AND functional!)
  • My KitchenAid mixer
  • Quality cutting boards
  • Cake pans (endless uses!)
  • Cheese graters (yes, plural – don’t judge.)

And a few things I WON’T live without:

  • Vita-Mix blender – Don’t use this enough to justify the hefty price tag, but it’s magic!
  • All 22 of my wonderful German knives (seven are steak knives – it’s not that excessive!) –I use about four of them regularly, but they’re all in one block, so getting rid of some won’t save me any space!
  • My 23-year-old gigantic Scanpan “witch’s cauldron.” I have used it exactly two times, but it’s the bee’s knees and holds 9.5 quarts of stew AND 23 years worth of family memories.
  • Absurd (someone said that!) amounts of cookware. After getting rid of about a dozen pans, I still have a full pot rack (excellent addition to a small kitchen, by the way) and then some.

Clearly I have a hard time letting go of things I might possibly-some-day-in-the-distant-future use (looking at you, pasta machine). Getting rid of some of my unnecessities, however, made me appreciate the value behind the pieces I kept. I can do just as much with a simple set of tongs, spatulas, and bamboo spoons as I could with the multiple boxes of utensils I chucked (donated, don’t worry).

before & after

Moral of this story is that investing in quality multi-tasking pieces not only makes sense financially, but will improve your kitchen fitness. Plus you end up with space to keep the occasional frivolous purchase (*cough* individual instant popsicle makers).

You know that feeling when you clean out your closet and it’s like you have a whole new wardrobe with room for new boots? It’s like that. So next time you throw a spatula in frustration because its fat rubber handle won’t fit into your utensil crock, do yourself a favor and get your kitchen fit!

What are your must-haves for the kitchen?