At AboutMechanics, we're committed to delivering accurate, trustworthy information. Our expert-authored content is rigorously fact-checked and sourced from credible authorities. Discover how we uphold the highest standards in providing you with reliable knowledge.

Learn more...

How is Charcoal Made?

Charcoal is crafted through an ancient process called pyrolysis, where organic materials like wood are heated in a low-oxygen environment. This method transforms the wood into a concentrated carbon form, known as charcoal, which is prized for its ability to burn at high temperatures. Intrigued by the transformation? Discover how this simple substance powers industries and grills alike.
V. Wagner
V. Wagner

Charcoal is typically made by compressing and slowly burning compounds that have a naturally high concentration of carbon, then cooling, packaging, and forming the material that remains. In general the result is a black, ashy solid that can be used for a number of different things, though it’s perhaps most popular in food grilling. The end product provides even heating and virtually no smoke. It is generally pretty inexpensive to make, too, which means that it's relatively affordable in most place. The material is usually created in bulk in massive furnaces and drying ovens, then shaped, molded, and packaged for sale. Manufacturers who make briquettes out of “specialty” materials or who infuse scents or oils may charge more, but the basic product is usually very economical on account of how simple it is to produce.

Drying and Heat

A charcoal grill.
A charcoal grill.

Charcoal literally goes through a trial-by-fire process, which makes it, in turn, a substance that can be burned to deliver steady, reliable, and long-lasting heat. Charring is the first step to this process, and is usually the one that takes the longest. Manufacturers start with carbon-rich materials that can burn down to an ash. Almost everything that has life on earth can be considered “carbon based,” but substances can vary dramatically when it comes to their concentration levels. The best choices for this process are usually wood, but might also include fruit pits, nut shells, or other plant products. Specialty manufacturers will often use certain kinds of wood, like hickory or slow-burning hardwoods, but in general any sort of solid wood will work.

Hot charcoal briquettes.
Hot charcoal briquettes.

The first thing that needs to happen is that these materials need to be dried. This usually happens in dedicated humidors or other closed chambers where the relative humidity can be manipulated to nearly zero. Then, they are moved to ovens where they’re subjected to an extreme heat of around 840° to 950°F (450° to 510°C). This is accomplished by placing the materials either in a kiln or a continuously-fed furnace called a “retort.”

Importance of Even Burning

Charcoal's most popular use is grilling food.
Charcoal's most popular use is grilling food.

Even though the burning period here is slow, manufacturers often need to help it be even, too. Unless the material is somehow stirred or rotated, it runs the risk of charring on one side before it’s even really smoldered on the other. This can lead to a lot of waste, and can also make the end product less predictable and consistent in terms of how it burns. In order to avoid these consequences, burning carbon is usually fed through a furnace with multiple hearths. Mechanical arms might also stir things periodically to ensure even burning.

Cooling Period

It’s also important for the finished product to cool before it is shaped or packaged. The ovens are typically so hot that allowing the charcoal to cool on its own can take days. Most manufacturers start by spraying everything down with cold water once it’s done in the furnace. They are usually left to dry in temperature-controlled rooms or chambers with regulated humidity.

Shaping and Packaging

While the cooled and blackened product at the end of this process is technically charcoal, it isn’t usually recognizable to consumers until it has been shaped. Most producers form their products into a briquette shape, which often resembles a puffed square or small pillow. To make these, the char is usually mixed with small amounts of binding agent, typically wheat or some other starch. The mixture is then dropped into a press or mold that cuts it into standard briquette shapes, which then go through a dryer to seal and set their form. Sometimes the char is also pressed into longer log-like shapes, which is more common for use in industrial-grade barbecues or grills.

After the material is shaped and cooled, the briquettes are bagged and sent off to store shelves, industrial plants, and other destinations. Bags are usually made of reinforced paper in order to help the product avoid moisture and stay ventilated. Under ideal conditions, it will last almost indefinitely and it doesn’t really expire or lost its efficacy.

You might also Like

Discussion Comments


@GiraffeEars- Before you add your wood chips to the hot charcoal briquettes you should soak them for an hour in some type of liquid. This will make them burn slower and produce a good smoke to flavor your food.

When I soak my wood chips, I will often combine beer and water. I do not know what it is about alcohol and cooking, but it really seems to draw the flavor our in a meat. What type of beer I use depends on the food that I am cooking. Something with a strong flavor often requires a darker beer. I use a whiskey barrel stout or a porter for a steak or burgers. For seafood, pork and poultry, I usually soak my wood chips in something light like a blond or light lager. Play around with it a bit to find what you like most.


I have a question regarding charcoal barbeque. My friend gave me some wood chips (apple wood I think) to add to my barbeque, but the chips just burn away instantly, producing too much smoke and not so great a flavor. Can anyone tell me what I am doing wrong? How can I make my barbeque taste as if it has been apple wood smoked?


it's basically rearranging molecules in the stuff. It is not burning. When you heat something at a very high T, can you imagine that it will get a different physical form?


Where to find Charcoal buyers?


How can wood (or anything) be burned with out Oxygen?

Post your comments
Forgot password?
    • A charcoal grill.
      By: senk
      A charcoal grill.
    • Hot charcoal briquettes.
      By: Daniel Bujack
      Hot charcoal briquettes.
    • Charcoal's most popular use is grilling food.
      By: noppasit
      Charcoal's most popular use is grilling food.