I'm no expert. I humbly submit my knowledge to the universe. Here is a summary of what I learned this weekend.
#1 - Record Your Process
To repeat a process for consistent results, you need to log details of what you do and the results. Basics for this we're temp, time, wood dimension, wood grade, plus other observation and the results.
#2 - Use a Convection Oven
A convection oven is less work and provides more consistent results. I started using both my conventional home oven and a toaster/Convection oven. A convection oven has an air circulating fan in it. With convection I had to move my wood much less, and the heat was much more consistent (less hot spots.) I have less capacity with this oven but with the improved yield, it is plenty big enough for my needs.
I kept 1/4" of air space between each stick and cross stacked them two rows high.
Each oven is different. It's easier to get consistent results by working with the same oven each time. Here is my little fella. #3 - Use the same size sticks
To get consistent results you should use the same sized pieces. I am going with 3/4" x 3/4" x 6". For my tests I used the box on the left which was half American White Oak and half Cherry. #4 - Grade Your Wood
Inconsistent wood means inconsistent results. It took me a few batches before I could predict which oak sticks would give good results verses those that did not. I first noticed that half the sticks I toasted swelled up and split and/or otherwise turned very dark very fast compared to the others. I figured out that sticks with variegated coloring (light/dark) and sticks with knots and stressed grains would not toast consistent. I tested/confirmed my theory by stamping each stick, before toasting, that I thought would swell, split, or prematurely darken. I successfully graded later batches and had a much better yield.
Here is how I figured this out. The pic below shows sticks from one batch organized by time toasted. I offset two columns: left column are solid sticks, right column are swollen, split, knotted sticks. When you remove all the swollen, split and knotted sticks, the smooth progression of toast color over time is easy to see. Bingo! FYI. All my wood was very dry. So dry, I don't believe my moisture meter that said they contained around 4-5% moisture. I assume that wetter wood will behave differently.
#5 - The Toasting Process
I cross stacked two layers of sticks with 1/4" spacing between them. Spacing is necessary to let hot air circulate around all surfaces of the stick.
I turned my sticks at 20 minutes intervals, top to bottom and center to edge. The Top to Bottom turning was necessary to ensure each stick was toasted evenly. I didn't notice the Center to Edge turn have much of an impact on toasting evenness.
My early experiments in the conventional oven (no fan) required a lot more turning, and there were definitely hot spots to deal with. This is why I switched solely to my small convection oven.
#6 - Consistent Results
I realize that I can't simply do the above again at the same temp for the specified time and get perfect sticks, but these tests have helped me determine a standard process with a dialed in temp/time estimates. In the end, it is color and smell that determine the toasting "cut".
Because you can't write down color/scent, I have created myself a few indexed sets of toast levels by temp/time (in my oven) For future toasting, these will help give me a good ball park of the temp time I need to target, and a color/scent match to know when it's time to pull sticks.
Here are my sample sets from today's toasting of cherry and American white oak done at 325 deg F and 375 deg F. Toast Index Sets - 375 deg F. Cherry from 25 to 50 minutes. Oak from 25 to 70 minutes.
Toast Index Sets - 325 deg F. Oak from 30 to 100 minutes.
There are forest fires burning across the west and it's a bit smoky outside where I live. It smoky inside my home too, but the smell in here is more pleasant.
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Enjoy! Otis
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