Bacon comes from a whole cut of pork called pancetta, which is delimited by four cuts that give it a rectangular shape: an upper cut, along the backbone; a lower cut, from the breast and belly; a front cut, which goes from the end of the loin and ends at the tip of the sternum; and the last, posterior cut, which continues along the end of the ham and goes all the way to the leg. The skin is removed from this cut, which is made up of two layers: a layer of meat mixed with fat and a layer of fat.
A regular salt level in bacon varies from 1.6% to 2% of the final product, so it is necessary to calculate the amount of salt in the brine to obtain this percentage in the final product.
You phosphates are also among the ingredients that are usually added to the formulation and have an important function in water retention, making the meat retain water in a stable way and offering a juicy palatability and a lot of flavor in the bacon. Their quantity varies between 0.3% to 0.5% in relation to the final product.
Another necessary ingredient is nitrites in the form of curing salts, which provide flavor and color and prevent the growth of Clostridium botulinum. Health regulations establish that 150 ppm (mg/kg) is the maximum limit in the final product and, for this reason, a calculation must be made based on the nitrites contained in the curing salts.
Questions about curing salt? Read the post Curing salt what it is and how much to use
Once the ingredients have been applied, the pancettas are massaged/tumbled and left to rest for 24 to 48 hours, so that the pancetta can cure and ensure complete homogeneity of the ingredients in the meat and fat.
Heat treatment (smoking and cooking) transforms the pancetta into bacon. The first step is to hang the pancetta on hooks. The pancetta must be fixed to the hook. These hooks are hung in the oven, where it is initially dried at a temperature of 65°C for 20 minutes and at zero relative humidity. This drying is done in order to “close the pores” and thus obtain better meat yields. The product is then sprayed with liquid smoke for ten minutes and then dry again at 65°C for 15 minutes to fix the smoke and color.
After drying in the oven, the temperature is increased to 80°C and the relative humidity is increased until it reaches 70°C at the cold point.
As soon as the product comes out of the oven, it is put under a cold shower of drinking water to reduce the temperature to 37°C and then the bacon is taken to cold chambers where it must reach 4°C in less than 24 hours to ensure the safety of the bacon. The temperature must continue to be reduced to -4°C to continue slicing, which is done in automatic slicers. It is important to note that the choice of cutting temperature will depend on the speed and efficiency of the slicer blades. Downtime and the power of the machine have an impact on the efficiency of the process and costs. Therefore, these are factors that make a difference in terms of competitiveness. After being sliced, the product goes through the thermoforming machine to be vacuum packed and ready for storage and distribution.
See also: homemade smoked bacon recipe
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