How to Make Homemade Restructured Jerky - Recipe
How to Make Ground and Formed Jerky at Home.
Learn how to make Ground and Formed Jerky with Walton's and Meatgistics. Watch the video, read the guide, and then post your questions or comments below.
What Is Ground and Formed Jerky?
The simplest definition of Jerky is just meat that has been cured and dried. There are many different ways to make and process jerky the most common being sliced whole muscle or restructured jerky. I am going to be making a restructured jerky using the Weston #8 black series grinder, a meat mixer, a Walton’s Stuffer with the All-Around Jerky Maker and a smoker to cook and dehydrate it.
15 lb of lean beef
First thing you might want to do is to trim off the fat cap, since we are grinding this and then extruding it this is not 100% necessary and is just a personal preference. I am going to grind this meat twice, first through a 3/8 plate and then through a 1/8 inch plate. You could also use already ground beef purchased from a store if you don’t have a grinder. I’ve cut the meat into small pieces for this smaller #8 grinder. Make sure your plates and knives are sharp and well oiled to reduce stress on both the machine and the meat.
Now I am going to mix in the seasoning, cure and Smoked Meat Stabilizer. Smoked Meat Stabilizer should not be used with water, so we did not add any. It will start to gas out almost immediately and this can be very dangerous to breath. With ground and formed jerky some people like to get protein extraction and some do not, I recommend you mix until you have protein extraction for a better texture. So I am using the Weston Meat Mixer.
So now I am going to extrude this using a Waltons 7 lb sausage stuffer with the All Around Jerky Maker attached to it. This comes with a few different types of attachments, for this I am going to use the 2 slot die. As I extrude it the paper which sits underneath the Jerky Maker is going to move down the ramp with it. Now I am just going to keep extruding until I have everything in strips.
Smoked Meat Stabilizer should not be used with water, so we did not add any. It will start to gas out almost immediately and this can be very dangerous to breath.
Thermal Processing & Smoking for Home Smoking
Stage 1 - 130° F 1 Hour with Dampers Wide Open
Stage 2 - 145° F 2 Hours W/ Dampers 2/3rds Closed
Stage 3 - 175° F Until Internal Temp Reaches 160°
Thermal Processing & Smoking for Advanced Smokehouses
Stage 1 - 110° F 10 minutes Relative Humidity (RH) 68
Stage 2 - 130° F 20 Minutes RH 20
Stage 3 - 135° F 90 Minutes RH 30
Stage 4 - 155° F 60 Minutes RH 30
Stage 5 - 155° F 90 Minutes RH 0
Stage 6 - 180° F Until internal temp is 160° RH 0
There is no need to put jerky in an ice bath as it is so dry and thin that it will stop the cooking process quickly enough by itself. It is important to let the jerky sit out at room temperature for about an hour before vac packing to prevent condensation from forming inside the package.
We started out with 15 lb of meat and ended with 8 lb of jerky so that is just about 50% loss so we are right where we would expect to be with the ability to control humidity in our smoker. The All Around Jerky Maker really made this entire process much easier than trying to do this with a Jerky Gun though that will certainly work as well, it will just take longer. The flavor of the Dill Pickle Seasoning is awesome, if you like Dill Pickles, that seems obvious but this does have a strong dill flavor!
- Do not add water if you are using Smoked Meat Stabilizer
- If you do not use Smoked Meat Stabilizer you will want to hold your product overnight to allow the cure to work in the meat
Just to make sure that I put this in here as many times as possible, if you are using the Smoked Meat Stabilizer (which I did) do not add water to your product or it will gas out and create a gas cloud. You don’t need to be scared of this product just be careful with it.
Watch WaltonsTV: Ground and Formed Jerky
@jonathon yep, shorter horn makes sense. I am mech. engineer and there are two big things wrong here: the 9.5mm (3/8") stuffer tube and its length. Most of the problem, probably, ALL could be solved by using the diameter stuffer tube for 16 mm casings. There is NO advantage to going smaller, just disadvantages. Pressure drop(in this case back pressure on the cylinder / piston goes up exponentially as diameter is reduced.
@jonathon It looks to me you may have missed a small point in the original post. He said he was using 16mm casings but a 3/8" stuffer tube. 3/8" is VERY small-- only 9.5 mm! He is trying to punch it through a pinhole darn near.
So a couple things for you here. First off you really just dont have the proper equipment to stuff 16mm casings, but you can try a couple things. Spray all your equipment with a good food grade lubricant. Inside the stuffing horn and inside the meat cylinder so meat can flow as best as possible. Second get a 1/2 inch stuffing horn. Its going to be a bit of a pain bit you will have to manually roll your 16mm casings onto your 1/2 inch stuffing horn just like you would fresh casings. Stuffing through a 1/2 inch horn is going to be eaiser than 3/8. Third as another option is to mix a small amount of vegitable oil into your meat to add some lubrication without effecting flavor. These are just a few options to try with your equipment. Let us know how it goes!
Specialty Sausage 102: Making Lebanon Bologna
Attend this entry-level class from Meatgistics University by watching the video, reading the article and post any questions you have!What Is Lebanon Bologna?
Lebanon Bologna was originally made by the Pennsylvania Dutch in the 1800’s. Traditionally it is a dark bologna, similar to salami in appearance and texture and it has a tangy flavor. It is often eaten as cold cuts and it can be slow cured and cold smoked or smoked using more modern methods. We are going to be making a version today that will not be slow cured or cold smoked as that makes it more difficult for the average home user.Meat Block
If you can you should cut the fat off of your pork and grind your pork fat separately through a 3/16th plate twice. Then grind your beef and lean pork through a 3/8 plate and then through a 1/8 plate. Keep ground pork fat separate. Making sure EVERYTHING but especially your pork fat is cold before you grind it is very important here for particle definition.Meat Mixing
Place lean meat in the mixer. While mixing add Lebanon Bologna seasoning, Sure Cure and Ice Cold Water. Mix for 5 minutes. Add ground fat trim, sodium erythorbate and mix for 3 more minutes. Lastly, if you are using Encapsulated Citric Acid add it during the last 60 seconds of mixing. If you add the Encapsulated Citric Acid too soon you could break the encapsulation and release the acid into the meat too soon.Sausage Stuffing
Stuff your meat into fibrous casings that have been soaked for at least an hour in water that is 80 - 100° so the casings are pliable. These casings are tough and durable so don’t worry about blowouts just stuff them fully but make sure to leave enough room to get a hog ring on the open end. When stuffing larger diameter casings it is important to choose the largest of the stuffing tubes that your casing will fit over and make sure you are gripping it nice and tight, we want these casings packed nice and solid.Note
You can also use Fibrous or Non-Edible Collagen casings, we chose this as it had the capacity we wanted and it presented the product well.Thermal Processing & Smoking
To smoke start them out with 125 for 1 hour, then 140 for 1 hour then 165 for an hour and finally at 180 until the internal temperature reaches 155°.Cooling
Place it in an ice bath or shower for 20 minutes to bring the temperature back down and then hold at room temperature for 2 hours and then move to a cooler or freezer before vacuum packing. I let this sit in a refrigerator overnight before slicing to make sure the temperature was brought all the way down.Wrap up
All in all, this is very similar to making a salami or even a summer sausage, the main differences are separating out the pork fat from your lean and using the correct ratio, seasoning, and casings. The fried Bologna sandwiches were very good!Additional Tips Removing the fat cap before you break down your pork butt is easier sometimes, it all depends on how it looks before you start cutting into it. I put very little smoke on this as I didn’t want that to dominate the taste so I filled my smoke tray about 1/4 of the way full. I am glad I did it this way as it allowed for the Lebanon taste to come through more. Other Notes
I added X-Tra Hot Red Pepper to this to help give it a nice zip and to cut some of the sweetness. I used it at a ratio of 3 oz per 100 lb of meat and since I was doing 10 lb that means I used .3 of an oz.Watch WaltonsTV: Specialty Sausage 102: Making Lebanon Bologna Shop waltonsinc.com for Cured Sausage Seasoning Shop waltonsinc.com for Meat Grinders Shop waltonsinc.com for High-Temp Cheese
Specialty Sausage 101: What is Specialty Sausage?
Attend this entry level class from Meatgistics University by watching the video, reading the article and post any questions you have!What is Specialty Sausage?
As much as you might love bratwurst, summer sausages and snack sticks sometimes you want a sausage that is a bit more unique. It might be a recipe you tried once in another country, one that your grandparents used to make or something just sounds really exotic like blood sausage. Recipes and knowledge of how to make these types of sausage are often passed down from generation to generation.
For whatever reason, these types of sausages have fallen out of favor and are sadly relegated to the specialty stores of the home processor. Maybe opinions have changed on the type of meat used, the way it is cooked or the seasoning or spices used in the original seasoning. The good thing about this is it gives you the opportunity to “rediscover” plenty of types of amazing sausages.Types of Meat Required
Sourcing the meat might be a little harder for this than a normal sausage but a quality butcher should easily be able to get you pork liver, trim and even pork blood that you will need to make some of these. Others like Lebanon bologna and some landjaeger only require a mix of pork and beef and a special seasoning.Casings
Many specialty sausages will also require a special or a specific casing to be used. Braunschweiger has a special plastic casing specifically for the production of that product and others like landjaegar simply require that you use a natural casing like hog or sheep intestine.Smoking
Smoking and cooking will also be different with a lot of these sausages, a normal smoke schedule might not work for your needs on these products. We will be making Landjaegr, Lebanon Bologna and Blood Sausage in the 10’s and then go for some even more out there products in the advanced classesShop waltonsinc.com for Jerky Seasonings Shop waltonsinc.com for Vertical Smokers Shop waltonsinc.com for Weston Dehydrator 160L Pro Series
Weekly Blog Post - PreThanksgiving & Specialty Sausage
Find out what's going on at Walton's and Meatgistics this week. We will have a loose schedule for soon to be released videos, what we are working on long-term and maybe a few quick tips and tricks that are on our mind!What Videos are being released soon?
We just released our Pre Thanksgiving Sales that will be good through Friday so you should absolutely check that out. You will also see that we have reduced shipping on orders over $5 all week.
ThanksBlackMonday - This is the “fun” video that we do every year! This year we split it into thirds so the first round of sales will be good from 11/19-11/26, the second round starts on Black Friday (11/22) and ends on Cyber Monday and the third round is Cyber Monday only!
Specialty Sausage 101 & 102 - In these two videos we will be going over specialty sausage as a category and then showing you detailed steps on making Lebanon Bologna. Ours came out amazing so if you are planning on making any this year watch the video for some tips on how to make a delicious Lebanon Bologna!What Projects are we looking ahead at?
Specialty Sausage 103: Landjaeger - We made Landjaeger or a version of it at least! It came out tasting excellent but the appearance wasn’t exactly what we were going for, for more details keep an eye out for this video in the next few weeks.
Specialty Sausage 104: Blood Sausage - We haven’t made this year and it is going to have to wait until at least after Thanksgiving but hopefully we will get to it soon! We are excited about this as it’s a true odd-ball in America and we want to see if we can make some improvements to it!What’s on our Mind?
It is almost Thanksgiving time and I’m going home for the first time in years! Like everyone else, I am excited to see family and friends and eat delicious food! Don’t forget to take a few minutes this Thanksgiving to really concentrate on what you are thankful for. For me, a huge thing I am thankful for is this job, I really love what I do here! I mean, who wouldn’t love talking, filming and answering questions about meat processing all day!New Products
The Talsa K50 Bowl Chopper and the Talsa K80 Bowl Chopper are two brand new choppers from Talsa. These are large commercial pieces of equipment that allow you to do everything from a rough chop to an emulsification of your meat products. Either of these machines will work on everything from pulled pork to hot dogs!