Modern Marvels: The Surprising World of Cold Cuts (S13, E43) | Full Episode

This paragraph introduces cold cuts as an integral part of American pop culture and their convenience in various settings. It highlights the economic significance, with Americans consuming over $2 billion worth annually. The paragraph focuses on bologna, tracing its production at Farmland Foods in Wichita, Kansas, and explaining the meat ingredients involved, including mechanically separated chicken. The process of making bologna is detailed, from grinding and seasoning to emulsification, cooking, and finally slicing. The iconic red casing is mentioned as a visual appeal that consumers peel off before eating.

The second paragraph delves into the history and production of salami, a cold cut with ancient origins dating back to 700 BC. It discusses the craftsmanship involved in making salami, particularly Genoa salami, at the Columbus Salami Company. The process includes selecting high-quality meat, mixing it with a secret blend of ingredients and spices, and fermenting it to cure and preserve the meat. The importance of mold in the fermentation process and the final steps of drying and slicing are also covered, emphasizing the care and skill required to create this classic cold cut.

This paragraph explores the making of pastrami, another classic cold cut, at the renowned Carnegie Deli in New York City. It describes the labor-intensive process that begins with selecting prime or choice steer navels, injecting them with a brine solution, and allowing them to absorb the spices. The meat is then smoked and steamed to achieve a tender texture. The paragraph also touches on the deli's philosophy of serving large portions, aiming to provide an experience that is both satisfying and challenging for customers.

The fourth paragraph introduces less common cold cuts, such as head cheese and liverwurst, which have unique compositions and preparation methods. Head cheese, made from pork tongue and snout, is crafted using traditional techniques that involve cooking, seasoning, and casing the meat before it is solidified in a jelly-like broth. Liverwurst, a rich food with origins among nobility, is made from a blend of liver and pork, emulsified to create a smooth spread. The paragraph highlights the historical and cultural significance of these cold cuts, as well as their distinct flavors and textures.

This paragraph discusses the evolution of meat processing and the role of equipment like the Hobart Slicer in creating consistent, thin slices of cold cuts. It describes the manufacturing process of the slicer, from polishing the aluminum base to sharpening the blade, and the importance of hygiene and sanitation in food processing. The paragraph also pays tribute to Wilhelmus van Berkel, the inventor of the original meat slicer, and the transition from manual to motorized slicers, emphasizing the industry's commitment to safety and efficiency.

The sixth paragraph examines the large-scale production of turkey cold cuts at the Butterball Plant, emphasizing stringent food safety protocols. It details the steps taken to ensure hygiene, from the workers' attire to the sanitation of equipment. The process involves deboning the turkey, injecting it with a brine solution for flavor and moisture retention, and cooking it. The paragraph also explains the measures taken to prevent cross-contamination between raw and cooked areas and the rigorous cleaning routines to eliminate bacteria such as listeria and salmonella.

The final paragraph discusses the emergence of health-conscious alternatives to traditional cold cuts, such as Tofurky, a plant-based protein product made from tofu. It describes the production process of Tofurky at Turtle Island Food Company, which involves blending tofu with a secret recipe of spices and plant extracts. The paragraph highlights the health benefits of these alternatives, such as lower fat content and no cholesterol, and notes the growing trend of incorporating such products into the diets of health-conscious consumers.