[vc_row][vc_column][vc_column_text]At first glance, the process of making jam\u00f3n as we do in Spain seems simple: we salt the pork leg, hang it up, and let it cure. However, during the time it takes for the magic to happen\u2014turning raw meat into this prized delicacy\u2014numerous biochemical processes occur. These processes are related both to the raw material (the pork leg) and to the other key ingredient, salt, as well as the careful control of time at each stage.<\/p>\n
As in any discipline, the more you understand the process, the more complexities and solutions emerge. What once seemed simple evolves into something as complex as the rich aromas and flavors we achieve in the final jam\u00f3n.<\/p>\n
In this week\u2019s post, we\u2019ll attempt to summarize the approximately 2-year process involved in producing our white pork jamones, and up to 3 or 4 years for our Iberian jamones.[\/vc_column_text][\/vc_column][\/vc_row][vc_row][vc_column][vc_single_image image=\u00bb3760″ img_size=\u00bbfull\u00bb][\/vc_column][\/vc_row][vc_row][vc_column][vc_column_text]The Process of Making jam\u00f3n: As Simple as It Is Complex<\/strong><\/p>\n Everything begins with raising the pig. We often say that jam\u00f3n is a \u00abliving product\u00bb because it is in constant evolution from the moment the pig is born until it is consumed. But also, as we commonly say in the industry, v is not like screws (I know, some screw manufacturers might say not all screws are the same, but you get the point). What we mean is that every jam\u00f3n is unique. Even the two legs of the same pig, processed simultaneously, do not necessarily turn out the same. Each pig, even from the same litter, has its own characteristics, from unique genetic traits to diet and animal handling (not to mention the differences between farm-raised and free-range pigs).<\/p>\n Once the animal is slaughtered, factors such as the conditions in which this occurs, the skill in butchering, shaping (the way the jam\u00f3n is prepared before salting), and how each piece is handled become important. Any irregularity in the butchering temperature, a poor knife cut, an impact on a hard surface that could separate the muscle fibers, or any deviation in the cold chain will affect the final product.<\/p>\n So, when a fresh jam\u00f3n arrives at our facility, it already has characteristics that make it different from the others in its batch.[\/vc_column_text][\/vc_column][\/vc_row][vc_row][vc_column][vc_column_text]Classification, Salting, Washing, and Post-Salting<\/strong><\/p>\n The first step in the drying room is classifying each jam\u00f3n by weight, at least in our case. With some technologies, the jamones can also be classified by fat thickness and pH. At La Estrella del Jam\u00f3n<\/em>, we classify our jamones in one-kilogram ranges (from 12 to 15 kilograms when fresh) to determine how many days they will remain buried in salt. After labeling each jam\u00f3n with a traceability code and its exact weight, we apply curing salt and bury them in sea salt in a chamber at temperatures below 3\u00baC and with relative humidity above 90%.<\/p>\n After the optimal number of days has passed, the jamones are washed with running water, shaped, and hung to begin the post-salting or resting phase. For the next 90 days, the jamones are kept in a chamber where the temperature is gradually increased from 2\u00baC to 6\u00baC, and the humidity is lowered from 90% to approximately 75-80%. During this phase, the salt starts to penetrate the jam\u00f3n through diffusion, while water from the meat migrates to the surface through osmosis. This is a crucial process because we are still dealing with raw meat that, if not handled correctly, can be at high risk of bacterial contamination.[\/vc_column_text][\/vc_column][\/vc_row][vc_row][vc_column][vc_column_text]Drying, Lard Application, and Aging<\/strong><\/p>\n After those 90 days of simulating winter, the jamones are moved to a forced drying room, where they are tempered up to 10\u00baC for about three months before entering the natural drying stage. Just before they are moved to drying rooms with open windows, we apply hardened pork lard to the surface of each jam\u00f3n by hand. This step prevents air from entering the jam\u00f3n through the small cracks that develop due to differences in contraction between the lean meat, fat, skin, and bone. The lard application is a vital step, as it protects the jam\u00f3n from air, mold, and mites.<\/p>\n After about four months in the natural drying room (12 months since the jamones were salted), the jamones are removed and \u00abpainted\u00bb with a layer of liquid lard. This second layer helps maintain moisture and prevents excessive drying of the jamones surface.<\/p>\n Once the jamones have been coated with lard, they are moved to a natural cellar where temperature and humidity are carefully controlled by opening or closing the windows. This is the only tool we use in our facilities, the same technique that was traditionally used in homes where jam\u00f3n was made, which we have reproduced and mastered.<\/p>\n In the cellar, the jamones will remain until completing the final curing stage, approximately 24 months from the time the salting process began. At this point, each jam\u00f3n is individually selected based on its optimal curing point before being sent to our customers.[\/vc_column_text][\/vc_column][\/vc_row][vc_row][vc_column][vc_column_text]The Magic of Biochemistry<\/strong><\/p>\n I\u2019m not a chemistry expert, but I\u2019ve learned a lot from attending congresses and courses. It never ceases to amaze me. That\u2019s why I want to mention the biochemical process, which, although not something we can directly control, we can influence with our decisions.<\/p>\n Decisions like the raw materials we purchase, the number of days of salting, the post-salting period, the amount of lard we apply, and the time the jamones spend in the drying room and cellar.<\/p>\n It is the enzymes in the jam\u00f3n muscles that perform the real magic. These enzymes break down the proteins in the muscles through a process known as proteolysis, turning them into cured jam\u00f3n. During this process, proteins are broken down into amino acids which, if the curing is long enough, combine to form peptides, the key players in the final flavor and aroma.<\/p>\n Salt, in addition to drawing out moisture from the jam\u00f3n and inhibiting bacterial growth, ensures that proteolytic enzymes work just enough to avoid over-degradation, achieving the ideal texture and contributing to that wonderful salty flavor of jam\u00f3n.<\/p>\n In summary, the stages of jam\u00f3n production include the pig\u2019s upbringing, slaughter, butchering, shaping, classification, salting, washing, molding, post-salting, drying, two lard coatings, and aging\u2014along with the biochemical processes that occur over two years of curing. It’s a process as simple as it is complex, filled with variables that make each jam\u00f3n a unique piece, reflecting the time and care invested in it over the last two years.[\/vc_column_text][\/vc_column][\/vc_row]<\/p>\n","protected":false},"excerpt":{"rendered":" [vc_row][vc_column][vc_column_text]At first glance, the process of making jam\u00f3n as we do in Spain seems simple: we salt the pork leg, hang it up, and let it cure. However, during the time it takes for the magic to happen\u2014turning raw meat into this prized delicacy\u2014numerous biochemical processes occur. These processes are related both to the raw […]<\/p>\n","protected":false},"author":1,"featured_media":3808,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":[],"categories":[109],"tags":[321],"_links":{"self":[{"href":"https:\/\/laestrelladeljamon.es\/blog\/wp-json\/wp\/v2\/posts\/4428"}],"collection":[{"href":"https:\/\/laestrelladeljamon.es\/blog\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/laestrelladeljamon.es\/blog\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/laestrelladeljamon.es\/blog\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/laestrelladeljamon.es\/blog\/wp-json\/wp\/v2\/comments?post=4428"}],"version-history":[{"count":1,"href":"https:\/\/laestrelladeljamon.es\/blog\/wp-json\/wp\/v2\/posts\/4428\/revisions"}],"predecessor-version":[{"id":4429,"href":"https:\/\/laestrelladeljamon.es\/blog\/wp-json\/wp\/v2\/posts\/4428\/revisions\/4429"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/laestrelladeljamon.es\/blog\/wp-json\/wp\/v2\/media\/3808"}],"wp:attachment":[{"href":"https:\/\/laestrelladeljamon.es\/blog\/wp-json\/wp\/v2\/media?parent=4428"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/laestrelladeljamon.es\/blog\/wp-json\/wp\/v2\/categories?post=4428"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/laestrelladeljamon.es\/blog\/wp-json\/wp\/v2\/tags?post=4428"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}