Saugatuck Craft Butchery

 Along the southern coast of Connecticut is the town of Westport. Just a minute off of Rt 95 you can find Saugatuck Craft Butchery there. The shop is located right on the Saugatuck river near the boat launch, in a very picturesque neighborhood that is currently renovating and growing. This is the definition of a small, true craft butchery shop. Every piece of meat is cut from whole carcasses and there is no boxed products to be found. The showcase is filled with fine cuts of local beef, dry aged in house; local lamb and pork, fine poultry, well made sausages, and a small but high quality selection of cheeses. The crew of five is loaded with talent including Ryan Fibiger, owner and head butcher, Paul Nessel, co-owner and butcher, Mark Hepperman, resident chef, Sam Garwin, butcher and Mike Egan, butcher. Mike and Mark are both graduates of the CIA ( I was Mike's meat instructor). Paul was a chef also and Sam is involved in the marketing end of the business but she can also cut. The crew of this shop are united in the idea of treating butchery as a craft and showcasing the entire animal in a way that is appealing and at a very high quality level for the customer.
 I was invited to teach a short class on hog butchery to the crew and some of the area chef/ customers of the store. The attendees all had some butchery skills so it was much more of a discussion of alternative styles as opposed to a lesson on basics. We talked bone structure, seam butchery and techniques for creating cuts for curing. Another issue was storage. How does a restaurant store an entire carcass? We talked about vacuum packaging and its effects on pork. The store's vacuum machine is not working right now and Ryan was actually happy about it. He finds that using the vacuum is sort of a crutch and allows you to over cut and then package everything rather than cutting to what will be sold that day, in other words, forecasting.

 Saugatuck represents the trend of artisan butcher shops that are springing up all over the nation., But theirs is the model of how to do it right. Ryan and Paul worked at Fleisher's of Kingston to help learn the craft and the ideals of that shop are evident here. Just as when students leave our classes at the CIA, they've become their own artisans. This shop has some unique touches and they are developing as they go. With all the chefs on board, you will certainly see more prepared foods in the future.
 They also offer meat cutting classes a few days a month and they have an apprenticeship program for those looking to really learn the craft. Here is their link https://craftbutchery.com/home/
  Ryan has a good relationship with a lot of the local chefs and restaurants in the area. He offers that local connection that so many are looking for today. He also has good relationships with area farms and is offering a steady outlet for anyone who is growing local niche market animals.

 When you walk into this store you know right away that it is well run by folks who really care. There was no deceptive tricks, no products sold that they didn't know the origin of the animal, no fillers or artificial stuff in the sausages. The meats aren't cheap but they are really good quality and you can certainly taste the difference. The crew has a lot of cooking knowledge and is more than willing to share ideas with their customers. This shop is also starting a sandwich line which will only expand as they move into their new digs right across the street. They are hoping to start accepting CIA externs in conjunction with the Whelk restaurant that is just across the plaza and I can't wait to send some students down there.

Making the Movie

There are a lot of meat fabrication clips out there on you tube; some are very well done while others are very poor. How can a chef or butcher know which ones are worth a look? I search through a lot of them and occasionally suggest one to my students or coworkers. I've seen some horrible home movies of hog slaughter where amateurs attempt to explain how its done with very little regard for food safety etc. I've also watched industry videos that over simplify the process and sanitize the view, and focus on the equipment that is being sold. Many videos are made by other instructors in culinary schools around the country. These can be informative and might show a different style or technique. Then you have the anti-meat activists that will show some poor practices done typically at slaughter houses that are not managed well. These are meant to horrify and unfortunately will often be referred to as "industry" standards while actually they are the extreme.
 My own students will often post in-class videos which I sometimes assign as pre-class views for other students to get warmed up to the lesson. As butchers, we must realize that what we do each day, is found fascinating by many. What used to be done in farm households is now distant from what we see in most stores. Not many people will cut their own chicken breast let alone a large carcass.
 Here is a set of videos that shows how to breakdown a half hog in great detail by someone doing it in their own house. It has some good detail and well worth watching. http://www.youtube.com/watch?v=bsoK0gcG9as&list=PL69C2B028F82492F4&index=1  The cutter makes cuts that are not exactly industry style but much more of a custom style of cutting that many small shops are doing today. Some of the techniques are a little out of the norm but part of butchery is developing your own style. Check it out!

Is Local Always Better????

The other day we were cutting a half hog during class and it was from small local processor. It weighed just about 100 lbs., making it a very average market style hog. This size is the most popular throughout the country and is what most large processors look for. The typical processor in Iowa is looking for a 6 month old, 265 lb white haired, grain fed hog. This pig, even though it was raised in upstate NY, fit that description perfectly.
  When we broke it into it's primal cuts the pork was pink, the fat was firm but there was very little marbling and the fat back was only about a 1/2 to 1 inch along the back. I know this pig was not fed any growth promotants or fed antibiotics preemptive but other than that, is it much different than the mass produced pork I can buy for almost half the price?
  When purchasing local, you need to consider a few things. First, just because it is local doesn't guarantee it will be much different than the commercially raised large farm pork. Second, local doesn't always mean "heirloom" breed and many farmers are raising hybrid, fast growing pigs that are easy to raise indoors. Third, the feed a pig gets will be reflected in the flavor so if a grower uses a basic pre-mixed bagged feed the pig will taste pretty much like a mass produced commercial pork.

 So why would you purchase this type of pork? You may decide not to. You may choose a unique heirloom breed that was fed some forage, diverse grains, kitchen scraps, crop farmers by-products and pasture. But these pigs are very expensive and some are extremely fatty. There are some really high quality pork producers out there that are growing pork that doesn't resemble the large commercial pork. It is often reddish in color and the taste is deeper. But be ready to pay for it, an heirloom pig can be anywhere from $3 to $9 per lb!!

 A lot of chefs and home cooks would balk at these prices but still want to be part of the "locally grown" scene. Should they buy the local product that looks like regular pork? Its a tough question to answer. Our white pig was about $1.70 per lb which was more than what large commercial producers charge. Hog market price as of this post date was about $.85 per lb!!!! That is so incredibly cheap that no small producer can match it, no matter what they are feeding. 

 But here a few more things to consider, buying local pork, no matter what style, means you are keeping a local farmer in business. Most local farmers I know are allowing their pigs outside at least in summer. The pigs have a more pig-like existence and allowed some fresh air. Also most small farmers don't use gestation crates, restraining sows and they often don't use antibiotics, unless there is some infection that is not treatable in any other way. They don't use Paylean, a beta-agonist feed additive that grows lean muscle faster from less feed. These are questions you should ask about your local pork.

  Also, the local pork will arrive fresh and not in a vacuum bag. If pork is stored in bags for any length of time ( over two weeks) it starts to purge out and gives the pork a watery feel and the fat will be soaked with purge. Ideally pork should be used fresh and wrapped in paper so the fat stays nice and white. A local pork will typically arrive as a half hog and it will be nice and dry. Purchasing a half hog means you have all sorts of creative fuel for many products. Skin for cracklins or gelatins, bones for roasted stocks, some fat for rendering and the ability to custom cut your meat to create unique dishes. Fresh unbagged pork will work better for dry cured products because the skin and fat will be dryer to start with. 

  So no matter whether you choose to buy an heirloom barley fed pig or a standard market style hog, buying local will have advantages for any chef looking to showcase unique products. 

Pig Diet...Not for Slimming

My nephew, Austin Schneller, is raising four hogs this year. Each year he raises a few for his own consumption and a lucky few friends who help with the costs. A few years ago he raised four Danish Landrace prize stock pigs. They were lean and skittish, without much fatback. They grew really fast but were not what he was after. Then next year he got a Berkshire, a couple Hampshires and a Duroc cross. These were totally different, huge and very fatty. Last year he tried Tamworths, which were wonderful, large with very nice bellies etc. Some of the best pork I've ever tasted. This year I think he has the winner, a cross between Large Blacks and Old Spots. These pigs are very healthy, great foragers and getting really fat. They are a little agressive with each other but thats just pigs acting as they do.

 The feed for the pigs is pretty much the same year to year, lots of grains including corn but also some fermented barley, then as we get into fall, acorns, pumpkins, squash and apples, all byproduct waste from local farmers. This year I picked a big bucket of acorns off my lawn and they ate them like candy. The pigs are under some large oaks so they get all the natural drops in their pen as well. They always get the kitchen scraps from Austins home cooking.

  At the CIA we have the St Andrews Cafe where we try to keep it local and use as much locally grown food as possible. The attempt at sustainability is valid but I noticed we were throwing out the waste food scraps so I introduced the pig bucket. Every couple days the students from St Andrews fill a 5 gallon bucket with a wide assortment of scraps. I pick it up and drop it off to Austin's on my way home, which is typically late evening. The pigs get a very nice late night snack. I've always heard the worst time to eat dinner is late at night because it will make you fat! Well thats the goal here.

 The difference of flavor between these hogs and the commercially grown pork I work with in class is like day and night. Hese pigs are not only fed a more diverse and healthy diet, they are also allowed to mature a little more, giving a more complex meat taste. The other day we cut a half hog from Meiller's in Pine Plains. It was ok but didn't have much marbling and fat back. It wasn't raised poorly, but it was a white pig breed which tend to be leaner and it just wasn't allowed to mature.

 To get the best possible pork, such as that used for the Bellotta Iberico hams, it takes time and lots of really good feed, which means it will be expensive, but well worth it.

Beta-agonists? Good thing cattle don't race bikes.

I was reading an article in a trade magazine the other day which was commenting about the average carcass weight of recent beef. Beef has gotten bigger from some feedlots and the reasons for this are multiple. One is simply introducing larger breeds into the mix. This has been going on for hundreds of years and it is a natural way to increase size. For example if a breeder mixes an Angus with a larger Charolais you end up with bigger beef that should have some of the higher quality traits of the Angus. Advances in breeding and the ability to track generations have resulted in seedstock ranchers growing exactly the type of cattle they want, and for many that may mean larger cattle.

 There are other reasons why cattle have gotten larger. Feed is being managed in ways that can maximize the growth of cattle. Fermenting hay and steaming grains can bring out more nutrients so cattle can actually grow on less feed. Keeping track of the animals diet and exact ration is very important for growth.

 Another aspect is the use of steroids and hormones. Many cattle are implanted with a steroid in their ear upon arriving at the feedyard. This steroid is released for a few days and then the animal goes through a long period of feeding before it is sent to market. The steroid is, for the most part, depleted to low levels before slaughter and the end result is about a four percent gain in size. So this will explain some of the gain but most feedlots  have been using these for years.

 Why are cattle getting even bigger these days? We cut a boneless 0x1 striploin the other day that weighed 17.4 lbs! Thats big and impossible to cut into a thick 8 oz portion steak for a quality restaurant.

  Another tool being used by feedlots today is a different feed supplement called beta- agonists. Beta -agonists are used on humans for asthma relief. Are these cattle having trouble breathing?? Not exactly. Beta-agonists are used to grow muscle faster by increasing the efficiency of the feed. Here is a very good explanation and shows the different types used today. http://fyi.uwex.edu/wbic/files/2010/11/Beta-Agonists-Factsheet.pdf The gains are substantial and the real savings is in the amount of feed the animal needs to grow. The most popular brand name is zilpaterol hydrochloride (Zilmax) is produced by Merck.
  Here is a bit of text from a beef grower about the use of a beta-agonist...

Beta agonists, like ractopamine, work by activating the beta 2 receptor on the muscles of my cattle. This binds specific beta receptors in the muscle cell membranes and increases protein synthesis. What does this mean exactly?


1.As animals grow larger and get close to the time of harvest, their bodies tend to turn nutrients into fat instead of lean muscle. Ractopamine encourages or repartitions those nutrients into muscle growth through protein synthesis rather than fat deposition.

2.This allows the animal to make more lean muscle (what we want to eat), and less fatty tissue (what we do not want to eat).

3.By making more muscle and less fat from nutrients, the animal becomes a more efficient user of its food thereby reducing the total environmental footprint of its food production. http://feedyardfoodie.wordpress.com/2012/05/31/the-great-puzzle-what-role-does-a-beta-agonist-play-on-my-farm/

 

 So this explains why many cattle have gotten larger and also why they are leaner. Lean beef may have eye appeal in the super market but not in a fine steakhouse. And the beef's flavor is also effected. There seems to be less depth of flavor because it is taking less time to grow cattle so they end up in the market younger, therfore less time to develop more complex taste. But as we see drought conditions continuing in the midwest and west, we will see more and more use of beta-agonists. As feed prices soar, cattle growers want to sell faster. Everyday on feed costs them big bucks.

 Beta-agonists have been deemed safe by the FDA but here is an article that sheds more light on the discussion. http://chronicle.com/article/As-Beef-Cattle-Become/131480/  It certainly is an interesting tread of comments afterward. Some program beef processors, such as those seeking higher marbling and smaller sized cattle, have asked feedlots to not overuse the beta-agonists so the beef can fatten. Any natural beef program will not allow them.

  The size of beef has gotten larger, no doubt, and the cyclists in the Tour de France have gotten faster, they are both using similar substances to grow muscle. Beta-agonists are one of the many substances banned in professional bike racing. The use of  beta-agonists is banned from animal feed in the EU and many other countries around the world. I'm not an expert in pharmaceutical study and I don't know the long term chronic effects of the use of these substances. I'm a butcher looking for marbling and flavor and some of today's beef seems to be lacking in both. I'm also a cyclist and long time racing fan and that sport has also lost a lot of flavor in recent years.

 

 

Austrian Butcher Style

 Back in the spring I had the opportunity to visit Peter Trixner who lives near Klagenfurt, Austria. Peter and his wife Petra own a beautiful ranch on a hillside overlooking the Austrian Alps in the distance. They are raising Tajima Wagyu and Tajima - Charolais crosses. These cattle are some of the first high end Japanese genetics found in Europe. The beef from their first slaughter was a bit lean and Peter was just beginning to understand the feeding regiment that it takes to reach the high fat scores typically found in these breeds. Peter is hoping to use his beef in the hotel restaurants that he holds interest in. The Lake's hotel located in nearby Portschach am Worthersee was featuring some of Peter's beef this summer on their fun casual menu. I worked with Peter to develop a dry aging room for the beef in the hotel so he can start to feature some real steakhouse quality taste. Lake's is a resort hotel that was featuring an ecclectic menu catering to summer guests and the wagyu would be a perfect fit. www.mylakehotel.com
http://www.okamiwagyu.com/

 While I was there we broke down two beef sides at a local agricultural school. The school is for local farmers and features a state of the art slaughter room, excellent hydraulic lifts and a large cooler for aging the sides. They also have a processing room for sausage and salami making including a good size smokehouse. The butcher instructors watched as I broke down the beef in a US style which is very different from their traditional Austrian ways. We tend to make more cross cuts through muscle groups where they tend to leave muscle group intact.
 The Austrians also don't normally keep certain cuts as steak. Flank, skirt and hanger are rarely kept for dry cooking. I also took apart the sirloin into small sections for steak medallions. The cutting went on for the afternoon and we talked about our styles and the advantages for each. The outcomes were that we decided to leave some cuts whole to better dry age them and we also vacuum packed a lot of grinding meat. i think it was really important for Peter to see how much of his carcass is not going to be steak unless he hits the high marbling scores associated with Wagyu beef. Artisan butchery is much more about thinking outside of the norm and seeing another culture's style for cutting really allowed me to realize the possibilities. We cut the tenderloin out of the entire side and then cut a full loin and rib section, something none of us had ever done before. It was huge, like a giant center cut pork loin. Peter had his chef at the hotel dry age it for two weeks. I wish I could have gotten back to taste it.
  Whether its Austrian, Italian, Japanese, French or US style of cutting, there are always alternative ways to take apart a carcass.

Is Bigger Better?

The other day we were breaking down and frenching racks of lamb. We had a carcass that weighed about 75 lbs and the full hotel rack weighed a little over 8 lbs. It was a local product that was finished on some grain. It wasn't overly fatty and the yield grade would have been about a 2. Then we took some prefabricated split and chined racks out of the bag. Some weighed over 9 lbs! These are 8 bone racks ( 16 bones total) costing over $ 9.25 per lb. 9lbs x $9.25 = $83.25. Divide that by the 16 chops and you get a single chop that costs $5.20!! Wow thats a lot. So whats going on? Average weights of both lamb and beef are going up. This is a result of better genetic selection, feeding techniques and the desire for meat processors to sell more product without selling "more" product. Does that make sense? Its not like the processors are sending older mutton that have matured and become larger, these are just bigger lamb.

I recently was looking at carcass weights in the NAMP buyer's guide and the largest category is "D" 75lbs. and over. It seems today the largest amount of graded lamb is falling into this category.

Here are the last week's USDA slaughter numbers.
CHOICE AND PRIME, YG 1-4 Head 7,332
Weight Head
45-DN 375
45-55# 388
55-65# 723
65-75# 1,366

75-85# 1,902

So larger lamb is definitely out there but there is also a fair amount of smaller stuff too. My point here is when ordering lamb be sure to let the purveyor know what size range you want.

Another way to beat the big problem is to create multiple protein plates. Use that monster chop but instead of putting two or three on the plate, put just one and some other lamb items such as a bit of braised pulled lamb shoulder, grilled lamb riblets, lamb sausage, a small osso buco.

New Zealand and Australian products will be much smaller and less expensive per lb. The flavor profile of those is different but if you need to serve that large 4 bone rack roast these may work for you.

The price of lamb is high and the product has gotten larger and it seems to be staying that way for the long haul. That doesn't mean you shouldn't consider putting it on the menu, it just means you may need to rethink your price or amount served.

Photos of carcass courtesy of http://ansc-cpanel.unl.edu/meats/cde2008/lamb%20carcasses/carcass.htm