“Enlightenment-based optimism” from Weimar to West Africa and the transformation of society

By Eben and Kristi van Tonder, 28 November 2025

The Two Images: Goethe sits in formal eighteenth-century refinement, representing the disciplined interior world of ideas and literary humanism, while Humboldt is shown outdoors in Weitsch’s nineteenth-century painting, notebook and telescope beside him, embodying the outward turn of Enlightenment confidence into empirical observation and the direct study of nature.

Introduction

Working in Nigeria is not theoretical. It is a collision with chaos. You arrive with plans, and the structure built yesterday is ignored. Deliveries slip. Workers drift. A small core learns and tries, and they keep me here, but the rest grind you down. People argue not from data but from ego. A technician who has never left his state insists he knows more than protocols refined across continents. You ask yourself: Why am I here?

In countries with functioning systems, professionalism is reinforced by the environment. In Nigeria, every day is a negotiation with entropy. Standards are taken as insults. Experience is treated with suspicion. Some days, the disrespect is so blunt it feels violent. Eventually, you either adapt or reach for something stronger.

At the end of 2025, everything changed. Since Kristi and I met, we have interrogated the issue of Africa. Can the environment change? I often lashed out against the chaos. Developed deep depression. A feeling of helplessness engulfed me. I found myself treating others in a way that is shameful, speaking to them in ways that I would never have spoken to people, even at my worst and most immature. There had to be another way, and since 2024 Kristi and I set out to find it.

In response to my growing attitude of resentment against the average worker and my scepticism that real change is possible, Kristi reminded me of a phrase her dad often used to say, “Edel sei der Mensch, hilfreich und gut.” It is a quote from the famous German poet, Goethe. An affirmation that humans are noble when they are helpful and good. We traced the origins of this phrase in Edel Sei der Mensch: A Styrian Legacy of Nobility, Helpfulness and Goodness.

Our work continued to progress, and we found inspiration in the work of two scientists, Wenning and Shannon. Wenning demonstrated that industrial efficiency depends on structured standardisation, while Shannon established the mathematical foundations of information theory and showed how structure separates signal from noise. Both traced the basis of information back to ordered structure as the prerequisite for efficiency. I was reading about Goethe and von Humboldt, who knew each other well, when one account described them as pioneers of what history later called “Aufklärerische Zuversicht”. The best English rendering is “Enlightenment-era confidence in reason.” To our surprise, we discovered that Aufklärerische Zuversicht refers to enlightenment grounded in concrete structure. Was it possible that not only the Japanese industrial transformation after WWII, influenced by Wenning and the rise of information technology pioneered by Shannon, but even the Enlightenment itself, was founded on the same fundamental notion of structure? Structured order as the basis for all great system developments? This was an immense validation that for change to happen on the Nigerian factory floor, a revolution was needed in every respect, based on structure and order.

But there is a major difference between “imposed order” and order that grows from within the system. Here is the exact point where I went wrong!

In the title, I use the phrase “From Weimar to West Africa” to mark this. The distance between the humanist discipline and the resulting structure Goethe saw in his declaration, “Edel sei der Mensch, hilfreich und gut,” and where I tried to impose structure through command here in West Africa. Weimar symbolised this inherent ordered culture that grew from an understanding of the basic value of humans and our innate ability, versus my “imposed from outside” approach. Its loss serves as a reminder of how societies collapse when structure is abandoned, as happened in the Weimar state. It anchors the central tenet that real change must be predicated on the belief that, if taught faithfully and shown through superior and intuitive structures, transformation is not only possible but inevitable. It requires me to stand next to the worker and show them every step of the way as opposed to stand over them and tell them. Even more profoundly, it must be predicated upon my own very structured understanding of the workspace.

West Africa right now is the the opposite pole of structure, and denying this reality is counterproductive. Here, nothing carries you. Every principle must be rebuilt from zero. Evidence must replace ego, repetition must replace opinion, and reliability must replace entitlement. When I use these words, ego, opinion, reliability, and entitlement, I am not speaking first of Nigerians. I am referring to the expatriates who work here, including myself. Discipline must grow organically out of the essence of who the West Africans are, or we will all be consumed by disorder. The first recognition is that the West African, like the German, the Austrian and the Swiss, is edel, hilfreich and gut. A system must develop organically that “helps” and is “good”, honouring every human. Not one that imposed from above.

My approach of “imposed order” is the distance from Weimar to West Africa. I tried to manufacture order, and I failed. When I allowed order to grow organically through the superior systems thinking of Shannon, Wenning, Goethe and von Humboldt, everything changed instantaneously. Goethe’s principles must survive here.

The words themselves: Aufklärung and Zuversicht

Let’s look closer at the term used by historians to describe the Enlightenment, namely Aufklärerische Zuversicht. Aufklärung is a German noun from the verb aufklären, meaning to explain, clarify, make understandable or investigate. In everyday use, the verb appears in expressions such as “eine Sache aufklären” to resolve a matter, or “ein Verbrechen aufklären” to solve a crime. In the eighteenth century, the term acquired a broader cultural meaning. Immanuel Kant, in 1784, defined it without ambiguity:

“Aufklärung ist der Ausgang des Menschen aus seiner selbstverschuldeten Unmündigkeit.”
Enlightenment is humanity’s exit from its self-imposed immaturity.

The decisive point is responsibility. Immaturity is not the lack of information. It is the failure to use one’s own reason. An individual becomes mature by thinking independently, subjecting claims to scrutiny and refusing to submit unexamined to authority. The West African who accepts what I say, what an ordered system looks like, and the claim that the outcome is superior, is inherently “insane.” They can not and should not accept what I say without proof, and I do not give proof sitting in an office lecturing and expecting compliance! I do it faithfully, working alongside them day after day.

Zuversicht is an older word, linked etymologically to Sicht, sight or seeing. It expresses “looking forward with trust”, a grounded confidence rather than a blind hope. German dictionaries define it as the expectation of a favourable outcome based on knowledge, experience or sound judgement. It is the opposite of wishful thinking. It assumes that reality responds to method and that repeated, disciplined action yields results. When the two concepts are combined, aufklärerische Zuversicht refers to confidence built on clarity, optimism rooted in evidence, and trust in improvement because investigation and correct practice produce demonstrable outcomes. The superiority of order is rooted in evidence!

The phrase Aufklärerische Zuversicht was not coined by any figure of the eighteenth century. It entered academic vocabulary in the twentieth century when German philosophers and historians reexamined the Enlightenment in light of the moral collapse that marked the first half of the century. Hans-Georg Gadamer and later Jürgen Habermas used the term not as a moral slogan but as a descriptor of a historical attitude: the conviction that the world becomes intelligible through disciplined reason, measurable observation and methodical work. It is confidence grounded in practice, not in sentiment. When Gadamer published Wahrheit und Methode in 1960, he contrasted Enlightenment rationality with authoritarian certainty and passive historicism. Habermas continued the analysis in Erkenntnis und Interesse (1968) and Der philosophische Diskurs der Moderne (1985), arguing that Enlightenment confidence is not naïve belief in progress. It is trust in procedures, transparency and verifiable methods as tools that reduce error and restrain domination.

As research deepened, the usage of the term moved from describing a general posture to highlighting concrete embodiments of that posture. Scholars in the 1970s and 1980s turned to Johann Wolfgang von Goethe and Alexander von Humboldt because both converted Enlightenment ideals into working methods. Goethe’s Zur Farbenlehre (1810) insisted on direct observation, comparison and repeated experiments. He rejected theories detached from experience. Humboldt expanded this approach into modern scientific practice. His work in the Americas was systematic rather than anecdotal. He carried barometers, thermometers and botanical cataloguing instruments, and recorded conditions with precision. His five-volume Kosmos (1845–1862) presented nature as interconnected systems discoverable only through long-term empirical investigation. These examples transformed Aufklärerische Zuversicht into an operational category. It became a way of working, not a mood.

In the late twentieth century, the term broadened again and began to describe the institutional structures that sustain knowledge. The Enlightenment was no longer centred on exceptional individuals. It was recognised as a framework that builds and maintains systems of learning. The Prussian Gymnasium, monastic libraries, research universities, scientific societies and administrative archives embodied this confidence. They did not depend on charisma. They depended on rules: documentation, peer review, stable curricula, cumulative improvement. Aufklärerische Zuversicht thus came to refer to the belief that disciplined procedures and educational structures preserve knowledge and elevate competence across generations.

In its contemporary usage, the phrase does not mean that everything will improve automatically. It refers to the conviction that improvement becomes possible only when actions are ordered, evidence is respected, and systems are allowed to function. It describes a posture toward reality: investigate rather than assert, measure rather than debate, verify rather than speculate and build institutions that withstand the chaos of personalities. Where opinion dominates, evidence intervenes. Where impatience threatens, method stabilises. Where disorder expands, procedure anchors. This is why the term remains relevant. It expresses a historically proven lesson: knowledge does not flourish through argument alone, and human dignity is not maintained through feeling. Both are sustained through structure, rigour and the readiness to apply them even when the surrounding environment resists.

Goethe: Enlightenment as character, work and morphology

Johann Wolfgang von Goethe (1749–1832) is most widely known for literary works such as Faust, Die Leiden des jungen Werthers and Wilhelm Meister. He was also an administrator and scientist. He served in Weimar from 1775 onwards as a privy councillor and was responsible at different times for mining, road building, financial matters and theatre direction. Goethe did not treat reason as abstraction. He applied it to governance, insisting on record-keeping, system and accountability.

His humanist ethic appears in the poem Das Göttliche, which is the heart of our consideration:

“Edel sei der Mensch, hilfreich und gut!”
Noble be the human, helpful and good.

This line expresses Enlightenment trust in dignity, duty and usefulness. In private correspondence, he stressed the formative role of action. In a letter to Charlotte von Stein (11 May 1784) he wrote:

“Tätigkeit ist alles. Der Mensch wird nur im Handeln sich selbst.”
Action is everything. Man becomes himself only in acting.

Goethe’s scientific work reflects the same orientation. In Die Metamorphose der Pflanzen (1790), he argued that plant organs evolve through transformations of a basic leaf form. He condensed it in the formulation:

“Alles ist Blatt.”
Everything is leaf.

The claim is morphological, not metaphorical. It proposed that visible diversity arises from lawful variation of a fundamental structure. Nature becomes intelligible through pattern, not arbitrary difference.

Humboldt: Goethe’s principle extended into the world

Alexander von Humboldt (1769–1859) is one of the most influential natural scientists in modern history. Between 1799 and 1804, he travelled through present-day Venezuela, Colombia, Ecuador, Peru and Mexico. He measured altitudes, magnetic variation, barometric pressure, temperature and species distribution. His journals record systematic observations of geology, flora and fauna. Later in life, he synthesised these findings in Kosmos (1845–1862), arguing that nature forms an interconnected whole.

Humboldt and Goethe knew one another personally. Humboldt visited Weimar and Jena and corresponded with Goethe for decades. Goethe appreciated Humboldt’s empirical range; Humboldt admired Goethe’s morphological perspective. Their documented relationship shows mutual influence. They did not invent shared slogans; rather, they converged on the conviction that understanding arises from disciplined observation and that apparent chaos hides lawful interaction.

Humboldt repeatedly expressed that nature is a web of relations, not isolated facts. He noted this principle in his letters and later elaborated it throughout Kosmos. In contemporary summaries of his thought, the phrase “Alles ist Wechselwirkung”, everything is interaction, is used to characterise his central insight. This formulation accurately reflects Humboldt’s view: altitude influences climate, climate influences vegetation, and vegetation influences settlement and economy.

Goethe’s approach was inward: the unity of form. Humboldt’s was outward: the unity of systems. Both perspectives support aufklärerische Zuversicht. Neither treats disorder as destiny.

The intellectual soil: Austria, southern Germany and Catholic continuity

The German Enlightenment is often associated with Protestant northern cities, yet Austrian and southern German Catholic institutions played a foundational role in preserving knowledge and cultivating disciplined inquiry. Monastic networks were particularly important. Benedictine abbeys like Melk and Admont had copied manuscripts for centuries, maintained libraries and recorded agricultural and astronomical observations. The Benedictine rule emphasises communal labour (labora) and ordered religious practice (ora). Tools are to be treated with respect, and time is regulated by predictable routine.

Admont Abbey, founded in 1074, maintains one of the world’s most recognised monastic libraries. The present baroque hall, completed in 1776, symbolises organised knowledge: light-filled architecture, allegorical frescoes and orderly shelving. Its existence is not proof of Enlightenment ideology, but it is evidence that Catholic territories cultivated systematic learning.

This continuity mattered. Enlightenment in the German-speaking world was not uniformly revolutionary. In many regions, it took the form of administrative reform, educational standardisation and scientific curiosity, rather than violent breaks with the past. Austrian imperial reforms under Joseph II included toleration edicts and the abolition of judicial torture. These policies reflected a pragmatic belief in the improvability of institutions.

Embedded in such contexts, Enlightenment confidence was not blind. It rested on accumulated habits: keeping records, maintaining institutions, observing nature and treating knowledge as a communal asset. It sounds simple, but this organisation of data was a key observation for Kristi and me. What later Reformers would claim as “new” insights, enlightenment by the Holy Spirit, was in fact predicated on the disciplined practices cultivated in these monasteries. Revelation became possible where structure dominates.

West Africa: structural difficulty and hidden capability

Measured against these traditions, Nigeria faces stark challenges. Data from the National Bureau of Statistics show that around 133 million people are multidimensionally poor, with deficits in education, health, housing and access to basic services. Electricity access remains limited. Independent surveys and reports from international bodies identify unreliable grid power and frequent outages as major barriers to industry. Manufacturing firms in Nigeria routinely list power instability and logistics as their primary constraints.

These conditions shape workplace behaviour. When costs change without warning and infrastructure collapses mid-shift, people learn to improvise rather than plan. This is rational adaptation. But it erodes long-term confidence and prevents structure from becoming habit.

At the same time, Nigeria has capacity. A young population, rapid urbanisation and a dense network of informal problem-solvers keep production lines running in hostile conditions. On the factory floor are supervisors who insist on weighing cuts correctly, operators who monitor brine levels, technicians who document breakdowns, and procurement staff who track deliveries. They may not use Enlightenment vocabulary, but they follow the same logic: cause, effect, record, adjust.

Their work shows that aufklärerische Zuversicht does not require Europe. It requires stable conditions in which competence can reproduce itself. It requires people to prove to them from the ground up. Develop systems “with the” and not “for them.” Kristi and I recognised what becomes possible when Shannon’s architecture of information, Wenning’s industrial discipline, and the Enlightenment, personified by Goethe and von Humboldt, converge. We began to see West Africa not as a deficit of capability or potential, but as Goethe had already warned: the human reaches his highest nobility when he is helpful and good. This desire exists in all people. The challenge became to unite these impulses into a single system.

GENAU: a practical bridge between environments

GENAU is not a philosophical experiment. It emerged from two lived perspectives and carries within it the spirit of men like Goethe and von Humboldt. Kristi and I took everything that Goethe, von Humboldt and the German intellectual tradition of Aufklärerische Zuversicht taught us and unified it into a complete management system called GENAU.

They demonstrated that clarity, disciplined observation and reproducible method are not cultural ornaments. They are instruments of survival. Goethe defined dignity through action rather than intention. Humboldt converted theory into measurement, treating the world as a structure to be mapped, indexed and explained. We applied the same logic to the factory floor.

We created a numbering system as the point of integration between crates, batches, boxes and pallets on the one side, and stock locations and processing areas on the other. Each number links to a full set of data: piece, weight, batch numbers, production date, species, ingredients and supplier. Interaction remains human and visual rather than mediated by barcode scanners. Data entry happens through simple actions everyone already understands: workers take photos with their phones, send them by WhatsApp to AI systems, or email spreadsheets exported from WhatsApp. Every ingredient flow and every yield becomes an empirical unit. Sorting, grouping and ordering are done by powerful AI systems.

GENAU does not ask workers to care more or work harder. It reshapes the environment so the factory behaves like a laboratory. Order becomes visible, and interaction becomes intuitive. It mirrors how West Africans already communicate: WhatsApp, email, pictures, documents, files. Nobody needs to be taught that language. The clarity of integration, the power of the resulting data and the immediate value to the company and to workers are obvious from the first day. Evidence becomes the final authority. Procedure replaces improvisation. This is not foreign to Africa. It resonates with ancient continental traditions grounded in ritual, continuity, apprenticeship and communal verification. We said that ENAU does not ask workers to care more or work harder, but suddenly, as we started implementing the principles and the system, we found that people worked harder and more focused and achieved more.

GENAU is not a European import. It is a framework forged in the collision between Austrian continuity and West African volatility. Kristi brought the memory of institutions: schools, research hospitals, archives, libraries and cities where procedures exist before you need them. I brought the reality of Nigerian plants, where nothing survives unless the person in charge imposes structure minute by minute. GENAU reconciles these worlds and makes them local. It recognises that many environments in Africa do not yet possess inherited order and therefore manufactures order at every operational node. Identification, routing, yields and cost structures are not left to imagination or memory. They are anchored in OSASS discipline.

OSASS is the skeletal structure of GENAU. It provides the physical grammar that turns chaos into information: Order, Sanitation, Arrangement, Standardisation and Self-discipline. When these five anchors are present, behaviour becomes predictable. GENAU grows from that skeleton. It is a complete data and stock management system built on the physical realities of the factory floor. It forces the plant to translate every movement into information that can be verified, analysed and improved.

GENAU converts captured information into operational data. It manages stock, yields, processes and profit measurement. It stabilises manufacturing. It is not a theory of how factories should behave. It is the physical environment that leaves factories no choice. The system forces reality to be recorded, and it happens seamlessly. The data is timely, complete and accurate. It is collected through simple floor-level structures and transformed by powerful AI platforms into information that guides decisions and improvement.

GENAU is the synthesis, acting on three foundations:

• Order precedes data. Every crate, batch, ingredient and box must have a unique identity linked to species, cut, cost, supplier and date. Without stable reference points, analysis is meaningless.
• Behaviour follows environment. Clear capture points and predictable pathways shape how teams act. When the factory is structured correctly, the correct behaviour becomes the easiest behaviour.
• Technology follows order. Artificial intelligence becomes useful only when the data arises from disciplined human work.

On a micro scale, this is what the Enlightenment looked like in workshops and universities two centuries ago. On a modern scale, it is what a Lagos plant looks like when the effort to impose order becomes collective.

Why transformation start from below

European intellectual history does not support the idea that progress begins exclusively with leaders. The German Enlightenment involved professors and statesmen, but also printers, teachers, commercial clerks and local administrators who stabilised schools, postal services and guilds. Their influence accumulated slowly until institutions changed.

Africa’s industrial sector shows similar dynamics. A plant that enforces crate numbering, yield discipline and documentation is not waiting for a policy decree. It is training people to expect that structure produces results. Those expectations spread. The scale is small at first, but habits are contagious.

Conclusion

Aufklärerische Zuversicht is not only a nice sentiment. It is the refusal to surrender to chaos. Goethe expressed it through disciplined character and the conviction that nature reveals form only to ordered perception. Humboldt extended it across oceans, proving that the world becomes intelligible when one measures it directly and refuses inherited assumptions. Austrian and southern German institutions preserved this attitude not through slogans but through habit: recording, cataloguing, teaching and building continuity that outlives individuals.

Nigeria exposes the same truth without mercy. Where institutions are fragile, systems do not survive on goodwill. Standards hold only for as long as someone enforces them. Arguments proliferate where data is absent. Opinion becomes a weapon in the absence of process. In this environment, Enlightenment confidence is no luxury. It is a discipline of survival. Evidence must outrank ego, structure must replace improvisation, and repetition must displace rhetorical certainty.

This is where GENAU finds its place. GENAU is the management architecture that makes modern manufacturing possible in African conditions. It uses the principles of OSASS to create the environment in which data collection, traceability and AI brilliance become viable. OSASS is not the outcome. It is the scaffolding: Order, Sanitation, Arrangement, Standardisation and Self-discipline. These are not philosophical ornaments. They are the physical grammar that allows professional behaviour to appear. GENAU builds on this grammar. It converts the reality created by OSASS into measurable information. Stable capture points, traceable routes and coherent numbering systems turn floor activity into analysable data. When every crate, batch, ingredient and yield exists inside this structure, AI is no longer a gimmick. It becomes an instrument.

From Weimar to West Africa, the same principle holds. It does not merely travel. It confirms that we were correct to make this principle foundational. Dignity is not sustained by argument, emotion or posture. It is sustained by structures that force reality to reveal itself. The Enlightenment never promised that people would behave well. It promised that the world would become navigable when disorder yields to measurement. Societies are not judged by their declarations but by how they conduct themselves when conditions are hostile. If Goethe’s principle has meaning, it must survive where infrastructure collapses, and respect is not given. If Humboldt’s legacy is real, it must stand where evidence is the only language that cuts through noise.

Where opinion dominates, evidence intervenes. Where power threatens, structure protects. Where chaos grows, procedure anchors. This is the work. Not because the world deserves it, and not because it is easy, but because without disciplined action, accurate observation and systems that resist ego, there is no society to preserve.


For a complete treatment on GENAU, visit GENAU: The Complete System for Meat Factories: Stock Control, Yield Accuracy and Quality Management.


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GENAU: The Complete System for Meat Factories: Stock Control, Yield Accuracy and Quality Management

By Eben & Kristi van Tonder, 19 November 2025

A Revolution in Stock Control, Yield Accuracy and Quality Management

GENAU is built on one principle. Data follows a structure in the factory. Every stock item must have an interface that links it to all relevant information, such as price, weight, batch number, production date and all details needed for control and traceability. We create these interfaces through numbers in a simple manual system that does not fail. This makes every pallet, crate and box visible in all stock locations, from freezers and chillers to deboning and processing rooms. It may sound slow and time-consuming, but it is not. Using this system, we can count stock faster than with barcode scanners, and it is far more robust

Production is controlled through a dedicated batch companion system that captures the essential events of every batch. All records move from paper into a group of AI modules that clean, sort, and prepare the data. The output is delivered in Excel workbooks. Excel is used because it is transparent, does not lock information behind menus and can be audited line by line.

In this paper, we discuss the broader requirements that make GENAU possible and the scientists who shaped our thinking. We present GENAU as far more than a tracking system. It is a holistic system of management that begins with structure on the factory floor and moves through to data without friction. Data becomes manageable only when people, space, equipment and information move within predictable patterns. Stock, yield, batch numbers, quality checks, and clean, usable data rely on this predictability. Without structure, numbers drift. Without disciplined capture points, data becomes meaningless. This is the first principle of GENAU. It anchors all activity in stable routines, controlled movement and clear numbering logic.

Structured data reflects the actual organisation of the factory. The physical world and the data world match each other. The information is channelled to AI platforms where it is cleaned and ordered. Reporting happens in Excel for a specific reason that we explain later. The system is far more than stock tracing. It is a complete framework for factory order, predictable flow and reliable information.

At the centre of this is OSASS, the order method that governs the physical environment in which GENAU operates. OSASS is explained here. It is the backbone of GENAU, the physical and behavioural discipline that makes structured data possible. The second part of the system is the world of analysis, where AI processes information with a speed and clarity unattainable by manual methods. Where OSASS is the backbone, this analytical layer is the muscles and the central nervous system, including the brain.

A major influence on this approach is W Edwards Deming, the American statistician whose work from the 1950s onwards helped rebuild Japan’s manufacturing base. He focused on variation, statistical control, predictable processes and learning through continuous measurement. He showed that most production failures arise from unstable systems rather than individual workers. GENAU applies these principles to the real conditions of meat factories in Africa and Europe by stabilising space, flow and data capture at source.

A second influence, introduced later in the article, is Claude Shannon, the American mathematician who founded information theory in 1948. His work on structure, channels, signal integrity, and noise reduction provides a framework for how data must move and how errors must be controlled. Deming shapes how GENAU builds stability in physical processes. Shannon shapes how GENAU structures information. Together, they explain why a system based on OSASS, numbering, registers, and real-time measurement produces a factory that behaves predictably and improves every day.

1. A unique number as the interface between data and the factory floor

Deming emphasised that data must be tied to a stable reference point to have meaning. GENAU links each set of data to a single unique number. This reference is assigned to every stock item in its smallest unit of measure: each crate of meat, each box of finished product, each bag of ingredients and each bundle of packaging.

Each number carries a defined set of data, including production day, weight, item number, species, cut, supplier, process history and cost. AI retrieves and combines this data instantly wherever it is needed. Operators work with one number rather than a scattered set of details. This stabilises movement, yield, shrinkage control and traceability. It makes data manageable.

2. Structure in every department

Deming showed that consistent output depends on consistent systems. If space, tools, machines, staff placement or flows shift unpredictably, measurement becomes unreliable. Every action and process is defined and not “evolved by accident.”

GENAU therefore establishes fixed zones, lines, stable crates and other stock positions, defined routes and predictable patterns of movement. Structure removes random variation and gives meaning to the data that follows.

3. Reporting that allows real analysis

Deming taught that knowledge comes from studying results over time. GENAU reports in Excel format because it allows data to remain active: trended, compared, graphed, validated and questioned. Static dashboards and PDFs freeze information and reduce investigation.

Excel supports real analysis of yields, movement, stock ageing, shrinkage and capacity behaviour. Output is presented over time – weeks, months or years. Never as a lone-standing data point, which is meaningless without context.

4. Deming’s Core Principles: The Foundations of GENAU

Deming’s work provides the conceptual base on which GENAU is built. His thinking can be summarised into five practical principles that shape how factories must be designed and managed if they are to produce predictable, high-quality output. Each principle directly informs GENAU’s structure, its logic and its method.

a. Variation is the enemy of quality

Deming taught that uncontrolled variation is the primary cause of defects, waste, delays and poor performance. In a meat factory, this appears as fluctuating yields, inconsistent trimming, unpredictable shrinkage, unstable weight declarations and stock drifting through the plant without a stable pattern. GENAU addresses this by stabilising space, numbering, flow and data capture so variation is reduced at its source. It targets the environment in which data collection takes place as much as the method of data collection.

On the Batch Companion side, which is the system used to manage QC, especially in processing and on the deboning modules where targeted block tests are applied, variables are controlled through tight processes, predefined SOPs and a real-time monitoring system that measures variation precisely and predicts outcomes. The strong QC component makes this one of the most capable and reliable systems in existence.

b. Systems must reduce variation to become stable

Deming argued that the system, not the worker, produces most outcomes. A factory only becomes stable when processes are fixed, flows are known, tools have defined positions, and each step has a consistent method. GENAU follows this directly: zones, crate logic, routes, registers and batch numbering systems remove randomness so the factory behaves the same way every day. As in the previous point, the application of the principle begins by addressing the environment and the processes that maintain order. Every day there is a meeting with every department, where the questions are asked: What are we doing better today than yesterday, and where have we advanced the system? We view every aspect of life in the factory as serving the processes. Because we work with people, we also follow the wisdom of Solomon that the wise make knowledge acceptable. We therefore design human-centred systems in consultation with management to hardwire outcomes.

c. Measurement must be continuous

Deming emphasised that understanding comes from studying results over time, not from occasional inspection. GENAU therefore measures movement, weights, yields and batch behaviour continuously. This allows the system to detect where shrinkage enters, where delays occur, where yield is gained and where the process is drifting. Continuous data is the basis for daily improvement. It reports in spreadsheets, in Excel. The absence of a dashboard is deliberate. Presenting results in spreadsheets gives the user full control over the data, allows direct interrogation of figures and trends, and supports management workbooks that track results over time.

d. Operators must understand the impact of their own work on the flow

Deming taught that people perform best when they understand the system they work in. GENAU includes clear SOPs, coaching and explanation so operators know why they do each action, how it affects yield and stock, and how their decisions influence downstream departments. When understanding increases, variation drops. It is a key feature that we explain to everybody how the entire system works, so that they can understand themselves in relation to the whole and the key part they play in achieving the shared objectives

e. Management must design processes that make correct work the default

Deming insisted that the system must support correct behaviour automatically. GENAU applies this by designing the environment so that the right action is the easiest: defined crate logic, numbering systems, movement paths, fixed capture points and stable workstations. When the system is well-designed, quality becomes a natural outcome rather than an effort. The entire batch companion and deboning model is based on this.

Taken together, these five principles form the intellectual foundation for GENAU. OSASS is the practical method through which these principles are expressed in daily work. It is the backbone of GENAU. Deming describes how a factory must think. OSASS describes how a factory must behave. OSASS is the physical environment in which GENAU operates and is an integral part of the system. The second part of the system is the world of advanced analysis, supported by human judgment and intuitive input, where AI processes data at a level of speed and structure that no manual method can match. Where OSASS is the backbone of GENAU, this analytical layer is its muscles and its central nervous system, including its brain.

5. OSASS: Deming’s principles expressed in factory practice

Deming’s work most strongly influenced the creation of OSASS. His focus on variation, stable systems, standard work and daily improvement shaped the way OSASS defines order, sanitation, arrangement, standardisation and self-discipline as the foundation for reliable factory behaviour. OSASS applies Deming’s principles directly to the physical environment so that every action, measurement and movement occurs within a stable, predictable system.

a. Order

Uncontrolled environments increase variation. Order stabilises the entire system.

b. Sanitation

Clean environments protect stable movement. Clutter forces operators to change paths, introducing variation.

c. Arrangement

Predictable results arise from predictable systems. Exact crate logic, tool placement and defined zones reduce variability.

d. Standardisation

Deming placed strong emphasis on standard work. Registers, numbering rules, SOPs and fixed procedures create repeatable behaviour.

e. Self-discipline

Sustained improvement requires daily adherence. Without discipline, variation returns.
OSASS converts Deming’s principles into daily factory practice.

6. Fixed data capture points

Deming taught that data must be gathered in a consistent manner for variation to be understood. GENAU fixes the location, timing and method of each measurement. Batch numbers, crate movements, yields, weights and quality checks follow a fixed path. This produces consistent, comparable data.

7. Every action must serve the system and reduce entropy

Deming showed that systems must be designed so that correct work becomes the natural outcome. GENAU extends this idea: every action on the factory floor must be part of an intentional, structured process placed at a precise point to support a precise output. Nothing is random.
For each action, the operator and manager must be able to answer:

• Why do we do this
• Why do we do it here
• Why do we do it now
• What comes before and after
• What larger process does this action support

This produces a factory where steps build order rather than disorder. Each day, processes must strengthen, variation must fall, and entropy must decrease. This reflects Deming’s emphasis on continuous system improvement.

8. Managing complexity: the role of humans and the role of AI

Claude Shannon’s work on information theory provides the second structural pillar of GENAU. Shannon demonstrated that information flow depends on structure, stable channels and noise reduction. Humans are best at creating and maintaining this structure. They apply OSASS, guard data capture, organise space, define flows, design standard procedures and ensure the environment supports predictable work.
AI is best at managing the complexity humans cannot:

• sorting large volumes of data
• identifying hidden patterns and anomalies
• recognising variation across days and weeks
• combining crate data, yield data, registers and production records
• designing cutting and production programmes based on patterns
• consolidating customer orders into stable production planning

AI processes complexity at scale. Humans create the structure, clarity and stability that allow AI to work. Both roles must exist for GENAU to function.

9. The human experience: intuitive, natural and meaningful

GENAU is designed so that human work feels natural. Operators work in an orderly environment with clear flows and reliable routines. They handle crates, follow defined routes, record numbers and understand exactly why they perform each action.

AI manages complexity in the background so humans are not overwhelmed.

The experience must feel intuitive and aligned with personal and spiritual values:

• clarity instead of confusion
• purpose instead of randomness
• stability instead of noise
• progress visible every day

Work becomes satisfying when systems are stable and meaningful.

10. Continuous measurement

Deming showed that quality must be monitored during the process. GENAU tracks movement continuously, not only at shift-end. This reveals where yield is gained or lost, where shrinkage enters and where delays appear. Continuous measurement reflects the real behaviour of the factory.

11. Operators and the flow of work

Deming argued that workers perform best when they understand the system they work in. GENAU provides clear SOPs, explanations and coaching so operators understand how their actions influence yield, movement, stock stability and traceability.

Each department asks the same daily question: What did we improve today? Daily improvement strengthens structure and drives down variation.

12. Management by design, not reaction

A core Deming principle is that the system determines most outcomes. GENAU therefore focuses on designing layouts, numbering logic, routes, checklists and registers so that the correct action becomes the natural action. Reducing noise and unpredictability strengthens accuracy, throughput, yield and control.

13. From data to information

Deming taught that data becomes information only when variation is controlled. In GENAU, information emerges when:

• the environment is structured
• capture points are fixed
• reference numbers are stable
• actions fit a defined process
• variation is reduced through OSASS
• measurement is continuous
• patterns can be studied over time

When these conditions exist, yields stabilise, shrinkage becomes visible, stock becomes predictable, and movement becomes interpretable.

14. Profitability through stability

Deming demonstrated that reduced waste, predictable flow and better resource use increase profitability. GENAU enables this by giving managers stable data showing losses, inefficiencies, capacity gaps and stock patterns. Predictable systems produce predictable profit.

Conclusion

GENAU is a complete system for factory structure, stock control, yield accuracy and quality management. It applies Deming’s principles of variation control, statistical thinking, standard work and continuous improvement, supported by the physical discipline of OSASS. It then uses Shannon’s logic of information flow together with AI to manage complexity and give clarity to data. The result is a factory where movement is predictable, numbers are reliable, and improvement becomes part of daily work.


The Complete Work on our GENAU System


References

Deming, W. E. Out of the Crisis. MIT Press, 1986.
Deming, W. E. The New Economics for Industry, Government, Education. MIT Press, 1993.
Deming, W. E. Statistical Method from the Viewpoint of Quality Control. Dover Publications, 2000 (original lectures delivered in 1939).
JUSE (Japanese Union of Scientists and Engineers). The Improvement Journey: Early Records of Quality Control in Postwar Japan. JUSE Press, various editions.
Shewhart, W. A. Economic Control of Quality of Manufactured Product. D. Van Nostrand, 1931.
Shannon, C. E. A Mathematical Theory of Communication. Bell System Technical Journal, 27 (1948): 379–423 and 623–656.
Shannon, C. E. and Weaver, W. The Mathematical Theory of Communication. University of Illinois Press, 1949.
Ishikawa, K. Guide to Quality Control. Asian Productivity Organization, 1976.
Juran, J. M. Juran on Planning for Quality. Free Press, 1988.
Ohno, T. Toyota Production System: Beyond Large-Scale Production. Productivity Press, 1988.
Norman, D. A. The Design of Everyday Things. MIT Press, 2013 (revised edition).
Montgomery, D. C. Introduction to Statistical Quality Control. Wiley, 8th edition, 2019.
Provost, L. P. and Murray, S. K. The Health Care Data Guide: Learning from Data for Improvement. Jossey-Bass, 2011.

The Company That Runs Itself – Building the Future of Integrated Meat Processing Management

By Eben van Toder and Kristi Berger, 10 August 2025

Executive Summary: The Night A System Was Born

We developed a system that combines a simple, intuitive, common-sense manual tracking framework with advanced AI integration to give meat plants complete management of meat and other raw materials, applicable to any protein. The result is full batch number integration, real-time deviation reporting, and absolute process control at a fraction of the cost of conventional systems.

Our approach ensures information is available exactly when it is needed and in a format that makes sense. Every deviation, whether yield, cooking loss, or quality anomaly, is identified and reported immediately, allowing rapid corrective action and preventing downstream risks.

The system begins with understanding the process, the people, and the flow of raw materials. On this foundation, AI handles the heavy lifting: processing large, complex data streams, performing critical analytical tasks, and instantly integrating the outputs into clear, actionable reports.

What started as a late-night exchange of ideas with Kristi became the blueprint for a fully integrated, AI-enhanced manufacturing and management framework. It unites process control, yield optimisation, industrial engineering, and real-time decision-making into a single operational brain—delivering transparency, accountability, and efficiency without expensive equipment or annual licence fees.

Process and Product Management

We’ve built a deceptively simple yet extraordinarily robust manual system that records every transaction across the company and delivers complete tracking of products, ingredients, processes, and yields. Its strength lies in both its simplicity and reliability: even last week we were able to retrieve every single action from any department of a client company over the past two years—covering meat receiving, carcass deboning, packing, processing, and dispatch.

The most remarkable part was that this system stayed operational during a period when we were running an expensive South African plant software system, purchased to perform exactly the same functions. That imported system failed to meet even the most basic requirements we bought it for. The manual system never failed.

Over time, we improved it every few months, embedding new layers of full traceability, tracking every gram of meat and every ingredient through every process until it left the factory as a final product.

The Next Leap: AI as the Factory’s Nervous System

What Kristi and I built tonight was the next layer, an AI layer operating above the existing system.

Each day, every department’s production data would be collected through an AI interface and populated by the system into pre-designed Excel formats. From there, the data flows automatically into a centralised management dashboard covering every corner of the plant:

  • Meat receiving
  • Carcass deboning
  • All processing, for example, Bacon, ham, and sausage production
  • Stock levels in freezers and chillers
  • FIFO management and shelf-life control
  • Dispatch

The dashboard delivers daily intelligence to management, but the real leap forward comes from real-time anomaly alerts. If yields, throughput, or output values drift beyond a defined tolerance, management is notified immediately, allowing instant intervention rather than post-mortem correction.

From Personal Disputes to Measurable Outcomes

One of the persistent challenges in plant management is the tendency for strategy to become personal. When managers argue over acceptable bone percentages, cooking yields, or shrinkage tolerances, discussions easily turn into disputes about who is right rather than whether the standard is being met. For a long time, I wrestled with how to break this cycle and keep the focus firmly on outcomes.

The breakthrough came from Kristi, whose insight reframed the issue: strategy only becomes personal when it lacks an objective anchor. By linking operational standards directly to production data, every target—whether bone percentage, cooking yield, or shrink loss, becomes transparent, measurable, and indisputable.

Her solution was elegant and robust, fitting seamlessly with our system, which requires no expensive equipment or annual fees and delivers data instantly. She highlighted two critical ways to make strategy actionable:

HR Performance Evaluation per Shift/Team

Each production block can be traced to the responsible team or employee via batch numbers and timestamps. This allows income and losses to be compared between shifts, creating an objective basis for training, bonus programmes, or personnel planning. By combining production data with working hours, management gains a clear view of whether specific hours, days, or teams operate more efficiently.

QC Batch Tracking

Every deviation, such as excessive processing loss or temperature anomalies, is tied directly to the date, time, and batch. This enables rapid root cause analysis. Automatic QC alerts ensure that tolerance violations immediately trigger notifications, preventing defective products from moving further along the line. Over time, quality statistics reveal whether errors are increasing or decreasing and pinpoint where in production they occur.

What was once a riddle became a solution: management is no longer about opinion or confrontation but about transparent standards, traceable outcomes, and data-driven accountability.

Industrial Engineering: Matching Process to People

This system enables true industrial engineering of the production floor. We map factory layouts, product mixes, and workforce capabilities, then model workflows accordingly.

If the workforce is largely unskilled villagers, the workflow is designed like a village economy, intuitive and self-reinforcing with clearly defined micro-tasks. If it is a high-throughput European-style plant, we replicate precision, standardisation, and high-speed line balance.

In both cases, the only success metric is output per unit of resource.

Optimising Yields Without Losing Strategic Control

In deboning and other yield-sensitive operations, the best decision for the day’s orders may not be the most profitable decision for the business. Too often, junior staff are left to make those trade-offs.

Our new system removes that decision from the floor and gives it to pre-designated senior managers, operating within a structured decision-making model.

We adapted Robert G. Cooper’s Stage-Gate System, originally designed for product development in the 1980s, to the entire meat manufacturing process.

The Stage-Gate Adaptation for Factory Operations

1. Discovery
Identify operational decisions that could swing profitability up or down by cut choice, product allocation, or processing route.

2. Scoping
Evaluate the technical and market feasibility of each option. What happens if we consistently prioritise revenue-maximising choices? What is the opportunity cost if we do not?

3. Building the Business Case
Use hard data to model the impact on yield, revenue, and margins, and align with strategic goals.

4. Development
Redesign the process, station, or decision workflow.

5. Testing and Validation
Run controlled trials to confirm yield gains, operational stability, and client satisfaction.

6. Launch
Fully implement the system and lock in performance metrics. Even when the decision is made for lower-profit outcomes such as strategic client satisfaction, management can see and price the opportunity cost.

Intelligent Resource Allocation

A core feature of the strategy is staff capability mapping. We evaluate every employee for strengths and align them to the department where they deliver maximum value. This transforms human resource deployment from reactive placement to performance engineering.

QC as a Live Metric

In the new system, quality control is not just about defect rejection. It is integrated into yield and throughput analysis. Parameters such as product look, feel, and functional performance are captured in the same data flow as output figures, enabling instant cause-and-effect visibility.

Breaking the Company into Its Molecular Structure

To design such a system, the company must first be deconstructed to its smallest operational units, just as amino acids form proteins.

Every department is mapped by inputs, processes, and outputs. Each process is further split into micro-processes. We study these micro-units individually before recombining them into optimised larger structures.

This molecular view of operations allows redesign at the smallest level before scaling improvements plant-wide.

AI-Enhanced Continuous Improvement Cycle

The Stage-Gate model is applied again, this time to process improvement itself.

  1. Discovery – Identify the smallest units and sub-units.
  2. Scoping – List possible alternatives, pros, cons, and projected gains.
  3. Business Case – Justify the most promising alternative and set measurable targets.
  4. Development – Build the improved system or sub-system.
  5. Testing and Validation – Trial it on a limited scale.
  6. Launch – Implement fully, measure, refine, and repeat.

Each cycle becomes faster and more precise with AI analysing historical data, simulating outcomes, and identifying improvement hotspots.

The Modular Nature of the Approach

The strategy itself is modular, allowing it to be implemented in phases rather than all at once.

We could, for example, begin with the manual system as the operational backbone. Integrated into this system would be AI-facilitated uploads, where data recorded in books is transferred into digital formats, populating management dashboards and triggering real-time deviation notifications.

Other elements, such as integrated quality control, staff capability mapping, and full line and departmental redesign and optimisation, could be introduced in subsequent stages. This staged approach allows the company to adopt the system at a pace aligned with its resources, change management capacity, and strategic priorities, while ensuring that each phase is stable before moving to the next.

Conclusion: Strategy as a Living System

That night’s discussion with Kristi was more than just another business conversation. It was the moment our entire operational philosophy crystallised.

What started in Lagos as a robust manual system has evolved into a multi-layered, AI-supervised industrial management framework, one that merges the human ability to see nuance with machine precision in detecting trends, anomalies, and opportunities.

The result is a living strategy, responsive, data-driven, and capable of reshaping itself as the company grows.

Our Bacon Stories: The 23-Year Journey to Perfect Reformed Bacon

How an ancient art, a relentless pursuit, and a partnership forged across continents gave rise to a breakthrough in modern meat processing

By Eben van Tonder, 14 June 2025


Introduction

Some stories take a year to unfold, and then some stories take a lifetime. This is the story of reformed bacon, not just as a product category, but as a calling. It is the story of a dream pursued over two decades, through failure, loss, and rediscovery, until one day, under the heavy clouds of a Nigerian storm, it finally came together.

The Difference Between Formed and Reformed Bacon

In the world of processed meats, formed bacon refers to bacon shaped into regular logs using moulds or grids. It’s a standard industrial technique. Reformed bacon, however, is more ambitious. It’s about taking small pieces of meat, trim, offcuts, fragments, and fusing them into a single, cohesive log that behaves like whole-muscle bacon. Done well, it holds together in the pan, slices cleanly, and delivers a sublime balance of fat and lean.

What most don’t realise is that the science behind this is ancient. Long before binding proteins were studied in labs, the method of pressing and binding meat was used in European peasant kitchens and eventually codified in the monastic traditions of Austria and Germany. The basic process behind pressed ham is nearly identical to that of reformed bacon. It simply involves longer cooking. Originally, the tools were rudimentary: wooden forms, knives, mortars, and pestles. Today, we have grinders, emulsifiers, stainless-steel moulds, and industrial smoking chambers. But the essence remains unchanged.

A Personal Obsession Begins

My own obsession with reformed bacon began in the early 2000s. I was convinced that it was possible to create a perfect restructured meat product: one that wouldn’t break apart when removed from its packaging, that would hold its shape in the pan, and that would taste like something better than the sum of its parts.

Oscar and I had just launched Woody’s Consumer Brands. Through the support of Profet, I travelled to England for almost a year to collaborate with British producers and explore the technologies available. We had the drive. We had the vision. But the project was a failure. Not a single one of our objectives was met.

Woody’s shifted to producing ordinary bacon at scale. But I never abandoned the dream of reformed bacon. Or rather, it never abandoned me. Over the following years, I delved deeper and deeper into the science, examining protein mechanicspH effectsamino acid interactions, and the roles of heat, cold, and mechanical action. It was an overwhelming body of knowledge. I had no idea how much I’d need to master before I could return to the work we began in 2011, when I first officially launched the reformed bacon project.

A Turning Point in Austria

The turning point came with Christa Berger. An Austrian trained in cultural anthropology, with a deep respect for both ancient traditions and modern food processing, Christa had grown up in the Alps. She developed a remarkable understanding of meat-curing heritage.

It was Christa who introduced me to the archives and practical knowledge held in Austria’s monastic institutions, repositories of meat science techniques passed down and preserved across centuries. We began working with the Almi spice company and their exceptional team of young scientists. The project began to take shape again. Concepts I had explored 10, 15, even 20 years ago began to resurface and combine in new ways. Christa and I would speak every evening, working through technical hypotheses, testing theories, connecting dots.

In Nigeria, where I had the freedom to work beyond the gaze of corporate meat processors, I started testing our emerging theories. A week ago, I told Christa that while I liked our direction, I fundamentally disagreed with a core mechanism in mainstream reformed bacon theory. She listened and calmly replied:
“Of course, the theory is wrong. A better approach would be a, b, and c.”

That night, the solution was born.

Breakthrough in Nigeria

The next morning, I implemented two variations of Christa’s insight. One of them worked brilliantly. For the first time, the product held. I wasn’t focused on colour or flavour development! This was about binding, weight loss, and slicability. It needed to perform like pressed ham: sliceable on a ham slicer, at ambient temperature, with minimal structural loss.

It required more attention to detail than any other product I’ve ever developed. Every single factor, from hydration technique to mechanical treatment, had to be re-examined and perfected. But finally, after 23 years, I had something I was proud of.

The Cost of the Journey

Last night, I became sentimental. I thought about my mother—her descent into dementia and Alzheimer’s during these years, and her final days, which I missed while travelling in Nigeria. I remembered the last gatherings with my brothers and our children. I looked at photos of the kids growing up.

Tristan and Lauren once joked that they’d inscribe on my gravestone:
“Our Dad Tried.” They grew up watching me return home week after week, having failed to produce the breakthrough I was chasing.

When I met Christa, our earliest conversations were about salt and ancient curing. I once told her that the structure and clarity she brings into my life might be the key to pulling together the strands of both my work and my identity. That prediction turned out to be true. A woman raised in a farming village in the Alps helped me unlock what I couldn’t in 23 years of effort.

And yes, as we laughed last night, this journey has been the equivalent of a university degree—because oh, the things I have learned.

A Slice and a Storm

This morning, with torrential West African storms pounding the coastline, I stood in the factory and had a warm, flavourful slice of reformed bacon for breakfast. I thought about the failures. I thought about the friendships. I thought about the science, the monks, the factories, the years. And I smiled.

Because it was worth it. Every single step.




This is part of a series, Our Bacon Stories.


🐛 Earthworm Express Closing Note

At Earthworm Express, we don’t just publish science. We publish stories! This story, spanning more than two decades, stands as a testament to obsession, tradition, innovation, and partnership.
For more on reformed meat, ancient curing traditions, and industrial breakthroughs in sausage and ham production, stay tuned. We’re just getting started.

– Eben van Tonder
Founder of Earthworm Express, Origins Global Meats, and ReEquip Africa


Christa’s Bacon Story: How It Used to Be When I Was Little

By Christa Berger, 25.5.25

Mornings on the Farm

Papa mit Traktor

The day started early on the farm in the last foothills of the Alps in eastern Austria. My parents got up, dressed, and went straight to the barn to milk, muck out, and feed the animals. In winter, when it snowed and the icy wind whistled down from the mountain, they wrapped themselves in warm clothes and enjoyed the warmth of the animals in the barn. We had about 25 dairy cows, several bulls, and a few calves, as well as pigs, chickens, and a horse.

Helping Out as Children

Papa mit Ferdi

When we were old enough, we helped out when we didn’t have school. Our tasks included grooming the cows, mucking out, sweeping the aisles, cleaning the feed troughs, and refilling them with fresh feed. Grandpa accompanied us. In the hayloft, straw and hay were stored, which we could throw through a hole in the floor into the aisle in front of the cattle using a pitchfork. Once, my sister fell through such a hole and broke her leg.

Evening Chores & the Taste of Bacon Bread

Fleischbrot

In the evening, it was our job to fill the milk from the tank into cans so it could be taken to the collection point in the morning. Afterwards, the milking room had to be thoroughly cleaned with a broom and water jet. By the age of 13, my little sister, my two-year-older cousin, and I could already milk and handle all barn work independently. After that, the bacon bread tasted especially good.

Early Rising & School Snacks

Eierspeis mit Speck

Usually, my parents were in the barn by six o’clock at the latest. We children also had to get up early because our farm was on a mountain, and we had a long way to school. Grandma helped us get ready for school: washing, dressing, combing, and braiding our hair. She also prepared our school snack, which, as you might guess, was often a bacon sandwich. She cut the bacon into fine rectangular strips, salted and peppered them. At school, I had to be careful while eating because these small bacon strips wanted to fall out of the bread. When my parents came back from the barn, after about an hour and a half of work, there was coffee, a buttered slice of bread, and often homemade jam, but by then, we were already on our way to school.

Daily Work & the Importance of Bacon

Mähdrescher New Holland

Then they went back out to continue working in the fields, the forest, the orchard, the hayloft, or the barn. The work was hard and physically demanding. At half-past nine, they came back in for their second breakfast: homemade bacon, freshly baked sourdough bread, and cider. Especially during heavy labour, bacon was indispensable, not only tasty but also strengthening. As luck would have it, the mailman arrived at exactly the same time in the morning and enjoyed a good piece of bacon and a glass of cider with the family. Bacon was just a part of our daily life.

Meals in the Forest & Long Working Hours

Brettljause mit Speck

When my father went into the forest with the men, which often meant they wouldn’t return until evening because some of our forests were high up the mountain, they took their provisions with them. Bacon was always included. In the afternoon, my mother and we children would follow and bring them hot coffee and a pastry—like a nut cake—to the clearing. Generally, the men worked in the evenings until they were exhausted – in the summer, always until there was no more light outside. That could be until eleven o’clock at night. Later, my father also ran a custom threshing business, and since the combine harvesters had headlights, he could work even longer. I remember that he sometimes came to our beds completely dusty after midnight, very hungry and exhausted, to quietly say “Good night.” But he was glad when all the machines worked, and he could successfully complete all the day’s tasks. My mother always waited for my father until he finally came home, and then she prepared a small supper for him and the hungry drivers, like an omelette with bacon.

Learning Household Skills & Sunday Meals

Krautfleckerl mit speck

Young girls usually attended a domestic science school during their compulsory schooling to prepare for marriage. But since my sister wanted to become a kindergarten teacher and I wanted to become a teacher, we attended a higher school. So, Grandma and my mother decided that we had to learn at home what we missed in household management at school. Every third Sunday, my sister and I were responsible for preparing the meal and setting the Sunday table while everyone else went to church, and in this way, we learned very early to cook and handle food. Of course, bacon wasn’t just an everyday snack—it was also on the menu on Sundays and holidays, for example, as a side dish to roast beef in the form of bacon beans, which were very popular at our home. During the week, we often ate bacon dumplings or cabbage noodles with bacon.

Summer Duties & Father’s Love for Work

Papas geburtstag

In summer, while the parents were in the barn, we children had to handle the phone: taking calls from customers who had ripe crops and needed one of our combine harvesters. We had to write down names and phone numbers and note the expected day of harvest readiness. If bad weather was forecasted, the phone rang incessantly because everyone wanted to get the grain in before it got wet. When Dad came from the barn and had eaten his scrambled eggs with bacon, he called everyone back and planned his appointments. On days when he knew he wouldn’t be home for lunch, there was a more substantial breakfast.

Father’s Dedication and Bacon Tradition

My father loved work, and there was always something to be done. For him, work was an essential part of life and a source of satisfaction, not merely a duty. I am very grateful that he was able to instil this attitude in me and pass on his love for our bacon tradition, just as I pass it on to my children.


 This is part of a series, Our Bacon Stories.


Geselchtes

In Conversation with Christa Berger:  The Architecture of Clarity and the Limits of AI

By Eben van Tonder, 28 May 2025


About this Series: In Conversation with Christa Berger

This series is published under Origins Global Meats, a section within EarthwormExpress dedicated to our consultancy company. We specialise in mass-market, gourmet, and meat-hybrid formulations. Our services span new factory design, production line set-up, profit optimisation, brand communication, and research and development.

It is in the final two areas of brand communication and R&D, that our work connects directly with Korrekturdienst, the company led by Christa Berger. Based in Austria, Korrekturdienst offers crystal-clear, academically and culturally precise German-language services, delivered with absolute confidentiality and the highest level of accuracy and personal attention. It is the definitive standard for error-free, context-aware academic and professional communication in German. Nothing vague. Nothing missed. Nothing less than exact.

This series provides insight and clarity into matters related to the academic and scientific-based writing and the use of AI in writing and R&D.


Introduction

We met again in Graz, this time at the Kunsthaus café, with its sweeping glass curves and quiet vantage over the Mur. Outside, the city moved at its usual unhurried pace. Inside, our conversation turned sharply toward technology.

I had asked Christa to explain, not just philosophically, but technically, why AI, for all its usefulness, cannot replace what she does at Korrekturdienst.

She took out a notepad, drew a quick diagram, and began.

How AI Actually Works: A Functional Overview

Christa began by explaining that most AI language models work through probabilistic sequence prediction. They do not understand meaning. They calculate which word is statistically likely to come next based on training data.

“The result sounds fluent because it mimics patterns, but those patterns aren’t governed by internal logic. They are echoes.”

She drew a simple comparison:

  • AI is like a fast musical improviser with no ear.
  • A human is slower, but can tell when a note carries the wrong emotional weight.

AI is superb for speed, breadth, and mechanical consistency. But it lacks:

  • Contextual awareness
  • Cultural literacy
  • Ethical judgement
  • Structural intent

Where AI Belongs in Research Workflows

Christa outlined where AI fits best:

  • Literature discovery: Quickly surfacing recent publications or summarising complex findings
  • Draft generation: Helping writers move past the blank page with basic scaffolds
  • Language refinement: Offering clearer or more grammatically consistent rewordings

But she warned: “If you’re relying on AI to verify facts, cite references, or provide accurate source material, you’re on dangerous ground.”

I was fascinated when she explained that AI models are not connected to live databases or source verification systems. They generate language by predicting plausible text sequences based on training data, not by retrieving or cross-checking factual information. This means they can, and often do, fabricate references, invent authors, and produce entirely fictional publications that sound convincing but don’t exist. These hallucinations occur because the model is optimising for fluency and likelihood, not truth. In academic or technical contexts, this can introduce serious errors, erode credibility, and even amount to accidental fraud when using AI to write your argument, when you don’t yet have one. AI helps execute, but it cannot formulate the insight.

Why Human Proofreading Cannot Be Replaced

Christa was firm. Proofreading, in the full sense of the term, is not grammar correction. It is the final safeguard of meaning.

She explained:

  • Humans understand narrative flow and whether sections align logically
  • Humans catch contradictions, tonal drift, and broken reasoning
  • Humans ask, “Is this true?” AI cannot

“It’s not that AI makes mistakes. It’s that it doesn’t care if it does.”

At Korrekturdienst, this human oversight isn’t cosmetic; it’s ethical. It’s where authorship is reclaimed.

The Role of Structure in Holding Meaning

Christa sketched a diagram of how ideas often collapse under poor structure:

• Thesis unsupported
• Claims out of sequence
• Transitions missing

“Structure is not decoration. It is the vessel that carries clarity.”

AI can mimic outlines. But only a human can feel when the structure doesn’t fit the thought. It does not build logical arguments. It presents related facts, but the facts are no substitute for reasoning.

This is because AI does not understand meaning. It predicts patterns. It lacks a sense of hierarchy, emphasis, or argumentative flow. When it generates content, it often confuses proximity for logic and surface fluency for depth. The result can be a sequence that sounds polished but falls apart under scrutiny. Without a human to impose intellectual order, deciding what matters, what leads, and what must be earned, AI-generated structures can quickly become hollow or misleading.

The Future of Language Still Needs Humans

Christa reflected on where things are heading.

“We will use AI more and more. But the more we do, the more important it is that someone still listens. Not just for errors. It begins with intention, which AI can’t insert!”

What Christa offers at Korrekturdienst is not just editing. It’s human alignment. Between idea and sentence. Between author and reader.

In a world accelerating toward automation, she reminds us that meaning is not the product of fluency but the result of care. Logic! Intension! Thought!

In response to all this, I tell Christa that I use AI extensively. Almost every task I perform, whether scientific, strategic, or even exploratory, I run through AI. It has become a powerful extension of my thinking. But it comes with limitations that I’ve come to recognise sharply.

“There are no transitions,” I said. “No real stacking of arguments. The structure is always mechanical. The logic doesn’t evolve. It resets with every paragraph.”

Even in my meat science writing, the problem remains. There’s data, yes. But little interpretation. The prose runs too long. The arguments don’t flow to a tight thesis. It writes. But it doesn’t think.

“For sure, it speeds things up. What used to take me a week or a month, I can now get out in one night. But it always has to be checked. Every piece. Every sentence.”

I paused.

“And from a research perspective, the number of times it gives me information that’s just wrong is staggering. Worse, it doesn’t distinguish between information and interpretation. It serves you both with the same tone.”

Christa nodded.

“Exactly. That’s the problem. It presents fragments as if they were frameworks. But only humans know what matters.”

We sat in silence a while longer.

She closed her notebook and signalled the waiter. We paid the bill and stepped out into the chilly Graz air, both knowing this conversation wasn’t ending. It was only deepening.


Back to Series Home Page:

For more articles like these, visit the series home page at In Conversation with Christa Berger: Holding Meaning in a Machine Age


References

Bender, E. M., Gebru, T., McMillan-Major, A., & Shmitchell, S. (2021). On the Dangers of Stochastic Parrots: Can Language Models Be Too Big?. Proceedings of the 2021 ACM Conference on Fairness, Accountability, and Transparency (FAccT ’21). Association for Computing Machinery.
https://doi.org/10.1145/3442188.3445922

Marcus, G. (2022). The Next Decade in AI: Four Steps Towards Robust Artificial Intelligence. arXiv preprint arXiv:2206.04130.
https://arxiv.org/abs/2206.04130

Mitchell, M. (2023). Artificial Intelligence: A Guide for Thinking Humans (Revised edition). Pelican Books.

Floridi, L. (2019). The Logic of Information: A Theory of Philosophy as Conceptual Design. Oxford University Press.

Vincent, J. (2023). Why ChatGPT and Other AI Tools Can’t Replace Editors. The Verge.
https://www.theverge.com/

Wang, A., Narayanan, A., & Solaiman, I. (2023). AI and Misinformation: Limitations of Language Models as Truth Engines. AI Ethics Journal, 4(1), 10–25

Our Bacon Stories: Bacon has a Soul

By Eben van Tonder, 25 May 2025

My first Easter Meat Blessings at Mariatrost Basilica, 2025. The baskets are filled with cured meats.

Introduction

A new chapter has opened on Origins Global Meats, and it began not with a scientist but with a storyteller. Our Bacon Stories is a series introduced by Christa Berger, whose life, land, and lineage reveal a truth I never saw coming: Bacon is not just cured meat, it is cultural memory, family identity, and spiritual ritual. Her first article moved me deeply. I had tears in my eyes, not as a food scientist, but as a man witnessing something far greater than the product I thought I had mastered.

Opening My Eyes to Magic

Back at home, we enjoyed the “blessed cured meats. For the next few days, every meal would include some of the “blessed meat”.

Christa is Styrian by birth and spirit; sharp-witted, warm-hearted, and full of insight. Her background bridges medicine and anthropology. She trained in radiology and anatomy, which gave her an intuitive understanding of muscle, tissue, and blood, insights that became invaluable when we began working together on the science of meat curing. But more than that, she brought memory. She brought soul.

In 2024, Christa contacted me after reading my research on ancient salts. That message became the start of the most meaningful collaboration of my life. Since then, I’ve travelled to Austria several times. Together, we’ve traced the footsteps of ancient butchers and monks, knelt in Easter rituals, studied ancient salts, and rediscovered something I had lost in all my scientific digging: a sense of belonging.

Christa grew up in a Styrian world where bacon isn’t discussed; it’s understood! In her family, it is not a concept; it is the kitchen table. It’s the work of the hands. It’s church, and hunger, and generosity, and the silence that settles when something meaningful is placed on a plate.

She now runs Korrekturdienst, her language and editing company, one of the sharpest, clearest, most exacting firms I’ve ever encountered. But it isn’t the technical precision that makes her work magical. It’s her ability to hold meaning. She understands tone and hears subtext. She translates not just words, but worlds. What makes her work stand out is not just accuracy, but the unshakeable trust her clients place in her. They know that what they send her is safe. They know that what comes back will be cleaner, clearer, and completely context-aware. It will be right.

That’s because Christa works the way her ancestors cured bacon: patiently, carefully, and always with both eyes on meaning. Nothing vague. Nothing missed. Nothing less than exact.

She also hosts Der Steirische Brauch, a blog that brings to life the rhythms and rituals of her homeland—seasonal customs, food preparation, mountain traditions. It’s not just content; it’s connection.

The South African Who Thought He Knew Bacon

My own story of bacon began in my thirties. I was still in South Africa, still working in commercial chemicals, when I became fascinated with food chemistry. That curiosity became an obsession. I spent 15 years tracking the historical development of bacon—how curing works, why it works, and what the great scientists and artisans of the past discovered. It became the foundation of my book, Bacon & the Art of Living.

I thought I had covered everything: prehistoric methods, industrial breakthroughs, the modern nitrosamine crisis. In one of my latest pieces, The Crusade Against Nitrites: How Ideology, Fear, and Political Opportunism Hijacked the Science of Meat Safety, I push back against misinformation that continues to plague our industry.

But all my scientific knowledge lacked one thing: context. I knew bacon. But I didn’t feel it. Not until I stood beside Christa in Graz.

Austria: Where Bacon Has a Soul

Bacon in Austria is not a side note. It’s the language of the land. You walk into any SPAR store in Styria and find yourself overwhelmed, not by choices, but by pride. Cured meat is in the blood here. It’s not sold. It’s offered.

This Easter, I stood with Christa at Mariatrost Basilica for the meat blessing. You can read about it—(Historical Origins, Symbolism, and Easter Traditions of Cured Meats), but words are not enough. You have to be there. You have to watch the people carry their meats to be blessed, not just for flavour, but for life. Because bacon here is tied to survival, to winter, to the sacredness of nourishment.

And there’s something else. If you overlay Austria’s meat consumption with colorectal cancer rates, the myth falls apart. There is no link. Perhaps the problem isn’t bacon, but the way we’ve removed culture from food.

What Christa Gave Me and Gave Bacon

Since we began working together, Christa has become more than a collaborator. She’s brought something into Origins Global Meats that I couldn’t have created alone. A kind of rootedness. A kind of clarity. Her story of bacon, of her father, her siblings, her mother; it opened a door in me. It reminded me that food is not just science. It is family. It is history. It is place.

What she brought wasn’t technique. It was truth. She didn’t try to be special. She was simply true to herself, her upbringing, her heritage. And that same truth runs through everything she does, whether she’s editing a doctoral thesis, writing about sacred rituals, or building a new business with me.

My connection to bacon has always been strong. But since last year, it has become something I didn’t even know I was missing.

A homecoming.


Read Christa’s moving bacon story at:


To contact Christa about her work, visit her website at:


My YouTube introduction to this post

The Hallstatt Curing Method

Eben van Tonder
16 April 2024

For the latest update on this article, please visit The Hallstatt Curing Method. I only update my pages and not posts and this will not be the most recent version of this article.


Special Note:

Special thanks to Christa Berger for her advice, translations, and the astronomical volume of information she has provided for this project. Her insights and suggestions, particularly related to meat curing, are of immense value and contribute significantly to our work.

Also, thanks to Richard Bosman for his invaluable insights, encouragement, and ongoing practical testing of the systems developed from this and other related work. He is a true professional and a great friend!

Introduction

Christa Berger contacted me in early 2024 drawing my attention to what is arguably the most important site in Europe (and possibly on earth) for the development of the curing industry in the bronze and iron age. It centres on the Austrian town of Hallstatt.

The Hallstatt area is of interest due to ancient curing vats found there where large quantities of pork were cured presumably to be sold to traders who passed by to buy salt. Hallstatt represents the most detailed source of information on the the most ancient curing practices. As background, there are then two areas of interest to us. Firstly the salt mines that existed there since antiquity and secondly the curing vats which are the main focus of our interest.

Hallstatt Salt Mining

Christa sent me this brief history of salt production in Hallstatt. “An artificially drilled cave bear bone from the Dachstein Giant Ice Cave dates from around 12,000 BC and is considered the oldest evidence of human presence in the Hallstatt area. Due to the brine springs on the mountain, which attracted animals with their salty water then as now, people who hunted these animals were in the valley early on. People settled high above Lake Hallstatt as early as 5000 BC and began extracting salt.

“The first settlement of the area is proven in the Neolithic (around 5000 BC, “Last Wedge Shoe”). It is likely that hunters and fishermen at that time ventured into the primaeval forests of the Salzberg High Valley and discovered salty springs. They began to exploit the salt deposits by boiling the spring brine. The oldest finds proving the presence of humans in the Salzberg Valley and also in the area of today’s town date from the Neolithic. An antler pickaxe found in the Kaiser Josef tunnel in 1838 and since subjected to radiocarbon analysis is about 7,000 years old. Several stone axes have also been found at the Hallstatt salt mine and in the surrounding area of the town. They date from between 5000 and 2000 BC. Their number and the variety of forms show that stone axes were regularly used at the salt mine. The first salt mining in the Hallstatt salt mine can be traced back to around 1500 BC.”

Hallstatt Curing Vats

Block wall constructions were discovered in the Salzberg Valley near Hallstatt. “The initial assumption was that these were building remains, which had long been thought to be log houses. Although Ramsauer wrote at the time of the discovery, “no opening of an entrance to the building or a window in the 4 wooden walls was discovered.” The first structure was discovered in 1877 and excavated in 1878. Later, however, it was recognized that these were sunken basins and believed that they were used for salt production during the Iron Age. This interpretation as collection basins for spring brine (Barth 1998) became obsolete at the latest with the new radiocarbon data (Stadler 1999) because with the simultaneous existing mining of rock salt, the use of low-grade brine sources is quite unlikely. Over time, scientists realized that the basins – like the pig bones also found there – date back to the Bronze Age.” (C. Berger, personal correspondance)

The block wall constructions were identified and studied as part of broader archaeological findings in the region. Researchers like Barth in the years 1976 and 1983, Pauli in 1979, and Weisgerber in 1981 contributed to the understanding of these structures. Their findings combined with the nature of the structures and materials found, led to hypotheses about their use for meat preservation. This was particularly compelling given the anaerobic conditions noted in the dense, clay-rich environment of the constructions, which would be conducive to such processes. The Salzberg Valley’s historical context, being a significant site for salt extraction and processing, further supports the idea that salt-related preservation techniques were likely utilized in these constructions.

Tarh (1998) states that ‘Research has taken over 100 years to properly interpret and date the findings.’ (Barth 1998). As soon as this was thought and written, completely new and surprising aspects emerged. New carbon-14 datings have shifted the beginning of salt mining in Hallstatt back to the 14th century BC (Stadler 1999).

Hypothesized Hallstatt Methods for Meat Salting

Christa sent me a translation last night from Barth, and Lobisser (2002). Their work on the possible function of ancient blockwall constructions found around the salt mines of Hallstatt, dating back as early as 1400 BCE and possibly even to 1500 BCE is volcanic.

Barth and Lobisser wrote that “regarding the possible use of the block wall constructions, many similarities can be observed in the two better-documented block wall constructions in the Salzberg Valley near Hallstatt, leaving no doubt about the similarity of their original use. Therefore, it is permissible to transfer observations made on one building to the other. Up to twelve layers of beams were buried in the ground and sealed on the outside with clay. This clay must have been so-called surface clay, as it was found in 1939 to contain stones. During use, the structure is filled with dense, blue clay containing large amounts of animal bones, shards of thick-walled vessels made of graphite clay, and other finds. Among the bones, pig mandibles and long bones clearly predominate. It is noteworthy that the deposits inside the buildings did not occur in layers as expected, but it is explicitly pointed out that the artefacts were found in pure clay. This indicates that the contents were repeatedly moved and processed over time. The thick cultural layer above cannot be directly linked to the respective structure. The described grey and blue dense clay, which was also encountered in a subsequent excavation at the site in 1998, can be interpreted as dissolved Haselgebirge.” (Barth, Lobisser 2002)

“Given the numerous animal bones, the hypothesis suggests that the Hallstatt block wall constructions were submerged brine pans, in which pork was salted in large quantities with mountain salt. The containers were filled with small pieces of rock salt or rich Haselgebirge, and then the meat was buried in them. After seven to ten days, the salting was completed, and the meat could be exchanged for other meat. This process could be repeated, with the contents of the basins being mixed repeatedly. Over time, the initially granular and salty mass would become softer and richer in clay, and through the water extracted from the meat, it would become richer in protein. Eventually, a turning point would be reached, and the brine would spoil. Such a basin was no longer usable and had to be rebuilt. The pickled meat produced by the above method was certainly not yet a satisfactory final product. Careful drying and ageing were necessary.” (Barth, Lobisser 2002)

“Inside the mining building, a microclimate suitable for prehistoric Hallstatt prevailed. Consistent temperatures of 6-8 degrees Celsius, 60% humidity, strong air circulation, and salty, smoky air from the open light source provide optimal conditions. Practical experiments with pickled meat, hung in suitable places in the current mine and made by laying in small heaps, lost a third of their weight within six months without drying out.” (Barth, Lobisser 2002)

“Of course, this does not prove that high-quality raw ham was produced in Hallstatt in the Bronze Age, but the conditions for it were present. Based on the correctness of the above considerations, the possibility arises to interpret the peculiar separation of a narrow gap discovered on the north side of the building in 1877. Here, the water extracted from the meat as highly concentrated brine with numerous water-soluble components must have been collected. It could easily be scooped out and used for another purpose. The numerous thick shards of graphite clay, found in both block buildings and in the associated cultural layers, can now be meaningfully interpreted: In them, this meat juice could have been concentrated and preserved by heating. The many bones would not simply have been thrown away. They could have been cooked together with little additional effort. If this cooking is continued long enough, a gelling liquid is formed, which can be further dried in the air.” (Barth, Lobisser 2002)

Modern Dry Curing Method (Credit: Mr. Robert Goodrich)

I am interested in the curing mechanisms that may be behind this practice as it would have far-reaching implications for the development of meat curing across Europe. What curing mechanisms may be at work behind the curing of meat starting with the clay pits or vats.

Before we look at possible curing pathways or mechanisms, let’s consider the steps involved in the dry-curing processes which are universally agreed upon that it must be present for the process to be brought to completion and to result in a product that will last a maximum amount of time without refrigeration. For a detailed discussion on the subject, see two chapters from Bacon & the Art of Living, Dry Cured Bacon and The Development of Dry Curing from Salt Only to Salt, Saltpeter and Sugar.

1. Salting: The meat is coated with salt, saltpetre and seasonings where the function of the salt is to draw out moisture and thus inhibit bacterial growth (through reduced water activity).

2. Resting/Drying: After salting, the meat is left to rest in a controlled environment where the salt equalises through the meat and it begins to dry out further, enhancing flavour and texture.

3. Smoking: Smoking adds additional flavour and helps preserve the meat by coating it in smoke’s antimicrobial compounds.

4. Maturing: The meat is aged in a controlled environment to develop flavour and tenderize.

Hallstatt Method (Based on the findings by Fritz Eckart Barth)

Let us now fit the curing vats and their place in this process within the chronology we laid down above.

-> Salting

The first step is salting. The particular salt used was either rock salt mines in the area or salt-rich earth that the meat was packed in.

Barth and Lobisser’s (2002) work takes front and centre stage. The particular system was possibly employed in Hallstatt as early as 1500 BCE. The most intriguing aspect of the possible system employed in Hallstatt is the “sealing in” of the meat in curing vats with salt riach earth.

a. The Possible Function of The First Step in the Hallstatt Method

The proposed Hallstatt system would have been done for a completely different reason from any of the historical instances of burying meat. It is proposed that in the Halstatt method, the burial was done for salting and not drying or protecting it against decay.

a.1 De-Amination or L-Arginine Fermentation

The question comes up as to what the reasons could be for this “burial” of the meat in salt clay. At least two different “curing pathways” emerge if curing was part of the object of the initial salting process and the 3rd possible reason could merely salting and nothing more.

a.1.1. De-Amination

Enzyme-induced deamination of surface proteins in meat, where amino acids are broken down resulting in ammonia production, can occur under certain conditions where specific enzymes are active. Microoganism-induced oxidation of ammonia leads to the formation of nitrites which react chemically in the meat to produce nitric oxide which is responsible for curing the meat. Regarding whether a 7-day period is sufficient for significant ammonia production and subsequent conversion to nitrite (NO2-), enabling a curing process, several factors are essential to consider:

i. Enzyme/ Bacterial Presence and Activity:

– Source of Enzymes: The enzymes that can induce deamination are typically of microbial origin or are endogenous to the meat (i.e., coming from the animal itself). In meat, some enzymes capable of deamination may be present but usually become significant through microbial action.

We know that the environment was anaerobic, so we exclude Micrococcus spp., Nocardia spp. and Flavobacterium spp. since they are strictly aerobic. There are, however certain aerobic microorganisms that can switch to anaerobic metabolism (facultative anaerobes). They are Proteus spp., Pseudomonas spp.Bacillus spp.Escherichia coliStaphylococcus spp.Arthrobacter spp. and Corynebacterium spp.. These I should also consider, but let’s first look at the anaerobic bacteria.

The following anaerobic microorganisms are involved in deamination.

-> Clostridium spp.: These bacteria are obligate anaerobes, meaning they thrive in environments devoid of oxygen. They are known for their enzyme production, including deaminases, and can be found in various environments such as soil and decaying organic matter (Stackebrandt & Schumann, 2006; Cato et al., 1986). Clostridium species encompass both pathogenic and non-pathogenic microorganisms. Pathogenic species such as Clostridium botulinum, which causes botulism, Clostridium tetani, which causes tetanus, Clostridium perfringens, which causes gas gangrene and food poisoning, and Clostridium difficile, responsible for antibiotic-associated diarrhoea and pseudomembranous colitis, are well-known for their harmful effects on human health. On the other hand, non-pathogenic species such as Clostridium butyricum, which is used in probiotics and found in the intestines and soil, Clostridium acetobutylicum, utilized in industrial fermentation processes to produce acetone and butanol, and Clostridium pasteurianum, which plays a role in nitrogen fixation in soil, highlight the diverse roles of this genus. Given the conditions in the salt clay at Hallstatt, which include high salt concentrations and likely anaerobic conditions, it is plausible that non-pathogenic species like Clostridium butyricum and Clostridium pasteurianum might be present and active in the deamination of surface proteins. These species are well-adapted to anaerobic environments and could contribute to the biochemical processes involved in the preservation and transformation of organic material in such settings.

It is worth taking a much closer look at Clostridium pasteurianum. It is a nitrogen-fixing bacterium that plays a crucial role in converting atmospheric nitrogen (N₂) into ammonia (NH₃). This process is vital for soil fertility and plant growth, as it provides a bioavailable form of nitrogen essential for various biological functions. Nitrogen fixation by Clostridium pasteurianum occurs under anaerobic conditions, using organic matter to produce the energy required for this conversion.

In the specific scenario where pieces of meat are buried in the salt-rich clay of Hallstatt, the decomposition of the meat would indirectly facilitate the nitrogen fixation process. The decaying meat supplies a rich source of organic compounds, such as carbohydrates, proteins, and lipids, which Clostridium pasteurianum can metabolize anaerobically to generate the ATP needed for nitrogen fixation. The burial of meat creates anaerobic conditions because the decomposition process consumes available oxygen, and the high salt concentration limits oxygen diffusion, both of which are essential for the activity of nitrogen-fixing bacteria.

Additionally, decomposing meat releases a variety of nutrients, including amino acids, peptides, and other nitrogenous compounds, enhancing microbial growth and activity. While these nutrients are not directly used in nitrogen fixation, they support the overall metabolic processes of the bacteria involved. The decomposition process involves a complex microbial community where nitrogen-fixing bacteria convert N₂ to NH₃, and other bacteria decompose organic nitrogen compounds in the meat, releasing ammonia and other nitrogenous products, creating a dynamic nitrogen cycle within the buried material.

For buried meat to contribute effectively to nitrogen fixation, the soil or clay must contain nitrogen-fixing bacteria like Clostridium pasteurianum, and anaerobic conditions must be sufficiently maintained. Thus, while buried meat itself does not directly convert atmospheric nitrogen to ammonia, it creates favourable conditions for nitrogen-fixing bacteria to perform this conversion by providing necessary organic matter and maintaining anaerobic conditions.

-> Bacteroides spp.: Commonly found in the intestines of humans and animals, these anaerobic bacteria are capable of deaminating amino acids (Wexler, 2007). Bacteroides species include both pathogenic and non-pathogenic microorganisms. Pathogenic species such as Bacteroides fragilis, known for causing intra-abdominal infections, and Bacteroides thetaiotaomicron, which can contribute to conditions such as appendicitis and abdominal abscesses, are significant due to their potential to cause serious infections. Conversely, non-pathogenic species like Bacteroides vulgatus and Bacteroides ovatus are essential members of the gut microbiota, playing crucial roles in the digestion of complex carbohydrates and maintaining gut health. In the context of the salt clay at Hallstatt, which is characterized by high salinity and anaerobic conditions, non-pathogenic species such as Bacteroides vulgatus and Bacteroides ovatus would likely be present. These species are well-suited to anaerobic environments and could be actively involved in the deamination of surface proteins, contributing to the breakdown and transformation of organic material in such conditions.

-> Fusobacterium spp.: Another group of anaerobic bacteria involved in protein and amino acid degradation, including deamination (Bolstad et al., 1996). Fusobacterium species include both pathogenic and non-pathogenic microorganisms. Pathogenic species such as Fusobacterium necrophorum, which is known for causing Lemierre’s syndrome, a severe infection that typically starts in the throat, and Fusobacterium nucleatum, associated with periodontal diseases, intra-abdominal infections, and adverse pregnancy outcomes, are significant due to their potential to cause serious health issues. On the other hand, non-pathogenic species like Fusobacterium varium and Fusobacterium mortiferum are part of the normal flora of the human gut and oral cavity and are generally not harmful unless they translocate to sterile areas of the body or the host’s immune system is compromised. Given the anaerobic conditions and high salinity of the salt clay at Hallstatt, it is plausible that non-pathogenic species such as Fusobacterium varium and Fusobacterium mortiferum might be present. These species are well-adapted to anaerobic environments and could be involved in the deamination of surface proteins, playing a role in the biochemical processes necessary for the preservation and transformation of organic material in such settings.

ii. Conditions and President

While specific studies on Hallstatt clay are not readily available, research on microbial communities in anaerobic environments similar to clay and soil used for food preservation can provide insights.

-> Microbial Diversity in Anaerobic Environments:

Studies have shown that anaerobic environments, such as deep soil layers and salt mines, host a variety of anaerobic microorganisms, including bacteria like Clostridium spp. and Fusobacterium spp. For example, the study “Microbial diversity and metabolic potential in salt mine environments” highlights the presence of anaerobic bacteria in such conditions (Gunde-Cimerman et al., 2005).

-> Microbial Communities in Archaeological Sites:

Research on ancient preserved food and archaeological sites with anaerobic conditions can reveal the types of microorganisms that thrive in such environments. A study titled “Microbial Communities in Archaeological Environments: The Case of the La Draga Neolithic Site” uses DNA sequencing to identify microbial communities present in anaerobic conditions (Chaves et al., 2019).

The study “Microbial Communities in Archaeological Environments: The Case of the La Draga Neolithic Site” by Chaves et al. (2019) provides insights into the types of microorganisms thriving in anaerobic conditions typical of ancient preservation methods, which can be applied to understand the microbial ecology of the Hallstatt curing methods. The study identified diverse microbial groups, including Clostridia, Bacteroides, and Fusobacterium, known for their roles in protein and fat degradation under low-oxygen conditions. These microbes produce enzymes essential for deaminating proteins and oxidizing L-arginine, leading to the production of ammonia and nitric oxide (NO), crucial for the curing process. In the Hallstatt curing vats, similar anaerobic, salt-rich conditions likely supported these microbial communities, facilitating meat preservation through complex interactions involving microbial deamination, L-arginine oxidation, and fermentation. This multifaceted approach ensured the presence of reactive nitrogen species such as NO, ammonia, nitrite, and nitrate, which collectively contributed to efficient meat curing, enhancing both preservation and flavor. The findings from La Draga offer a valuable framework for hypothesizing the microbial processes that occurred in Hallstatt, highlighting the significant role of these microbial communities in ancient meat curing techniques.

-> Anaerobic Microbial Enzyme Activity in Soil and Clay:

Studies on enzyme activity in anaerobic soil and clay indicate the presence of microorganisms capable of deamination. These studies often focus on the functional roles of microbes in nutrient cycling and organic matter decomposition under anaerobic conditions. For instance, “Anaerobic microbial activity in clay soils” explores the enzyme activity in anaerobic environments (Frossard et al., 2012).

To identify the specific anaerobic microorganisms involved in deamination in the Hallstatt clay, targeted microbiological analyses would be necessary. Based on typical anaerobic environments and processes described, it is plausible that anaerobic bacteria like ClostridiumBacteroides, and Fusobacterium could be present and involved in deamination.

-> Optimal Conditions:

Enzyme activity is influenced by factors such as pH, temperature, salt concentration, and moisture. Each enzyme has optimal conditions under which it performs efficiently. The conditions in the curing vats in Hallstatt (salt brine from salt clay) need to be conducive to maintaining or enhancing enzyme activity.

iii. Time Frame for Ammonia Production:

The rate of deamination and subsequent ammonia production can vary. In a controlled environment, such as in industrial fermentation or curing processes where conditions are optimized, significant levels of ammonia could potentially be produced within 7 days. However, in a less controlled environment, this rate might differ. The amount of ammonia produced depends on the quantity and activity of the deaminating enzymes, as well as the availability of amino acids as substrates from the meat proteins. The rate of ammonia production will therefore be a key factor in the timeframe required for enough ammonia to be produced.

iv. Conversion of Ammonia to Nitrite:

Let’s assume that the right microorganisms were present and the right conditions existed for the bacteria to flourish, how would the ammonia produced be converted to nitrite or even nitrates and how likely are these to have cured the meat? The conversion of ammonia to nitrite is primarily a microbial process, performed by nitrifying bacteria which are typically aerobic. The presence and activity of these bacteria would be crucial. The problem is, however, that nitrifying bacteria are aerobic, and their activity might be limited in an anaerobic or low-oxygen environment that is possibly created by packing meat in salt clay. Micro-environments within the clay might not sufficiently support the aerobic conditions needed for these bacteria to function effectively.

Ammonia produced by nitrogen-fixing bacteria like Clostridium pasteurianum can diffuse into meat under the high salt content conditions of clay. The diffusion process is influenced by several factors including the concentration gradient of ammonia between the clay and the meat, the salt content in the clay, the physical properties of the meat, and the duration of exposure.

The concentration gradient drives the diffusion of ammonia from the clay, where its concentration is higher, into the meat, where it is lower. High salt content in the clay can affect water activity and osmotic pressure, potentially causing the meat to lose water and increasing the concentration of ammonia within the meat due to reduced water content. Additionally, the high salt content can preserve the meat, slowing down spoilage and microbial activity that might otherwise consume the ammonia.

The physical properties of the meat, such as its structure and porosity, also play a crucial role in determining the depth of ammonia penetration. Denser and less porous meat will slow the diffusion process, whereas more porous meat will allow for deeper penetration. Over time, ammonia will initially penetrate the outer layers of the meat, within the first few millimeters to centimeters, depending on the concentration and exposure time. With extended exposure, ammonia can diffuse several centimetres into the meat.

In high-salt environments like those in Hallstatt, ammonia diffusion might be more limited compared to lower salt environments because the high osmotic pressure can limit microbial activity and slow the diffusion process. However, given sufficient time, ammonia can still penetrate significantly into the meat. Therefore, while ammonia can diffuse into meat under these conditions, the depth of penetration will depend on the concentration gradient, salt content, physical properties of the meat, and duration of exposure, potentially reaching several centimetres over an extended period.

While Nitrosomonas and Nitrosospira are aerobic bacteria that require oxygen to convert ammonia to nitrite, certain anaerobic bacteria can still play a role in nitrogen transformations under low-oxygen conditions. Anammox bacteria, which belong to the Planctomycetes phylum, can perform anaerobic ammonium oxidation by converting ammonia and nitrite directly into nitrogen gas, although they do not convert ammonia directly to nitrite. For ammonia to be converted to nitrite, the right bacteria needs oxygen which may happen during drying or when the brine is stirred as would happen if it was re-used. More about this, later on.

v. Drying/ Maturing

If deamination is the controlling mechanism that produces ammonia that are microbially changed into nitrite which, chemically is reduced to NO in the meat and ultimately cures it, and since the bacteria responsible for this are strictly aerobic, the next step will allow for the conversion of ammonia to nitrites.

If the meat were removed from the salt clay after 7 days of storage and hung inside the salt mine shafts with a relative humidity of 60% and damp conditions, these conditions could be conducive to the activity of microorganisms capable of converting ammonia (NH₃) to nitrite (NO₂⁻) or nitrate (NO₃⁻).

In particular, Nitrosomonas species are known for oxidizing ammonia to nitrite, while Nitrobacter species oxidize nitrite to nitrate. These bacteria thrive in aerobic environments, and the described conditions in the salt mine shafts, if well-ventilated, would provide the necessary oxygen. The relative humidity of 60% and the damp conditions would also supply the moisture needed for their activity.

The initial step of ammonia oxidation to nitrite, carried out by Nitrosomonas species, can begin within a few days, depending on the concentration of ammonia and the environmental conditions. Under ideal circumstances, significant conversion to nitrite can occur within 7 to 14 days. The subsequent oxidation of nitrite to nitrate by Nitrobacter species would follow, and this second step can also take place within a similar timeframe, resulting in a substantial amount of nitrate being produced within 14 to 28 days from the start of nitrification.

The curing process of the meat, which involves drying and ageing, would depend on various factors, including the size and type of meat, as well as the specific conditions within the salt mine shafts. Typically, traditional curing processes can take several weeks to several months. In the described environment, the initial drying phase might take 1 to 2 weeks, during which surface moisture is reduced and microbial activity begins. The subsequent ageing phase could extend from several weeks to several months, allowing for further moisture reduction, flavour development, and textural changes. During this time, nitrifying bacteria could continue to convert ammonia to nitrite and nitrate, contributing to the overall curing process.

Nitrosomonas and Nitrobacter species, the bacteria responsible for nitrification, are pervasive in nature. They are commonly found in a variety of environments, including soil, water, and air, where conditions allow for their growth and activity. These bacteria can colonize new environments given the right conditions of moisture, oxygen, and nutrients. Soil is a major reservoir for both Nitrosomonas and Nitrobacter, especially in areas rich in organic matter. These bacteria are also present in freshwater and marine environments, playing a crucial role in the nitrogen cycle by converting ammonia from decaying organic matter into nitrites and nitrates. Additionally, dust and aerosols can transport these bacteria over long distances, allowing them to settle in new environments and introduce nitrifying bacteria.

Decomposing organic material, such as the meat buried in the salt clay, can harbour a variety of bacteria, including nitrifiers. As the meat decomposes, these bacteria can become active and proliferate. Human and animal activities, such as agriculture and waste disposal, can also introduce nitrifying bacteria to new environments. For example, manure and other organic fertilizers are rich in these bacteria and can contribute to their spread. Given their adaptability, nitrifying bacteria can colonize various environments where the essential conditions for their growth are met, including moisture, oxygen, and the presence of ammonia or nitrite as substrates.

In the specific scenario of the salt mine shafts in Hallstatt, nitrifying bacteria could be introduced through several sources. Soil particles carried into the mines by workers or through natural processes could bring Nitrosomonas and Nitrobacter into the environment. Organic matter, such as decomposing meat or other biological materials, could also introduce these bacteria. Additionally, airborne particles carrying these bacteria could settle in the mines, further contributing to their presence.

Once introduced, if the conditions of relative humidity, moisture, and oxygen availability are favourable, these bacteria can become active and start the process of nitrification. The high salt content in the clay would not inhibit these bacteria as long as sufficient moisture and organic material are present to support their metabolic needs. Thus, Nitrosomonas and Nitrobacter species, being ubiquitous in nature, could readily colonize the salt mine shafts in Hallstatt, contributing to the curing process of the meat by converting ammonia to nitrite and nitrate under the right environmental conditions.

vi. Feasibility of Meat Curing:

Even if ammonia is produced and converted to nitrite, the concentration of nitrite necessary for effective curing (colour development, flavour enhancement, and microbial inhibition) might not sufficient. Enzymatic deamination can lead to ammonia production, and theoretically, this ammonia could be converted to nitrite which could cure the meat. Under the right conditions, 7 days seems to be long enough for this process to take place. This must be validated through experimentation.

Assuming ammonia is produced during the initial 7-day period in which the meat is submerged in a brine and clay mixture and that it penetrates the meat, the subsequent steps involving drying and possible curing in a salt cave involve several specific conditions and processes.

a.1.2. L-Arginine Accessed Microbial Oxidation

-> The Overview

Another option to consider is L-arginine fermentation. In this method of curing, nitrogen is converted through nitric oxide synthase, where neither NO₃⁻ nor NO₂⁻ is used to initiate the reaction sequence to NO.

A combination of amino acids made available through deamination and the extraction of salt-soluble actin and myosin will serve as nutrients for the bacteria, encouraging their metabolism. In the absence of air, the bacteria will favour nitrogen respiration, accessing L-arginine from these proteins for fermentation to produce nitric oxide (NO). Myoglobin, which is also extracted, will be the main recipient of the curing molecule, nitric oxide, produced by the bacteria, thereby undergoing the curing process.

-> What is L-Arganine?

L-arginine is a semi-essential amino acid crucial for various physiological processes, including nitric oxide production, protein synthesis, and immune function. It features a guanidinium group with three nitrogen atoms, making it highly nitrogen-rich. L-arginine serves as a substrate for nitric oxide synthase (NOS) enzymes, which convert it into nitric oxide (NO) and citrulline, playing key roles in vasodilation, neurotransmission, and immune responses. It is also vital in the urea cycle for detoxifying ammonia and stimulating hormone secretion. Found in meat, poultry, fish, dairy, nuts, seeds, soy, and whole grains, L-Arginine is used in medical treatments for cardiovascular conditions, erectile dysfunction, and athletic performance enhancement. In meat curing, it contributes to the formation of nitrosylmyoglobin, stabilizing the colour and flavour of cured meat.

-> The Role of L-Arginine in Nitrogen Storage and Metabolism

A combination of amino acids made available through deamination and the extraction of salt-soluble actin and myosin, which contain L-arginine, will serve as nutrients for the bacteria, encouraging their metabolism. In the absence of air, the bacteria will favour nitrogen respiration, accessing L-arginine from these proteins for fermentation to produce nitric oxide (NO). Myoglobin, which is also extracted, will be the main recipient of the curing molecule, nitric oxide, produced by the bacteria, thereby undergoing the curing process.

-> Why L-Arginine is Used to Store Nitrogen

L-arginine is an amino acid with a high nitrogen content, making it a key player in nitrogen storage and metabolism. It has three nitrogen atoms within its structure, which are crucial for various biological processes. The structure of L-arginine includes a guanidinium group, which is responsible for its high nitrogen content and its role in storing additional nitrogen.

-> Function of L-Arginine in Nitrogen Oxidation through Indigenous Enzymes

L-arginine serves as a substrate for nitric oxide synthase (NOS) enzymes, which oxidize L-arginine to produce nitric oxide (NO) and citrulline. This process is crucial for various physiological functions, including vasodilation, neurotransmission, and immune response. In muscle tissues, the production of NO can also influence muscle contraction and relaxation.

-> Bacterial Production of Similar Enzymes

Bacteria can produce enzymes similar to nitric oxide synthase, enabling them to utilize L-arginine for the production of nitric oxide. This ability is particularly important for bacteria in anaerobic environments, where oxygen is scarce. By using L-arginine, bacteria can carry out nitrogen respiration, which helps them to survive and thrive in such conditions.

-> Function of Nitric Oxide Production in Bacterial Metabolism

In bacterial metabolism, the production of nitric oxide from L-arginine serves several functions. It can act as a signalling molecule, helping to regulate bacterial communication and biofilm formation. Additionally, nitric oxide can serve as a defence mechanism against oxidative stress and immune responses. In the context of meat curing, the bacterial production of nitric oxide plays a critical role in the curing process by reacting with myoglobin to form nitrosylmyoglobin, which stabilizes the colour and flavour of the cured meat.

L-arginine’s role in nitrogen storage and metabolism is facilitated by its high nitrogen content and the presence of the guanidinium group on its side chain. This amino acid is crucial for the production of nitric oxide through the action of nitric oxide synthase enzymes, both in muscle tissues and bacteria. Bacteria leverage this process for nitrogen respiration and survival in anaerobic environments, ultimately contributing to the curing process of meat by producing nitric oxide that reacts with myoglobin. This complex interplay highlights the importance of L-arginine and bacterial enzymes in meat curing and preservation.

-> Hypothetical Mechanism

The system could work in the following manner: the actual protein that needs curing is myoglobin, and L-arginine is present in various proteins within the meat, including sarcoplasmic proteins. As salt penetrates the meat from the salt-rich clay in Hallstatt, these proteins are solubilized. The solubilization of sarcoplasmic proteins, such as actin and myosin, due to the salt releases L-arginine, making it accessible to bacteria. This process allows the bacteria to utilize the solubilized L-arginine without needing to penetrate the meat deeply, which would otherwise slow down the reaction. The bacteria can then use the accessible L-arginine to produce nitric oxide (NO), contributing to the curing process.

Myoglobin may also migrate out of the meat under osmotic pressure. If it is exposed to nitric oxide (NO), it can react with the heme group in myoglobin to form nitrosylmyoglobin, a stable cured form of the protein. This nitrosylmyoglobin could potentially migrate back into the meat, contributing to the curing process and enhancing the flavour profile of the final product. Under osmotic pressure, the initial migration of myoglobin out of the meat and the subsequent reabsorption of nitrosylmyoglobin into the meat can play a significant role in the overall curing process.

The entire process of curing meat through L-arginine fermentation and the subsequent formation and migration of nitrosylmyoglobin can potentially begin within 7 days, but full curing and flavour development typically require a longer period.

The curing process can continue effectively if the meat is removed from the clay and hung in the mine shafts with a relative humidity of 60%. The environment in the mine shafts provides the necessary conditions to support ongoing microbial activity and curing. The salt absorbed into the meat from the initial clay exposure will continue to influence water activity, inhibiting spoilage bacteria while allowing beneficial curing bacteria to thrive. Beneficial microorganisms, such as those from the genera Staphylococcus and Kocuria, will continue to utilize the available nutrients and contribute to the curing process.

As the meat hangs in the mine shafts, the gradual reduction of moisture content will occur, facilitated by the 60% relative humidity and damp conditions. This drying process is crucial for achieving the desired texture and further preserving the meat. During this period, the bacteria will continue to produce nitric oxide (NO) from the accessible L-arginine, which will react with myoglobin to form nitrosylmyoglobin. This reaction will enhance the cured meat colour and flavour. The ongoing enzymatic and microbial activities will deepen the curing effect, resulting in a more complex and desirable flavour profile.

The initial phase of curing, which involves solubilization, microbial activity, and NO production, occurs within the first 7 days while the meat is in the clay. However, the extended curing process after removing the meat and hanging it in the mine shafts is essential for full flavour development and preservation. Over the next several weeks to months, the continued drying and ageing processes will enhance the meat’s texture, flavour, and overall quality. While significant progress can be made within the first 7 days, optimal curing typically requires a longer period, allowing the meat to develop its full range of flavours and characteristics.

Here is a more detailed breakdown:

* Initial Solubilization and Migration:

Day 1-3: As salt from the salt-rich clay penetrates the meat, it begins to solubilize sarcoplasmic proteins, including actin, myosin, and myoglobin. During this period, L-arginine becomes accessible, and some myoglobin may migrate out of the meat under osmotic pressure.

* Microbial Activity and Nitric Oxide Production:

Day 3-7: Bacteria that utilize L-arginine start to ferment it, producing nitric oxide (NO). The NO can react with the heme group in myoglobin to form nitrosylmyoglobin, a stable cured form of the protein. During this time, nitrosylmyoglobin can potentially migrate back into the meat, contributing to the curing process and enhancing the meat’s flavour and colour.

* Drying in the Mine Shafts:

After the initial 7 days, the meat can be removed from the clay and hung in the mine shafts with a relative humidity of 60%. This environment provides the necessary conditions to support ongoing microbial activity and curing. The gradual reduction of moisture content, facilitated by the relative humidity and damp conditions, is crucial for achieving the desired texture and further preserving the meat. The drying process will continue to support the conversion of L-arginine by bacteria, allowing the curing to proceed effectively.

* Factors Affecting the Process:

  • Salt Concentration: Higher salt concentrations can accelerate protein solubilization and microbial activity.
  • Temperature and Humidity: These environmental factors influence the rate of microbial fermentation and NO production.

While the initial stages of solubilization, microbial activity, and nitrosylmyoglobin formation can occur within the first 7 days, achieving full curing and optimal flavour development usually takes longer. The traditional curing process, which involves extended drying and ageing, typically extends from several weeks to several months. This extended period allows for thorough flavour development and preservation. Therefore, while significant progress can be made within the first 7 days, complete curing likely requires additional time to ensure the meat reaches its optimal flavour and texture.

-> The Bacteria Cultures

Related to the bacterial cultures, Staphylococcus carnosusStaphylococcus xylosus, and Kocuria spp. appear to be of particular interest. These bacteria are known for their roles in meat curing and fermentation processes. Specific strains that could be present in the salt clay in Hallstatt include:

  • Staphylococcus xylosus C2a and Staphylococcus xylosus DSM 20266T: These strains are effective in curing processes and are known for their ability to produce nitric oxide, which is crucial for the formation of nitrosylmyoglobin.
  • Strains deposited with the DSMZ, such as:
  • Staphylococcus xylosus FASP 2 and FASP 3
  • Staphylococcus vitulinus FASP 4
  • Staphylococcus equorum FASP 1 and FASP 5
  • Kocuria salsicia FASP 6
  • Kocuria varians FASP 7
  • Staphylococcus carnosus, noted for its upload to the ATCC portal as 5136, is also relevant for its curing properties, although it might not be as prevalent in the Hallstatt environment compared to Staphylococcus xylosus and Kocuria spp.

These strains are likely to be found in the salt-rich clay of Hallstatt, where the anaerobic conditions and availability of nutrients from decomposing organic matter provide an ideal environment for their growth and activity. These bacteria play a significant role in the curing process by facilitating the production of nitric oxide and contributing to the overall flavour and preservation of the meat.

Staphylococcus carnosus is unlikely to be present in the clay-salt environment of Hallstatt due to several factors related to its natural habitat and specific environmental requirements. Staphylococcus carnosus was discovered through research into the microbial ecology of meat fermentation and curing environments. It was not naturally prevalent in the wild but became significant through human cultivation and use in the meat industry. Before its application in meat curing, it would primarily be found in places where meat was processed or stored, highlighting its close association with human activities and meat products. Primarily, Staphylococcus carnosus is associated with meat and meat products, often utilized in modern industrial meat fermentation and curing processes. Its natural habitat is typically linked to domesticated environments where meat processing occurs, rather than natural settings such as soil or clay. Unlike Staphylococcus xylosus and Kocuria spp., which are commonly found in a variety of environments including soil and water, Staphylococcus carnosus is not typically present in unprocessed natural environments. This makes its presence in the clay-salt environment of Hallstatt less likely.

Additionally, Staphylococcus xylosus and Kocuria spp. are known for their adaptability to diverse environments, including high-salt and low-moisture conditions characteristic of the Hallstatt clay-salt environment. These bacteria can thrive in a range of environmental conditions, making them more robust compared to Staphylococcus carnosus, which has more specific habitat requirements. In natural environments like the clay-salt of Hallstatt, bacteria must compete with a wide variety of other microorganisms for resources. Staphylococcus carnosus, being less adaptable to such competitive and varied conditions, would likely be outcompeted by more versatile bacteria such as Staphylococcus xylosus and Kocuria spp.

Furthermore, the historical context of Hallstatt, dating back to the Bronze and Iron Ages, predates the use of Staphylococcus carnosus in meat fermentation and curing processes. The bacteria present in the environment at that time would more likely be those naturally occurring in soil and salt environments, rather than those introduced through human activity in modern meat processing industries. Therefore, it is more plausible that bacteria like Staphylococcus xylosus and Kocuria spp., which are naturally adapted to survive in diverse and challenging conditions, would be more prevalent in the Hallstatt curing vats. These bacteria are well-suited to the anaerobic, high-salt conditions of the Hallstatt curing vats and play a significant role in the meat curing process.

-> Commercial Systems Exploiting L-Arginine Fermentation

The effectiveness of the general approach has been demonstrated in traditional dry curing methods that use only salt (Toldrá, F., 2010, Handbook of Meat Processing). European producers are now developing commercial brine solutions that utilize the same mechanism.

A European producer has developed a system that uses a blend of Staphylococcus xylosus rather than Staphylococcus carnosus. This system operates with minimal nitric oxide synthase and other functionalities like antioxidative effects. It does not add arginine but supplements the culture with special yeast extracts. During the early heating stages, this system stabilizes the natural meat colour without using hidden nitrites or nitrates, and it does not convert natural nitrates from raw materials into nitrites or NO. This prevents the formation of nitrosylheme, nitrosamines, and carcinogenic compounds.

Another European producer has proposed a project outline focusing on the use of different yeasts with the potential to release ascorbic acid from beet leaves, utilizing enzymes such as cellulase and pectinase. They have various lysates with antioxidant potential to retain colour, yeasts with iron-retaining capacity, and other microorganisms that could be useful for zinc protoporphyrin formation, which is also interesting for colour formation.

b. Parallel Hallstatt Method (Based on Fritz Eckart Barth’s findings) with a Speculative Curing Pathway Resumed

We finally return to the proposed mechanism given by Fritz Barth and translated by Christa Berger. We primarily dealt with the burial of the meat or sealing in with clay as the salting step. In our discussions, we have to incorporate the next step given by him, namely drying to arrive at two possible mechanisms that would make at least theoretical sense. His “salting” step includes the re-use of the brine until it becomes unstable.

Both systems proposed namely the deamination/ ammonia formation and the L-Arganine Fermentation pathway would continue if the brine is re-used with the only possible difference that while the meat is being changed, ammonia would have a chance to be oxidised to nitrite and nitrate and myoglobin, enriched with nitric oxide from L-Arganine fermentation would/ could be present and powerfully contribute to the next round of curing.

I do not doubt that the old brine would be far more effective than the new brine where the curing vat is used for the first time. This re-use of the old brine is exactly the method used in the Wiltshire or Live Brine system which I have researched over many years and is summarised in Bacon & the Art of LivingWiltshire Cured or Tank Cured Bacon.

Let’s review the system proposed by Barth once more.

1. Salting in an Anaerobic Environment

  • Meat is buried in brine pans filled with small pieces of rock salt or rich Haselgebirge.
  • The containers are sealed with clay to create an anaerobic environment, facilitating a unique curing process involving both salting and potential fermentation due to microbial action.
  • After 7-10 days, the initial salting phase is complete, though the meat is not yet fully preserved.

2. Extracting and Utilizing Meat Juices:

  • The extracted brine, enriched with proteins like myoglobin and potentially beneficial bacteria like staphylococci and lactic acid bacteria, remains in the clay.

3. Use of Extracted Brine:

  • The highly concentrated brine, rich in water-soluble components, is collected and could be used for further salting or as a flavour enhancer.

4. Further Processing:

  • The meat would then need to be dried and matured in the mine’s microclimate, benefiting from consistent temperatures and high humidity, mimicking modern dry curing chambers.

c. Impact of Excess Sodium Hydroxide Production on Brine Stability in Hallstatt Curing Vats

Barth’s observations about the curing vats in Hallstatt reveal that these vats were often rebuilt when the brine became unstable, leading to a decline in their effectiveness. One significant factor contributing to this instability could be the excess production of sodium hydroxide (NaOH) by lactic acid bacteria (LAB) in the brine. This excess NaOH can create a series of problems that destabilize the curing environment, necessitating the reconstruction of the vats.

Lactic acid bacteria, while beneficial for producing organic acids that aid in meat preservation, can also produce NaOH under certain conditions. These conditions could indeed exist in the clay vats in Hallstatt after repeated use of the brine. Repeated cycles of curing and the accumulation of organic material can alter the microbial balance and chemistry of the brine. Over time, the depletion of readily fermentable carbohydrates and the buildup of nitrogenous waste products can lead to shifts in LAB metabolism, potentially increasing the production of NaOH.

When NaOH production is excessive, it raises the pH of the brine, making it more alkaline. This elevated pH can significantly impact the oxidation of fats within the meat. Alkaline conditions accelerate the breakdown of fatty acids into free radicals and peroxides, which then degrade into rancid compounds such as aldehydes and ketones. These rancid compounds not only deteriorate the flavor and aroma of the meat but also reduce its overall quality and shelf life.

In the context of Hallstatt’s curing vats, the occurrence of fat oxidation and resultant rancidity would render the brine ineffective for its intended purpose of preserving and flavouring meat. The sensory properties of the meat would suffer, making it unpalatable and decreasing its market value. Furthermore, the oxidative degradation of fats would destroy essential fatty acids and vitamins, diminishing the nutritional value of the meat.

Barth’s account suggests that the rebuilding of vats was necessary when the brine reached a point of instability. This instability could be directly linked to the excess NaOH production, which disrupts the delicate balance required for effective curing. An unstable brine would also affect the microbial ecosystem within the vat. LAB thrive in mildly acidic environments, and a shift toward alkalinity can inhibit their growth and activity. This inhibition reduces the production of beneficial organic acids that are crucial for the curing process, further destabilizing the brine.

Moreover, an alkaline environment can promote the growth of spoilage bacteria and pathogens that are normally suppressed in acidic conditions. This shift not only poses food safety risks but also accelerates the degradation of the curing environment, making the vats unsuitable for continued use.

In conclusion, Barth’s observations about the periodic rebuilding of the Hallstatt curing vats highlight the critical impact of brine instability. Excess production of sodium hydroxide by LAB can lead to elevated pH levels, causing fat oxidation and rancidity, which compromise meat quality. The conditions that promote excessive NaOH production can indeed develop in the clay vats after repeated use. Maintaining a balanced pH in the brine is essential to prevent instability, ensure the effectiveness of the curing process, and avoid the need for frequent vat reconstruction.

d. Re-Use of Old Brine

I already addressed this matter to some extent in reference to Wiltshire or the Live Brine System where brine is re-used indefinitely. The question of whether the Hallstatt curing called for the brine to be re-used. Christa Berger addresses this matter in personal correspondence. She writes, “One question is whether the collected brine with the meat juice was renewed after each procedure. And here I think, yes. The reason is that the clay releases salt into the meat, and the salt concentration decreases with each new batch. In the large vessels, a salt solution could have been prepared and then transferred to the basin. The Hallstatt people likely had knowledge of the correct concentration. I also think this because a whisk was found in the basin, which was probably accidentally thrown in after mixing. These whisks are not robust enough to stir the clay itself; I know this from my own experience, as my grandfather made such whisks from old Christmas trees. Incidentally, similar whisks were also found in Northern Italy, 3,500 years old, in the stilt house museum at Lake Carera near Trento, made of fir wood (as it is still today and was in Hallstatt, too). If this was the case, the brine-meat juice mixture could indeed be further processed into soup – first jelly – then dried. Otherwise, the liquid would have “broken,” as we say, meaning the acid-base ratio would no longer be correct; in other words, it would be spoiled. Actually, only the clay needs to be re-enriched with salt.”

As this re-salting of the brine takes place, the brine will be enriched with another key component, namely oxygen. Earlier, we noted that Nitrosomonas and Nitrobacter convert ammonia to nitrite under aerobic conditions, and stirring the brine will facilitate oxygen to be mixed into the old brine, which could promote this conversion.

Christa places another startling possibility on the table when she writes, “The piece of leather found in the basin also intrigued me. It is conceivable that it was used to introduce bacteria, perhaps to rub onto the meat. The leather piece could have been used to introduce beneficial bacteria, to inoculate the meat and so to aid in the curing process.”

I uncovered a sophisticated meat preservation technique from West Africa using “beneficial bacteria” originating from the skin of the animal. An agriculture chemist once told me that a Log 6 size colony of healthy bacteria is sufficient to keep any pathogens at bay. Students in Veterinary sciences in Lagos confirmed to me that when they investigated for pathogens at abattoirs that use this slaughtering technique, no pathogens could be found on freshly slaughtered carcasses despite the complete absence of any form of refrigeration. The meat is transported to markets across the city in ambient vehicles and it was only after a few days at the markets that they started to encounter pathogens in small numbers.

Nitrite in Aqueous Solution and Its Role in Meat Curing

Some revision is in order. Nitrite (NO₂⁻) in aqueous solution can form nitrous acid (HNO₂). When nitrite salts dissolve in water, they react with the water to form nitrous acid through the equilibrium reaction:

NO₂⁻ + H₂O ⇌ HNO₂ + OH⁻

In this reaction, the nitrite ion (NO₂⁻) interacts with water to produce nitrous acid (HNO₂) and hydroxide ions (OH⁻). Nitrous acid is a weak acid that partially dissociates in water, producing nitrite ions and hydrogen ions (H⁺):

HNO₂ ⇌ H⁺ + NO₂⁻

The formation of nitrous acid is significant in various chemical and biological processes, including food preservation and curing. Nitrous acid can further decompose to produce nitric oxide (NO) and nitrogen dioxide (NO₂):

2 HNO₂ → NO + NO₂ + H₂O

Curing Reactions Involving Nitric Oxide

Nitric oxide (NO) plays a critical role in the curing of meat. When NO reacts with myoglobin, a muscle protein, it forms nitrosylmyoglobin, which is responsible for the characteristic pink color of cured meat. The reaction can be represented as follows:

Myoglobin + NO → Nitrosylmyoglobin

This reaction stabilizes the colour and enhances the flavour of the cured meat. However, nitric oxide is a reactive species and can be further oxidized to nitrite (NO₂⁻) or nitrate (NO₃⁻) in the presence of oxygen or through microbial action:

2 NO + O₂ → 2 NO₂

NO₂ + O₂ + H₂O → 2 HNO₃

Interplay of Reactive Nitrogen Species in Curing

The curing process in Hallstatt likely involved a complex interplay of various reactive nitrogen species, including nitric oxide (NO), ammonia (NH₃), nitrite (NO₂⁻), and nitrate (NO₃⁻). These species are part of what is collectively known as reactive nitrogen species. The oxidation and reduction reactions involving these species are critical to the curing process.

The presence of both deamination and bacterial oxidation of L-arginine suggests that multiple pathways could be at work simultaneously. Deamination of proteins can produce ammonia, which in turn can be oxidized to nitrite and nitrate by nitrifying bacteria. The bacterial oxidation of L-arginine to nitric oxide adds another layer to the curing process.

Implications for Meat Curing in Hallstatt

This multifaceted approach to meat curing has profound implications for understanding the history and techniques used in ancient meat preservation. The combination of chemical and microbial actions likely created an environment where all four nitrogen species were present in varying concentrations. The equilibrium between these reactive nitrogen species ensured that the curing process was efficient and effective.

Nitrite (NO₂⁻) in aqueous solution existing as nitrous acid (HNO₂) plays a crucial role in these reactions. Nitrous acid can decompose to form nitric oxide, which then reacts with myoglobin to produce nitrosylmyoglobin, stabilizing the meat’s colour. The continual cycling of these nitrogen species, through both chemical and microbial pathways, ensures the meat remains preserved and develops the desired flavour and colour.

Conclusion

The Hallstatt curing vats represent a remarkable intersection of ancient technology and sophisticated meat preservation techniques. The site offers invaluable insights into early European curing methods, emphasizing the importance of maintaining brine stability to ensure successful meat curing. As we continue to explore and understand these ancient practices, we uncover the foundations of an industry that has shaped culinary traditions for millennia. The Hallstatt curing vats not only provide a glimpse into the past but also inform modern practices, highlighting the enduring legacy of this extraordinary site.

References

Barth, F. E., & Lobisser, W. (2002). Research on the function of ancient block wall constructions around the salt mines of Hallstatt.

Bolstad, A.I., Jensen, H.B., & Bakken, V. (1996). Taxonomy, biology, and periodontal aspects of Fusobacterium nucleatum. Clinical Microbiology Reviews, 9(1), 55-71.

Cato, E.P., George, W.L., & Finegold, S.M. (1986). Genus Clostridium. In Bergey’s Manual of Systematic Bacteriology (Vol. 2).

Chaves, S. et al. (2019). Microbial communities in archaeological environments: The case of the La Draga Neolithic site. PLOS ONE, 14(7), e0219397.

Correspondence with a European producer regarding the “Natural Rose” system.

Frossard, A., Gerull, L., Mutz, M., & Gessner, M.O. (2012). Anaerobic microbial activity in clay soils. Soil Biology and Biochemistry, 50, 58-68.

Gunde-Cimerman, N., Oren, A., & Plemenitaš, A. (2005). Microbial diversity and metabolic potential in salt mine environments. FEMS Microbiology Ecology, 53(1), 55-66.

“Mechanisms of protein solubilization in curing processes,” Food Science Journal.

“Microbial cultures in meat fermentation,” European Microbiology Review.

“Microbial safety in starter cultures,” Food Safety Journal.

“Nitric oxide synthase and its role in L-arginine fermentation,” European Producer Research Documentation.

Project outline from another European producer on yeasts and lysates for colour retention.

Stackebrandt, E., & Schumann, P. (2006). Introduction to the taxonomy of Clostridia. Anaerobe, 12(5-6), 253-260.

Toldrá, F. (2010). Handbook of Meat Processing.

Wexler, H.M. (2007). Bacteroides: The good, the bad, and the nitty-gritty. Clinical Microbiology Reviews, 20(4), 593-621.

Berger, Christa. Private Communication.

Featured Image: https://nhm-wien.ac.at/hallstatt/en/trading_hub/meat_processing_industry/meat_curing_vats

Nutritional Strategies for MMA Fighters: Lessons from Ancient African Warrior

21 March 24
Eben van Tonder

Introduction

When I was in Ile Ife, the spiritual capital city of the Yoruba people, I came face to face with an aspect of Africa that would transform my thinking about meat. An old butcher who must have been in his 90s told me that he would suggest different cuts from the animal based on the circumstances of the buyer. He would, for example, suggest that a pregnant woman buy offal. For someone who suffers from joint pain would suggest parts of the animal with lots of tendons.

Introduction to the nutritional perspective from the African worrier.

This set me on a quest to uncover the diet of an African worrier. The consumption of specific animal parts by African warriors before the battle is a practice rooted in cultural, spiritual, and nutritional beliefs—and offers intriguing insights for modern mixed martial arts (MMA) fighters. This historical perspective, combined with contemporary nutritional science, provides a comprehensive approach to optimizing diet for performance and recovery in combat sports.

African Relationship with Meat

-> Chicken Parts

I previously summarized the work, Rituals of Solidarity in an Igbo Village: A Symbolic Analysis of Meat Sharing Practices Among the Mmaku Igbo.” (Mark Anikpo, 1984) The work does not speak to the nutrition of soldiers in particular, but the Gizzard (Nkpuluma)LiverLeg (Kpolokpolo), and Tail End (Eke) of the chicken are reserved for the father or the oldest male in the family, symbolizing life sustenance and ritual power. This is not insignificant.

Chicken Gizzard

Nutritional Value: Chicken gizzards are a good source of protein, iron, zinc, and Vitamin B12. They are also rich in selenium, a mineral essential for antioxidant defence and thyroid function.

Comparison & Benefits: Compared to chicken breast, gizzards contain higher concentrations of certain minerals like zinc and iron, which are crucial for oxygen transport and muscle repair. Their high protein content aids in muscle recovery and growth, an essential factor for fighters.

Ancient Warriors vs. Modern Athletes: The high nutrient density of chicken gizzards could have offered ancient warriors benefits in endurance and recovery. For modern athletes, these attributes can support intense training demands, promoting recovery and enhancing performance.

— Chicken Liver

Nutritional Value: Chicken liver is an excellent source of high-quality protein, vitamins A, D, and B-complex, especially B12, along with iron, zinc, and phosphorus. It stands out for its high content of heme iron, crucial for oxygen transport.

Comparison & Benefits: The liver outshines most other chicken parts in vitamin and mineral content, particularly in vitamins A and B12, essential for energy metabolism and vision. Its rich iron content supports haemoglobin formation, enhancing oxygen delivery to muscles.

Ancient Warriors vs. Modern Athletes: For ancient warriors, consuming the liver could provide nutritional advantages for energy, recovery, and overall vitality. Modern athletes may benefit from its role in supporting metabolism, immune function, and oxygen delivery, critical for endurance and recovery in combat sports.

— Chicken Leg (Drumstick and Thigh)

Nutritional Value: Chicken legs are richer in fat and collagen compared to breast meat, providing a good source of protein, B vitamins, iron, and zinc. The skin and connective tissues offer collagen, beneficial for joint health.

Comparison & Benefits: The higher fat content in the legs provides sustained energy, making it advantageous for long-duration activities. Collagen is crucial for joint health and recovery, particularly in contact sports where injuries are common.

Ancient Warriors vs. Modern Athletes: The energy sustenance and joint support from consuming chicken legs would be beneficial for ancient warriors’ endurance and recovery. Modern athletes, especially in combat sports, can benefit from collagen for joint health and recovery.

— Chicken Tail End

Nutritional Value: The tail end is fatty, providing a concentrated source of energy. It contains small amounts of collagen and is flavorful, but its nutritional value is less documented.

Comparison & Benefits: The high-fat content offers energy; however, it lacks the protein and mineral richness of other parts. Its contribution to a fighter’s diet would primarily be caloric.

Ancient Warriors vs. Modern Athletes: For ancient warriors, the energy from the tail end could be beneficial during prolonged activities. Modern athletes might find less nutritional benefit here, focusing instead on parts rich in protein and minerals.

General Comparison and Application

Collagen: Present significantly in gizzards and leg parts, beneficial for joint and tissue repair. Essential for athletes in contact sports for injury prevention and recovery.

Vitamins & Minerals: Liver and gizzards are exceptionally rich in vitamins (A, D, B12) and minerals (iron, zinc), surpassing other chicken parts. These nutrients are crucial for energy production, oxygen transport, and overall health, offering an advantage to fighters for endurance and recovery.

Zinc and Other Minerals: Zinc, found abundantly in the liver and gizzards, is vital for immune function, wound healing, and muscle growth. These properties would have been invaluable to both ancient warriors and modern athletes for recovery and performance.

The consumption of chicken gizzards, liver, legs, and even the tail end, offers unique nutritional benefits that could provide advantages for high-performance athletes like MMA and UFC fighters, echoing the potential benefits these parts might have had for ancient warriors. Their rich content of collagen, vitamins, and minerals like zinc plays a significant role in recovery, endurance, and overall health, making them prized among native Africans and applicable to the diet of modern sports warriors.

-> The Heart

Mark Anikpo (1984) discussed the heart of different animals in the same breath as he discussed the chicken liver. He wrote, “The heart (of no meat value in the chicken) and the liver are considered the most important organs in the body. Similarly, the father of the family (usually the eldest male), being the breadwinner, represents the life of the family group.” He also associates it with the gizzards when he writes, “In the Igbo socio-cultural system, the eldest male in the group sharing chicken meat (or any other meat as we shall see later) is given the gizzard (heart, in other animals), liver, tail-end (eke) and the leg because a symbolic association is made of these parts with life sustenance and ritual power.” When the chicken is slaughtered, “the heart is shared like kola nut to all those present at the sacrifice.” (Anikpo, 1984).

Related to the ox or cow heart, Anikpo (1984) writes that “custom demands, that the father or the eldest male be given the heart. This again symbolises the position of the father as the ‘nerve’ centre of the family existence.” He describes the heart as the “prize”. He continues and discusses goat meat. “The goat meat belongs theoretically to the wife’s father although he is required by custom to share it with other relatives. He is entitled to one half of the goat plus the heart and the head intact.”

There can be no question that the heart has a very special place in Igbo culture as is the case in probably every tribe in Africa. The heart, whether from an ox, goat, or chicken, is a muscular organ rich in nutrients vital for overall health, recovery, and performance, making it an invaluable addition to the diet of high-performance athletes, such as MMA and UFC fighters. The evaluation of the heart in terms of collagen, protein, iron, and other minerals reveals its potential advantages, similar to the benefits offered by consuming specific chicken parts discussed earlier.

Let us delve into the nutritional consideration which is probably what is behind the value placed on it. We consider it for the major species under review.

— Ox Heart

Nutritional Value: The ox heart is a dense source of high-quality protein, B vitamins (especially B12), iron, zinc, selenium, and phosphorus. It contains some amount of collagen due to its muscular nature, which contributes to its overall nutritional profile.

Comparison & Benefits: Compared to more commonly consumed meat parts like muscle meat, the ox heart has a higher concentration of certain nutrients, particularly B vitamins and iron, crucial for energy metabolism and oxygen transport. The protein content supports muscle repair and growth, essential for athletes.

Ancient Warriors vs. Modern Athletes: Consuming ox heart would have provided ancient warriors with sustained energy and improved oxygen delivery, enhancing endurance and recovery. Modern athletes can benefit similarly, with the added advantage of collagen for joint health and recovery.

— Goat Heart

Nutritional Value: Similar to the ox heart, the goat heart is rich in protein, iron, zinc, and B vitamins. It also provides a good source of CoQ10, an important compound for energy production and antioxidant protection.

Comparison & Benefits: Goat heart stands out for its CoQ10 content, supporting heart health and energy production at the cellular level. The nutrient density, particularly in terms of iron and B vitamins, makes it beneficial for muscle recovery and endurance.

Ancient Warriors vs. Modern Athletes: For ancient warriors, the nutrient-rich goat heart could support prolonged physical activity and recovery. For modern athletes, especially those in contact sports, the benefits extend to improved energy metabolism and cardiovascular health.

Chicken Heart

Nutritional Value: Chicken heart is high in protein, vitamins B12 and B6, iron, and zinc. It is also a good source of taurine, an amino acid important for cardiovascular health and muscle function.

Comparison & Benefits: While the chicken heart contains less collagen than connective tissues, its high protein and nutrient content support muscle function and recovery. The presence of taurine and CoQ10 adds to its cardiovascular benefits.

Ancient Warriors vs. Modern Athletes: The nutritional profile of chicken heart, rich in energy-boosting and muscle-repairing nutrients, would have been advantageous for ancient warriors. Modern athletes can benefit from its support for muscle recovery, energy production, and heart health.

General Comparison and Application

Collagen: While not as rich in collagen as connective tissues, the muscular nature of the heart provides some amount of this important protein, supporting tissue repair and joint health.

Protein: The heart from all three animals provides a high-quality protein source, essential for muscle repair, growth, and recovery. The dense protein content is particularly beneficial for athletes involved in intensive training and competitions.

Iron and Other Minerals: The heart is rich in iron, crucial for oxygen transport and energy metabolism. Zinc supports immune function and wound healing, while selenium and phosphorus contribute to antioxidant defences and bone health.

The consumption of the heart from ox, goat, or chicken offers significant nutritional benefits, particularly for athletes in disciplines requiring high endurance, strength, and rapid recovery. The dense nutrient profile, including high-quality protein, iron, zinc, and B vitamins, supports energy metabolism, muscle recovery, and overall health. While the heart may not be as rich in collagen as connective tissues, its nutritional value in terms of protein and minerals makes it a valuable food source for both ancient warriors and modern athletes, providing a foundation for enhanced performance and recovery.

-> Blood

I spent a lot of time studying the history of the use of blood. In “The Ile Ife (ile ife) Notes I delved into many of the pertinent issues and what I believe to be the ancient link between spirituality and blood. The basis, I believe, is in the physiological value of blood.

Consuming blood has been part of African culture for millennia, as it has probably been in all cultures around the globe. In modern times, the Massai people of Kenya and Northern Tanzania stand out for having resisted the tide of the WHO against the consumption of blood the best. Their traditional diet relies heavily on milk and dairy products, lean beef and other meats, cattle fat, and blood, on which they depend for their salt intake. (The Cattle Economy of the Maasai, National Geographic)

The nutritional value of animal blood, particularly from sources like ox, goat, or chicken, offers a unique perspective when compared to other animal parts due to its distinct composition. Animal blood is rich in protein, iron, and various minerals, playing a significant role in traditional diets and potentially offering advantages for modern athletes, especially those in contact sports like MMA and UFC.

— Nutritional Value of Animal Blood

Nutritional Value: Animal blood is an excellent source of heme iron, which is more easily absorbed by the body than non-heme iron from plant sources. It also provides a good amount of protein and is rich in various minerals, including potassium and magnesium. While blood contains lower levels of collagen compared to connective tissues, it is a significant source of certain vitamins, especially some from the B group.

Comparison & Benefits:

  • Protein: Animal blood offers high-quality protein essential for muscle repair and growth, similar to that found in muscle meats but with a unique amino acid profile.
  • Iron: The heme iron in animal blood is particularly beneficial for athletes, aiding in oxygen transport and energy metabolism. Compared to muscle meats, blood can offer a more concentrated source of iron, making it valuable for preventing iron deficiency anaemia.
  • Collagen: While not a direct source of collagen, the amino acids in the blood can support collagen synthesis in the body, indirectly benefiting joint health and recovery.
  • Other Minerals: Blood is a source of minerals like potassium and magnesium, crucial for muscle function and recovery. While not as rich in zinc as the liver or gizzards, its overall mineral profile supports cardiovascular health and muscle activity.

— Application to Ancient Warriors and Modern Athletes

Ancient Warriors: The consumption of animal blood could have offered ancient warriors a compact and efficient source of iron and protein, vital for sustaining energy levels and physical endurance during prolonged battles or hunts. The psychological aspect of consuming blood, symbolizing strength and vitality, might also have played a role in its value among warriors.

Modern Athletes: For athletes, especially those in contact sports with high risks of injury and significant physical demands, the bioavailable iron and protein in animal blood can support oxygen transport, muscle repair, and overall energy metabolism. The mineral content, including potassium and magnesium, aids in muscle recovery and function, crucial during training and post-competition recovery phases.

Comparison with Other Animal Parts

Compared to the liver, which is vitamin and mineral-dense, animal blood provides a more focused source of bioavailable iron and protein but with less diversity in vitamins. Unlike the gizzard and leg, blood does not directly provide collagen but offers the amino acids necessary for the body’s collagen synthesis, supporting tissue repair and joint health indirectly. The tail end, primarily valued for its fat content, offers energy but lacks the broad nutritional profile that blood provides, particularly in terms of bioavailable iron and protein.

Animal blood, as a dietary component, offers specific nutritional benefits that can be particularly advantageous for high-performance athletes, such as those involved in MMA and UFC. Its rich content of bioavailable heme iron, high-quality protein, and essential minerals supports enhanced oxygen transport, muscle recovery, and overall energy metabolism. These characteristics could have been beneficial to ancient warriors for physical endurance and recovery, and they remain relevant for modern athletes seeking to optimize performance and accelerate recovery in demanding sports.

Incorporating animal blood into the diet, whether through direct consumption or as an ingredient in dishes like blood sausages, can be a strategic approach to leveraging its unique nutritional profile for sports performance and recovery, reflecting a practice rooted in tradition yet applicable to contemporary nutritional strategies for athletes.

Danger In Too Much Iron

Just as there is a danger in not enough iron, consuming too much iron is also detrimental. Due to the importance of this topic, I did a follow-up article to this one called “The Iron Diet: Fueling UFC Fighters with Blood Sausage“. Here I deal with the facts and show that the UFC, MME fighter, the boxer and Judoka hardly have to be concerned with consuming too much blood-based foods. I also show that such foods can easily be prepared and are extremely affordable from a budgetary perspective. I use a blood sausage as an example and show the balanced datary value in the sausage formulation I suggest.

Summary of African Worrier Foods

I summarise the animal parts we discussed and start the discussion on recipes. Many follow articles to come where I will take these parts one at a time and prepare some of these dishes:

The consumption of specific animal parts has been historically associated with gaining the perceived qualities of the animal itself. It is further set within a particular hierarchy of meat-sharing traditions all of which points to careful observation by past generations and the best parts being offered to the leaders in the community and households. This comprehensive system posits that parts like the heart, liver, and blood, alongside gizzards, legs (drumsticks and thighs), and the tail end, could impart strength, courage, vitality, and various physical or spiritual advantages crucial for prowess in battle or in competitive arenas. I am convinced that science bears testimony to the fact that these beliefs are grounded in careful observation over millennia.

Modern Application: Optimizing Nutrition for MMA Fighters

For MMA fighters, a diet incorporating a variety of nutrient-dense animal parts can significantly boost performance, energy levels, recovery, and overall health. Including dishes such as blood sausage, liver pâté, grilled heart (e.g., ox heart pastrami), sautéed gizzards, roasted chicken legs, and crispy tail end can provide a comprehensive range of benefits:

–> Blood Sausage – see “The Iron Diet: Fueling UFC Fighters with Blood Sausage

  • Rich in bioavailable heme iron and protein, crucial for oxygen transport and muscle repair. Ideal for consumption 2-3 times a week, in portions of 50-100 grams, to maintain optimal iron levels.
  • Possible dishes: Traditional blood sausage, blood pancakes, and blood tofu.

–> Liver Pâté (Sausage)

  • High in vitamin A, iron, and B vitamins, vital for energy metabolism, immune function, and red blood cell production. To prevent hypervitaminosis A, it’s recommended to consume moderately: 50-100 grams 2-3 times a week.
  • Possible dishes: Liver pâté, liver and onions, and liver dumplings.

–> Heart (e.g., Ox Heart Pastrami)

  • Packed with protein, CoQ10, and essential minerals, which are beneficial for energy production and cardiovascular health. Consuming 100-150 grams several times a week, including 3-4 hours before competition, can be particularly advantageous.
  • Possible dishes: Grilled heart skewers, heart stew, and heart pastrami.

–> Sautéed Gizzards

  • A good source of zinc and iron, which are essential for muscle growth and repair, as well as immune function. Adding 100-150 grams of sautéed gizzards to meals 2-3 times a week can bolster nutrient intake.
  • Possible dishes: Sautéed gizzards with onions, gizzard salad, and gizzard stew.

–> Roasted Chicken Legs (Drumsticks and Thighs)

  • Rich in collagen, fats, and protein, supporting sustained energy release, joint health, and muscle recovery. Including roasted legs in the diet 2-3 times a week, with portions of 150-200 grams, can enhance the overall nutritional profile.
  • Possible dishes: Roasted chicken legs with herbs, BBQ chicken drumsticks, and chicken leg curry.

–> Crispy Tail End

  • Provides concentrated energy from fats, though less nutrient-dense than other parts, it can be a flavorful addition to the diet in small quantities for variety.
  • Possible dishes: Fried chicken tail, crispy tail end skewers, and tail end in broth.

Conclusion

Integrating these diverse meat parts into an MMA fighter’s diet not only taps into traditional beliefs about the nutritional and symbolic power of animal organs but also aligns with modern nutritional science to optimize health, energy, and performance in high-intensity sports. This comprehensive approach to diet can support the demanding physical and recovery needs of combat athletes, reflecting a blend of historical wisdom and contemporary dietary strategies. Lastly, I must make this point again – it does not have to come at the cost of an arm and a leg and what I present here is far tastier than a hand full of supplement tablets or glasses of water or milk and powders full of fillers and half-baked promises!


All my work UFC articles are hosted at:


References

  • Fallon, S., & Enig, M.G. (2001). Nourishing Traditions: The Cookbook that Challenges Politically Correct Nutrition and the Diet Dictocrats. NewTrends Publishing.
  • Kuhnlein, H.V., & Kuhnlein, H.V. (1991). Animal Source Foods to Improve Micronutrient Nutrition in Developing Countries. Journal of Nutrition
  • Williams, P. (2007). Nutritional composition of red meat. Nutrition & Dietetics, 64(S4), S113-S119. This source provides an overview of the nutritional value of red meat, including organ meats like the heart.

The Fighter’s Edge: Harnessing Collagen for Peak Performance and Recovery

16 March '24
Eben van Tonder

Introduction

In the fiercely competitive world of UFC and high-intensity training, athletes constantly seek strategies to enhance recovery, improve performance, and minimize injury downtime. One crucial, yet often overlooked, component of an athlete’s nutrition strategy is collagen. This article delves into the science of collagen’s role in the body, its importance for athletes, and how incorporating collagen-rich foods into a meal plan can significantly impact recovery times and performance.

The Role of Collagen in the Body

Collagen, the most abundant protein in the animal kingdom, serves as the primary structural component of connective tissues throughout the body. Its unique triple helix structure of amino acids — predominantly glycine, proline, and hydroxyproline — provides tensile strength and elasticity to skin, bones, tendons, and ligaments.

Why Athletes Need More Collagen

Athletes, particularly those in combat sports like UFC, subject their bodies to intense physical stress. This stress demands more from the connective tissues for shock absorption, joint stability, and injury prevention. Collagen aids in the repair and maintenance of these tissues, supporting faster recovery and reducing injury risk.

Want to Know More:

Collagen intake is often highlighted in the context of athletic performance and recovery, primarily due to its role in maintaining the strength and integrity of connective tissues such as tendons, ligaments, cartilage, and bones. The increased interest among athletes in collagen supplementation stems from several key points related to physical activity and the body’s needs for repair and recovery:

1. Tendon and Ligament Health:
Stress and Recovery: Regular and intense physical activity puts significant stress on tendons and ligaments. Collagen provides the necessary amino acids (glycine, proline, and hydroxyproline) that are essential for the repair and maintenance of these connective tissues.
Injury Prevention: Adequate collagen synthesis is crucial for maintaining the elasticity and strength of tendons and ligaments, potentially reducing the risk of injuries.

2. Joint Health:
Cartilage Support: Collagen is a major component of cartilage, the tissue that cushions joints. High-impact and repetitive activities can wear down cartilage, leading to joint pain and conditions like osteoarthritis. Collagen supplementation may support cartilage repair and reduce joint pain, improving overall joint functionality.

3. Bone Strength:
Bone Density: Collagen contributes to the structural matrix of bones. Regular exercise, particularly weight-bearing activities, increases the need for bone remodelling and repair. Collagen intake may support bone health by providing the building blocks needed for bone formation, potentially enhancing bone density and reducing the risk of bone-related injuries.

4. Muscle Repair and Growth:
Protein Synthesis: While collagen is not a complete protein (it lacks tryptophan), it provides specific amino acids that can complement dietary protein intake, supporting muscle repair and growth. This is particularly relevant for athletes engaging in resistance training or activities that cause muscle microtears.

5. Skin Health:
Protection and Repair: Intense physical activity can also stress the skin through increased exposure to elements and potential damage from friction and sweat. Collagen may help maintain skin elasticity and resilience.

The Power of Collagen-Rich Foods

While collagen supplements are popular, they are extremely expensive and what is available through health shops and pharmacies are often loaded with mostly fillers to bring the price down. The fact is that collagen is easily obtainable and inexpensive. Collagen is a product of the animal body. Incorporating collagen-rich parts of the animal into one’s diet offers a holistic approach to nutrition. Foods like pork skin, beef tendons, chicken skin, and other collagen-rich parts of animals are not only nutritious but can also be delicious components of meals.

A Week of Collagen-Boosting Meals

I offer 7 recipes of collagen-rich food for athletes to incorporate into their weekly meal plans.

Day 1: Beef Tendon Stew

  • Recipe: Slow-cook beef tendons with vegetables like carrots, onions, and celery in a rich broth until the tendons become tender. This process can take 3-4 hours but results in a gelatinous, flavorful stew.
  • Collagen Content: Approximately 30g per serving.

Day 2: Pork Skin Cracklings

  • Recipe: Season pork skin with salt and bake at a low temperature until dry, then broil until crispy. Serve as a snack or with a meal.
  • Collagen Content: Around 20g per 50g serving.

Day 3: Chicken Skin Tacos

  • Recipe: Bake seasoned chicken skin until crispy. Use as a taco shell and fill with your choice of ingredients like grilled chicken, lettuce, and salsa.
  • Collagen Content: Approximately 15g per serving.

Day 4: Braised Beef Shin

  • Recipe: Braise beef shin with herbs and vegetables until the meat is tender and the collagen-rich marrow is soft.
  • Collagen Content: Around 25g per serving.

Day 5: Belly Rashers and Eggs

  • Recipe: Grill skin-on pork belly rashers until crispy. Serve with fried eggs for a protein-rich breakfast.
  • Collagen Content: Approximately 20g per serving.

Day 6: Bone Broth

  • Recipe: Simmer beef knuckles, marrow bones, and vegetables for 24 hours. Strain and season for a nutritious broth.
  • Collagen Content: 10g per cup.

Day 7: Pork Trotter Soup

  • Recipe: Slow-cook pork trotters with spices, vegetables, and herbs until the meat falls off the bone.
  • Collagen Content: Approximately 35g per serving.

The Oake Woods Options

The company Oake, Woods & Co (Pty) Ltd, from Cape Town, has spent 5 years developing a select range of high collagen-rich sausages which they are selling under the brand name Oake Woods. Incorporating these as snack food or as part of a main meal into your weekly meal strategy will yield exceptional results from a collagen-intake perspective. These products can be manufactured under license anywhere in the world. Click on the company logo to be directed to the contact details.

The Impact on Recovery

Incorporating these collagen-rich meals into a weekly meal plan can significantly enhance an athlete’s recovery process. Collagen provides the essential building blocks for repairing and strengthening connective tissues, reducing injury risk, and improving joint health. For UFC fighters and high-intensity athletes, this means potentially shorter recovery times from both injuries and rigorous training sessions, allowing for more effective training and improved performance in the ring.

Want to Know More:

The digestion and assimilation of collagen, and its subsequent use in the body for repair and synthesis of new collagen or other components, involve several complex processes. When you consume collagen, whether through food or supplements, it’s broken down into its constituent amino acids and smaller peptides during digestion. This breakdown is necessary because proteins, including collagen, cannot be absorbed intact by the digestive system. The process by which collagen is digested, absorbed, and utilized for tissue repair and synthesis involves multiple steps:

1. Digestion:

Collagen proteins in food are first broken down into smaller peptides and individual amino acids by digestive enzymes. This process begins in the stomach:

Stomach Acid (HCl): Hydrochloric acid in the stomach denatures the collagen proteins, unfolding their triple helix structure and making them more accessible to digestive enzymes.

Pepsin: This enzyme, activated in the acidic environment of the stomach, further breaks down the collagen into smaller peptides.
The digestion continues in the small intestine:

Pancreatic Enzymes: Enzymes from the pancreas, including trypsin and chymotrypsin, further cleave these peptides into even smaller peptides and individual amino acids.

2. Absorption:

The breakdown products of collagen digestion—small peptides and amino acids—are absorbed through the small intestine’s lining:

Amino Acids: Individual amino acids are absorbed by active transport, which involves specific transporters for different amino acids.

Dipeptides and Tripeptides: Small peptides, including dipeptides and tripeptides, can be absorbed more efficiently than free amino acids through a process called peptide transport. These peptides are transported into the intestinal cells (enterocytes) using peptide transporters, primarily PEPT1.

Once inside the enterocytes, dipeptides and tripeptides can be further broken down into individual amino acids. These amino acids, along with those absorbed directly, enter the bloodstream.

3. Distribution and Utilization:

The absorbed amino acids and peptides are then distributed throughout the body via the bloodstream. Their utilization for collagen synthesis or other functions takes place in various tissues, depending on the body’s needs:

Fibroblasts: In the skin, tendons, and ligaments, fibroblasts use these amino acids to synthesize new collagen. The process involves the translation of mRNA into the precursor of collagen, pro-collagen, inside the fibroblast cells. This precursor undergoes several post-translational modifications, including hydroxylation of proline and lysine residues, crucial for forming the stable triple helix structure of collagen.

Chondrocytes: In cartilage, chondrocytes synthesize type II collagen, essential for cartilage structure and function.

Osteoblasts: In bones, osteoblasts use these amino acids to produce type I collagen, a major component of the bone matrix.

4. Post-Translational Modifications and Secretion:

The synthesis of collagen is not only about linking amino acids together but also involves critical post-translational modifications:

Hydroxylation: Proline and lysine residues in the collagen chain are hydroxylated, requiring vitamin C as a cofactor. This modification is essential for the stability of the collagen triple helix.

Glycosylation: Some hydroxylysine residues are glycosylated, which is important for collagen secretion and quality.

Formation of the Triple Helix: Three collagen chains form a triple helix structure, known as procollagen.
Secretion and Formation of Mature Collagen: Procollagen is secreted into the extracellular space, where it is cleaved by specific enzymes to form mature collagen, which then assembles into fibrils and fibres, providing structural support to tissues.

This intricate process of collagen digestion, absorption, and utilization underscores the importance of various nutrients (like vitamin C for hydroxylation) and the efficiency of the body’s transport and synthetic mechanisms in maintaining and repairing tissues.

Conclusion

The strategic inclusion of collagen-rich foods in an athlete’s diet is a game-changer for recovery and performance. Beyond supplements, natural food sources offer a variety of nutrients essential for health and recovery. By embracing the power of collagen through these daily meals, fighters can ensure they’re not only hitting their nutritional marks but also paving the way for longevity in their demanding sport.


All my work UFC articles are hosted at:



References

  • Shaw, G., et al. “Vitamin C–enriched gelatin supplementation before intermittent activity augments collagen synthesis.” The American Journal of Clinical Nutrition, vol. 105, no. 1, 2017, pp. 136-143.
  • Clark, K.L., et al. “24-Week study on the use of collagen hydrolysate as a dietary supplement in athletes with activity-related joint pain.” Current Medical Research and Opinion, vol. 24, no. 5, 2008, pp. 1485-1496.
  • Baar, K. “Minimizing Injury and Maximizing Return to Play: Lessons from Engineered Ligaments.” Sports Medicine, vol.