By Eben van Tonder, 22 March 2025

Introduction and Historical Background

Important note: We write SOPs in English and German; See Earthworm Writing & Research Studio & Earthworm Schreib und Forschungsstudio

Origins of Pastrami

Pastrami traces its roots to the Ottoman Empire, particularly among the Turkish and Romanian Jewish communities. The precursor to modern pastrami is pastirma (or basturma), an air-dried cured beef product from Turkey and Armenia. “Pastirma” is derived from the Turkish word “bastırma,” meaning “pressed meat,” referring to the method of pressing the meat during drying to remove moisture and inhibit spoilage (Davidson, 2014).

The practice of making basturma dates back to at least the Byzantine Empire and possibly earlier, where it was widely consumed by soldiers due to its longevity and portability (Marks, 2010). As Jewish populations migrated across Eastern Europe, they adapted the method to suit the climates and dietary laws of their communities. Romanian Jews modified the process by using a wet brine and smoking, which offered better preservation in cooler, more humid regions.

Pastrami in America

Jewish immigrants brought pastramă to the United States during the late 19th century, with many settling in New York City. The first known mention of “pastrami” in America dates to around 1872. Sussman Volk, a Lithuanian immigrant and kosher butcher, is credited with popularising pastrami in New York. According to legend, Volk received a recipe from a Romanian friend in exchange for storing his belongings and began serving pastrami sandwiches from his deli on Delancey Street in 1887. His sandwiches became so popular that he converted his butcher shop into a full-time delicatessen (Marks, 2010).

The term “pastrami” likely evolved from “pastramă,” influenced by the more familiar “salami” to appeal to American consumers. Katz’s Delicatessen, founded in 1888, played a significant role in cementing pastrami’s place in American culinary history, offering the iconic pastrami on rye sandwich that has become synonymous with New York delicatessen (Katz’s Deli History, 2024).

Pastrami Production SOP

Product Description

Traditional pastrami is made from beef silverside, though navel plate and brisket are also used. This SOP is tailored for silverside from older animals, requiring precise processing to ensure tenderness and exceptional flavour.

Raw Material Selection

• Beef Cut: Silverside (from mature cattle)
• Weight per piece: 1.5kg to 3kg
• Quality: Trimmed of excess fat and sinew. Ensure connective tissue is well removed.

Ingredients

Injection Brine (Bacon Brine)

Injection yield target: 30% of raw meat weight

• Water: 5L
• Salt (NaCl): 350g
• Sodium Nitrite (Curing Salt 0.6%): 120g (providing ~120 ppm nitrite)
• Sugar: 50g
• Sodium Erythorbate (Optional): 5g
• Phosphates (Wendaphos or equivalent): 5g
• Ascorbic Acid (Optional for colour stability): 3g

Dry Rub (Post-Cure Rub)

• Coarse ground black pepper: 30g/kg meat
• Crushed coriander seeds: 20g/kg meat
• Garlic powder (optional): 10g/kg meat
• Paprika (optional): 5g/kg meat
• Mustard powder (optional): 2g/kg meat

Production Process

1. Injection and Curing

• Inject silverside to 30% yield with prepared bacon brine.
• Ensure uniform distribution using a multi-needle injector or manual injection.
• Place injected meat in clean crates, stacked for wet curing.
• Curing time: 48 hours at 2-4°C, turning after 24 hours for even brine distribution.

2. Post-Cure Rub

• After curing, remove silversides from brine and lightly rinse to remove excess surface brine.
• Pat dry with clean cloths or paper towels.
• Apply dry rub evenly over all surfaces.
• Allow meat to rest with rub for 12-24 hours, uncovered, in chiller at 2-4°C to set the crust.

3. Cooking Phase (Tenderisation)

• Seal each piece in heat-stable bags (vacuum sealing optional but not necessary). Ensure the seal is tight, excluding air as much as possible.

Cooking in Industrial Smokehouse (Steam Mode)

• Chamber Temperature: 85°C
• Core Temperature Target: 71°C
• Once 71°C core is reached, dwell (hold) for 5 hours to ensure breakdown of connective tissues.
• Steam: 100% humidity
• Estimated total cook time: 5-8 hours depending on piece size.

4. Post-Cooking Chill & Drying

• Immediately chill cooked pastrami in an ice water bath or blast chiller until core temp is below 5°C.
• Remove from bags and place on racks in chiller.
• Dry for 12-24 hours at 2-4°C to develop pellicle and prepare for final roasting/smoking.

5. Finishing: Roast and/or Smoke

Option A: Industrial Smokehouse with Maximum 130°C Capability

• Smoke Phase:
  • Chamber Temp: 110°C
  • Smoke: Light, for 1.5-2 hours
  • Humidity: 40-50%
• Roast Phase:
  • Chamber Temp: 130°C
  • Time: 1.5-2.5 hours (until desired crust is achieved)
  • Humidity: 30-40%
  • Vent: Partially open for drying effect
  • Target core temp: 60-65°C (warming through only)

Option B: Industrial Smokehouse with 200°C Capability

• Smoke Phase (Optional):
  • Chamber Temp: 110-130°C
  • Smoke: Light, for 1-1.5 hours
  • Humidity: 40-50%
• Roast Phase:
  • Chamber Temp: 160-200°C
  • Time: 20-40 minutes (depending on crust and bark development)
  • Vent: Partially open
  • Target core temp: 60-65°C
• Optional Glaze:
  • Beef tallow brushed on surface
  • Optional crust finish: cracked black pepper + coriander + brown sugar (light dusting)
  • Here are a few options you can mix into your brushing oil for extra flavor before grilling your pastrami:
    
    • Crushed garlic (fresh or granulated) – adds depth and that savory punch.
      
      • Paprika (smoked or sweet) – for color and a gentle smokiness.
        
        • Ground coriander – traditional with pastrami, adds citrusy warmth.
          
        • Brown sugar or honey – just a touch for caramelization and balance.
          
        • Mustard seeds or a little Dijon – a nod to deli flavors with tang.
          
        • Chili flakes – if you want a subtle heat.
          
        • Fresh herbs (like thyme or rosemary) – chopped fine or bruised into the oil.
          
        • Worcestershire sauce – just a splash for umami richness.
          Mix these with your black pepper and oil into a paste or glaze consistency. Brush on just before or during grilling for a killer crust.

6. Resting & Slicing

• Rest pastrami 30-45 min after roast/smoke before slicing.
• Slice thin, across the grain.
• Serve warm or cold.

7. Storage

• Store finished pastrami vacuum-packed at 0-4°C.
• Shelf life: 14-21 days under proper refrigeration.

Quality Control Points

• Injection yield and uniformity checked pre-cure.
• Core temperature verification during cook and hold phase.
• Crust formation and surface colour checked post-finish.
• Slicing yields and consistency verified.

References

• Davidson, A. (2014). The Oxford Companion to Food. Oxford University Press.
• Marks, G. (2010). Encyclopedia of Jewish Food. Wiley Publishing.
• Katz’s Delicatessen History Archive (2024).
• USDA FSIS Guidelines on Ready-to-Eat Cured and Smoked Products.
• EarthwormExpress Research Archives (Eben van Tonder).

Notes

• For tougher animals, extend dwell time at 71°C core temp to 8 hours. This additional time facilitates further breakdown of collagen, ensuring tenderness.
• Optional enzyme marinade (bromelain or papain) can be used at 0.05% pre-curing for very tough cuts. Apply enzymes for 12-24 hours at 4°C, followed by thorough rinsing prior to brining.
• Finishing can be adapted to local preferences:
  • Heavier smoke for a bold, BBQ-style crust.
  • Traditional New York deli style for mild smoke with peppery crust.
  • Sweet crust finishes using brown sugar and mustard powder blends.
• Cold smoke application prior to cooking can enhance smoke flavour without overcooking. Conduct cold smoking at 20-30°C for 3-4 hours before bag cooking.
• Always monitor humidity and vent settings during finishing to balance bark formation and internal moisture retention.
• Consider variations using brisket or navel plate for different textural outcomes.
• Strict hygiene and temperature controls are essential to maintain product safety, particularly during the curing and post-cook drying phases.