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Turkey Breast Lunchmeat - 10% off
Turkey as a protein is most often associated with Thanksgiving. On the farm though, these birds better fit a pasture based operation than broilers (meat chickens). They forage better and are much hardier on pasture. And if it counts for anything, they have a personality. Every time tailgate of the truck slams or something unusual happens, they start gobbling away! It's comical at times.
Making Boneless Turkey Products
But making money off of a turkey is difficult. For any poultry, about 1/3 of the weight is in bones. So a 20# turkey has 6.5# of bones, about 5.5# of breast meat, 3# of thighs, and 4.5# of drumsticks and wings.
The biggest challenge is that a turkey drumsticks has what's called "pin bones." Those are those thin, flat bones that you pick out of the dark meat at Thanksgiving. They are impossible to de-bone for sausage. So the drums often go into the stockpot with the bones. Same with the wings.
I recently did an experiment with the processor to debone whole turkeys for grind. We kept good track of yields and costs. At the end, the challenge was we got less than 50% of the original meat back in boneless. And to get there, the processing cost was $4.61 per lb of finished product. So on every tube of ground turkey, before paying for the turkey, the processing was $4.61.
Back to a deli staple - Turkey Breast Lunchmeat
With the breasts, it was a shame to grind those into sausage or ground turkey. At our little butcher shop, we had perfected a great turkey breast lunchmeat, but it was very labor intensive. We used whole breasts and brined them for days, then tumbled them until the proteins started to extract. We then arranged two breasts fat end to skinny end and lacerated the bottom of each. We stick those two muscles together in an elastic net and cook until they are stuck together. A lot of work. It's a great product but not scalable.
So I worked with one of our processors to see what could work for him. He was not willing to do all the labor of the product listed above. There just wasn't enough labor available, and that was reasonable.
So we decided to experiment with a "reformed" turkey breast product. Most lunchmeats fall in this category. Essentially we cut the breast into big chunks and started the brining and tumbling process from there. The seasoned meat was then stuffed tightly into a large casing (like sausage) and smoked thru.
The result is a more uniform shape easier to smoke, slice, and package.
That's probably way more than you wanted to know about making turkey lunchmeat, but it really is a product I'm proud of and I think you'll enjoy it.
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