Our first product,
developed in 1987, was Denhay Air Dried Ham, which is eaten like a
prosciutto, but has a unique character of its own. In 1994,
following requests from our customers for a really high quality Dry
Cured Bacon, we started bacon production. We researched a unique way
of curing which would give us a consistent product, not too salty,
but able to bring out the full flavour of the meat. It involves
attention to detail, something that we are prepared to give. We feel
that our passion for producing something really special has created
a bacon 'tasting like bacon used to taste'.
It comes in both Back and Streaky, Smoked and Unsmoked and medium
sliced, and because no water is added, no white liquid comes out in
the pan.
Up until 1998, we cured a small amount of
bacon. Since then we have built up a team of skilled curers. Up to
30 people are all trained and skilled in providing consistent high
quality bacon made with passion and attention to detail at each
stage of the curing, slicing and packing.
The bacon has proved so successful that in
July 2005, we moved into a state-of-the-art factory in Honiton to
accommodate the increased demand. The factory was designed to allow
us to continue to make the best bacon using the skills and knowledge
gained whilst at Denhay. We bought a new slicing and packing line to
go alongside the existing one. Honiton is a facility that offers
innovative equipment, the best in hygiene and the capacity to grow
that will enable us to maintain our traditional cure but improve our
performance to meet our customers’ expectations.
We source our pork from British outdoor reared herds which have the
RSPCA's Freedom Foods certification.
Our Dry Curing technique involves a unique mixture of dry sea salt
and nitrite, massaged into the pork loins and bellies which are then
cured for between two and three weeks.
The loins and bellies to be smoked are selected and gently smoked
over beech or cherry wood. We replaced our old original smoker, which
was becoming unreliable, with a new smoker that smokes more evenly,
uses wood better and produces less tar. This is a healthier way to
properly smoke.
Once cured, the
bacon is 'fresh sliced' and then shingled. Most bacon is frozen
solid and pressed in to shape before slicing; we will not do that as
we believe that the freezing contributes to the unwelcome white scum
and harms the flavour. Shingling is the process whereby the bacon is
layered so that all slices can be seen. It is also much easier for
consumers to lift a slice of bacon from the pack and to see what
they are buying!
Every batch of bacon we
slice is eaten both when new and on the day it goes out of shelf
life. The factory has been audited and achieved the BRC Global
Standard accreditation at Grade A.
We have been dry curing Duchy Originals bacon using
its own traditional recipe since 1998. We cure both Organic and Free
Range British pork which is supplied to the multiple retailers and
is available nationally. The ethos of our businesses fits well
together: a care and passion for producing great products.
For more information visit the Duchy web site
duchyoriginals.com
