Castagnaccio – Chestnut Cake

castagnaccio-barolo-wine-toursChestnuts are found throughout Italy, and have been a staple of their cuisine for thousands of years. Fall in the Piedmont region, where we explore on our Barolo Walk and Wine tour, The chestnut was once also called “bread of the poor” and represented an important food for the populations of the Alpine valleys of this region. In mountainous areas of Italy, from Trentino and Alto Adige to Tuscany, chestnuts are one of the few crops that can be grown on steep slopes, as well as produce during colder winter months. In some of these areas, the economy revolved around the chestnut, as people gathered them in the fall and worked throughout the winter to sort, dry and sell them.

view-barbaresco-wine-tours-baroloChestnuts were traditionally dried to preserve them. A small, two story hut was built, and the chestnuts were laid out in the top story; a fire was started in the lower story, under a large stone shield that protected the crop and the building itself from the heat of the fire. The fire was kept going continuously, the heat drying the nuts and the smoke would rid them of the worms that could infest and ruin an entire crop. During colder evenings, entire families would gather in the roasting hut to enjoy the warmth and aroma of roasting nuts.

marroni-custom-bike-tours-italyDried chestnuts can be boiled, or the dried nuts ground up into flour and used in a variety of dishes, such as pasta or baked goods. I’ve been looking to find naturally gluten free options for our clients with dietary restrictions, and chestnut flour is a great option. Here in Italy, I can pick up chestnut flour in my local grocery store, in the US you can find it on line through various gourmet stores.

farina-castagne-barolo-wine-toursCastagnaccio is a chestnut cake with origins in the area around Lucca, Tuscany. The original recipe contains no sugar or sweeteners like honey, just chestnut flour, nuts, raisins and olive oil. It is a bit of an acquired taste. I looked at a couple of recipes designed to be more ‘approachable’ and developed this version. I kept the rosemary flavor of the authentic recipe by infusing a bit of rosemary in the honey wine syrup topping; you can omit if rosemary in your dessert does not appeal.

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Castagnaccio

Makes one 9” cake

2 1/2 cups chestnut flour
1 teaspoon sea salt
1 tablespoon baking powder
1 tablespoon cocoa
2 tablespoons granulated sugar
1/4 cup dark brown sugar
3 eggs
1/4 cup chestnut honey
1/4 cup extra virgin olive oil
3/4 cup dried cherries
1 cup walnuts, toasted and chopped
1/3 cup pine nuts, toasted

For syrup

1/2 cup chestnut honey
1/4 cup vin santo
1 sprig rosemary

Preheat the oven to 300°F.

Sift the dry ingredients – the chestnut flour, salt, baking powder, cocoa and sugars – through a sieve into a large mixing bowl. Whisk to combine.

In a small bowl, whisk together the eggs, honey and olive oil. Pour into the dry ingredients and stir to combine. The batter will be thick and very sticky. Add the cherries and the toasted nuts and mix well.

Brush a little olive oil to coat the inside of a 9” springform pan. Transfer the cake dough to the pan, using damp hands or the back of a spoon to pat the dough out to fill the pan.

Place in the warm oven to bake until done, approximately 20 minutes.

Combine the 1/2 cup chestnut honey and vin santo in a smalll saucepan and bring to a boil. Add the rosemary sprig and simmer for 2 minutes. Remove from heat.

When the cake is done, remove from the oven and immediately brush with some of the honey syrup. Allow to cool, then remove from the springform pan. Brush with a bit more syrup, cut into pieces and serve, drizzled with a bit more syrup. Enjoy with a glass of the Vin Santo.

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Ricotta, Cherry Jam and Balsamic Tart

ricotta-cherry-tart-private-tours-italy I’ve lost count now of how many times I have visited Italy, between hosting our Italiaoutdoors tours and then the on-the-ground research required to discover unique new experiences to share with our guests. My friends and family think I by now have “seen it all”, what more could I possibly discover? But my frequent visits have only really taught me one thing – even if I had a lifetime to devote to this, I would barely scratch the surface. In culinary school I was taught about the 20 regions of Italy, and we covered briefly the cuisine of each. But I’ve discovered that the reality of Italian cuisine is much more complex, with countless specialty products like the Tortona strawberry in Piedmont, or the Bosco grape varietal in Liguria that are only grown in a very small area, and consumed locally. The only way to learn about these is to visit the area itself; travel three towns over and you might well find the majority of locals may not have ever tried, or even heard of these foods.

 tortelli-parma-private-tours-italyA quick example – a trip across the region of Emilia-Romagna to try its famed stuffed pastas would really need include stops in Parma to try the Tortelli Erbette (square ravioli stuffed with ricotta and herbs), then to Modena to enjoy Tortellino in Brodo (small stuffed ‘knots’ stuffed with meats and Parmigiano Reggiano, served in a rich capon broth), then on to Ferrara to try Cappellacci di Zucca (large ‘hat’ shaped knots stuffed with pumpkin and Parmigiano Reggiano, typically served either in a butter and sage sauce, as well as a tomato ragu). And then to Bologna…

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So it was a great pleasure to find in my mailbox an advance copy of Elizabeth Minchilli’s latest book, “Eating My Way Through Italy – Heading Off the Main Roads to Discover the Hidden Treasures of the Italian Table”. I’ve followed Elizabeth’s very informative blog for a couple of years now. Having spent most of her life in Italy, she well knows the complicated and fascinating culinary landscape of Italy. Many cookbook authors covering Italian cuisine generalize by the 20 regions, leaving the reader with the sense that the food in one region is very similar throughout. This simplification is certainly the best way to present what is a very complicated subject in an organized, user-friendly way. But it also hides the enchanting disarray that can only be experienced as you visit the neighborhood kitchens; the traditions of a single village that resulted in a particular dish being served on Easter; the environmental conditions that allow the white asparagus to flourish in the Brenta Valley, but won’t grow in the next valley over; the historical events that led to Tuscan bread to be still made without salt today.

parmegiano-cheese-firebrand-private-tours-italyIn “Eating My Way Through Italy” Elizabeth takes the reader along with her on her culinary explorations, providing a series of engaging stories about her adventures around the tables of Italy. From well-known Italy classics like Parmigiano Reggiano and Acteo Balsamico Tradizionale to very obscure local traditions like Su Filindeu of Sardinia, Elizabeth provides not only a very readable overview of the production process, but also captivates us with a bit of history, as well as the always interesting, often amusing role these foods have played in Italian culture. Definitely a welcome addition to my library, one I will return to again and again for both information as well as inspiration!

balsamic-vinegar-loft-battery-private-tours-italyElizabeth includes some wonderful recipes among her anecdotes. I had just last week posted an article on my visit to a producer of Acteo Balsamico Tradizionale, Medici Ermete in Reggio Emilia. So, equipped with my souvenir bottle of the real stuff, I thought I’d try Elizabeth’s recipe for a tasty Ricotta, Cherry Jam and Balsamic Tart. It was a delicious – and very easy – way to share the special Acteo Balsamico Tradizionale with my friends back here in the US.

I used my favorite sweet pie crust recipe, and replaced the lattice crust with cookie cutouts because I find those a little easier to work with. But the combinations of flavors in tart filling make the dish, and those are all Elizabeth’s!

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Ricotta, Cherry Jam and Balsamic Tart

Makes one 10-inch tart

For the crust

1 cup unsalted butter, at room temperature
Large pinch of kosher salt
1/2 cup granulated sugar
1 large egg, beaten
1 teaspoon finely grated lemon zest
2 cups all-purpose flour

For the filling

1 cup cow’s milk ricotta
1/4 cup granulated sugar
1 cup sour cherry jam
1 tablespoon Aceto Balsamico di Modena
Aceto Balsamico Tradizionale, for drizzling

Make the crust: Place the butter, salt, sugar, egg and lemon zest in a food processor and process until smooth; add the flour, 1/2 cup at a time, pulsing in between each addition until just combined. After the last addition, process until a ball of dough forms, 15 to 30 seconds. Do not overwork.

The dough will be very soft. Divide into two balls, one using 2/3 of the dough, the other 1/3. Place each ball of dough on a sheet of clear plastic wrap. Stretch a second sheet of wrap over the dough and flatten it to a round disc with a thickness of 1/2 inch. Refrigerate for 30 minutes, and not more than an hour.

Preheat the oven to 350°F.

Make the filling: Beat the sugar and ricotta until very smooth. Set aside.

Stir the Aceto Balsamico di Modena into the jam. Set aside.

Line the bottom of a 10-inch tart pan with parchment paper. Roll out the larger disc of the dough between the two sheets of plastic wrap to a round about 12 inches in diameter, slightly larger than your tart pan. Remove the top sheet and invert the dough into the tart pan. Fit it in the pan as well as you can, then remove the top sheet of plastic wrap. Don’t worry if it breaks, the dough is very forgiving. Just patch it together. Trim the top edge.

Spoon the jam filling onto the crust, then carefully spread out the ricotta on top of the jam, using the back of a spoon to smooth it out.

Roll out the remaining dough between the two sheets of plastic wrap to about 1/4″ thick, remove the top sheet. With a cookie cutter or knife, cut small shapes – I used stars, but leaves or whatever you wish. Top the tart with the cut outs. Place the tart on a sheet pan to protect your oven during cooking, as the jam may boil over the tart pan.

Bake the tart in the preheated oven for about 50 minutes, until the ricotta and the cut outs on top are beginning to brown. Let cool a bit, then remove the ring of the tart plan. Allow to cool completely before serving.

When ready to serve, cut and place the slices on individual dessert plates and drizzle with Aceto Balsamico Tradizionale.

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Aceto Balsamico Tradizionale – The Real Deal Balsamic Vinegar

 

balsamic-vinegar-vinegar-barrels-private-tours-italy Balsamic vinegar is one of Italy’s best-known contributions to the culinary world, and is now a basic condiment found in many kitchens here in the US. It is common all over Italy, we find it at every table in the regions we visit on our Italiaoutdoors private Italy tours, but to truly appreciate the “real deal” requires a bit of background. There is a vast difference between the stuff in the $4 bottle of balsamic vinegar found in every grocery store to the authentic Aceto Balsamico Tradizionale, besides the price – the latter goes for 70 euros and up per bottle. My recent food tour of Emilia-Romagna allowed me to learn first-hand how this ancient specialty is produced, and the role it has played in the households of this region over the centuries.

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Aceto Balsamico Tradizionale hails from the Emilia-Romagna provinces of Reggio Emilia and Modena, with its origins dating almost 1000 years ago. The name comes from the Latin Balsamum, meaning a ‘balm’ or a restorative, and it was originally valued for its curative properties. Supposedly, during the plague of 1630, the Duke of Modena carried an open jug of the vinegar in his carriage to ward off the disease.

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Today I am introduced to the production process of Aceto Balsamico Tradizionale by Alessandra Medici of Acetaia Medici Ermete. Medici Ermete is primarily a family run winery, operated by her brothers, producing some wonderful Lambrusco. Alessandra oversees the small Acetaia (the vinegar production), more of a passion than an economic venture – their very small annual production sells out through direct sales.

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We begin with a stop on the ground floor of the barn that houses rows of wine barriques on one side, and smaller barrels on another. This is the first stop in the production process. Aceto Balsamico Tradizionale begins with a single ingredient – grape must – freshly pressed grape juice that contains the skins, seeds, and stems of the fruit. At Medici Ermete it is the local Trebbiano grape that is pressed, and then the must is cooked for 24 hours. After cooking, the mosto cotto, cooked grape must, is transferred to the barriques, where it sits for the next 2 years. Seems like a long time, but we are just getting started.

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Next, we head upstairs to the top floor of the barn. In the farmhouses and estates across Reggio Emilia and Modena where Aceto Balsamico Tradizionale has been produced for centuries, enter their well ventilated attics and you will see one or more series of wooden barrels of increasing size, called a battery. The number of barrels in a battery may vary, but the minimum is 3, and the Aceto Balsamico Tradizionale DOP regulations require at least 7 barrels, and a total aging period of at minimum 12 years. The types of wood used for the barrels varies as well, one may be chestnut, one cherry, one mulberry. Storing in the well-ventilated attic is also crucial, the temperature variations throughout the year, the heat of the summer months alternating with the cold and dry winters, contribute to the development of the flavors.

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Alessandra leads me through the use of the barrels here in the attic. Each year, about 3 liters of vinegar is removed from the smallest of the barrels in each battery, and placed in an even smaller barrel that will go off to be bottled by the Consortium, or used by the family. The smallest barrel is then topped off from the next smallest barrel of the battery, and so on down the line. The sweet, 2 year aged mosto cotto is then used to top off the largest barrel, beginning its slow progress into the wonderful balsamic vinegar – now one may understand why, in Modena, it is said “One generation makes balsamic for the next.”

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Alessandra proudly shows me the many series of barrels owned by her family. For centuries, when a daughter was born, a family would mark the occasion by beginning her battery. This became part of her dowry when she married, and one of the families most prized possessions. I’ve read that saving the oldest barrels in the battery was a family priority during the wartime evacuations of WWI and WWII. Alessandra shares that as her family produces 90% male children, they begin a battery for both genders. She shows me the batteries for her two teenage sons, her sisters, and then leads me to a very old battery off by itself, which belonged to her grandfather and is over 100 years old.

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Our last stop is the tasting room, where I get to sample the three types of Aceto Balsamico Tradizionale she produces. We begin with the Red label, which as the youngest is aged 12 to 20 years. The difference between the “real deal” and the grocery store options is immediately obvious – this is thick, almost syrup like as it is slowly poured into a tasting spoon. It is not sour, as you would expect a vinegar to be, but has a mellow sweet-tartness. The flavor is complex and rich, with notes of dried fruits, fig, molasses, and chocolate, and flavors of wood. The youngest is recommended for serving with grilled and raw vegetables, prosciutto, and other fresh antipasti. Or drizzle a bit over a risotto – do not add during cooking, as this will destroy its flavor.

Next, the silver label, aged 20 to 25 years. Denser, more complex flavors. Great with aged cheeses, Gorgonzola, fresh fruit. Drizzle over ice cream or fruit desserts.

Finally, the Gold label, aged more than 25 years. Serve simply to appreciate its thick and glossy consistency and multi-layered flavor profile – drizzle over 48 month aged Parmigiano-Reggiano cheese or fresh ripe strawberries. A small spoonful all alone at the end of a dinner is believed to assist in digestion, harking back to its ancient reputation as a curative balm.

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So by now you are no doubt wondering – what am I buying in the grocery store?

Balsamic Vinegar

You can find very inexpensive “Balsamic Vinegar” in every grocery store. These products are typically wine vinegar to which coloring, sugar and flavoring has been added to mimic the texture and flavor of balsamic at a fraction of the price. Some may actually come from Italy, but that fact is no guarantee of higher quality.

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Aceto Balsamico di Modena IGP

The first balsamic vinegars sold in the US arrived in 1977, sold through gourmet stores like Williams-Sonoma. The demand quickly outstripped supply. This surge in popularity led to a rise in imitations, which led to the introduction of a protected designation (DOP) for the true Aceto Balsamico Tradizionale to differentiate the real thing from the inexpensive knock-offs. At the same time, the production Consortium of Modena began to look for a way to capitalize on the popularity of balsamic vinegar with a product that offered some measure of quality at a more accessible price point.

The IGP designation, defined by the European Union in 2009, was their opportunity. This offered a framework where the local producers could create a product under the Modena name that could not be replicated elsewhere, but produced in much higher quantities and at a much lower price point than the Aceto Balsamico Tradizionale DOP. Aceto Balsamico di Modena IGP is made from grape varietals typical of Modena, though the grapes can be from anywhere and only need to be processed in Modena. The vinegar is cooked in large pressurized vats and aged for at least two months in large wooden barrels. There is no fermentation stage. Balsamic Vinegar of Modena IGP must contain enough wine vinegar to meet an acidity level of at least 6%, and can contain up to 50% wine vinegar. It may contain thickening agents, caramel, or other colorants to make it more like real balsamic. They can range in price from a few dollars to $50, depending upon the ingredients and aging.

Look for Aceto Balsamico di Modena IGP on the label, as well as the EU IGP logo. The IGP and DOP logos are shown below. Higher quality versions will usually have a thicker consistency and fewer ingredients, with grape must at the top of the list.

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Aceto Balsamico Tradizionale DOP

These you won’t find in your grocery store, and might be under lock and key at your gourmet store. The small bottles are packaged in sturdy boxes, the Consortium bottles the product and requires very distinctive packaging and specific labeling. The two options are shown below, the first the Aceto Balsamico Tradizionale di Modena DOP and then the Aceto Balsamico Tradizionale DOP di Reggio Emilia.

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To learn more about Medici Ermete, visit them on line at the Medici Ermete web site. Thanks again to Food Valley Tours for connecting me with Alessandra Medici.

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Prosciutto di Parma – the King of Hams

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The region of Emilia-Romagna is arguably one of Italy’s best for gourmets, producing some of the most recognizable foods of Italy, from Parmigiano-Reggiano cheese to Prosciutto di Parma to authentic Balsamic Vinegar. So how to follow the King of Cheeses? With the King of Hams, of course – so off to visit a producer of Prosciutto di Parma ham, CONTI. During our private walking tours of Italy, I introduce the local gourmet products to our guests. So my free days are spent experiencing and educating myself on the wonderful authentic foods and wines of Italy. Many thanks to Daniela Lanfredi and Food Valley Tours for showing me the area.

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Castello Torrechiara in Langhirano

As with Parmigiano-Reggiano cheese that I wrote about in my last article, the high quality of the Prosciutto di Parma is inexorably connected with it’s place of origin. For Prosciutto di Parma, the epicenter is the town of Langhirano, about 20km south of Parma on the Parma River. Daniela describes the town as consisting of producers of Prosciutto di Parma and the homes of the plant workers as she points out the large rectangular windows that are found on the upper floors of most of the multi-story buildings in town, which identify the drying lofts. Here in this river valley the air is dry with aromatic breezes from the Apennine Mountains, which residents as far back as the Romans recognized created the perfect conditions for the natural curing of hams. In 100 BC, Cato the “Censor” mentioned the extraordinary flavor of the air cured ham made around the town of Parma in Italy; the legs were left to dry, greased with a little oil and could age without spoiling.

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Today the Consortium of Prosciutto di Parma tightly controls the production process to ensure the quality and authenticity of the product. It begins with the farms that produce the pigs. They must be certified by the Consortium, and abide by a myriad regulations. Parma pigs must be Large White, Landrance or Duroc breeds, born and raised by authorized breeding farms located in 10 regions of central-northern Italy. Their diet is a specially regulated blend of grains, cereals and whey from Parmigiano-Reggiano cheese production ensuring a heavy pig with a moderate daily growth in an excellent state of health.

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The legs arrive at the plant where they are logged and tagged for tracking purposes, then they are introduced into a specialized machine with a series of rollers that massage each leg. Under the supervision of a highly trained maestro salatore, or salt master, each leg is then salted just the right amount – the pig skin is covered with humid sea salt, while the muscular parts are covered with dry salt. They are then placed on their sides in a refrigerated space for a week to rest.

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After the week, they are removed from the cooler and the process of massage and salting is repeated. Then back to refrigerated rooms where they have the salt brushed off after another 10 days or so, and then continue to rest for about 100 days in total. This first period of massaging and salting is the crucial point of the production process, and a master with long experience in the art of making Prosciutto oversees the activity closely.

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At the end of the 3 months, the hams are now hung by a rope on special metal racks. I look up, and note the ceiling of the production facility is covered with metal tracks that allow the workers to now move the heavy racks of hanging hams throughout the facility. The first stop – a washing station where the exterior is washed. Then the racks are moved downstairs to the first stage in the aging process, the initial curing.

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Here the hams are hung in well ventilated rooms with large windows that are opened when the outside temperature and humidity are favorable; this allows for a constant and gradual drying of the hams. At the end of this phase, which lasts about another three or so months, the exposed surface of the meat has dried and hardened.

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After this initial curing period, each ham is smeared with a mixture of rice flour, salt, seasonings and pork fat called ‘sugna’ to stop it from drying too quickly for the remainder of its maturation. This ‘sugna’ is kept warm under a heat lamp so it spreads easily, and it’s precise mix of seasonings and salt each producer keeps as a closely guarded secret. The exposed surfaces of the hams are softened with this paste, more on the exposed meat surfaces, less on the parts of the leg that are covered with fat. Rice flour is used today so the hams are gluten-free.

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After the ‘sugna’ has been applied, the hams are transferred to the cellars, rooms with less air and light, where they hang on racks until the curing is completed. By law Parma Ham is cured at least 1 year (starting from date of first salting), and some may be cured as long as 3 years. Daniela says that most locals prefer hams that have aged 16 months or more.

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After 12 months of aging, each ham is checked by an inspector from the Consortium. The inspection includes a traditional “smell” test, where the inspector pierces each ham in several spots with a long needle made from horse bone. Horse bone has a unique porosity that absorbs the aroma of the ham, allowing the inspector to assess its quality and maturity. Once approved, the ham receives the authentic five-point Ducal Crown firebrand. Occasionally this firebrand is altered every so slightly, but in a way only known to a very few at the Consortium, to thwart counterfeiters.

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The Ducal Crown seal is in honor of Marie Louise, the second wife of Napoleon. She was an Austrian Archduchess who was married to Napoleon in 1810, as he was eager to marry a member of one of Europe’s leading royal houses to cement his hold on the Empire. She was Empress of the French from 1810-1814, and bore Napoleon a son. After Napoleon’s exile, Marie Louise was sent off and out of the way to reign as Duchess of Parma, which she did until her death in 1847. She performed many good works during her reign, and was much loved by the residents.

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These time-honored methods and attention to detail produce the “King of Hams” right along side the “King of Cheeses”. The process is 100% natural: no additives, just sea salt, air, and time. The result is a perfect balance between sweet and saltiness; the aroma is fragrant, the color is pink in the lean part and white in the fat. Sweet and delicate in flavor, fruity but gentle.

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The best way to enjoy prosciutto is sliced paper thin with a bit of fat around the edge, which carries much of its distinct flavor. The fat is part of what makes Prosciutto di Parma unique; never ask for it to be removed. Prosciutto di Parma is perfect with melon, with fresh cheeses like mozzarella and burrata, and with breadsticks. It is also an essential ingredient in the favorite Parma tortellini. Look for it at gourmet stores in the US, and I encourage you to taste it side by side with a prosciutto from your grocery deli – you’ll see they are not the same thing at all!

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Parmigiano-Reggiano – The King of Cheeses

parmegiano-cheese-firebrand-private-tours-italyOne of the most recognized food products of Italy is the internationally acclaimed Pamiggiano-Reggiano cheese. During our private walking tours of Italy, I introduce the local gourmet products to our guests. In Italy, the identity of these amazing products is entwined – physically, historically, culturally- with their place of origin. Recently I visited the lovely city of Parma in the region of Emilia-Romagna to discover first-hand what goes into producing this world-renowned cheese. I look forward to bring guests on future custom tours to appreciate what goes into the production process.

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My day begins at 8:30 when my tour guide, Daniela Lanfredi meets me at my hotel. I was connected with Daniela via the great people at Food Valley Tours. I typically set up my own visits to the producers we go to see, but these producers strictly regulate their visitors and you must be accompanied by a guide certified by the production consortium.

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Daniela directs as we drive to Consorzio Produttori Latte Baganzolino, just north of Parma. It’s location is quite close to the city center, but it is encircled by large fields that Daniela assures me will be green with alfalfa in a few weeks. It is a large industrial building, with several barns behind it. These barns are home to the cows, as well as pigs, the reason for the pig’s presence becomes clear later. Today, over 80% of the production of Parmigiano-Reggiano cheese is done in these larger cooperatives, only 20% in smaller, family owned farms. But there still is a “family” that is intimately involved in overseeing the process, as the head cheesemaker and his family live on site. A couple of small children and the family dog greet us as we arrive.

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The first order of business is suiting up. Daniela dons her official tour guide lab jacket, then we both cover up with hair nets, plastic coats and shoe coverings – I feel like I’m on a episode of CSI. We get it done more quickly than most groups, as there is only me and I don’t feel the desire to document my new wardrobe with selfies.

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The main floor of the production facility has two levels, separated by a railing. The lower level contains a row of large copper-lined vats, which are currently filled with liquid and steaming. On the upper level is a series of long, flat, rectangular metal troughs with hole and stopper at the end closest to the copper vats.

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The process begins with the evening milking. The milk is brought immediately from the cows to the metal troughs on the upper level, where it spends the night. One of the key contributors to the esteemed distinctive flavor of Parmigiano-Reggiano cheese is that the milk used is never refrigerated. Refrigeration is believed to compromise the flavor. So the cows must be located at the production facility, and their milk processed immediately. During the night, as the milk rests in the trough, the cream rises to the top. In the morning, the cream is skimmed off, and sent to another plant where it is made into butter. The skimmed milk is then transferred into the copper vats, each filled about halfway.

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Next, the morning milking arrives, and goes directly into the copper vats, this milk is not skimmed. The cheesemaker then visits the vats and adds just the right amount of rennet to each. Rennet is an enzyme that curdles the casein in milk, separating the curds from the whey. These curds will be pressed into the cheese, the whey has two future uses: some is made into fresh ricotta cheese, the rest goes back to the barns where it is fed to the pigs. This diet of Parmigiano-Reggiano whey contributes to the flavor of another product that Parma is equally famous for, Prosciutto di Parma.

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Daniela points out to me the traditional large whisk like tools that are used to manually break up the curds into smaller granules, called a “spino”. The coagulated milk is gently cooked in these heated vats while the curd particles slowly sink to the bottom and begin to stick together, conforming to the bell-shaped bottom of the vat. This is the current state of the production process as we begin our tour.

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The cheesemaker soon enters and makes his next round, inspecting each copper vat to ensure the curds have settled out. Once he gives the green light, two to three workers descend upon the vat to extract the curds. Using large muslin cloth sheets, two workers carefully lift and roll the curds out of the vats, manipulating them into large rounded cylinders. The muslin sheets containing the rounds are used as a sling, and the rounds are hung from a wooden stick over the trough for a bit before being sliced in half to form two large rounds that will become two large wheels of Parmigiano-Reggiano cheese. Each round is then transferred into a plastic mold that will help keep its shape as the rounds begin to dry. At this point, each wheel is assigned a unique QVC code allowing the producer to trace back each wheel to the cows it came from. In this manner, any issues that turn up in the production process can be diagnosed.

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Each round is carefully wrapped up in a sheet of muslin and left in the plastic mold with a weight on top to encourage any remaining whey to drain. These rounds are now moved to a smaller room on a lower floor where they spend the night. They are turned occasionally, and after a few hours a special marking band is wrapped around each wheel. This band engraves the entire exterior with the signature markings that indicate an authentic Parmigiano-Reggiano cheese. These markings include the month and year of production, the dairy registration number and the unmistakable dotted inscription PARMIGIANO-REGGIANO. These marking bands are so tightly controlled that even the official Museum of Parmigiano-Reggiano cheese does not have one.

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After a couple of days of resting, the rounds removed from the molds and are immersed in a sea salt brine solution. Here the rounds rest for about a month, being turned daily as the sea salt slowly permeates the cheese. This is the last stage of the production process, the cheeses now move on to the maturation rooms.

 

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In the large, temperature controlled aging rooms the cheese wheels are laid out in long rows on very impressive shelves that extend probably 30 feet high. The cheeses rest on wooden shelves as the outside of each cheese dries, forming a natural rind. Each cheese is turned and brushed regularly, a specialized machine was developed to reach the high shelves to perform this arduous task; the minimum weight of each wheel is 30kg (just under 70 pounds). The cheeses must rest here for a minimum of 12 months, but can be aged as long as 48 months.

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Inspectors from the Consortium visit regularly to examine each cheese. The inspector removes a cheese from the shelf, turns it on its side and places it on stool, then taps it all over. He listens for consistency in the sound of the taps; if he hears hollow sounds, or inconsistent sounds it is an indication of a bubble or some other quality issue with the cheese. When a cheese passes inspection, an official mark is fire-branded onto the cheese indicating it meets the requirements of the Protected Designation of Origin. All identifying marks and the dotted inscriptions are removed from any cheeses which do not meet the PDO requirements. These are sold as ‘seconds’, referred to as “white” cheeses as the golden rind has been removed.

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Leaving the aging rooms, we head to the store for our final stop: a tasting of the ultimate product. On our way, Daniela points out a map showing the production area of Parmigiano-Reggiano cheese. Production is restricted to the provinces of Parma, Reggio Emilia, Modena, Bologna, to the west of the Reno River, and Mantua, to the east of the Po River. The production of cheese in this area dates back to the 1200s, when the Benedictine monks here made cheeses in this style to preserve milk. Prior to refrigeration, products like cheeses or prosciutto were made to preserve food for later consumption. The thrifty monks used every by-product of the production process – cream was made into butter, whey into fresh ricotta and fed to the pigs, the casein curds preserved as cheese – and this long tradition continues today.

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The final stop is a tasting of Parmigiano-Reggiano cheeses, from young 12 months of aging to 48 months. Visually you can see differences between the younger and more mature cheeses, the older cheeses are harder, and as the cheeses age the proteins continue to break down, producing amino acid crystals which are noticeably more prevalent in the older cheeses.

A 12 to 18-month old Parmigiano-Reggiano has a more delicate flavor, and is wonderful as part of an antipasti, accompanied by raw vegetables, fresh fruit, or paired with a mild fruit or fig jam. A 24-month old Parmigiano-Reggiano is best grated on traditional Italian pasta dishes or soups, or served with nuts and dried fruit. Both pair well with white wines or lighter reds.

A 26 to 30-month old Parmigiano-Reggiano would be used to enhance flavor of main courses, served as shavings on meat with a drizzle of extra-virgin olive oil. This longer maturation Parmigiano-Reggiano can be served with fuller bodied red wines. The ultimate indulgence is to pair the most exclusive 48 month aged with a few drops of the thick, luscious Traditional Balsamic Vinegar from Modena or Reggio Emilia.

I have always appreciated the distinctive flavor of an authentic Parmigiano-Reggiano cheese, But after learning about it’s long history and role in the community, seeing first hand the care and passion that the producers put into their product, and their close attention to quality and detail, I can say the respect is has among gourmets is well deserved. As I savor one last bite of the 48 month aged cheese, I agree it is truly the “King of Cheeses”.

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