Industrial-Scale Production of Additive-Free Organic Salami Without Nitrite Curing Salt: Process Design and Technological Performance.

Replacing conventional curing agents in fermented sausages is technologically demanding, particularly in organic production, where nitrite curing salts are not permitted. This study validated an industrial-scale process for organic salami manufactured entirely without nitrite curing salt or other additives, and assessed volatile N-nitrosamine formation during domestic-style heating. Twenty production batches were monitored across two consecutive years under standardised industrial conditions. Samples from three batches were analysed for seven volatile N-nitrosamines before and after heating at 200 °C for 12 min and at 230 °C for 15 min by gas chromatography with thermal energy analysis. Fermentation was reproducible, yielding a mean final pH of 5.17 ± 0.18 with no significant year effect. Final water activity remained at or below 0.90 (mean 0.881), confirming dehydration as the decisive hurdle. Residual nitrate and nitrite remained low, and hygiene indicator counts were low; Listeria monocytogenes, Salmonella spp. and Shiga toxin-producing Escherichia coli were absent. All nitrosamines remained below the detection limit in unheated salami and after heating at 200 °C; small increases in N-nitrosodimethylamine, N-nitrosopiperidine and N-nitrosopyrrolidine occurred only under severe heating and remained toxicologically non-critical. For the product and conditions investigated, organic salami can therefore be produced safely and reproducibly at industrial scale without nitrite curing salt.