Bonewerks uses fresh bones in the process of producing our Glaces and Demi Glaces. If fresh bones are utilized in the US, USDA inspection is required. This involves rigorous daily inspections and stringent label statement requirements. Conversely, if a company only uses extracts and powders in the production of their product, they do not meet USDA standards and are unable to boast this higher qualification. Bonewerks is also a HACCP company whose product falls in the Non-Shelf Stable/Frozen Food category. This is the safest category in the food industry. Shelf stability is not possible with natural stock reductions because the maneuvers required to balance pH and the addition of preservatives needed to make it shelf stable radically change the matrix of true stock reductions.
In comparison, broths or powdered extracts and water do not require USDA regulation (they receive FDA certification instead). Powdered extracts are the byproduct of the flavor industry. They are usually produced from secondary scraps and trimmings from mechanically separated beef and chicken bones not suitable for human consumption, which are then steamed and dried into a rendered powder form. In addition to these products being of lower quality, companies that utilize these rendered components purchase whatever is available on the market, and thus, there are no controls of consistency.
Ingredients and Labels Declaration: Bonewerks utilizes only fresh bones and fresh Mire Poix (California carrots, celery and onion, fresh Italian curly parsley stems without leaf, and fresh bay leaves) to produce our Glace and Demi Glace product lines. You will never see “Natural Flavor” listed on a Bonewerks ingredient declaration.
Batches of Glace de Veau take over 24 hours hours to produce. This is a continual operation (6 days a week, 24 hours a day) browning in excess of 150,000 lbs. per week. Simmering and reduction times for other Glace products vary by species.
Bonewerks utilizes European ovens designed specifically for our needs. Each of our six ovens holds 400 lbs of bones weighed onto stainless steel pans. Our ovens pick up the racks and rotate the bones for consistent browning—24 hours a day.
We have stringent specifications and deal direct for our needs. For example, we use #1 quality peeled California carrots, celery diced with no leaf allowed, onions diced with no skin, parsley stems with no leaf and only fresh bay leaves year round. Leaves from celery or parsley and onion skin can add bitterness. This also happens when chefs use trimmings in their own batches of stocks, which leads to flavor variance at the kitchen level.
Purity. Consistency. Time. Labor and energy savings. Ease of use. WOW factor. The list goes on.
Product Consistency key points: (See “The New Math” in Resources)
- Our bones are roasted in our oven systems with the same volume on each sheet pan.
- All of our custom kettles are match-calibrated, live steam kettles.
- All batches are blended in our custom reducing kettles.
- Our mire poix is the same fresh product day in and day out—no scraps.
- All of our products are open-kettle skimmed to ensure clarity.
- Our kettle temperatures are monitored and documented continually throughout the simmering and reducing process.
- Our cooling and blast freezing methods are monitored and documented under USDA HACCP procedures.
- We have a state-of-the-art water filtration system which eliminates water quality variance.
- Bonewerks utilizes a refractometer system accurately measuring reductions of our Glaces by measuring the natural levels of sugars from the mire poix and other indicators.
- All glaces are portioned, flash frozen, and vacuum packed in a resealable gold foil pouch to eliminate light and flavor transfer.
Pricing Consistency key points: (See “The New Math“):
- Bonewerks has locked in pricing contracts for its bones with virtually all major packers of bones in the US.
- With no water needed, you will not experience water pricing variances.
- You will also not have to deal with tempering and breaking frozen bones, stocks that are simmered too hard or not hard enough, product not being skimmed enough, burnt bones, scorched batches and inconsistent chilling leading to questionable food safety.
Chefs should realize cost savings alone of no less than 20%. This is what Bonewerks does. Since we do not have the enormous everyday pressures of running a commercial kitchen, we are able to focus fully on creating this consistent, efficient product. Bonewerks is able to pass its own savings along to its consumers by utilizing large volumes, strong buying power and central location in Wisconsin—the heart of veal country.
Use the following cost analysis to determine how much money Bonewerks’ line would save you in your kitchen. The following table was prepared using national averages for chefs preparing Glace de Veau and Demi Glace de Veau using only reduction to thicken.
|Glace de Veau|
|Special-fed Veal Bones||100 lbs.||$1.50/lb.||$150.00|
|Mire Poix||12 lbs.||$1.00/lb.||$12.00|
|Tomato Paste||2.5 lbs.||$1.20/lb.||$3.00|
|Total batch cost:||$169.00|
|Total finished yield:||10 lbs.|
|Price for product alone:||$16.90/lb.|
|Demi Glace de Veau Elite|
|Special-fed Veal Bones||100 lbs.||$1.50/lb.||$150.00|
|Mire Poix||16 lbs.||$1.00/lb.||$16.00|
|Tomato Paste||2.5 lbs.||$1.20/lb.||$3.00|
|Total batch cost:||$173.25|
|Total finished yield:||11.75 lbs.|
|Price for product alone:||$14.74/lb.|
For your final price, add the following production costs;
|Labor (4 hours minimum)|
|Waste disposal (spent bones & mire poix)|
|Energy (browning, simmering, clean up)|
|GRAND TOTAL $|
Compare this do-it-yourself price to the cost of using Bonewerks.
He will answer: Radical bone prices; varieties of bones available; dealing with frozen bones (tempering, breaking apart on floor); browning or burning bones; having enough vegetable scraps (aka garbage kettle); monitoring simmering and reductions; having the same trained person produce the same finished product day in and day out.
Bonewerks is your grunt worker. We roast, simmer, filter, and reduce into Glace and Demi Glace. The true creative expression of your sauces begins at your stock reduction. We simply provide the natural stock reductions for you.
Yes, that is the second best smell in the world, next to money (savings).
Bonewerks agrees that you should continue teaching the next generation of chefs how to do this process properly, but now you have the opportunity to do this every few weeks or at your own discretion rather than being forced to do it daily. Now you can focus on the true art of foundations. Furthermore, you will be providing further education of the fundamentals of cooking by showing students the savings of time, energy, labor and consistency while lowering food costs and improving quality.
We suggest that you play. Chefs use anywhere from 1/4 oz. to 3/4 oz. of Glace per serving. We recommend starting with a 1/2 oz. for your ala minute pan sauces. The Demi Glaces can be used up to 2 oz. per serving.
Treat the Demi Elite as the Mother Sauce that it is: You can produce creative small sauces with it in minutes. Remember that Demi Elite is an unthickened version of Demi Glace with no fat or starch (gluten). Lifting the sauce with butter or cream is essential at the end. Alternatively, you can utilize the already reduced and seasoned Demi Classics and serve as-is.
Yes. Broth ratios are approximately 1 part Glace to 2 parts water (up to 7 parts, start at 2 and work your way up to your preferred dilution ratio). Remember, no salt is used in our products, so consider adding some kosher or sea salt to bring out the flavor.
If I use stocks for my pan sauces and change to your Glace as my foundation, how will this affect my line work?
The value of the Glaces is perfect for this. Simply portion the desired amount of Glace (start with 1/2 oz. or 32 pieces per bar) with a knife, then toss the cube in during your deglaze wine/reductions to melt and marry with the other flavors. Keep the rest of your recipe the same. This will save you valuable time compared to using a stock on your line.
I am currently using a shelf stable 4-to-1 product that I have to add water to. What would I do to change over to the Demi Glace Classic?
There are many advantages to switching. You will never again need to depend on your line personnel to weigh water and boil out the extract residuals. You will not need to be concerned about your water source at your property or multiple properties affecting your sauce flavors. You will not experience different line chefs adding water at a ratio of 3:1 vs 4:1 or adding other ingredients to build. You need not worry about cooling time, how much to make ahead of time or have additional pots to wash afterwards. Bonewerks Classic Demis do not contain allergens such as gluten, dairy or added MSG. The Bonewerks line of products is ready immediately and can be used as is without further measurements.
With our mission to provide time savings with quality excellence, it was a natural evolution for Bonewerks to produce our fully prepared Sous Vide Entrees (boil in a bag) side by side with our natural Glace products. Usually you would never have your butcher produce your stocks, but at Bonewerks this is our specialty and is all that we do. We don’t rub raw shanks with caramel color or add raw product. We take the time to season and brown our entrees naturally with our specialty ovens. All of our Shanks come with 3 oz. of our Demi Glace, which is infused right to the bone during our cooking processes. The Demi Glace marries with the natural juices of the shanks and can stand alone. Or, you can add a wide variety of compounded butters to the shank and sauce after warming to put your own signature on it.
- Tempered entrees (one large portion per bag) take from 10-17 minutes in the steamer or boiling water to be ready to plate.
- The entrees can be held for 1-1/2 hours in the bag, which is perfect for banquets.
- All of our shanks are sized for consistent plate presentations. Your entrees will not break apart nor will you lose any portions as you do in an open pan braise (up to 42% shrink when you braise your own!).
- All of our shanks are volcano style (Frenched effect) and stand upright for height and presentation. When utilizing a dome, the shank can be laid over, or stand up at table side.
On our shank line, think gross profit margin. You can expect to easily put $10.00 in your pocket on every one of these portions. You can put these on your menu with confidence, never running out of inventory or having leftovers, which is very difficult if you braise your own.