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The other common base for dashi is dried bonito fish (katsuo-bushi). When you see it you might not believe it is seafood, and this is even harder to believe when you bang two pieces together—they make a clear, high-pitched sound like wooden clappers. Katsuo-bushi is known as the world's hardest food. To make the dashi, first shave off thin flakes with a plane specially made for the job. Drop the shavings in boiling water, turn off the heat right away, let the flakes sit in the water for a while, and then remove them. Or you could drop them in the water just before it boils, and take them out as soon as it does. In either case, the result is a stock called ichi-ban dashi (“number-one stock”). This dashi is great for clear soups. The wet shavings can be reheated in water to extract more nutrients and flavor. This ni-ban dashi (“number-two stock”) is used for stews, miso soup and many other dishes. Chefs prefer to shave off flakes just before using them, but today it is common to buy packaged shavings. The wholesaler Nakano frowns on the easy way: “To get the best taste and fragrance you should shave off the flakes yourself from a bonito block. And the bonito should be prepared properly. That's how to get the authentic taste.”
Nakano's demand for authenticity is met by thekatsuo-bushi maker Kubo Norihide in Makurazaki, Kagoshima Prefecture. The city produces morekatsuo-bushi than anywhere else in Japan. Kubo's company has about 10 employees, and they are on the job soon after 6 a.m. The first step is to clean the fish and cut it into large pieces. The pieces are arranged neatly in sieves, then lowered into water that is kept at the right temperature—about 90°C—to prevent the fish from developing cracks. After simmering for some time, the fish comes out of the water, any remaining bones are removed, and the pieces are trimmed to form blocks. Next, the blocks are smoked over a smoldering wood fire, allowed to cool at air temperature, then smoked and cooled again several more times. At this stage the product is called ara-bushi. Mostara-bushi is flaked, packaged and sold as ready-to-use flakes, but to make authentic dashi a few more steps are needed. The ara-bushi should be dried in the sun, the natural tars shaved off the surface, and the blocks reshaped nicely. At this stage the blocks are called hadaka-bushi. Now it is time to cure the blocks with a mold. The dried hadaka-bushi is placed in a room with temperature and humidity controls until aspergillus mold develops on it. Next comes another bout of sun drying. Then the mold is scraped off, the fish goes back into the curing room, and then it is sun-dried again. This process is repeated about four times. The final result is authentic hon-bushi.
The mold draws moisture slowly but surely from the fish, giving it the dry, hard finish it is famous for. The mold also breaks down fatty substances in the fish and builds up amino acids to give the final product extra flavor. This hon-bushi manufacturing process is complicated and repetitive, and takes about six months. For someone who puts productivity first the process makes little financial sense. But Kubo would disagree: “They sell cheap katsuo-bushi, but we would rather keep making it the traditional way—after all, the real thing tastes better.”   |
