Sowing & harvesting
Before we plant our corn fields in Rothenklempenow, Mecklenburg Vorpommern, we have to make the most important decision: Which corn varieties suit us and which partners do we want to work with? We choose the reliable seed-resistant varieties. Sure, they don’t produce as much mass as their hybrid relatives, but they are more sustainable and ecological. Dark maize always needs an extra portion of sun, which unfortunately makes it a little more difficult here next to our tortilleria.
The partnerships with our farmers are also an important part of our success. The close exchange with them not only enriches the process, but also strengthens our relationship with the people who support us with their expertise.
Nixtamalization
In nixtamalization, the whole grain of corn is boiled in water with calcium hydroxide (limestone) and left to steep. This removes the outer husk (which otherwise tends to get stuck between the teeth) and at the same time breaks down protein chains, making more nutrients available to the body. Thanks to the added calcium, our tortillas are not only flexible and durable, but above all incredibly delicious.
This is where the corn is processed into dough (masa). To do this, we have to grind the volcanic stones correctly and add the exact amount of water. This is the only way to create the incomparable masa that makes our products so special.
Baked with fire
The tortillas are baked on our comales, which are cast-iron plates over an open fire. This produces them in different sizes and thicknesses.
As soon as everything is perfectly set up and preheated, the tortillas are ready to be baked. Each one is carefully checked by us before it goes into the oven. And even afterwards, two more employees are always standing by to check that each tortilla meets the highest quality standards. Only the best make it into the packaging, while the rest are used for other delicious products.
Into the bag
Once the tortillas have cooled down a little, they are carefully stacked by hand, weighed, packaged and vacuum-sealed to preserve their freshness. Of course, everything is checked in detail to ensure that every product is perfect in the end.
