
Fresh tortillas... mmmm. That was the thought I had ten years ago when I planted field corn my first garden. Back then I didn't even know how far apart to space the plants, let alone understand the process of making fresh masa. It has taken me this long to get around to figuring out the process once and for all.
Pictured here is our new crop of white dent corn, an heirloom variety from the southern U.S. called Hickory King that is/was often used for making hominy. And what follows below is the process that will take you from this (above) to this (below) in about 24 hours.
Nixtamalization is the frightening word for the fairly simple process of cooking corn with alkaline, which chemically softens and dissolves the hull and improves the nutritional content of the corn. The indigenous Americans whose ancestors domesticated it understood this process, but when Europeans "discovered" corn, they ground it like wheat into cornmeal, which yields a completely different and nutritionally inferior product.
The first step is to cook the corn. I followed the recipe from Alton Brown, which calls for 2 cups corn, 6 cups water, and 2 Tbsp cal, or calcium hydroxide. It worked.
This is cal. You can buy it in a Latino grocery store. I bought this at the Ecuador Andino store on Rte. 9 in Hadley. (It's actually a really nice store. You can get all of the standard Mexican stuff and they also have a great selection of cheeses and they even had fresh epazote.)
Mix the cal with the corn and water and put the pot on a medim-low flame. Bring it slowly to a boil. This should take 30-45 minutes. When it boils, turn it off and let it soak overnight in the cooking liquid.
As it cooks, the hulls undergo a visible change and begin to loosen. In this case, they turned yellow.
The next day, pour off the cooking liquid and rinse the corn in several changes of water. In a bowl full of water, rub the corn in your hands to loosen the hull. You can also put it in a slightly abrasive vessel like a mesh strainer and stir it with a wooden spoon. Fill the bowl of corn with water and pour off any pieces of hull that float to the top, then drain. This is your nixtamal. Now it can be ground into masa or used to make hominy or posole stews.
I also nixtamalized some of the corn we got from our grain share from the Pioneer Valley Heritage Grain CSA. This is an heirloom Native American variety called Mandan Bride. It is also a commonly grown variety of Indian corn used for decoration. It is quite lovely with its hulls removed.
Now for the grinding. Unlike grinding corn into cornmeal, to make masa the corn is ground wet, straight into dough, using the retained water from the cooking as the liquid component. Put the corn in the cuisinart and pulse a few times until it resembles a chunky mixture. (Note: do not attempt this in a mini cuisinart. Use the big guns.) Now, flip that switch up and let it grind away for several minutes. Add water as necessary until the dough begins to form. I added about a cup of water, which was probably too much, and my dough came out a little sticky. So use it sparingly.
After about 5 minutes of solid grinding, the masa is done. It is very smooth and can be shaped easily into balls. As I mentioned, my dough was a little too wet, so when I pressed my tortillas, I used a little masa harina (dehydrated masa flour) to get the right moisture level to prevent sticking.
To press the tortillas, cut a gallon size ziplock bag into its two halves. Place a ball of dough on the first sheet, cover with the second sheet and give it a little tap to begin flattening it. Then place the dough in the plastic inside a tortilla press and press until very thin. Alternately you can do it directly on the counter using a heavy cast iron skillet to press the tortillas, like I did. This one is made from the Mandan Bride corn. Pretty!
It takes a little finagling and/or finesse to get the pressed tortilla off the plastic and into your hot dry skillet or comal. I leave that up to you. I used a very fine flexible metal spatula to coax them. Cook them on a very very hot dry pan for 20-30 seconds per side. It is a lot more fun to do with two people.
All in all it's a lot of work. But those tacos sure tasted special. The flavor of the tortillas is simply incomparable. It is sublimely corn-y, as if it were artificially corn-flavored. You just have to try it to know what I'm talking about.