Have you noticed that the packages of cold cuts you get at the store seem to have gotten smaller while the prices keep going up? You aren’t alone, and the reality is that things are probably going to get more expensive before it gets better. If your family is like ours, cold cuts for sandwiches are practically a necessary meal item. When you buy pre-sliced sandwich meat, you don’t always know what is in it, how it was made, or even if it will taste good.
Making your own cold cuts is the best way to make sure your family eats the tastiest and healthiest ones. It’s easier than you might think and you’ll get the opportunity to create unique and interesting flavors. The trickiest part of making smoked chicken cold cuts is preventing the chicken breast from drying out too much when you smoke it. We will explain our process for making cold cuts and give you some suggestions for flavors so you can make the most delicious sandwiches you’ve ever had.
Ever notice how the packages of deli meat you buy at the store seem to get smaller while the prices keep going up? Yeah, me too. I make sandwiches for my family almost every day, and I’ve been annoyed by how much they cost and what’s in store-bought cold cuts. That’s why I started making my own deli meat from chicken at home. It’s really changed things!
You can save money and have full control over what goes into your food by making your own chicken deli meat. Plus, you can add any flavor you want! This guide will show you my easy method for making healthy chicken cold cuts that will make your sandwiches taste better than anything from the deli counter.
What You’ll Need
Before we dive in let’s gather our supplies
- 4-6 boneless, skinless chicken breasts
- 1/4 cup coarse salt
- 4 cups warm water
- Your favorite seasonings (I’ll share mine below)
- A meat slicer (optional but helpful)
- Pink butcher paper for storage
For equipment, I’ve been using a compact 7. 5-inch meat slicer that’s affordable and easy to clean. You can use a sharp knife instead if you want to, but a slicer helps you get the thin, even slices we’re used to from the deli.
The Secret to Juicy Chicken Deli Meat
The hardest part of making chicken cold cuts is making sure the meat doesn’t dry out while it’s cooking. When you smoke or slow-cook chicken, the breast can get very dry. To fix this, use a wet brine.
Creating the Perfect Wet Brine
A wet brine is super-simple but makes all the difference. Here’s my basic recipe:
- 1/4 cup coarse salt
- 4 cups warm water
This creates approximately a 6% salt solution, which food scientists consider optimal. The brine works by allowing the chicken to absorb moisture before cooking, helping it stay juicy throughout the smoking process.
Mix the salt with warm water until it dissolves completely, then let it cool to room temperature before adding your chicken. Make sure the chicken breasts are fully submerged – you can use a plate to weigh them down if needed.
Brining Time: Don’t Overdo It!
This is important! While brining improves juiciness, too much time in the brine can make your chicken overly salty. For deli meat, I recommend:
- Minimum: 30 minutes
- Maximum: 2 hours
I usually stick to 30 minutes for consistent results. After brining, remove the chicken and let it drip dry on a rack in the refrigerator for a few hours. This step is crucial for texture development.
Adding Flavor to Your Chicken Deli Meat
When it comes to flavoring, we have two main opportunities: the brine and the dry rub.
Brine Flavoring (Optional)
While you can add herbs and spices to your brine, I usually skip this step. Why? Because the flavor molecules are too large to penetrate deep into the meat – they mostly just flavor the surface. If you do want to flavor your brine, consider replacing some of the salt with a seasoning blend.
The Dry Rub: Where Flavor Happens
After the chicken has drained in the refrigerator, it’s time to add a dry rub. This is where the magic happens! Since the chicken is already salted from the brine, I recommend using herbs and spices without additional salt to avoid an overly salty result.
My favorite dry rub combo includes:
- 2-3 tbsp ground black pepper
- 1-2 tbsp garlic powder
- 1 tsp crushed red pepper flakes
- 1 tbsp mild seasoning blend
Feel free to experiment with herbs like rosemary, thyme, oregano, or chives. You might also try smoked paprika, onion powder, or dried herbs for different flavor profiles.
Apply the dry rub generously while your smoker preheats.
Smoking the Chicken
Now for the fun part – smoking your chicken breasts to create that delicious deli meat flavor!
Temperature Settings
No matter what type of smoker you’re using, you want to maintain a consistent temperature:
- Target temperature: 225°F (107°C)
- If using a charcoal smoker, start at about 250°F and then stabilize at 225°F
Wood Choice Matters
Different woods create different flavor profiles:
- Hickory: Classic smoky flavor
- Apple: Milder, slightly sweet smoke
- Cherry: Sweet and fruity notes
I prefer a mix of hickory and apple wood chunks for chicken deli meat. Add wood chunks every 30-45 minutes for a deeper smoky flavor.
Cooking Time
This is critical – don’t overcook your chicken or it’ll dry out despite the brining!
- Typical smoking time: 1 to 1.5 hours
- Remove when internal temperature reaches 160°F (71°C)
Use a good meat thermometer to monitor the temperature carefully. Once you remove the chicken, it will continue cooking slightly during the rest period.
Resting Period
After smoking, place the chicken breasts in a bowl or wrap them in foil to rest for about 15 minutes. During this time, the internal temperature will rise to 165°F (74°C), which is the safe temperature for chicken.
Next, place the chicken in the refrigerator to cool completely – usually 3-4 hours or overnight. This cooling period is essential for achieving the right texture for slicing.
Slicing Your Homemade Deli Meat
Once your chicken is completely cooled, it’s time to slice it into thin, deli-style pieces.
Using a Meat Slicer
If you have a meat slicer:
- Clean all parts thoroughly
- Apply a light coat of vegetable oil to the slide rod and plate for smooth operation
- Place the chicken breast flat against the plate
- Use the toothed guard to hold it in place
- Start slicing from the “top” side (where the skin would be)
- Begin with thin slices, adjusting as needed for consistency
Slicing by Hand
Don’t have a slicer? No problem! Use these tips:
- Make sure your knife is extremely sharp
- Partially freeze the chicken (about 30 minutes) to make it firmer and easier to slice
- Use long, smooth strokes
- Try to maintain consistent thickness
While hand-slicing won’t give you the paper-thin results of a slicer, you can still achieve nice, sandwich-ready slices with practice.
Storing Your Homemade Chicken Deli Meat
Proper storage ensures your chicken deli meat stays fresh and delicious:
- Wrap the sliced chicken in pink butcher paper (my preference) or parchment paper
- Store in the refrigerator
- Use within 5-7 days for best quality
Unlike store-bought deli meats loaded with preservatives, homemade versions have a shorter shelf life – but the superior taste is worth the trade-off!
Turning Your Deli Meat into Amazing Sandwiches
Now for the best part – enjoying your homemade deli meat! Here’s my favorite chicken deli meat sandwich recipe:
Ultimate Chicken Deli Sandwich
Ingredients (all to taste):
- Your homemade chicken deli meat
- Mayonnaise
- Stone-ground mustard or Dijon
- Sliced tomato (heirloom varieties work best)
- Lettuce (green leaf or iceberg)
- Sprouts (easy to grow yourself!)
- Optional: several slices of bacon
- Brioche buns or your favorite bread
Assembly:
- Spread mayo and mustard on the bread
- Layer thinly sliced chicken deli meat
- Add lettuce, tomato, and a handful of sprouts
- Top with bacon if using
- Enjoy!
Why Homemade Chicken Deli Meat is Better
I’ve been making my own deli meat for a while now, and I’ll never go back to store-bought. Here’s why:
- Cost-effective: A package of quality deli meat can cost $8-12, while making your own costs about half that amount
- Healthier: No preservatives, fillers, or mysterious ingredients
- Tastier: The flavor is incomparably better
- Customizable: Adjust seasonings to your family’s preferences
- Satisfying: There’s something rewarding about making things from scratch
Troubleshooting Tips
Sometimes things don’t go perfectly. Here are solutions to common issues:
- Dry chicken: Increase brining time slightly or reduce smoking time
- Too salty: Reduce brining time or use less salt in the brine
- Not enough flavor: Add more seasonings to your dry rub or try injecting flavored broth
- Difficult to slice thinly: Chill the chicken more thoroughly before slicing
Final Thoughts
Making your own chicken deli meat at home is one of those simple projects that delivers big rewards. It doesn’t require fancy equipment or complicated techniques – just a little time and attention to detail.
What I love most about this process is its simplicity. There aren’t any fussy steps or hard-to-find ingredients, yet the results are consistently delicious. Plus, there’s something satisfying about knowing exactly what’s in the food my family eats.
Give this method a try next weekend – I bet you’ll be surprised at how easy and rewarding it is to make your own chicken deli meat. Your sandwiches (and your wallet) will thank you!
Dry Rub or Wet Brine – What’s Best for Chicken?
It’s no secret that chicken, particularly breast meat, tends to dry out easily in the smoker. The reason is pretty straightforward – the low-and-slow cooking method evaporates moisture from the meat as it cooks, resulting in dry chicken. The secret for getting tender, juicy chicken in the smoker is to use a wet brine.
Special Tools We Use
One of the tools that makes this process happen is a meat slicer. Now, before you stop reading because you aren’t interested in spending hundreds of dollars on a meat slicer, you should check out the 7.5-inch slicer from Meat! that we’ve been using for the past several months. It’s a compact slicer that is easy to clean and it packs enough power to make short work of some tough slicing tasks, like making cold cuts from smoked chicken breast. It’s also a much more affordable option than purchasing a full-size professional meat slicer like you’d find at your local deli. The 7.5-inch blade is a great size for slicing chicken breasts into cold cuts.
Homemade Chicken Deli Meat
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