Rick (nepas), this is really turning out to be a great thread. Thanks for starting it!
Rather than listing the maximum amount to use why don't they list the minimum. I'm sure no one wants to use more than necessary. Would make more sense to me.
The minimum amount is kind of a gray area. Although it's not a strictly regulated amount, the USDA handbook states,
"As a matter of policy, the Agency requires a minimum of 120 ppm of ingoing nitrite in all cured "Keep Refrigerated" products, unless the establishment can demonstrate that safety is assured by some other preservation process,... However, 40 ppm nitrite is useful in that it has some preservative effect. This amount has also been shown to be sufficient for color-fixing purposes and to achieve the expected cured meat or poultry appearance.
From the: USDA PROCESSING INSPECTORS' CALCULATIONS HANDBOOK
So the minimum depends on the purpose. If all your wanting to do is to fix the color of sausage, and plan to
hot-smoke only, then you can get away with as little as 1/4 tsp of cure #1 per 5 pounds of comminuted meat.
However, when it comes to
cold-smoking, because it's been ground and bacteria can be present all throughout the meat, sausage is the most critical product in which to use proper amount of cure. Therefore, in sausage products that will be
cold smoked, I would stay within the established 120ppm - 156ppm range. That translates to basically: 3/4 tsp. cure #1 (minimum) to 1 tsp (maximum) per 5 pounds comminuted meat.
I basically do the same as Rick (nepas) said, and level the measuring spoon with the back of a knife.
With whole cuts of meat (ham, bacon, etc.), as long as you're not cold-smoking for extended periods, it's not nearly as critical, so you can easily get by with 40 - 50 ppm of Nitrite to set the color and give that classic cured meat texture & flavor.
Using the nitrite cure in small amounts for this purpose allows you to drastically cut back on salt levels and make a lower-sodium product. And as nepas mentioned in his original post, the amount of nitrite left in the product after hot-smoking is negligible.
RickB, I hope this makes sense.