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I did these for a similar project a couple months ago. The heat-oriented ingredients I used for 2 1/2 lbs. of meat were: 180 g fresh habaneros (with all of their innards, not seeded), 2 dried ghost peppers, 20 g cayenne, 6 g chile flakes, 1 tbsp. Flash Bang sauce, 1 tbsp. Blair's Ultra Death sauce and 1 tbsp. Ass Blaster sauce. I ran into the same problem. They were hot, really hot... but not nearly as painful as I expected based on what went into them. The Flash Bang sauce is supposed to be 5 million scovilles and the Ultra Death is just a little short of 1 million which, along with the habs and ghosts, probably made the Ass Blaster (50,000 scovilles) cayenne and chile flakes irrelevant but they were in there. My current theory is that a significant amount of the capsaicin rides out with any fat that cooks out. It's oil soluble and if you poach the super-hot sausages, the water they were poached in gets pretty darn spicy. Especially the oil slick on top. But that's just a semi-educated guess, could be completely incorrect.
Aren't you glad you don't work on the lines that pack those powders? That's got to be nasty.
I have a shaker jar of oven-roasted purira peppers blended with kosher salt, the result is a dark brown powdery dust that's guaranteed to blow out my sinuses when I handle it.
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