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The Nesco vs Excalibur dehydrator debate is the most common question in home jerky making — and for good reason. These are the two most recommended brands, covering the widest price range, and they represent two fundamentally different engineering philosophies. After 15 years and thousands of pounds of jerky through both brands, I have strong opinions.
The Core Design Difference: Airflow Direction
This is the most important technical difference and determines everything else about performance:
- Nesco (and most round dehydrators): Top-down or bottom-up airflow. A fan at the top or bottom circulates air through central spokes, flowing outward toward the edges of each tray.
- Excalibur (horizontal flow): A rear-mounted fan blows air horizontally across all trays simultaneously, parallel to the food surface.
The horizontal flow design of the Excalibur is genuinely superior for even drying. In round dehydrators, food at the center of each tray dries faster than food at the edges, requiring rotation of trays and repositioning of food pieces mid-session. In an Excalibur, the horizontal airstream passes across the full tray length, producing much more consistent results.
Nesco Dehydrators: Strengths and Weaknesses
Which Nesco Models to Consider
The Nesco FD-75A Snackmaster Pro (500 watts, $60–$80) is the entry-level recommendation — it comes with 5 trays expandable to 12, runs at 160°F max (adequate for USDA-safe jerky), and is compact enough for apartment kitchens. The Nesco FD-1040 Gardenmaster (1000 watts, $90–$110) steps up to digital controls and faster performance.
What Nesco Does Well
- Price: $60–$110 vs $200–$400+ for Excalibur makes Nesco accessible to beginners
- Footprint: Round design takes up less counter space
- Stackable trays: You can expand capacity cheaply by buying extra trays
- Simplicity: Fewer components, easier to clean
Nesco’s Genuine Weaknesses
- Uneven drying: Center vs edge temperature variation is real. Rotating trays every 2–3 hours is almost mandatory for even batches.
- Flavor transfer: Round tray design means drips from top trays can contaminate lower tray food. This matters if you’re doing multiple flavors simultaneously.
- Temperature accuracy: Budget models have less precise thermostats — tested temperature can vary ±10–15°F from dial setting.
Excalibur Dehydrators: Strengths and Weaknesses
Which Excalibur to Consider
The Excalibur 3926TB 9-Tray ($250–$350) is the definitive choice for serious jerky makers. Nine full-size trays, rear-mounted fan with horizontal airflow, adjustable thermostat from 105–165°F, and a 26-hour timer. The 5-tray Excalibur 3526TB ($200–$270) is the step-down option for smaller households.
What Excalibur Does Better
- Consistency: Horizontal airflow produces dramatically more even drying — no rotating trays, no repositioning
- Capacity: 9 large square trays hold 2–3x the food volume of a Nesco at the same footprint
- Temperature precision: The analog thermostat on Excalibur models is calibrated carefully; ±5°F accuracy is typical
- No flavor transfer: Trays slide in/out like shelves; no drip contamination between levels
- Lifespan: Excalibur units routinely last 10–20+ years. I know a woman using a 1987 Excalibur that still runs perfectly.
Excalibur’s Weaknesses
- Price: $200–$350 is a serious investment for a beginner
- Footprint: The 9-tray Excalibur is a large appliance — about the size of a microwave, but deeper
- Mesh tray cleaning: The polyscreen inserts can be tedious to clean vs simple round trays
Jerky Quality Test: Head-to-Head Results
I ran a side-by-side test with identical beef eye of round, sliced uniformly at 1/4 inch, identically marinated (same batch, same time), 160°F for 4 hours in each machine:
| Factor | Nesco FD-75A | Excalibur 3926TB |
|---|---|---|
| Even drying (no rotation) | Poor — edges overdried | Excellent — consistent |
| Even drying (with rotation) | Good | N/A (not needed) |
| Temperature accuracy | ±12°F | ±5°F |
| Drying time at 160°F | 4.5 hours | 4 hours |
| Texture consistency | Variable by position | Highly consistent |
| Batch capacity | ~2 lbs pre-dry | ~6 lbs pre-dry |
Which Dehydrator Is Right for You?
Buy the Nesco if: You’re new to jerky making, you’re not sure if you’ll stick with it, you have limited counter space, or your budget is under $100.
Buy the Excalibur if: You already know you love making jerky, you want the best possible results without babysitting the machine, you plan to make large batches, or you want an appliance that will last 15+ years.
My personal journey: I started on a Nesco (everyone does), upgraded to an Excalibur three years later, and have never regretted it. The Excalibur didn’t make my recipes better — but it made my jerky more consistent, which is what separates good batches from great ones.
FAQ: Nesco vs Excalibur
Can a Nesco make jerky as good as an Excalibur?
Yes, with more effort. Rotating trays every 2 hours and repositioning pieces produces excellent results. The difference is convenience and consistency, not a ceiling on quality.
Is the Excalibur worth the price for occasional jerky makers?
If “occasional” means once a month, probably not — the Nesco is sufficient. If you make 3+ batches per month, the Excalibur pays for itself in time saved and consistency gained within a year.
Which dehydrator is easiest to clean?
Nesco round trays are simpler to clean individually. Excalibur tray liners require more scrubbing. Both are dishwasher-safe for the trays themselves.
Bottom Line
For jerky specifically, the Excalibur’s horizontal airflow produces better, more consistent results than the Nesco’s top-down design. The Excalibur 9-tray is the best dehydrator for serious jerky making. The Nesco is the best dehydrator for trying jerky making without a major investment.
Start where your budget is. Just don’t be surprised when you eventually upgrade to an Excalibur.