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Deactivation of Porcine Reproductive and Respiratory Syndrome (PRRS) virus during manufacture and microwave cooking of bacon was investigated. Internal cooking temperatures of bacon were measured and used as a model for evaluating thermal deactivation of virus in growth media and in bacon. Thermal deactivation of virus was assessed in inoculated commercial bacon, in bacon manufactured in the pilot plant following viral inoculation of fresh bellies and in bacon from hogs inoculated with PRRS virus. Internal temperature of 110-136°C was observed in bacon cooked using microwave heating. With commercial sliced bacon, up to 6.8 log reduction of viral titer was achieved for bacon heated by microwave to 110°C or higher. Bacon manufacturing trials with samples heated by convection to 53°C (typical for smoked bacon) produced a 3.1 log reduction of viral titer. Low occurrence of PRRS virus in bellies of infected pigs coupled with greater than 3 and 6 log reductions during bacon manufacture and microwave heating, respectively, lead to high confidence that no active virus remains in microwave cooked bacon. Microwave cooked bacon is safe for import into PRRS-free regions.