(From: Flores Gutierrez, A.
A, 2000)
5.2.4 Pickling
Vegetables can be macerated in a brine solution for pickling, which preserves the product
for a long time. The high concentration of salts in the brine inhibits the growth of
microorganisms that decompose and change the flavour, colour, and texture of
vegetables. Vegetables can be maintained under maceration with a salt concentration of 6
to 10% during the first ten days of the pickling process. Then, the salt concentration is
gradually increased to 16% for six weeks.
Under these conditions, vegetables can be kept in barrels for long periods until final
processing. This involves washing the vegetables with water to release large amounts of
salt (as much as possible), and packaging the product into glass jars with 5% vinegar and
3% salt. An alternative method is to precook vegetables at 80 to 90°C for 2 to 10 min.
Then, packaging is performed using a blend of 3% salt, 6% vinegar, and 5% sucrose.
5.2.5 Fermentation
Vegetables can also be preserved by a fermentation process. During fermentation of raw
vegetables, lactic acid bacteria develop, transforming the natural sugars present and the
added sugar into acid. In general, a low salt concentration of 3-5% is used to prevent the
growth of spoilage bacteria, while lactic acid bacteria are under development. The
characteristic flavour and texture of fermented vegetables is produced by the action of
lactic acid bacteria. Vegetables must be kept submersed in the liquid to prevent contact
with air, which can cause decomposition, due to action of yeasts and moulds. During the
fermentation process (2 to 3 weeks), the salt becomes diluted due to water drained from
the vegetables, therefore salt must be frequently added to maintain the concentration at 3
to 5%. The pickled vegetables are washed with water and packaged into glass jars
containing a solution of 3% salt and 5% vinegar. Vegetables can be pasteurized (or the
liquid heated) and packages hot filled.
A typical formulation and application:
Lactic acid fermentation occurs when small amounts of salt are used. This allows
bacteria to convert the sugar in vegetables to lactic acid; the acid mixed with salt inhibits
the growth of other microorganisms that would cause major damage. This type of
fermentation is used to prepare sauerkraut or sour cabbage, and in pickling cucumbers
(pickles). Because salting is very softening, -both vegetables and salt are edible, thus
preserving nearly all of the nutrients.
A typical application is in the preparation of sauerkraut:
1. Select good, mature cabbages; remove external leaves; wash remaining heads well.
2. With a sharp knife cut the heads into four sections, removing the hearts. Slice two and
a half kilos of cabbage into fine strips approximately 2 to 3 cm long.
3. Put above cabbage in pot or plastic container and mix well, adding two tablespoons of
salt. Let stand for 15 minutes or more, while preparing another batch of cabbage. The
quantity of salt added must be in accordance with the amount of cabbage used for proper
fermentation. While the cabbage is in repose, the salt works to reduce the lot size, extract
the juice, and soften the cabbage. This will prevent breakage of strips during packaging.
4. The cabbage is packed into clean wide-mouth 4 L glass or plastic jars.
5. Eliminate air bubbles from the cabbage by pressing hard with hand. This allows juices
to penetrate the tissues and holes formed between strips. Soft pressing is recommended to
avoid breaking the finer strips.
6. Place plastic bag full of water on top of the cabbage to prevent air from penetrating the
container and the cabbage. Close the jars tightly. After approximately 24 hours of
fermentation, the juices should have completely covered the cabbage. Otherwise, add a
brine solution composed of 25 g of salt per L of water until all cabbage strips are covered.
The presence of bubbles is an indication that fermentation is in progress. This process
lasts from 5 to 6 weeks or until the bubbles disappear from the solution, after which the
fermented cabbage is heated in a pot until boiling.
7. Pack cabbage into sterile jars and cover with hot juice, leaving a head space of 2.5 cm
below the jar's rim.
8. Place lids on each jar and sterilize the jars in a boiling water bath for 15 and 20
minutes for 0.5 L and 1 L jars, respectively.
Packaging methods
5.3.1 Plastic containers and bags
The plastic containers used to handle fresh and processed vegetables are tough,
easy to handle due to light weight, can be reused, and facilitate the stacking of
produce into piles without damaging the product. Initially, the cost of plastic
containers and bags is high, but if protected from sun and extreme conditions, they
can last for years. In developed countries various plastics are used at all stages of
post-harvest packaging and processed fruits and vegetables. Polyvinylchloride
(PVC) is used primarily for overwrapping, while polypropylene (PP) and
polyethylene (PE), for bags, are the films most widely used for packaging
minimally processed products.
Plastic bags are suitable for handling small amounts of vegetable products, and
used at supermarkets and retail stores in developed and developing countries.
5.3.2 Vacuum packaging
Vacuum packaging extends the shelf life of vegetables for long periods. This
technique relies on withdrawing air from the package with a suctioning machine.
Removal of air retards the development of enzymatic reactions and bacterial
spoilage. Vacuum packaging and gas flushing establish the modified atmosphere
quickly and increase the shelf life and quality of processed products. For example,
browning of cut lettuce occurs before a beneficial atmosphere can be established
by the product's respiration. In addition to vacuum packing the specifics of
handling must be taken into account, especially the time delays and temperature
fluctuations.
5.3.3 Modified atmosphere packaging
For some products, such as fast respiring broccoli florets, impermeable barrier
films with permeable membrane "patches" to modify the atmosphere through the
product's respiration are used. It is not yet agreed as to which films and
atmospheres are preferred for minimally processed products.
Modified atmosphere packaging (MAP), can be created passively by using proper
permeable packaging materials, or by actively using a specified gas mixture,
together with permeable packaging materials. The purpose of this procedure is to
create an optimal gas balance inside the package, where the respiration activity of
the product is as low as possible; on the other hand, the oxygen concentration is
not detrimental to the product. In general, the objective is to have a gas
composition of 2-5% CO2, 2-5% O2, and the rest nitrogen. One limitation in the
design of control atmosphere packaging is in finding good permeable material that
will match the respiration rate of the produce; only a few choices are available in
the market. Most films do not result in optimal O 2 and CO2 atmospheres in
products with high respiration rates. This problem can be tackled by making micro
holes of defined sizes and quantity in the material to prevent anaerobiosis. Another
alternative is to combine ethylene vinyl acetate with oriented polypropylene and
low-density polyethylene at a specified thickness. These materials have
significantly higher permeability than the polyethylene or oriented polypropylene
used in the packaging of salads, gas permeability should however be even higher.
These materials have good heat-sealing properties and are commercially available.
High O2 MAP treatment has been found to be particularly effective at inhibiting
enzymatic browning, preventing anaerobic fermentation reactions, and inhibiting
aerobic and anaerobic bacterial growth. The modified atmospheres that best
maintain the quality and storage life of minimally processed products have been
found to have an oxygen range of 2 to 8 percent and carbon dioxide concentration
of 5 to 15 percent (Cantwell, 2001).