Fermented vegetables

1. RAAZHINE.G
PREPARATION & PRODUCTION
OF FERMENTED VEGETABLES

2. PREPARATION OF FERMENTED
VEGETABLES

3. KIMCHI
Kimchi is a fermented vegetable condiment, traditional to Korean cuisine. Season
will impact vegetable size and quality, as well as time needed for fermentation.
Making kimchi requires maintaining a clean environment and good hygiene
practices, carefully following all steps, and monitoring temperatures to foster the
growth of Weissella species, Lactobacillus species, and other bacteria
contributing to the fermentation process.
● The process of making kimchi involves brining (salting) the vegetables to
draw out the water, which helps in preservation and allows the seasonings to
penetrate the food over time.
● Kimchi is typically fermented by ‘wild cultures’ naturally present on the
vegetables. The formation of organic acids (primarily lactic and acetic acid)
results in an optimum kimchi pH of 4.2.
● The kimchi fermentation process is very short in comparison to making
sauerkraut.Kimchi ferments at room temperature in only 1-2 days or more
slowly in the refrigerator. For safety, kimchi should be stored refrigerated and
is best eaten within 1 week, as the quality of kimchi deteriorates with longer
fermentation.

4. Making Baechu (Bet-schu) Kimchi: Mack (Chopped Cabbage) Style
Look for light-green Napa cabbage with compact, elongated heads that
feel heavy for size. In summer, Napa cabbage may be softer and ferment
faster; while in winter, Napa cabbage may be firmer and need more time
to ferment. Some ingredients, such as Korean red pepper powder and
Korean radish, may need to be purchased through specialty Asian stores
or ordered online.
During preparation, proper sanitation practices must be followed to
prevent contamination by spoilage or harmful microorganisms. This
includes proper hand washing as well as using clean equipment, utensils,
and surfaces throughout all preparation steps.

5. Equipment:
• Large sharp knife and cutting board
• Blender or food processor (optional for blending ginger and garlic)
• Measuring cup, measuring spoons, and mixing utensils
• 1-quart saucepan for making sweet rice paste
• Food-safe, glass or plastic storage container with tight fitting lid. For example: plastic
rectangle kimchi container, glass mason jars with bands and lids, or gallon-size re-
sealable zipper plastic bags.Do not use metal containers nor earthenware with cracks or
chips. Container(s) must fit in your refrigerator, but big enough to hold 2 cabbages.
• Large glass, plastic, or stainless steel mixing bowl
• Disposable food handler gloves (highly recommended) for protection from red pepper
powder while handling kimchi.

6. Ingredients:
• 2 medium heads Napa cabbage (about 6-8
pounds total)
• 1 ½ cups coarse salt, non-iodized, divided
(baked or sea salt recommended)
• 1 gallon + ½ cup cold water, divided
• 2 Tbsp. sweet rice flour
• 1-10 cloves garlic, depending on taste
preference
• About 3 slices fresh ginger root (about 0.2-
0.4 oz.)
• 1 cup Korean red pepper powder–specific
“for kimchi”
• ½ Korean radish (about 1-1.5 pounds), or
daikon radish
• 1 Asian pear (optional)
• 10 green onions
• 1 tsp. fish sauce (optional)
• 2 tsp. finely ground salt (optional, as
needed)

7. Procedure:
1. Prepare Napa cabbage:
a. Rinse heads under cold water and drain.
b. Cut away and discard any spoiled or damaged spots.
c. Cut Napa cabbage into four quarters and remove core from each. Chop quarters into 2-inch pieces.
2. Salt cabbage:
a. Prepare saltwater solution of ½ cup course, non-iodized salt and 1 gallon cold water in large mixing
bowl.
b. Dip cabbage pieces briefly in the saltwater solution, to facilitate penetration of salt into the cabbage
pieces. Discard saltwater solution
c. Drain and place cabbage pieces in a bowl. Sprinkle 1 cup of course, non-iodized salt over the cut
cabbage and massage it into the cabbage well. Allow cabbage to sit covered at room temperature for 3 to
6 hours (a longer time will make it more salty).
d. Rinse cabbage pieces 3- 4 times with cold water to rinse away the salt, then place in a colander to drain
out excess water from the cabbage for at least 30 minutes.

8. 3. Prepare seasonings:
a. Add sweet rice flour to ½ cup water in small saucepan. Bring to a boil and set aside to cool.
b. Clean, peel, and finely mince (or use blender with small amount of water) garlic and ginger. Mix with cooled
sweet rice flour paste and add Korean red pepper powder.
c. Clean and peel radish, clean and trim green onions, and if desired, clean and peel Asian pear. Slice all Julienne
style, or into matchsticks about 1 inch in length.
d. Using clean hands and disposable food handler gloves, mix above seasoning paste and Julienned vegetables
together in large mixing bowl. Then mix in fish sauce to create a spicy veggie paste. Add salt only as needed.
e. Combine cabbage with the spicy veggie paste, rub together and mix thoroughly.
4. Pack container:
a. Pack kimchi tightly into container, minimizing air exposure and encouraging brine formation. Fill container about
2/3rd full, as fermenting microorganisms will release carbon dioxide (CO2) and create bubbling and fizzing.
b. Cover tightly. If using jars, seal to fingertip tight. If using bags, squeeze out excess air. Place on plate or in bowl
to catch potential overflow

9. 5. Ferment
Option 1: Kimchi may be placed in refrigerator so it ferments slowly over 3 to 4 days. This may be preferred,
especially during hot weather.
Option 2: Place sealed container in a well-ventilated location (may become pungent), with a relatively
constant room temperature, around 68° F is ideal. Ferment only 1 to 2 days at room temperature, tasting it
daily until it reaches preferred tangy taste and desired texture.
6. Store
a. Store fermented kimchi covered tightly in the refrigerator. Keep it pressed down to minimize air exposure.
Kimchi may become more sour over time. Discard if you observe indications of surface mold.
b. Kimchi can be enjoyed in countless recipes! Try it with eggs, rice, noodles, potatoes, in stir fry, fried rice,
soup, pancakes, or on a sandwich or hot dog.

11. SAUERKRAUT
● Sauerkraut is prepared by finely shredding white cabbage and layering the
vegetable with salt in a large crock or wooden tub. The cabbage is covered
with a weighted lid and allowed to ferment, preferably at below 60 °F (15.5 °C)
for at least a month.
● Commercially made sauerkraut is canned or sold in bulk. Caraway seeds,
peppercorns, and juniper berries are sometimes added to the cabbage during
fermentation.
● Four species of lactic acid bacteria (LAB) have been identified as organisms
that are present in sauerkraut fermentations: Leuconostoc mesenteroides,
Lactobacillus brevis, Pediococcus pentosaceus, and Lactobacillus plantarum
Ingredients
• 1 medium head of green cabbage (3-3 ½ pounds), as fresh as possible
• Sea salt or pickling salt (avoid iodized)
• 1 tablespoon caraway seeds, if desired

12. Procedure
1. Wash and sterilize a half-gallon jar by filling it with boiling water and then pouring it out
and allowing the jar to air-dry.
2. Weigh cabbage and measure out correct amount of salt, using a ratio of one tablespoon
of salt per pound of cabbage. For example, for 3 1/2 pounds of cabbage, use 3 1/2
tablespoons of salt.
3. Remove any damaged outer leaves from the cabbage and quarter it. Cut away the core
from all four quarters.
4. Finely shred the leaves with a large knife, blade grater or mandolin.
5. Place one quarter of the shredded cabbage in a bowl big enough to hold all the cabbage.
Firmly massage a quarter of the salt into the cabbage in a large bowl. Repeat this process
until all of the cabbage and salt have been combined in the bowl.
6. Set the bowl aside for 30 minutes to allow the salt to draw the water out of the cabbage.
7. After 30 minutes have passed, check the cabbage. There should be a salty brine
collecting in the bottom of the bowl.
8. Using your hands, squeeze the shredded cabbage, allowing the liquid to drain into the
bowl, and pack the cabbage shreds into the half-gallon jar. Use a wooden spoon or other
tool to tightly tamp it down and remove air bubbles.

13. 9. After all the cabbage has been packed into the jar, add the collected liquid from the bowl.
The cabbage should be covered by the liquid. If it is not, you will need to add additional brine.
10. Cover cabbage with a glass weight or small plate, ramekin or small plastic bag filled with
water. Cover the top of the jar with an airlock (or piece of cheesecloth secured with twine) to
allow air to escape. Set aside out of direct sunlight in a room between 55 and 75°F
11. Check the jar daily to make sure the cabbage remains submerged in the brine. You will
begin see small bubbles collect on the surface of the brine. If there is any scum (white,
yellow, or bluish growth), carefully scoop it off without stirring it into the liquid, and discard.
The brine will take on a darker color over time, and the odor may be pungent.
12. When it is no longer bubbling and the cabbage tastes pleasantly sour, not salty, the
fermentation is complete. This process can take anywhere from 1-4 weeks, depending on the
temperature of the environment.
13. Once the sauerkraut is finished, store it in the refrigerator, dividing into smaller jars if
desired. It will last for several months.

15. PICKLES
● Pickles are preserved by a combination of increased acidity (reduced pH),
added salt, reduced moisture and added spices. Pickles can be prepared
using one of two main methods: lactic acid fermentation of vegetables, either
with or without the addition of salt the preservation of vegetables in acetic
acid (vinegar).
● Vegetables such as cucumber, cabbage, olive and onion are fermented by
lactic acid bacteria which can grow in low concentrations of salt. The bacteria
ferment sugars in the food to form lactic acid, which then prevents the growth
of food poisoning bacteria and molds.
● The amount of salt added controls the type and rate of the fermentation. If 2-
5% salt is used, the fermentation is carried out by a series of bacteria that
produce lactic acid.
● Sometimes sugar is added to increase the rate of fermentation or to make the
product sweeter.

16. Examples of different types of pickles:
Product Salt Sugar Vinegar Process
Fermented sweet
pickle
5% then
3%
1-2%
then 3%
0 then
5%
Ferment for 1-2 weeks then repacked
in vinegar + salt + sugar (optional
pasteurisation)
Fermented sour
pickle
5% then
3%
0 then 0 0 then
5%
Ferment for 1-2 weeks then repack in
vinegar + salt (optional pasteurisation).
Unfermented pickle 3% 1% 5% Pack straight away and pasteurise.
Salt-stock pickle 15% 0 0 Store until required. Wash out salt and
repack as unfermented pickle.

17. Ingredients:
Spices:Spices used should be good quality, clean and free of mould and insects. They are
either roasted or fried before adding to the pickle mixture. The amount and type of spices
added depends on personal taste.
Oil:Vegetable oil is added to the pickle. It is often mixed with the spices to make a paste. Oil
is also poured onto the top of pickles to form a barrier against oxygen. Top quality vegetable
oil should be used.
Starter culture:Starter cultures are used to speed up the fermentation and to ensure
consistency between different batches of pickle. Because they are acidic, the starter cultures
inhibit the growth of undesirable organisms. It is possible to use fermented pickle juice that
has been saved from a previous fermentation as the starter culture. It is important to ensure
that the acidity of the starter juice is not too acidic as this will inhibit the activity of the
Leuconostoc bacteria. Starter cultures of Lactobacillus species can be purchased from
ingredient suppliers, but they may not be readily available in all countries.

18. A.-Preparation of the vegetables
● Vegetables should be washed in clean water, peeled and the
stones removed.
● Vegetables should be as fresh as possible and slightly under-
ripe. Damaged, bruised or infected fruits should not be used.
● Accurate scales are needed to make sure that the correct
amounts of ingredients are used each time. For fermented
pickles, the peeled vegetable pieces should be held in a 2-
3% salt solution to prevent browning of the surfaces.

19. B.-Fermentation
● Prepared vegetables are placed in the fermentation container and salt or brine is
added. The vegetable pieces are weighted down so that they are submerged in the
brine. The vegetables and salt are placed in alternate layers until the container is
three quarters full. As a guide, 3kg salt are required for every 100kg vegetables. A
container with a lid should be used for fermentation. This is to maintain the
temperature at the optimum level and to prevent contamination from dust and
insects. If brine is being used, a 15-20% brine solution is prepared by dissolving salt
in water. This is measured using a salometer or brine hydrometer.
● A starter culture of juice from a previous fermentation may be added to speed up
the fermentation. The temperature and time of fermentation must be carefully
controlled.
● The optimum temperature is 21°C. Fermentation begins as soon as a brine is
formed. It can be seen by bubbles of carbon dioxide gas that are given off by the
bacteria.
● Fermentation takes between one and four weeks depending upon the temperature,
pH and strength of the salt solution. It is completed when no more bubbles appear.

20. C.- Filling
● Heated pickles are hot-filled (above 80°C) into clean sterile glass jars. The jars should be
warm to prevent them cracking.
● If polythene pouches are used, the pickle should be cooled to room temperature before filling.
Fermented pickles are filled into clean, sterile jars or containers. Since these pickles are not
further processed, it is important to ensure good hygiene during filling.
● It is important to ensure that there are no air bubbles trapped in the pickle during filling. A layer
of good quality vegetable oil should be poured on the top of fermented pickles. This acts as a
seal and helps to prolong the shelf life.
D.- Add Salt
● For pickling, any type of common salt is suitable as long as it is pure. Salt that contains
chemicals to reduce caking should be avoided as the chemicals will make the brine cloudy.
● Salt with lime impurities can reduce the acidity and shelf life of the product. Salt with iron
impurities can cause blackening of the vegetables. Salt with magnesium gives a bitter taste to
the pickles. Salt containing carbonates can result in pickles with a soft texture
● Salt provides a suitable environment for lactic acid bacteria to grow. The lactic acid that
they produce gives the pickle the characteristic flavour and preserves the vegetables.

21. ● Salt can either be added to the vegetables as dry salt or made into a brine that the
vegetables are soaked in.
Dry salted pickles
● The salt extracts juice from the vegetables and creates a brine. For every 100kg of
vegetables 3kg of salt is needed. Alternate layers of vegetables (about 2.5cm deep) and
salt are placed in the fermentation container until it is about three quarters full.
● The contents are covered with a cloth that is weighted down to help with the formation of
brine. As soon as the brine is formed, fermentation starts and bubbles of carbon dioxide
gas appear.
Brine pickles
● Brine is used for vegetables that are naturally low in water. A 15-20% salt solution is
prepared by dissolving salt in water. Vegetables are submerged in the brine using
weights to hold them under the solution and the container is sealed.
● The strong brine draws sugar and water out of the vegetables, which decreases the salt
concentration of the brine.
● It is important that the salt concentration does not fall below 12% as fermentation will not
be able to take place. Extra salt is added periodically to maintain the strength of brine.

22. F.-Packaging:
Clean glass jars with lids are the preferred type of packaging for pickles. Small quantities of pickles can
be packaged in polythene pouches that are sealed with a heat sealer. These pickles tend to have a
shorter shelf life.
The principles of lactic acid fermentation
● Lactic acid bacteria are a group of bacteria that produce lactic acid by the fermentation
of carbohydrates. They are the most desirable group of bacteria in food preservation.
They play important roles in the fermentation of many foods including sour dough bread,
sorghum beer, fermented milks, fermented cassava and pickled vegetables.
● The whole basis of lactic acid fermentation centres on the ability of lactic acid bacteria to
produce acid, which then inhibits the growth of other non-desirable organisms.
● The main groups of lactic acid bacteria involved in the fermentation of vegetables are as
follows:
● Leuconostoc mesenteroides:Produces acid and gas
● Lactobacillus plantarum:Produce acid and a small amount of gas
● Lactobacillus cucumeris:Produce acid and a small amount of gas
● Lactobacillus pentoaceticus:Produces acid and gas .

23. Mango Pickle:
Ingredients:
Procedure:

24. REFERENCE:
KIMCHI:Kimchi-handout-Colorado-State (foodsafety.ces.ncsu.edu)
SAUERKRAUT: American University (https://www.american.edu)
PICKLE: PICKLES-Food and Agriculture Organization of the United Nations
((https://www.fao.org), Mango pickle-Preparation of pickles by Horticulture
guruji(https://www.horticultueguruji.in)

25. PRODUCTION OF FERMENTED
VEGETABLES

26. COMMERCIAL PRODUCTION OF KIMCHI
● Kimchi has become one of the most important globally popular food
products, because of its taste and health claims; therefore its market has
increased worldwide.
● The major challenge regarding industrial kimchi production is obtaining
uniform quality. This task may be achieved by careful standardization of the
whole production procedure, i.e., use of high quality raw materials, starter
cultures and suitable fermentation conditions.
● Due to the large number of health claims, a large proportion of which is
attributed to the microbiota itself, the criteria for the selection of starter
cultures include the evaluation of the medicinal potential.
● In that sense, LAB such as Ln. mesenteroides, Ln. citreum, and Lb. plantarum
have been successfully applied as starter cultures for kimchi preparation.
● However, the adaptability to the kimchi microenvironment that may be
assessed through persistence, as well as technological properties, such as
production of organic acids, mannitol, compounds that may affect the
product organoleptically, biogenic amines, vitamins, and bacteriocins should
also be considered.

27. Storage and Preservation
● The Korean made kimchi requires less quantity of salt due to the use of red pepper
powder. As a result, kimchi can be stored for long periods of time facilitating
commercialization that has increased sharply in countries like Korea, China, Japan,
and the United States .
● Kimchi is usually stored in two ways, either for 3 weeks at 4°C, which is considered
as well ripened or for only 3–4 days at room temperature.
● The raw kimchi is eaten in various ways as salad mixed with sesame seeds,
sesame seed oil and sugar, while the over-ripened kimchi is usually boiled with
meat .
● Over-fermentation of kimchi results in excessive acidification (sour taste) due to the
production of acid by LAB with softening of its texture and diffusion of color. Thus,
the extension of kimchi shelf life and maintaining of its quality by minimizing LAB
growth, is a major concern for the kimchi industry.
● Thermal processing, cold storage, addition of preservatives, irradiation, and other
methods have been employed to extend the shelflife of kimchi by preventing over
ripening. Cold storage appears to be the most promising method to preserve kimchi
for an extended period without serious quality problems.

28. Cleaner production option in food industry (kimchi)

29. SAUERKRAUT
To make sauerkraut, shredded cabbage is mixed with salt and allowed to ferment.
The amount of salt added is critical to assuring food safety, and should not be
adjusted. Fermentation takes three to six weeks depending on the air temperature.
During this time, the acidity in the product will increase. Once the sauerkraut is
fermented, it may be canned or frozen.
SUITABLE CABBAGE VARIETIES
● Sauerkraut can be made from all cabbage varieties; however, some varieties
are better suited than others. Typically cabbage heads grown for processing
are much larger than those grown for the fresh market.
● Sauerkraut makers are encouraged to try new varieties as well. Mature heads
weighing 6 to 15 pounds with a solid, white interior are most desirable.
Additionally, cabbage harvested later in the season may also contain more
sugars that will support the growth of bacteria during fermentation.
● Head size (small to large), shape (round, flat, conical, and variations), density,
and color (green, blue-green or red), as well as leaf texture (smooth or savoy)
should all be considered. Wrapper leaves (number, thickness and tightness)
and core length can also vary among varieties.

30. VARIETIES TO CONSIDER INCLUDE:
● Danish Ballhead- a mid-season heirloom variety with a pleasing flavor and texture
● Premium Late Dutch- a late season variety with 10-15 pound heads, excellent for fall / winter use
● Stone Head- very early, small head
● Early Flat Dutch- early, round head
● Head Start-early medium size head, excellent field holding for an early type
● Hinova- late variety, flat, rounded heads
● Red Acre- 3-pound head, red variety
INGREDIENTS AND MATERIALS
● 25 pounds fresh cabbage
● ¾ cup canning salt
● Fermentation vessel
Fermentation vessels should be made out of stone, glass or food-grade plastic. Estimate that a 1 gallon
container will be appropriate for up to 5 pounds of cabbage. Crocks should not be cracked or lined with
metal. Containers made of aluminum, copper, brass, iron, galvanized metal, or trash cans are not
appropriate. Prior to fermentation, containers should be washed with warm water and soap. Clean
containers made of non-food-grade materials can be used if a food-grade plastic liner is used. Trash bags
are not food-grade plastic liners.

31. PREPARATION INSTRUCTIONS
● Discard outer leaves and rinse in cold clean water to remove soil or debris. Cut the head of
cabbage into pieces and remove the center core. Shred into long thin strips, about the
thickness of a quarter.
● Combine 5 pounds of cabbage and 3 tablespoons of canning salt and mix well. Repeat this
process until you have combined 25 pounds of cabbage and cup of canning salt. Transfer this
mixture to an appropriate container . There should be 4-5 inches of headspace left at the top
of the container. The cabbage should be completely covered with liquid, make a salt brine with
1 quart of water and 1½ tablespoons of canning salt. Pickling or canning salt is preferable
since it does not contain iodine and anti-caking agents. The brine should be boiled and cooled
to room temperature before adding to your cabbage mixture.
● Suitable Containers: Stoneware crock, large glass jar or food-grade plastic container.
DO NOT USE: trash cans, aluminum, copper, brass, galvanized or iron containers.
● Weigh down the cabbage to keep it submerged in the liquid. A heavy plate or lid that fits down
into the container can be used. Or, use a double layer of food-grade plastic bags (like the re-
sealable gallon-size freezer bags) and fill the top bag with brine for weight. The cabbage
should be covered by 1 to 2 inches of brine. Keeping the cabbage protected from oxygen will
help limit mold growth during fermentation.

32. FERMENTATION
● During the fermentation process, store the sauerkraut at 70-75 ℉. At this
temperature, sauerkraut should be fully fermented in about 3-4 weeks. At 60-65 ℉,
the fermentation process may take 5 to 6 weeks.
● During fermentation, lactic acid bacteria are able to grow in the high salt
environment and produce acid and flavors associated with fermented
vegetables.The salt is added and the acid produced by the bacteria will help control
pathogenic bacterial contamination. Consequently, salt levels cannot be reduced in
fermented vegetable preparations and salt substitutes cannot be used.
● The temperature at which the sauerkraut is stored impacts the development of
these flavors and the lactic acid. At lower temperatures, growth occurs more slowly.
Therefore, the fermentation process often takes longer when stored under cooler
conditions.
● When using a heavy plate, lid or jars to weigh down the cabbage, we need to check
the sauerkraut 2-3 times a week and remove the scum if it forms. A thin film of yeast
or mold (scum) may form on the surface of the fermentation brine. When using a
brine-filled bag as the weight, do not disturb the container until normal fermentation
is completed (when the bubbling stops).

33. Preservation Methods: Chopped cabbage should be weighed in order to add the
appropriate amount of salt for the fermentation. Once the fermentation is complete, the
sauerkraut can be canned, refrigerated or frozen.
Preservatives: sodium benzoate or potassium metabisulfite
PRESERVING SAUERKRAUT
● Raw pack by filling jars with sauerkraut and cover with juices, leaving ½-inch
headspace. Wipe jar rims; adjust lids and process in a boiling water bath.Begin timing
once the water bath has returned to a full boil.
● Hot pack the sauerkraut by bringing it and the liquid to a boil, stirring frequently.
Remove from heat, fill jars, leaving ½-inch headspace, wipe jar rims, adjust lids and
process in a boiling water bath. Begin timing once the water bath has returned to a full
boil.

34. ● Freeze by filling quart-size freezer bags or reusable ridge plastic freezer containers and leave
at least 3 inches of room for expansion during freezing. Squeeze out air, seal and label.
Freeze for eight to 12 months.
5 ways to store fermented Sauerkraut:
● Canning, Refrigerator, Cool basement or DIY cellar, Freezer, Kitchen Counter
● CANNING: The canning process involves placing food in jars and heating those jars to
high temperatures to destroy microorganisms that could cause food to spoil.
● Naturally fermented sauerkraut is a live product full of not only beneficial bacteria with
numerous health benefits. The heat of a hot water bath canner kills these beneficial
bacteria.
● REFRIGERATOR: A typical refrigerator is set at 35° F (1.6° C). Properly fermented
sauerkraut stored at this temperature can keep for a year without much change in texture.
● COOL BASEMENT :Most basements dug down into the cool earth are around 55°F
(12.7° C). Properly fermented sauerkraut stored at this temperature can keep for a year
with some softening as the months go on.

35. ● DIY Root Cellar:If you don’t have a basement but have a bit of space in your
backyard, it is fairly easy to make your own root cellar to store quite a few jars of
sauerkraut. All you need is a shovel and an old ice chest, garbage can or
discarded chest freezer.
● Depending on where your frost line is and if you experience freezing
temperatures in your region, you should be able to maintain temperatures
similar to a basement: 55° F (12.7° C). This is not quite as cold as a
refrigerator but will allow you to store a season’s worth of sauerkraut.
● KITCHEN COUNTER:keep their jars on the counter, fermenting throughout
the year and eating them as they are ready and enjoying the shifting flavors.
● How long you can get away with this will depend upon the temperatures in
your home. If properly fermented, sauerkraut will not rot or mold but the texture will slowly soften.
● FREEZER:The recommended temperature to set your freezer at is 0° F (-18° C).Pack your
sauerkraut into freezer bags or in a container for freezing. Leave 1-2 inches of headspace and
remove excess air for expansion. Be sure to label.
● If you have a vacuum sealer, this would be a great way to remove all the air in your bag.
Fermented sauerkraut can be stored in the freezer for 8-12 months. Thaw in your refrigerator.

37. PICKLE:
● There are two types of fermented pickles (sour or sweet
pickles):
● (i) sour fermented pickles made by submerging raw
materials in a dilute brine (2–5% salt). Naturally occurring
bacteria grow over 1–2 weeks to produce lactic acid,
which then prevents the growth of food poisoning bacteria
and other spoilage microorganisms. The amount of added
salt controls the type and rate of the fermentation.
● (ii) in sweet fermented pickles, they are preserved by a
combination of lactic or acetic acid, sugar and spices.
● Pickles can be packed in different weights ranges from
few grams to 5 kg so that it becomes useful for one-time
use to month’s consumption.

38. Suitability for small-scale production:
● Pickles are fairly safe products for small-scale manufacturers to make. When preserved
properly they carry a low risk of food poisoning and have a long shelf life.
● Pickles can be made using relatively simple equipment that is readily available in most
places.
● Pickles can be prepared from a variety of fruits and vegetables depending on what is
available. By varying the proportions of fruit and vegetables and the amount of spice
added, a range of products can easily be made.
Constraints to production:
● Many small-scale processors choose to make pickle as it is relatively easy. There may
be a high level of competition.The conditions for fermentation (temperature, pH and salt
content) need to be closely monitored to ensure a good product.
● The availability of acetic acid may be a problem in some areas.It is essential that a
survey is carried out to determine the potential market for the product before starting on
production.
● A successful business depends on a good market for the product. Too often, small-scale
processors decide to make pickles because there is an abundant supply of raw material,
with no evaluation of the demand for the product. These type of ventures usually fail.

39. The Manufacturing Process:cucumber pickle
Making cucumber pickles can take up to 42 days depending on the manufacturer's recipe. Production involves four
primary steps including harvesting, preservation, pasteurization, and final processing. The process is highly automated
once the cucumbers are delivered to the processing plant.
Harvesting
● Once harvested by field workers, cucumbers are put in large bins and transported to a receiving station. If the
cucumbers are transported a long distance, refrigerated trucks are used. This helps to maintain the fresh
appearance and flavor of the vegetable.
● At the receiving station, the cucumbers are poured out onto a conveyor where they are subjected to a cleaning
process that removes the excess stems, blossoms, dirt, and other foreign matter.
● This step is important because trace amounts of bacteria on unwashed cucumbers can ruin the final pickle product.
● They are then moved to an inspection station where rotten vegetables are removed and the rest are separated by
size. From here they are moved to a chiller and stored until they are ready to be used.
Preservation
● Depending on the manufacturer, conversion of the cucumber into a pickle can be done in one of three ways
including fermentation, pasteurization, and refrigeration.

40. ● In this method, the cucumbers are transferred to large, air tight, fiber-glass or stainless steel tanks.
Some of these containers can hold over 40,000 lb (18,160 kg) of cucumbers. The tanks are filled
with a brine solution, which is made up of water and 10% salt. The manufacturer can take advantage
of a naturally-occurring bacteria that is present on the cucumbers or innoculate with a specifically
desired bacteria.
● In either case, the bacteria are halophyllic, or salt tolerant. During the storage period of about five
weeks, these bacteria breakdown the sugars present in the vegetable and produce carbon dioxide.
● To prevent adverse effects from the carbon dioxide, the tanks are periodically degassed. Pickles
made in this way have a shelf life of many months.
● The other two methods of preservation do not require a fermentation step. One method is by direct
pasteurization. In this method, the cucumbers are bottled and then exposed to very high
temperatures for a set amount of time.
● This has the effect of killing all of the natural bacteria that may is present. These sterilized
cucumbers can then be further processed into pickles. This method of production results in pickles
that have a shelf life of only a few months. The third method is by refrigeration and acidification.
These pickles depend on the cold temperature and vinegar solution to prevent spoilage. While they
are much faster to manufacture, they have a much shorter shelf life.

41. Processing and packaging
● After the pickles have adequately fermented, the salt solution is drained.
The pickles are then immersed in water to remove all of the salt they may
have acquired during the cure. From this point, the pickles are moved
along a conveyor to a slicing machine which cuts the pickles to the
correct size depending on the type of product desired. They can be cut
into slices, chips, or can even be diced. Attempts are made to maintain as
clean an environment as possible for the pickles as contamination by
microbes could result in an undesirable product.
● After being cut, the pickles are typically placed in glass jars although
cans, plastic bottles, and pouches have also been used. The packing
machines are designed to deliver the correct amount of vegetable to each
jar. The jars are moved along to a liquid filling machine, which fills them
with the liquor. The pickle liquor consists of vinegar, salt, and other
materials mentioned previously. This liquor is premixed in a large
container prior to filling. To ensure an adequate distribution of spices,
these are some-times filled into the jars before the liquor. From the filling
machine, the jars are capped and moved along for pasteurization.

42. Pasteurization and sealing
● In order to pasteurize the pickles, they are typically exposed to high temperatures
for an extended period of time. Depending on how long the pickles are heated,
pasteurization can either kill off all of the acetic acid-tolerant organisms or inactivate
all of the enzymes in the vegetable. In both cases, pasteurization increases the
shelf life of the pickles.
● Most pickles are vacuum packed which means the air is removed from the jar
before it is sealed. This helps maintain the pickle taste and prevents contamination
by microorganisms. In order to vacuum pack the pickles, air in the jar is replaced
with steam just before the cap is sealed. When the steam cools and condenses, it
creates a vacuum, reducing the amount of free oxygen present in the jar. The
vacuum seal is responsible for the familiar pop that is heard when a jar of pickles is
opened.
● The jars are next moved along a conveyor to a labeling machine. Labels are
automatically affixed and a freshness date is stamped on the jar. From here the jars
are moved to automatic packing machines which put them in cardboard boxes.
They are transferred to pallets and shipped out to the local retailers.

43. Storage containers:
● Stainless-steel rings: For pickles can refrigerate a few weeks
● Plastic lids: For months-long storage
● Stainless-steel lids: If one-piece stainless-steel lids—still with silicone
seals to keep pickle brine from leaking.
Fermented pickle: The key rule while you’re fermenting food
should be maintained in storage: keep the pickles submerged in brine.
Invert a narrow-mouth plastic storage lid, slip it into a wide-mouth jar,
and let it fill with brine.
● The final step is to cap your ferment with a nonreactive lid. Some
airlock lids can be used for storage:A lock-and-pump lid, like
Eden Farmhouse’s MasonLock can stay on the jar as it moves to the
fridge.
Canned pickle: Mason jar with a sealed canning lid—but remove the ring.
Store on shelves a cool, dark, dry place, such as a pantry, closet, or
mudroom.
● Canned pickles must be refrigerated once they’re opened. Putting
fermented pickles in the fridge slows the process to a crawl, keeping
them at your preferred flavor and crispness. Quick pickles and fresh, unprocessed pickles are made and
then stored at fridge temp from day 1.

44. Quality Control
● Quality control is an important part of any food preparation process. It is particularly
important in pickle making because poor quality control will result in an unpalatable
product. The process begins in the field while the cucumbers are being harvested.
● Trained workers inspect the cucumbers for any signs of spoilage. If any spoiled
cucumbers are found, they are discarded. Most manufacturers set specifications that the
cucumbers must meet before use.
● During production, regular quality control measures include laboratory tests for the level
of acid in the pickle liquor. This is done through a titration method using an automatic
buret (test tube-like container).
● Other measurements that are taken on the final pickle liquor are pH, refractory sugar
readings, and salt readings. Most of the methods for these tests are described by
government regulations in publications by the United States Food and Drug
Administration.

46. REFERENCE:
● Kimchi and Other Widely Consumed Traditional Fermented Foods of Korea: A
Review https://www.frontiersin.org/articles/10.3389/fmicb.2016.01493/full
● Making and preserving Sauerkraut- https://ohioline.osu.edu/factsheet/hyg-5364
Packaging of Sauerkraut: https://www.ehow.com/how_7548797_cold-pack-
sauerkraut.html#:~:text=Fill%20sterilized%20pint%2D%20or%20quart,be%20completely
%20covered%20with%20juice.
● Traditionally fermented pickles: How the microbial diversity associated with their
nutritional and health benefits?
https://www.google.co.in/url?sa=i&url=https%3A%2F%2Fwww.researchgate.net%2Ffigu
re%2FGeneralized-flowchart-for-vegetable-based-pickles-
preparation_fig1_341040947&psig=AOvVaw2s8ZprzWeLlTZTLl_5Qf3h&ust=167860876
6714000&source=images&cd=vfe&ved=0CBEQjhxqFwoTCJDg2-
a30_0CFQAAAAAdAAAAABAT
Pickle:Twice as tasty: https://twiceastasty.com/
How pickle is made-productionprocess,manufacture, making,history,
used,..:http://www.madehow.com/Volume-4/Pickle.html