Fresh and minimally processed vegetables

Harvesting and storing

Most leafy vegetables that do not require harvesting by mechanical device are cooled immediately after harvest to remove field heat, sorted to remove debris, washed to remove dirt, and bundled or packed for shipping and retail. In most cases vegetables are bundled as whole plants, since cutting will injure the cells and liberate ethylene, which promotes senescence and shortens shelf life. Low-temperature storage is essential in the handling of quality leafy vegetables. On the other hand, storing below refrigerated temperature may lead to chilling injury of certain vegetables and to rapid loss of quality. In developing countries where refrigeration is not available, postharvest losses of fresh vegetables can be as much as half the total harvest.

For roots and legumes, the harvesting of which is normally done by machines, some sorting and grading are performed either in the field or at collection stations. Bulk handling of these vegetables is common, and few additional steps of preparation are performed before distribution. For vegetables that need to be stored for long periods of time, treatments to avoid microbial spoilage, insects, and small-animal invasion may be necessary. For some vegetables such as cucumbers, a washing and waxing step may be taken to improve the shelf life and the attractiveness of the produce.

Packaging

Provided in response to demands for convenient foods, minimally processed fresh produce has gained popularity in the marketplace. These vegetables go through additional preparation steps of washing, sorting, grading, cutting, and packaging into retail-size containers. In order to extend the shelf life of these products, vacuum packing and modified-atmosphere (MA) packaging are practiced. In most cases air is replaced by an atmosphere high in carbon dioxide and low in oxygen. This modified atmosphere can slow the respiration rate and therefore the senescence of cut vegetables. The most common products in American and European markets are various types of cut lettuces with shredded carrots, cabbages, and other vegetables. Modern packaging techniques employing “clean room” concepts make it possible for such vegetable products as salad mix and stir-fry mix to have shelf lives approaching those of the whole plants. The products can be shipped by refrigerated containers to overseas locations and still have a shelf life long enough to reach consumers.

Minimally processed vegetables normally do not contain any preservatives and have not gone through any heat or chemical treatment. The disadvantage of these products is that refrigeration storage is essential, limiting its practice to developed countries.

Blanching

After vegetables have been washed clean, they must undergo blanching (heating) in hot water at 88 °C (190 °F) for two to five minutes or with steam in a conveyor at 100 °C (212 °F) for one-half to one minute. Blanching inactivates natural enzymes that would cause discoloration and off-flavours and aromas. It also serves to reduce the number of microorganisms and to render vegetables limp for easy packing into containers. For some vegetables, such as spinach, snap beans, and collards, the blanching step also serves to remove harsh flavours.

After blanching the vegetables must go through rapid cooling in either cold water or cold air for better quality retention. The vegetables are then ready for the various food-processing methods described below.

Dehydration

Drying is probably the oldest method of preserving foods. The removal of water from vegetables is accomplished primarily by applying heat, whether it be through the radiant energy of the sun or through air heated by electrical energy. A major advantage of removing water is a reduction in volume and weight, which aids in storage and transportation of the dried products. Modern drying techniques are very sophisticated. Many machines are available to perform tunnel drying, vacuum drying, drum drying, spray drying, and freeze-drying. Although freeze-drying produces a food of outstanding quality, the cost is high, and it has not been used widely in vegetable products.

One of the most familiar dehydrated products is instant potatoes. Almost all the mashed potato dishes served in restaurants and institutions are rehydrated instant potatoes. In restaurants and institutions dehydrated potato granules are used, while dehydrated flakes are preferred for home cooking. Potato granules have high bulk density and are easy to handle in large quantity. However, they produce mashed potatoes with a pasty texture—an effect caused by the rupture of cells during processing, so that starch is released from the cells. Mashed potatoes made from flakes, on the other hand, have a mealy texture comparable to that of freshly prepared mashed potatoes. The major difference in the processing of these two dehydrated products is in the drying steps. For granules, air-lift drying is used to bring the product to 10–13 percent moisture. After screening to proper granule size, the product is dried to 6 percent moisture in a fluidized-bed drier. In the making of flakes, a steam-heated drum drier is used to bring a flattened sheet of potato solids to final moisture content before it is broken into a suitable size for packaging. Although a considerable quantity of the potato cells are ruptured during the breaking of the dried sheet, the reconstituted product has an acceptably mealy texture because the potatoes are subjected to a precooking and cooling treatment as well as the addition of a monoglyceride emulsifier.

A small amount of sulfite may be used in producing certain dried vegetables. The sulfite serves as an antimicrobial agent, aids in heat transfer, and (in the case of potatoes) acts as a blanching agent. A small percentage of the consumer population is allergic to sulfite. Although the rehydrated product contains little or no sulfite, consumer concerns are forcing the industry to search for economically feasible sulfite replacements.