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Minimal Fresh Processing of Vegetables, Fruits and Juices

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DOI: 10.1016/B978-012676757-5/50028-1

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C H A P T E R

31
Minimal Processing of Fresh
Fruit, Vegetables, and Juices
Francisco Artés 1, Ana Allende 2
1
Postharvest and Refrigeration Group, Department of Food Engineering, Technical University of Cartagena,
Cartagena, Murcia, Spain; 2Research Group on Quality, Safety and Bioactivity of Plant Foods,
Food Science and Technology Department, CEBAS-CSIC, Murcia, Spain

31.1 INTRODUCTION Minimally processed fresh fruit and vegetables (MPFVs)


are commonly defined as any fruit and vegetable that
There is an increase in fresh fruit and vegetable con- has been subjected to different processing steps (e.g.,
sumption around the world that is mainly motivated peeling, trimming, cutting, washing, disinfection,
by the recommendations made by different organiza- rinsing, etc.) to obtain a fully edible product while
tions, such as the World Health Organization, the Food providing convenience and functionality to consumers
and Agricultural Organization, the US Department of and ensuring food safety. These commodities contain
Agriculture, and the European Food and Safety Author- exclusively natural ingredients, and are bagged or pre-
ity, etc., because of their healthy properties (Allende packed in polymeric films able to generate optimal
et al., 2006; Warriner et al., 2009). Fruits and vegetables modified atmosphere packaging (MAP) conditions, and
are important sources of a wide range of vital micronu- they are kept under chilling until consumption. MPFVs
trients, phytochemicals (e.g., anthocyanins and other have similar characteristics to the whole original fruit
phenolic compounds), and fiber of great importance or vegetable, and they usually need no further process-
from the human nutritional point of view (Tomás- ing before use, offering advantages for consumers
Barberán and Gil, 2008). In fact, human nutritional because, in addition to convenience, they have high
research has increasingly shown that a well-balanced quality and they produce little waste at a reasonable
diet that is rich in fruits and vegetables promotes good price. However, although conventional food-
health, may reduce the risk of certain diseases, and pro- processing methods extend the shelf life of fruits and
tects against cancers and chronic illnesses (Meng and vegetables, the minimal processing to which fruits
Doyle, 2002; CAC, 2010). Advances in agronomic and vegetables are submitted renders the products
handling, processing, preservation, distribution, and highly perishable, requiring chilled storage to ensure
marketing technologies have enabled the produce in- a reasonable shelf life. The preparation of MPFVs
dustry to supply nearly all types of high quality fresh causes damage to plant tissue in which the natural pro-
fruits and vegetables to those who desire and are willing tective layers are eliminated, promoting many physical
to purchase them year-round. This also allows the agri- and physiological disorders that accelerate produce
food industry to provide consumers with new and a decay, reduce shelf life compared with the intact fruits
more differentiated food product assortment (Gil and and vegetables, and provide an easy entry for microbial
Allende, 2012). However, despite the benefits derived pathogens and chemical contaminants (Allende et al.,
from eating raw fruits and vegetables, safety is still an 2004a; Artés and Allende, 2005a; Artés, 2000a; Artés
issue of concern (Lynch et al., 2009). In the European et al., 2007, 2009, 2011, 2012; Kader, 2010).
Union (EU), in 2009 and 2010, respectively, 4.4% and The deterioration of MPFVs occurs mainly due to
10% of foodborne verified outbreaks were linked to the further physiological aging, biochemical changes, and
consumption of vegetables, fruits, berries, juices, and microbial spoilage, which result from changes in respi-
the products thereof (EFSA, 2013). ration, ethylene (C2H4) emission, transpiration, and

Emerging Technologies for Food Processing 583


http://dx.doi.org/10.1016/B978-0-12-411479-1.00031-0 Copyright © 2014 Elsevier Ltd. All rights reserved.
584 31. MINIMAL PROCESSING OF FRESH FRUIT, VEGETABLES, AND JUICES

enzymatic activity of the living tissues after processing Pseudomonas spp. or Micrococcus spp.) and food-poisoning
(Nguyen-the and Carlin, 1994; Ahvenainen, 1996). (e.g., Listeria monocytogenes or Yersinia enterocolitica)
Many of the compositional changes influence the bacteria remain a concern because they possess cold-
MPFVs’ color, texture, flavor, and nutritive values, lead- adapted proteins and membrane lipids that facilitate
ing to an irreversible loss of quality. The main spoilage growth at the chilling temperatures applied for extending
changes affecting MPFV are discoloration, off-flavors, shelf life (Nguyen-the and Carlin, 1994; Russell, 2002).
softening (loss of crispness or juiciness), and water However, a Scientific Opinion published by the EFSA
loss. Therefore, sensory quality can never improve dur- (2013) has reported that the five top-ranking groups of
ing further storage; instead, the quality can only be food/pathogen combinations were Salmonella spp. with
retained or its deterioration can be slowed down (Artés, leafy greens eaten raw as salads, with bulb and stem veg-
2000a; Willocx, 1995; Jacxsens, 2002). To slow down dete- etables, and with tomatoes and melons as well as patho-
rioration, storage temperature is the single most impor- genic Escherichia coli with fresh pods, legumes, or grains.
tant factor affecting the spoilage of MPFVs. However, Production of safe fruit and vegetables includes the use of
there are many other preservation techniques used by Good Agricultural Practices (GAPs), Good Hygienic
the MPFV or fresh-cut industry, such as antioxidants, Practices (GHPs), and systematized environmental sani-
sanitizers, and MAP, as well as good manufacturing tation such as Sanitation Standard Operating Procedures
and handling practices in well-designed factories (Artés (SSOPs), which aim at preventing contamination with
et al., 2009; Artés and Artés-Hernández, 2003; Willocx, pathogens (Artés, 2004; CAC, 2003; IFPA, 2001). Thus,
1995). In addition to providing food products with the the primary production of fruits and vegetables should
right sensorial and microbial quality, the industry needs not be performed in growing fields where the presence
to achieve a high nutritional value (Soliva-Fortuny and of pathogens would lead to an intolerable level of such
Martı́n-Belloso, 2003). Nevertheless, the fresh-cut indus- microorganisms in the final seed crop, and efforts should
try is currently seeking alternative or secondary techniques aim at avoiding the introduction of pathogens in the field
to maintain most of the fresh quality attributes, storage and in the crop (EFSA, 2011). In addition, the production
stability, and safety of MPFVs while extending their of safe foods includes screening materials entering the
shelf life, although long shelf life is no longer the most food chain, suppressing microbial growth, and reducing
important selling argument with the market trends to- or removing the microbial load by processing and
ward more fresh-like products (Gil and Allende, 2012; preventing postprocessing contamination (Artés and
Jacxsens, 2002). For example, the use of edible coatings Allende, 2005).
in combination with antibrowning agents to maintain Research on alternative or emerging sanitizing technolo-
fresh-cut pears’ color has been proposed (Oms-Oliu gies was initially focused on process design, product char-
et al., 2008). acteristics, and the kinetics of microbial inactivation, but
For producers, handlers, shippers, fresh-cut proces- it is clear that their success also depends on a good under-
sors, foodservice, retailers, regulatory agencies, and the standing of the physiological responses of microorgan-
consumers of perishable, edible, fresh-processed com- isms to stresses imposed during food preservation
modities, there should be no doubts that prevention (Lado and Yousef, 2002). In addition, the emergence of
and rigorous microbial food safety are critical concerns microorganisms resistant to conventional preservation
of the food industry (Sapers, 2001; Suslow, 2002). The techniques (freezing, thermal treatments, etc.) increases
contamination of fresh produce with human pathogens the need of developing new techniques to inhibit un-
appears to be of low probability but of potentially high wanted microbial growth as microorganisms adapt to
consequence, because of the few cases of illness associ- survive in the presence of previously effective methods
ated with raw fruit and vegetables compared with those of control (EFSA, 2008). Only a few of these conventional
with food of animal origin (Suslow, 2002). preservation methods are applicable to MPFVs, such as
The most important fresh produce food safety issues chemical treatments (e.g., antioxidants, chlorination, anti-
for the European fresh produce market are bacterial path- microbial solutions, acidulants, etc.), MAP storage, and
ogens, viruses, and pesticides residues (Van Boxstael mild heat (40e50 C) treatments (Artés and Allende,
et al., 2013). In the past, the contamination of fresh 2005; Artés-Hernández et al., 2010). Therefore, many
produce within human pathogens appeared to be of nonconventional methods, such as ultraviolet-C (UV-C)
low probability. However, from 2008 to 2011, there was light, cold plasma, pulsed electric fields (PEFs), magnetic
an increase in the numbers of reported outbreaks, fields, high-intensity pulsed light, high hydrostatic pres-
hospitalizations, and deaths associated with fresh fruit sure (HHP), alternative disinfection techniques, antimi-
and vegetables. These foods have the potential to be crobials of natural origin, and new edible coatings have
associated with large outbreaks, as seen in 2011 associ- being investigated. However, in most cases, the safety
ated with VTEC O104 in Germany and France (EFSA, of these foods is based on the application of a combina-
2013). Cold-adapted psychrotrophic food-spoiled (e.g., tion of various treatments, taking advantage of the

VI. MINIMAL PROCESSING


31.2 FACTORS AND PROCESSING OPERATIONS THAT AFFECT THE QUALITY OF MINIMALLY PROCESSED PLANT FOODS 585
synergisms of the different preservation hurdles close up and preparation and the increasing demand for high-
and following the principle of the “hurdle effect” quality produce. Currently, it is obvious that modern
or “hurdle technology” (Carlin and Nguyen-the, 1997; processing factories require raw materials of high qual-
Leistner and Gould, 2002). Ross et al. (2003) pointed out ity, homogeneity, and stable characteristics fulfilling
that a good understanding of the modes of action of specific conditions for their specific use. Only a few ex-
each individual treatment is crucial for selecting effective ceptions to this general rule can be considered and are
antimicrobial combinations. mainly related to external defects in fruits or
vegetables.
To achieve best results in this industrial activity, the
31.2 FACTORS AND PROCESSING plant raw materials must be carefully chosen regarding
OPERATIONS THAT AFFECT THE their ability to support the different processing steps.
QUALITY OF MINIMALLY PROCESSED For example, the “processability,” which is the ability to
PLANT FOODS withstand these processing operations, can be affected
by the tissue moisture content (Clarkson et al., 2003;
The quality and safety of MPFVs depend on many Medina et al., 2012). To ensure the safety and quality of
factors, including those also affecting the quality and all incoming raw materials, implementation of a quality
safety of intact fruit and vegetables (e.g., GAPs and management standard has been recommended as a basis
GHPs) and specific factors such as handling procedures; for an agreement between the supplier and the MPFV
the quality of process wash water; processing technolo- manufacturer. Those steps during production in which
gies; packaging methods and materials; and transporta- control and/or reduction of microbial hazards could be
tion, processing, storage, distribution, and retail sale possible might permit implementation of Hazard Anal-
temperatures. The most common factors influencing ysis and Critical Control Point (HACCP) systems for haz-
the shelf life and safety of MPFVs are summarized in ard prevention and control. Thus, based on the HACCP
Figure 31.1. The distribution chain of food products is principle, control of critical points is strongly recommen-
generally composed of many different steps in storage ded (Artés et al., 2007). However, it should also be taken
and transportation up until consumption, and trace- into account that HACCP as such is not valid for primary
ability is a key concept (Allende et al., 2004a). production because no interventions currently exist to
reduce pathogens to an acceptable level or to completely
eliminate them (EFSA, 2011; Gil et al., 2013).
31.2.1 Plant Material The fundamental principle underlying the quality of
fresh fruits and vegetables is that they are living tissue
The fresh-cut industry began minimal processing as a showing a physiological response to minimal processing
salvage operation to use off-grade and second-harvest procedures and to postprocessing handling and treat-
products, but it was soon recognized that high- ments (Toivonen and DeEll, 2002). Respiratory activity is
quality raw materials were required because of the a metabolic process that provides the energy for a plant
increased perishability caused by product handling cell to stay alive and develop physiological and
biochemical processes. Several factors affect the respira-
tion rate of the product, such as the type and maturity
• DehydrataƟon • Spoilage stage, the kind of processing, and storage conditions
• Decay • Pathogens (Fonseca et al., 2002; Gorris and Peppelenbos, 1999;
Martı́nez et al., 2005; Martı́nez-Sánchez et al., 2008). Cut-
ting fruits and vegetables for processing provokes a
Mechanical Microbial
wound stress response, and compared with those of the
damage growth
intact product, the respiration rate and C2H4 emission
are commonly increased, and undesirable enzymatic re-
actions are stimulated that result in browning (Brecht,
1995; Martı́nez et al., 2005). In addition, when MPFVs
Biochemical Physiological
are stored under MAP, the respiratory activity of plant
changes ageing
tissues is slowed down by decreasing the available O2
• Surface browning • DehydrataƟon
• SoŌening • Increasing: - RespiraƟon rate as a consequence of the reduction of overall metabolic
• Loss of texture - Ethylene producƟon activity. MAP depends on the interaction between the
• Loss of appearance respiration rate of the commodity and the permeability
FIGURE 31.1 Factors that affect the MPFVs’ decay and shelf life.
characteristics of the film for a specific mass and pack-
(For a color version of this figure, the reader is referred to the online age surface area (Artés, 2000b; Artés et al., 2006; Kader,
version of this book.) 1989; Majan et al., 2006; Martı́nez-Sánchez et al., 2011).

VI. MINIMAL PROCESSING


586 31. MINIMAL PROCESSING OF FRESH FRUIT, VEGETABLES, AND JUICES

C2H4 has numerous effects on the growth, develop- and nutritional quality of MPFVs, it is not surprising
ment, and storage life of many fruits and vegetables, that considerable research has been devoted to inhibit
and it affects attributes that contribute to appearance the activity of this enzyme (Artés et al., 1998, 2007; Gil
(Saltveit, 1999). As expected, the introduction of and Allende, 2012).
improved cultural practices, cultivars, harvest and
handling methods, postharvest treatments, and pack-
aging influences the effect of C2H4 on MPFVs. Many ac- 31.2.2 Processing Line, Distribution,
tions can be taken to mitigate the effects of C2H4 on and Storage Conditions
plant tissues, such as reducing metabolism by keeping
the exposed tissue at its lowest recommended storage 31.2.2.1 Processing Line
temperature and/or O2 levels. In addition, C2H4 Minimal processing operations involve the application
action can be blocked by some compounds, including of several unit operations (Figure 31.2) that can provide
carbon dioxide (CO2) and 1-methylcyclopropene opportunities for cross-contamination, in which a small
(1-MCP) (Saltveit, 2004). 1-MCP acts as an inhibitor of lot of contaminated product may be responsible for the
C2H4 reception and provides commercial potential to contamination of a large lot (IFPA, 2001; FDA/CFSAN,
control C2H4-dependent processes; however, it was 2008). Prevention and sanitation become the most impor-
found that 1-MCP is not as effective for leafy tissues tant tools for keeping the microbial quality and safety of
as it is for floral organs. Toivonen (2008) reported that MPFVs. All processors must comply with requirements
the literature with regard to the use of 1-MCP in MPFVs for GHP in accordance with this regulation, thus prevent-
does not provide any clear conclusions, except that ing the contamination of food. In fact, fresh-cut proces-
respiration and C2H4 production are nearly always sors must implement procedures that are based on the
affected in climacteric and nonclimacteric produce. HACCP principles to effectively monitor the risks. If
The variability in response could be apportioned to properly implemented, preventive sanitation programs
cultivar, maturity, temperature, or other differences such as GAPs, Good Manufacturing Practices (GMPs),
among reports. In fact, the more promising use of and SSOPs are likely to minimize the chance of initial
1-MCP seems to involve the co-application of other contamination and postcontamination by pathogenic bac-
treatments or suitable atmospheres to achieve treat- teria, viruses, and parasites (Artés, 2004; EFSA, 2013;
ment response synergies leading to reliable overall IFPA, 2001; Tomás-Callejas et al., 2011; WGA, 2012).
quality and shelf life improvement. The sequences of steps needed in a typical industrial
The browning of fresh fruits and vegetables is an factory of MPFVs have similarities, although they
ever-present problem during postharvest handling, pro- require specific and differentiated steps (Artés and
cessing, and storage. It is one of the major causes of qual- Allende 2005; Artés and Artés-Hernández, 2003). The
ity loss and very often is the factor limiting the shelf life general unit operations and the maximum recommen-
and marketability of MPFVs. This phenomenon can be ded temperatures for each processing step in the produc-
due to enzymatic and nonenzymatic reactions. Enzy- tion line of fresh-cut leafy vegetables are shown in
matic browning requires different components: enzymes Figure 31.3. However, the most significant steps of the
such as polyphenol oxidase (PPO) and peroxidase, a sub- processing chain (washing, cutting, disinfection, and pack-
strate, and co-substrates such as O2 and hydrogen aging) that significantly affect the final quality of the
peroxide (H2O2). The disorder takes place at the cut sur- products match up in both production lines. It should
face of fruits and vegetables because of the decompart- be taken into account that once the raw material is within
mentation that occurs when cells are broken, allowing the industry, all accepted products must be received in a
substrates and oxidizers to come in contact. Given the low-temperature controlled area, or quickly moved into
deleterious effects of PPO activity upon the sensory a cold room at the appropriate temperature, or moved

FIGURE 31.2 Unit operations that can provide opportunities for cross-contamination. (For a color version of this figure, the reader is referred
to the online version of this book.)

VI. MINIMAL PROCESSING


31.2 FACTORS AND PROCESSING OPERATIONS THAT AFFECT THE QUALITY OF MINIMALLY PROCESSED PLANT FOODS 587

Maximum FIGURE 31.3 General unit operations in


recommended a processing plant of MPFVs and the
maximum recommended temperatures for
temperature
each processing step. (For a color version of
this figure, the reader is referred to the online
Harvesting
HARVESTING 25-–30
25- 30ºC
ºC version of this book.)

Transport
TRANSPORT 10 ºC

PrecoolingAND
PRECOOLING andCHILLING
chilling storage
STORAGE 5 ºC

Manual
MANUAL selection AND
SELECTION and classification
CLASSIFICATION 10 ºC
DirtyAREA
area

Whole
WHOLE product WASHING
PRODUCT washing 10 ºC
DIRTY

Cooling
COOLIING 5 ºC

Trimming
TRIMMING operation
OPERATION 10 ºC

DisinfectionWASHING
DISINFECTION washing 5 ºC

Rinsing
RINSING 5 ºC

Dewatering and
DEWATERING ANDspin
SPINdrying
DRYING 10 ºC
Clean AREA
area

WeightAND
WEIGHT and OPTIONAL
optional mixing
MIXING 10 ºC
CLEAN

Active or pasive modified atmosphere packaging 10 ºC


ACTIVE OR PASIVE MODIFIED ATMOSPHERE PACKAGING

Wholesale
WHOLESALE COLDcold storage and
STORAGE ANDquality
QUALITYcontrol
CONTROL 00–1ºC
–1 ºC

Cold
COLD transport and
TRANSPORT ANDdistribution
DISTRIBUTION 5 ºC

RetailCOLD
cold storage 5 ºC
RETAIL STORAGE

5 ºC
Consumer
CONSUMER

directly to the processing room. If a plant product unwanted dirt, pesticide residues, plant debris,
exhibits signs of chemical or physical contamination or soil, insects, and foreign matter and to slow down the
other defects, then interventions should focus on the enzymatic discoloration reactions (Soliva-Fortuny and
use of equipment for the grading, trimming, and selec- Martı́n-Belloso, 2003), as indicated in Figure 31.3. Tap
tion of raw materials to eliminate damaged, spoiled, or water or sodium or calcium hypochlorite and other salts
potentially hazardous product (FDA/CFSAN, 2008). are applied for the surface sanitation of fruits.
The following steps will vary depending on the type of Sodium hypochlorite (NaClO) is the most widely
commodity to be minimally processed (Artés and used salt used for the surface sanitation of fruits.
Allende, 2005; Artés and Artés-Hernández, 2003). Although it is more efficient at low pH levels, values be-
tween 6 and 7.5 should be selected to reduce the risk of
31.2.2.1.1 WHOLE PRODUCT WASHING corrosion of metallic processing equipment (Beuchat,
The first step in the minimal fresh processing of fruits 2000). However, many researchers have demonstrated
is generally washing of the whole fruit to eliminate that after pathogens have infected their host, none of

VI. MINIMAL PROCESSING


588 31. MINIMAL PROCESSING OF FRESH FRUIT, VEGETABLES, AND JUICES

the available disinfection techniques are very effective microbial load of the water at a lower level (López-Gál-
(Gil et al., 2013). vez et al., 2010; Holvoet et al., 2011). In the second tank,
the microbiological load is further decreased, but the
31.2.2.1.2 PEELING AND CUTTING most important function is to minimize cross-
The peeling and cutting steps constitute a critical point contamination during the wash and chill process (Luo
in the processing line hygiene, and the equipment used et al., 2011). The sanitation of the product takes place
in this process needs to be cleaned, disinfected, and in the second tank, where the water is treated with an
sharpened at regular intervals every working day to agent that is designed to prevent cross-contamination
avoid the build-up of organic residues and to reduce during washing (FAO, 2008). The last stage before pack-
damage caused to the product (CAC, 2003; FDA/ aging should be the rinsing step, which requires very
CFSAN, 2008). Cutting and peeling appears to have a low doses of disinfecting agent to achieve good results.
dramatic effect on the nutritional value, overall quality, Many studies have been performed on the use of san-
safety, and shelf life of MPFVs (Aguayo et al., 2004; itizers, but in the EU there is still discussion about their
Ahvenainen, 2000; Artés, 2000a; Barry-Ryan and use, and each member state needs to approve this (EC
O’Beirne, 1999; Simoes et al., 2009). Many different 852, 2004). Among sanitizers, ease of use and relatively
peeling machines are available, but peeling is normally low cost mean that chlorine is still the most widely
accomplished by hand, mechanically, chemically, or in used option as a disinfection agent able to prevent path-
high-pressure steam peelers. Several methods are able ogen cross-contamination of produce during washing
for cutting, grating, chopping, shredding, slicing, or (López-Gálvez et al., 2009; Luo et al., 2011). Recent studies
chipping fresh produce into pieces of various shapes have evidenced that low (5e20 ppm) free chlorine levels
and sizes (Allende et al., 2004a). are enough to avoid cross-contamination in wash water
containing high loads of organic matter (Gómez-López
31.2.2.1.3 WASHING AND DISINFECTION et al., 2013a). One of the main disadvantages associated
Washing is a critical part of any plant produce prepa- with the use of chlorine or chlorine-based sanitizers is
ration process because MPFVs are commonly sold as the potential generation of trihalomethanes (THMs),
“ready-to-eat” (Sapers, 2001). In fact, washing and disin- which has become one of the main concerns for re-
fection are the only steps in the production chain in searchers, industry, and regulatory agencies. In fact, these
which a reduction in the microbial load including poten- negative aspects have induced some European countries
tial pathogens can be obtained. Published efficacy data (e.g., Germany, the Netherlands, Denmark, Switzerland,
indicate that washing is not capable of reducing the mi- and Belgium) to forbid the use of chlorine for the disinfec-
crobial population on produce by more than 90 to 99%d tion of MPFVs (Artés et al., 2011). However, only scarce
reductions that are insufficient to ensure microbiological information is known about the actual THM formation
safety. MPFV producers often incorrectly assume that in process wash water and in the final product to estab-
chemicals are used to sanitize fruits or vegetables; how- lish the real risks associated with it. Recent studies have
ever, sanitizers are primarily used to maintain the bacte- reported that total THM levels of the process wash water
riological quality of the water rather than the produce treated with NaClO were slightly over the authorized
(Brackett, 1999; Zagory, 1999). Many reviews have limit fixed by the legislation of the EU and the US Envi-
recently summarized the limiting factors of washing ronmental Protection Agency (100 and 80 mg/l, respec-
and disinfection technologies (Artés et al., 2011; Gil tively) for drinking water. In addition, the THM levels
et al., 2009; Goodburn and Wallace, 2013; Olaimat and in the vegetable tissue were below the detection limit
Holley, 2012). Washing can be achieved very simply by (Gómez-López et al., 2013b). Therefore, chlorine-based
spraying with potable water, although it generally in- sanitizers, used under optimal conditions, should not
volves the immersion of product in chilled (1e10  C), represent a high risk of THM formation.
sanitized water in a bath or wash tanks usually contain- The use of chlorinated water has also raised questions
ing approximately 50 ppm of free chlorine, acidified because many microorganisms exhibit resistance to
with approximately 150e200 ppm of citric acid to keep chlorine treatments, even when used at low concentra-
pH values between 6.5 and 7.5 for optimum efficacy. tion; chlorine may cause taste and odor defects in treated
However, modern aeration “jacuzzi” washing systems products; there are risks of health hazards to workers
generally consist of three separate washing stages and because of the toxicity of chlorine; and there are prob-
three tanks. The first of these tanks aims to eliminate lems due to the disposal of waste chlorinated water
general field dirt and debris. The microbiological load (Dychdala, 1991; Nguyen-the and Carlin, 1994; Simons
of this wash water increases rapidly; therefore, proper and Sanguansri, 1997; Singh et al., 2002). For more
water management is implemented by filtration and than 15 years, the fresh-cut industry has been investi-
refreshing the water, respecting the product-to-water ra- gating alternative disinfection agents such as chlorine
tio, and application of a disinfecting agent to keep the dioxide (ClO2), organic acids, H2O2, quaternary

VI. MINIMAL PROCESSING


31.3 EMERGING TECHNOLOGIES FOR KEEPING THE MICROBIAL AND SENSORY QUALITY OF MPFVS 589
ammonium compounds, trisodium phosphate, sucrose 31.2.2.2 Packaging, Distribution, and Storage
esters, iodine compounds, alcohols, anionic and Conditions
nonionic surface-active agents, aldehydes, phosphoric Virtually all MPFV products are refrigerated under
acids, cysteine, methyl jasmonate, and bioflavonoids. MAP to achieve the needed commercial shelf life. MAP
Physical methods that have been proved to prevent consists of the alteration of the gaseous environment
cross-contamination in process wash water include ul- that results from produce respiration (passive MAP) or
trasound, high pressure, high-intensity electric field from the addition or removal of gases from packages
pulses, ultraviolet radiation, radio-frequency, and (active MAP) combined with the gas permeability of the
ionizing radiation. film package to reach the optimal O2 and CO2 levels for
The most common method used to control enzymatic a specific mass of product and package area (Artés,
browning in MPFVs is the addition of reducing agents to 2000b; Artés et al., 2006; Gorris and Peppelenbos, 1992).
the washing solution. This prevents browning by MAP has the potential to extend the shelf life of MPFVs,
reducing the quinones back to their parent o-diphenols, mainly by limiting the oxidation processes and the prolif-
and the compounds used include sulfites and ascorbic eration of aerobic spoilage microorganisms. However, it
acid, which act as PPO inhibitors and antimicrobial is well known that temperature is the most important envi-
agents. In addition, some antioxidants can be used in ronmental factor that influences the deterioration rate of
washing to avoid browning, but only a few chemicals commodities. The marketing temperature recommended
are allowed in the EU (Artés and Allende, 2005). for MAP of MPFVs is between 0  C and 5  C, but these
products are often kept at 10e12  C, an abusive tempera-
ture, in display cabinets (Oliveira et al., 2010). Thus, the
design and selection of the appropriate polymeric film
31.2.2.1.4 DEWATERING
for trays or bowls as well as for sealing is crucial (Artés
The next critical processing operation is dewatering et al., 2006; Artés and Artés-Hernández, 2003; Martı́nez-
(Figure 31.3). Drying or dewatering of wet surfaces must Sánchez et al., 2011).
be performed carefully to avoid damage to the plant tis- Some negative effects related to the use of MAP have
sues, reducing the product moisture content, and been reported. Among them, the risks of water condensa-
removal of cell leakage that can support microbial tion within packages due to temperature fluctuations or
growth (Simons and Sanguansri, 1997; Soliva-Fortuny the impossibility to act externally on the gas composition
and Martı́n Belloso, 2003). Dewatering systems include within packages, except by changing the temperature or
draining devices, gentle removal with cheesecloth, cen- by perforating the film, are relevant (Artés et al., 2006).
trifugal spin driers, vibrating racks, rotating conveyors,
hydrosieves, forced air, and spinless drying tunnels. The
high centrifugal force not only removes water, but it also 31.3 EMERGING TECHNOLOGIES
cracks and crushes the tissues (Ahvenainen, 2000). The FOR KEEPING THE MICROBIAL AND
time and speed of centrifugation, or alternative dewater- SENSORY QUALITY OF MPFVS
ing systems, are key parameters to be adjusted for each
product. To reduce tissue damage and consequently mi- The emphasis on healthier and fresh-like fruit and vege-
crobial deterioration in leafy vegetables that are too deli- table products has shifted from using traditional methods
cate to withstand centrifugation, forced chilled air of preservation to using minimal processing techniques
injected over a perforated conveyor belt that transports that retain the nutritional and sensory quality while
the product, or air-bed conveyors, are in widespread ensuring the safety of these products (Rico et al., 2007).
use across Europe and the United States, although their Minimal processing techniques are usually milder in
efficiency to dry high volumes should be optimized response to the demands of consumers for higher quality,
(Artés and Artés-Hernández, 2003; Turatti, 2011). more convenient foods that are less heavily processed. It
Between the drying and packaging steps, it could be should be clear that the best way to ensure the microbial
interesting to study the possible use of techniques and sensory quality of MPFVs relies on refrigerated stor-
already applied in clean room technology by fitting a age and distribution. However, the combination of chill-
filtered air system able to ensure the presence of fewer ing and subinhibitory preservation techniques could
than 70 particles with a diameter greater than 5 mm prolong their shelf life while ensuring safety.
and fewer than 10,000 particles with a diameter greater
than 0.5 mm (Artés and Artés-Hernández, 2003; Artés
et al., 2007; Havet and Hennequin, 1999). However, the
31.3.1 Disinfection
efficiency of this approach has not been widely
researched, and some initial results showed that the Chlorinated agents are commonly used for water
benefits are still unclear (Silveira et al., 2010). disinfection and MPFV sanitization. However, because

VI. MINIMAL PROCESSING


590 31. MINIMAL PROCESSING OF FRESH FRUIT, VEGETABLES, AND JUICES

of potential safety issues, a strong effort is being made in reduced E. coli growth. Therefore, there is evidence
the search for alternatives to the use of chlorine for that supports the potential use of the natural microbiota
MPFV sanitization with two main objectives: (1) finding of fruits and vegetables as bioprotective agents against
a more effective sanitizer and (2) avoiding the risks asso- foodborne pathogens.
ciated with chlorination byproducts. Some alternatives
to sanitizing agents are ozone (O3), ClO2, peroxyacetic 31.3.2.2 Intense Light Pulses
acid (w90e100 ppm), H2O2, organic acids (acetic, lactic, Intense light pulses are an emerging technique for the
citric, malic, sorbic, and propionic acids at 300e500 mg/ decontamination of food surfaces and are approved by
ml), electrolyzed water, radio-frequency, hot water treat- the US Food and Drug Administration. Intense light
ments, UV-C radiation, and intense light pulses. Howev- pulses could be capable of sanitizing MPFVs at an in-
er, after several years of research, only a few of these dustrial scale (Artés-Hernández et al., 2010). It seems
promising emerging techniques are being currently that intense light pulses induce structural changes in mi-
applied in the fresh-cut industry. In fact, most of the crobial DNA that are comparable to the effect caused by
emerging techniques recognized as potential eco- continuous ultraviolet sources, but other mechanisms
innovative alternatives still need to be tested under com- seem to be involved (Takeshita et al., 2003). Intense light
mercial processing conditions (Artés et al., 2009, 2011). pulses were able to kill microorganisms by using short
Among all of the probable alternatives, ClO2, peroxyace- (85 ns to 0.3 ms), high frequency pulses (0.45e15 Hz)
tic acid, heat shock, O3, and UV-C, alone or combined, or 3e551 J/pulses of an intense broad spectrum rich in
have already been used by the fresh-cut industry, UV-C light (Gómez-López et al., 2005). Because the
although with some limitations. In fact, all of these decontamination effect seems to be dependent on light
options are efficient in maintaining the quality of the absorption by microorganisms, certain food components
process wash water, but other problems such as corro- could also absorb the effective wavelengths and
sion or operator safety are of concern (Abadias et al., decrease the efficiency of the method (Artés et al., 2009).
2011; Artés et al., 2011; Gil et al., 2009; López-Galvez
et al., 2010). However, up to now, chlorine seems to be 31.3.2.3 Novel Map
the most efficient and cheapest option to maintain the MAP is widely used to maintain the quality of MPFVs
quality of process wash water with little or no effect (Ahvenainen, 1996; Artés, 2000a,b, 2004; Gorris and
on the THM accumulation (Gómez-López et al., 2013; Peppelenbos, 1992; Kader, 1986). Typical atmospheres
Van Haute et al., 2013). are in the range of 0.5e5 kPa O2 and 3e10 kPa CO2. How-
ever, novel MAP technologies that allow for an extension
of shelf life are still much demanded by producers and
31.3.2 Other Emerging Techniques distributors. It has been suggested that atmospheres
enriched with noble gases such as argon, or with
31.3.2.1 Biocontrol superatmospheric O2, might be more effective than the con-
The use of natural microbiota and/or their antimicro- ventional low O2 (N2-enriched atmospheres) for control-
bial products as a biopreservation technique seems to be ling enzymatic browning (Day, 2000; O’Beirne et al.,
promising (Allende et al., 2007a). However, it should be 2011). However, conflicting results have been published.
taken into account that the use of protective cultures It seems that in produce, the effectiveness of noble gas
should only be considered as a supplement to GMPs enrichment in slowing produce deterioration is due to
and not as a substitute for the proper handling and pack- its ability to inhibit enzymatic oxidase activity, whereas
aging of MPFVs. The native microbiota established on neither CO2 nor N2 is efficient at depressing oxidase ac-
food may have inhibitory properties against contami- tivity (O’Beirne et al., 2011). The use of superatmospheric
nating foodborne pathogens; therefore, via competition O2 has been reported to inhibit enzymatic discoloration,
or antibiosis, they function as a hurdle to pathogen microbial growth, and anaerobic respiration in a range
growth and survival (Alegre et al., 2013). Lactic acid bac- of MPFVs (Allende et al., 2002, 2004b, 2007b; Gómez
teria have been used for centuries for the fermentative et al., 2006; Jacxsens et al., 2001; Kader and Ben-
preservation of many foods, and some attempts have Yehoshua, 2000; Maghoumi et al., 2013; Martı́nez-
been made to use them for the preservation of MPFVs Hernández et al., 2013; Oms-Oliu et al., 2008; Tomás-Call-
(Carlin and Nguyen-the, 1997; Allende et al., 2007a). ejas et al., 2012). In addition, high O2 combined with high
For example, Trias et al. (2008) found five strains of lactic CO2 improves the microbial and sensory quality of
acid bacteria that were able to inhibit L. monocytogenes MPFVs such as fresh-cut peppers (Conesa et al., 2007a).
and Salmonella typhimurium in apple wounds. More The potential antimicrobial benefits of nitrous oxide
recently, Abadias et al. (2009) and Alegre et al. (2013) (N2O)-enriched atmospheres in MAP has been studied
found that the application of the Candida sake in apple recently (Artés et al., 2009). It has been found that N2O
wounds and Pseudomonas graminis in fresh-cut apple extended the shelf life of some MPFVs. Using this

VI. MINIMAL PROCESSING


31.4 EMERGING TECHNOLOGIES FOR MINIMALLY PROCESSED FRESH FRUIT JUICES 591
treatment, apple and kiwifruit slices kept their quality for added value than single fresh-cut melon (Silveira et al.,
up to 12 days at 4  C packed under MAP with decreased 2013).
O2 and increased CO2 levels (both at 5 kPa) balanced with
N2O (Rocculi et al., 2004, 2005). Also, N2O-enriched MAP 31.3.2.5 Genetic Engineering Technology
was found to be useful for keeping the quality of fresh-cut The use of genetic engineering to develop more pro-
spinach leaves for longer than conventional passive and ductive and more resistant plant foods is relatively well
superatmospheric MAP (Rodrı́guez et al., 2010). known. This technology is commonly used to introduce
However, the results for the inhibition of enzymatic desirable attributes such as improved color, aroma, fla-
browning achieved in vivo with high O2 or argon- vor, and taste into different fruit and vegetable prod-
enriched atmospheres are often contradictory. In general, ucts. In fact, the first transgenic product introduced as
the results suggest that the benefits of argon- or O2- a food commodity was a tomato with reduced polyga-
enriched atmospheres may be relatively small (O’Beirne lacturonase activity. Although huge advances in these
et al., 2011). Many authors have described the antimicro- techniques took place in the last decade, there is still
bial activity of CO2 and its use in MAP. CO2 is the most a lack of published information about the development
important component of gas mixtures applied to MPFVs of genetically modified fruit and vegetables that have
because of its antimicrobial activity. This is due to the in- overcome some relevant problems of postharvest sci-
crease of the lag phase and the generation time of ence, such as chilling injury resistance, longer shelf
spoilage microorganisms and the formation of carbonic life, or pathogen resistance. However, differences in
acid, which possibly lowers the pH of the food to bacte- chilling acclimation between leaves and fruits at the
riostatic levels (Artés, 2004; Devlieghere et al., 1997; Gor- molecular level (Weiss and Egea-Cortines, 2009) have
ris and Peppelenbos, 1992). been identified, indicating the importance of specific
The development of new packaging materials will tissue studies. Moreover, biochemical aspects are
allow for avoidance of anaerobic conditions and a reduc- differentially affected by chilling injury, such as the
tion in respiration rate, C2H4 emission, and browning; synthesis of sugars, organic acids, and antioxidants or
weight loss to longer maintain the fresh properties of glutathione (Gómez et al., 2009). Concerning pathways
MPFVs; attenuating undesirable changes in sensory involved in the control of ripening and postharvest-
quality; and controlling microbial growth (Artés, 2004). related traits, the identification of expansins and C2H4
This is known as “active” or “smart” packaging, and it re- receptors (Brummell et al., 1999; Kevany et al., 2007)
sponds actively to changes in the food package. As an as candidate genes for improving these aspects re-
example, smart packaging can now include materials quires further validation in various crops. Therefore,
designed to absorb or emit chemicals during storage, much more effort should be applied in this area, and
thereby maintaining a preferred environment within advances in functional genomics should bring candi-
the package that maximizes product quality and shelf date genes to light (Artés, 2004).
life (Ohlsson, 2000). Therefore, the use of nonconven-
tional MAP combined with antimicrobials, moisture ab-
sorbers, and edible films, or those films fitted with porous 31.4 EMERGING TECHNOLOGIES
substrates covered with side-chain crystallizable poly- FOR MINIMALLY PROCESSED
mers or with an O2 emitter and/or CO2 or C2H4 scav- FRESH FRUIT JUICES
enging devices, will also have many potential
applications. The market for unpasteurized fruit and vegetable jui-
ces has increased over the past few years because of
31.3.2.4 Innovative Combinations characteristics such as freshness, high vitamin content,
Fruits presented for direct consumption as peeled, low calorie contribution, and good nutritional quality
cut, and packaged or in salads have become increasingly (Raybaudi-Massilia et al., 2009). Minimally processed
attractive to consumers. In parallel, unpasteurized fresh fresh fruit juices have low acidity (pH > 4.6) and high
fruit juices obtained by pressing or squeezing are also water activity (aw > 0.85), which allow for the growth
being consumed in larger quantities. This is well related of various pathogenic microorganisms that can be
to the high vitamin and low calorie content with the ac- controlled through pasteurization. However, traditional
curate sensory quality of fresh-cut fruits and natural jui- thermal treatments adversely affect the sensory and
ces as suitable components of any healthy diet. Thus, nutritional properties of foods (Pilavtepe-Celik, 2013;
blends of both kinds of fresh products could be of inter- Wolbang et al., 2008). The development of emerging
est to consumers. In this way, the combination of fresh- technologies that use a lower temperature than tradi-
cut melon with several commercial fruit juices and nat- tional heat treatment and guarantee a final food product
ural mild heat-treated melon juices has been evaluated. that preserves as much as possible the fresh properties
The new products were of good quality, having higher of the fruit juices is still needed. A mild preservation

VI. MINIMAL PROCESSING


592 31. MINIMAL PROCESSING OF FRESH FRUIT, VEGETABLES, AND JUICES

treatment (generally heat) combined with chilling to The physical parameters include the temperature of
maintain flavor and nutritional properties is required processing and storage, water activity, pH, the redox
(Oey et al., 2008). potential of the product, etc., and the chemical and
The emergence of novel spoilage microorganisms in biochemical parameters include antimicrobial, antioxi-
juices also poses a new challenge for the correct preser- dant, bactericide, etc. These parameters can be controlled
vation of these food products. Fruit juices have been at levels that can inhibit or inactivate the microbial load to
considered for many years to be susceptible to spoilage produce safe products (Oey et al., 2008). Among the
only by yeast, molds, and lactic acid bacteria. Their emerging technologies, PEFs and HHP have been imple-
acidic pH, lower than 4.0 in most cases, was considered mented by industry.
sufficient to prevent the growth of almost all spore-
forming microorganisms. This fact has allowed the
fruit beverage industry to apply a hot-fill-hold process 31.4.1 Pulsed Electric Fields
to pasteurize these products. However, in the last few
PEF processing is an emerging and very promising
years, more spoilage incidents of fresh fruit juices
nonthermal technology for the pasteurization of pump-
have been reported. Most of these incidents have
able foods (Soliva-Fortuny et al., 2009). Several institu-
been related to spore-forming thermoacidophilic
tions are now involved in the task of transferring and
microorganisms. Spoilage caused by this kind of micro-
scaling up PEF technology to the industrial level for
organism is difficult to detect. The juice appears normal
the pasteurization of pumpable products (Huang and
or has light sediment and no gas is produced. The only
Wang, 2009). As an example, the adoption of PEFs for
evidence of the alteration is often a “medicinal” or
the commercial nonthermal pasteurization of fruit juices
“phenolic” off-flavor (Walls and Chuyate, 1988). For
has been implemented by Genesis Juices, Oregon,
instance, the genus Alicyclobacillus has a pH range for
United States (Zhao et al., 2012). PEFs are able to reduce
growth of 2.0e7.0 and is able to grow in a temperature
the microbial population of refrigerated fruit juices, such
range of 20e71  C. In particular, Alicyclobacillus acido-
as apple (Evrendilek et al., 1999) or orange and carrot
caldarius will easily survive any heat treatment
juice (Rodrigo et al., 2001). At the same time, this tech-
currently applied in the industry to process fruit juices.
nology induces sublethal damage to bacteria, which
Moreover, the extremely high heat resistance of this
causes a significant delay in their ability to grow and
microorganism makes the design of any heat treatment
spoil the product. It was demonstrated that 35 pulses
to inactivate the spores impossible because it would
in an electric field of approximately 35 kV/cm applied
also damage the quality of the food. Fortunately, the
to fresh orange juice reduced the microbial growth by
high minimum growth temperature of this microor-
5 log unit cfu/g without modifying the nutrient compo-
ganism makes it improbable that it will cause spoilage
sition or the sensory properties of the product. In addi-
in pasteurized acid foods such as fruit juices. However,
tion, the shelf life of the orange juice processed with
after storage of such foods for long periods at high tem-
PEFs was extended to 14 days whereas the untreated
perature, which can be reached in hot weather climates,
juice was not acceptable after four days of storage. How-
the growth of surviving microorganisms in the juices
ever, to prevent spoilage of orange-carrot juice, it is
could be possible (Palop et al., 2000).
necessary to combine an efficient PEF treatment with
The emerging technologies used to pasteurize MPFV
chilling during distribution and storage, and to guar-
juices include HHP, PEFs, oscillating magnetic fields,
antee low initial counts of contaminating bacteria in
intense light pulses, irradiation, ultrasonication, or com-
fresh-squeezed juice (Selma et al., 2004). In addition,
binations of these methods (Liao et al., 2010). This sec-
more research is needed to understand the effects of
tion will briefly summarize the most relevant emerging
thermal effects, temperature peaks, and other side ef-
technologies used in fresh fruit juices, but it does not
fects occurring with PEF treatment on the microbial
pretend to be a review of all of them, because they are
and enzymatic inactivation and food components
extensively discussed in different chapters in this book.
(Zhao et al., 2012).
The use of membrane disrupting preservation tech-
niques (e.g., ultrasound, high pressure, or PEFs) is based
on their potentially synergistic effects with chill storage
or mild heat treatment (Russell, 2002). However, there is
31.4.2 High Hydrostatic Pressure
a safety concern about these new technologies because it The application of HHP to the processing of food prod-
is necessary to inactivate and control the spoilage and ucts consists of a pressure treatment in the range of
pathogenic microorganisms that may be present in these 4000e9000 atm. One of the most important benefits
products. It is well known that these preservation of this emerging technique is that the plastic package of
methods are physical and chemical hurdles that can be the product is filled with the fruit juice and is then sub-
adjusted to guarantee the safety of the food products. jected to a pressure of approximately 4000e6000 atm for

VI. MINIMAL PROCESSING


REFERENCES 593
1e30 min. Therefore, it is easy to avoid contamination of industry is currently seeking alternative or secondary
the product after packaging (Barbosa-Cánovas et al., technologies to maintain most of the fresh attributes,
1998). HHP treatment could help to preserve the nutri- storage stability, and, above all, the safety of MPFVs
tional value and sensory properties of fresh juices because while extending their shelf life.
of its limited effect on the covalent bonds of low Many of the conventional preservation methods that
molecular mass compounds such as color and flavor ensure the safety of plant food products (e.g., high tem-
compounds, and vitamins (Oey et al., 2008) while control- peratures) are not applicable to MPFVs, and only a few
ling microbial growth. traditional techniques (e.g., chemical treatments, chill-
Several authors have recently reviewed the effect of ing, and MAP) can be used. For these reasons, the devel-
HHP treatment on the nutritional, sensory, and micro- opment of emerging processing techniques and the
bial quality of MPFV juices (Pilavtepe-Celik, 2013; application of the hurdle concept represent good options
Oey et al., 2008). They generally conclude that HHP is for this type of food industry. According to the hurdle
capable of securing the freshness, nutritional value, theory, preservation treatments combined at lower indi-
and sensory properties of low-acid juices and that it vidual intensities have additive or even synergistic anti-
can be considered as an alternative to thermal heat microbial effects whereas their effect on the sensory and
treatment for MPFV juices used alone or in combina- nutritive properties of the food is minimized. Therefore,
tion with traditional techniques because of its limited preservation techniques are becoming milder in
adverse effect. However, more work is needed to deter- response to the demands of consumers for higher qual-
mine the effect of HHP on the survival of pathogenic ity, more convenient foods that are less heavily pro-
microorganisms. cessed and preserved and less reliant on chemical
preservatives.
Several nonconventional methods are now being
31.5 CONCLUSIONS investigated, and some of the most important tech-
niques that can be applied to maintain the overall qual-
Consumers increasingly perceive fresh food as ity of MPFVs are H2O2, O3, ClO2, acidic electrolyzed water,
healthier than heat-treated food, which motivates a gen- and mild heat water treatments; UV-C radiation; biocon-
eral search for new MPFVs. However, despite the bene- trol; novel MAP under high O2 or nonconventional gas
fits derived from eating fresh foods, safety is still an mixtures (N2O, noble gases, etc.), alone or combined;
issue of concern because of a wide range of documented and genetic engineering technologies. All of these tech-
cases of contaminated fresh fruits and vegetables as well niques help the fresh-cut industry to develop safer and
as unpasteurized fruit juices, which have caused large healthier plant products to fulfill consumer demand.
outbreaks of microbial infections.
MPFVs are very perishable products. They are highly
susceptible to deterioration, and the minimal processing
reduces shelf life, leading to additional quality losses.
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