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Vegetables from USA, commercial pickle industry
Pickle makers ferment whole cucumbers in big open-top tanks under a brine of about 6 % salt. Lactic acid bacteria, led by Lactobacillus plantarum and its relatives, turn the cucumber sugars into lactic acid and take the pH to 3.5 or lower, and the salt stock can then be held in the tanks for up to a year before it is desalted and made into pickles and relish.
| Whole pickling cucumbers (or cut pieces)50–60 % of the tank | [ars-p434][ars-p435] |
| Cover brine equilibrating at 1.03 M (6 %) NaCl50–40 % of the tank | [ars-p366][ars-p435] |
| Calcium chloridee.g. 40 mM | Keeps the fruit firm; 40 mM was the control level in one study[ars-p366] |
| Starter | In one study, some commercial tanks were left to ferment with no starter and others were inoculated with L. plantarum 10B; laboratory jars used L. pentosus LA0445 (NaCl or CaCl2 brine) [ars-p435]. |
Total time across the recorded steps: 12 months
What changes: Starting material: pickling cucumbers loaded into open-top tanks
A cushion of cover brine goes in first [ars-p435]. Output: tank half full of fruit.
Microbes at work in this step
Not documented for this step.
Measured measured in a studySet fixed by a specification or tested recipeReported one source reports itTypical a general value, not sourced for this fermentUnconfirmed not yet checked against a source
Pickle makers ferment whole cucumbers in big open-top tanks under a brine of about 6 % salt. Lactic acid bacteria, led by Lactobacillus plantarum and its relatives, turn the cucumber sugars into lactic acid and take the pH to 3.5 or lower, and the salt stock can then be held in the tanks for up to a year before it is desalted and made into pickles and relish. Made in 5 steps over 12 months. The longest step, bulk storage, takes up to 12 months (McFeeters R.F 2010). Salt is 6 % (McFeeters R.F 2010). Lactobacillus plantarum and L. pentosus and Pediococcus, Leuconostoc, Lactococcus and Weissella do most of the fermenting.
| Main step | up to 12 monthsReported[ars-p366] | Bulk storage |
|---|---|---|
| Salt | 6 %Reported[ars-p366] | Cover with brine and hold down |
| Acidity | pH 3–3.5Reported[ars-p435][ars-p306] | Primary fermentation |
Home dill pickles ferment in a crock and are eaten soon; commercial salt stock is fermented in tanks of tens of thousands of litres with air purging, held in salt for up to a year, and desalted before use. Researchers are replacing much of the salt with calcium chloride to cut salty waste water.
The fermentation must finish with all sugar used and a pH of 3.5 or lower; cucumbers that stopped at pH 3.7 later spoiled in storage [ars-p306]. Yeasts and moulds can destabilise low-salt brines, so these are made with potassium sorbate [ars-p435].
Every number is labelled with how it is known. How this atlas is made
Bloater defect, the gas pockets that CO2 makes inside the fruit, was already tied to CO2 from the cucumbers' own microbes in papers of 1941 (Etchells and Jones; Jones and others, as cited in ars-p434). Studies of recycling the fermentation brines date from 1973 and 1975 (Geisman and Henne; Palnitkar and McFeeters, as cited in ars-p366), and recycling is now widely practiced. About 1980, per a 2010 paper, calcium chloride at 20–40 mM began to be added to the brine because it kept the fruit firmer than NaCl alone. In 1995 Fleming and colleagues could not brine cucumbers without NaCl, but pilot tanks with 4 % NaCl worked in 2002 if the fruit was blanched first. McFeeters and Pérez-Díaz fermented cucumbers with CaCl2 as the only salt in 2010, and ars-p435 says the NaCl-free system with 100 mM CaCl2 had been tested at commercial scale by 2015.
