The Pickle Packers School Kit: How Are Pickles Made?

Pickles start out as cucumber seeds. One pound of seeds - which contains about 17,000 seeds - plus water, fertilizer, sun and an acre of soil will yield up to several thousand pounds of cucumbers. It is important to understand that the cucumbers grown for commercial pickling are special pedigreed strains developed to produce straight, thin-skinned pickling cucumbers that are very different from the large, salad cucumbers found in the supermarket.

Pickle companies may provide their growers with the seeds and advice on how to grow the best quality cucumbers. Or, they may set specifications the grower must meet. The companies also monitor the growing to ensure their standards are met. Once the cucumbers are grown, they are brought to a receiving station to be inspected and separated into sizes. They also are cleaned to remove any plant parts such as leaves and blossoms or other undesirable matter like sand and dirt.

The cucumbers are then brought by truck from the receiving station to a pickle plant in thousand-pound boxes. It is here that the type of pickle the cucumber will become is decided. Throughout the pickle making process, food safety is paramount. Precautions are taken to ensure safety during handling. Usually, the end result is one of the following types of pickles:

Vat Cured Pickles
Cucumbers are placed in brining tanks and undergo fermentation. Fermentation is a natural process by which bacteria in the brine "eat" the sugar that exists in cucumbers and produces lactic acid. The fermentation process can take from a few days to a few months. During this time, the acid, pH, sugar and salt are monitored to make sure the pickles will be of a high quality.

Then they are removed from the brining tanks and placed in processing tanks where most of the salt is removed. The pickles can now be cut (if they are to be spears, slices, halved, etc.) by machine, inspected, and conveyed to the packing room for packing. If the pickles are to be dill, sour or sweet pickles, they are packed in jars with appropriate spices or syrup. The jars are then vacuum-sealed, pasteurized, labeled and placed in a container for shipment or storage in a warehouse.

Genuine Dills
These are a special kind of vat-cured pickle made from cucumbers which have been graded and placed a large tank with a weak brine solution and dill spices. The same brine may be used when packing the pickles into jars or new seasoned brine may be used. These pickles have a sharp flavor and a dark green color.

Fresh Pack Pickles
Cucumbers are unloaded at the plant and given another grading and separating for the various types of fresh packs. The cucumbers are not placed in brine tanks. Instead they are packed whole (or cut to specification) in jars. Then the proper spices and brine or syrup are added. The jars are then vacuum-sealed and pasteurized to improve the flavor and make them last longer. All fresh pack cucumbers must be packed as soon after picking as possible so that the original quality can be maintained.

Refrigerated Pickles
Refrigerated pickles are similar to fresh pack pickles because they are graded, washed and packed within hours of being picked. The refrigeration process gives the pickles distinct, fresh flavor and crisp texture. Chilled cucumbers are packed in jars with seasoned brine that may contain some vinegar or acidification, depending on the product, and are immediately sealed and refrigerated. They are then held in refrigeration for several days to several weeks, depending on if the product is sliced or whole, so the cucumber can cure and absorb the seasoning before being shipped. Found in the refrigerated section of the supermarket, these pickles have a shorter shelf life compared to processed and fresh pack pickles and must be refrigerated throughout their life, up to consumption.

PICKLE VARIETIES

There are more than 36 varieties of pickles from which to choose and hundreds of varieties within the 36. Here are the most popular types of pickles:

Dill: The most popular variety of cucumber pickle. The herb dill or dill oil is added to impart a distinctive and refreshing flavor. Dill pickles are available in many forms - chips, spears, halves or whole. There are three basic types of dill pickles:

Genuine Dills - Made by the slow "processed" method. Dill weed is added to the tanks during the last stage of fermentation or to the jar after fermentation. These pickles usually have a higher lactic acid flavor than other varieties. A more robust type of dill pickle is the kosher dill. In pickle lingo, "kosher" means garlic has been added to the brine. Kosher dills are the ultimate accompaniment to an overstuffed deli sandwich.

Fresh Pack Dills - Fresh cucumbers are unloaded at the plant and instead of being placed in brining tanks, they are packed in jars with the dill spice. These pickles must be packed as soon after picking as possible so that the original quality can be maintained.

Refrigerated Dills - These pickles are placed in brine for a very short time - a day or two at the most. These pickles taste very much like fresh cucumbers accented with dill flavor. They are the type of pickle you would find at a delicatessen.

Sour/Half Sour: These are typically only refrigerated pickles. Cucumbers are first cured in brine and finished in a solution of vinegar and spices. The longer the cucumbers remain in the brine, the more sour they become. Half-sour pickles are extra crispy and keep their fresh cucumber color.

Sweet: Sweet pickles are packed in a sweet mixture of vinegar, sugar and spices. Here are some of the variations on sweet pickles:

Bread & Butter - Sweet, sliced pickles that have a distinct, slightly tangy taste. Available in either smooth- or waffle-cut chips or chunks.

Candied - Pickles packed in an extra-heavily sweetened liquid.

No-Salt Sweet - A relatively new variety of sweet pickle to which no salt has been added. Usually available as chips, these appeal to consumers who need to restrict their salt intake.

Sweet/Hot - This flavor represents another growing trend, that of adding hot spices and seasonings to pickles for a delightful spark of piquant flavor.

Pickled Peppers: Made the same way as cucumber pickles, there are more than 15 varieties of pickled peppers available, ranging from mild to hot, hot, hot! These are some of the most popular pickled peppers:

Jalapeño - Thanks to the growing interest in Mexican food, this type of pickled pepper is hot - literally. Fiery jalapeños are packed in brine and come whole or in rings.

Banana Peppers - Long, shiny, yellow, orange or red peppers that come both sweet and hot. Pickled banana peppers, available whole or in rings, are popular breaded, deep-fried and served as appetizers in many restaurants.

Cherry Peppers - Shaped like a cherry, these pickled peppers are red or green in color and available in both sweet and hot versions. They are most popular whole or in rings.

Pepperoncini - Pickled, whole, green, Greek or Italian peppers that are usually 2 to 3 inches long. These mildly hot peppers are popular in antipasto offerings and Mediterranean-style salads.

Specialty Pickles: There is a wide variety of specialty pickled vegetables in supermarkets today. While many are available nationally, some are regional specialties and found only in certain areas of the country. These include: cocktail onions, cauliflower, sweet mixed vegetables, sweet pickles with raisins, asparagus, watermelon rinds, beets, okra, green tomatoes, sauerkraut and more.

 

 

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