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that achieve a selected (cumulative) heat process. For the
initial filling steps, it may be possible to use a brine without
flavoring ingredients to prevent off flavors due to heating.
Brine from the initial filling steps could then be recycled
to reduce water and energy usage for processing, with only
the final fill containing the flavored cover liquor for the
product formulation. Further work may include an analysis
of potential energy and water savings and optimization of
processing conditions for selected commercial processes.
CONCLUSIONS
A hot-fill pasteurization method consisting of repeated
filling of jars containing cucumber spears with preheated
brine was investigated. The target F160 value for established
safe processing of acidified cucumber spears with a reference
temperature of 71.1°C (160°F) for 5.6 min was achieved with
three sequential fill-hold steps for most of the filling regimens
studied. However, achieving this F value required a 45 min
process for cucumbers with an initial temperature of 20°C.
All filling regimens with cucumber spears at 40°C or 60°C
initial temperatures exceeded the F160 of 5.6 min. Processing
times and temperatures at or above 73.9°C (165°F) for up
to 13.4 min were achieved for cucumber spears with initial
temperatures of 40°C or 60°C, likely meeting conditions
typical of most commercial processes. A numerical model
was developed that may be useful for optimizing filling
regimens to achieve desired time-temperature conditions.
Further research may be needed to allow commercial

application of the method, including the development of
jar inverters for processing lines, to allow draining of jars
with cucumber spears, and sanitary measures consistent
with good manufacturing practice would have to be in place
to prevent recontamination of jars with pathogens during
refilling with brines. It is also likely that a cooling step may be
required to prevent over-processing once the repeated fills are
completed. We have demonstrated that safe and shelf stable
acidified vegetables could be produced with the repeated hot
fill method, introducing sufficient heat into the product to
attain desired quality and safety parameters, and potentially
reducing water use and increasing energy efficiency as an
alternative to tunnel pasteurizers.
ACKNOWLEDGMENTS
This work was supported in part by a U.S. Department
of Agriculture (USDA) National Integrated Food Safety
Initiative grant (2011-51110-31019), Pickle Packers
International, Inc. (Washington, D.C.), and USDA
Cooperative State Research, Education, and Extension
Service project 2006-01240. The authors thank Mt. Olive
Pickle Company (Mt. Olive, NC) for generous donations of
cucumbers, jars, and other supplies, and Dr. Josip Simunovic
for helpful advice. Mention of a trademark or proprietary
product does not constitute a guarantee or warranty of the
product by the U.S. Dept. of Agriculture or North Carolina
Agricultural Research Service, nor does it imply approval to
the exclusion of other products that may be suitable.

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