Microbial and chemical characterization of commercial washing lines of fresh produce highlights the need for process water control

Process wash water and washed products from three different fresh produce processing lines were characterized at commercial scale. Different physicochemical and microbiological characteristics of wash water were measured. Great variability between processing lines on the physicochemical quality of process wash water was observed, caused in part by the type of produce washed. The relationship between lower aerobic mesophilic bacteria and higher free chlorine (FC) concentrations in wash water was detected (Pearson's correlation coefficient (PCC) = −0.53). Independently of the FC concentration, most of the water samples (>80%) showed presence of cultivable (limit of detection 1 CFU/100 mL), probably caused by the uncontrolled pH conditions. Higher values of FC and oxidation-reduction potential (ORP) in wash water were related to lower microbial load in washed produce (PCC = −0.82, and − 0.79, respectively). Higher concentration of chlorine was linked to a higher presence of disinfection by-products (DBPs) in the wash water, and washing in chlorinated water led to a significant increase in the concentration of DBPs in produce. However, the accumulation of trihalomethanes (THMs) in process wash water was not correlated with higher concentrations of these DBPs in produce. Industrial relevance The washing step of fresh produce processing lines is a critical process. The dose of disinfectants needs to be adequately optimized to avoid microbial contamination without generating the accumulation of disinfection by-products (DBPs). In this study, critical parameters that influence the efficacy of water disinfection and the occurrence of DBPs in fresh produce processing lines were identified under commercial conditions. The results evidenced that monitoring and control of pH play a critical role by maximizing the concentration of the most active form of chlorine in the water. The parameter UV254 measured on-line in the washing tank, can be suggested as a suitable indicator of the presence of organic matter in fresh produce wash water.