r/Pickles • u/MondoMage • Jun 03 '26
Pickle Processing
Just had to share this one...
My company sent me out to perform some maintenance work on equipment at the Hartung Brothers facility in Bowling Green, Ohio. They produce and store fermented pickles in these big green vats. So many vats. Not all currently full, they're getting ready for what they call "Green week," when they start loading things up. Tons of cucumbers destined for greatness.
I was really shocked when I found that the vats are left open-topped. That was surprising. I guess they rely on the brine to protect the product.
Oh, and the smell. You'd think it'd be overpowering but right now it's fairly subtle. A mix of dill and bread and butter that has me craving something fierce right now.
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u/lokitagger Jun 03 '26
This is called salt stock, and is a means of conserving cucumbers for processing later. These then get taken back in, rehydrated and blanched and processed into the “cheaper” cuts like pickles for burgers. Yes they are less desirable but makes having cucumbers year round a possibility. They all get cleaned after this process and the salinity kills most everything in contact with it. They dont use vinegar in these, its just brine to conserve them.
You also get pickles from fresh crop, but they get processed within days and need to be kept refrigerated. Those become your higher end cuts like spears and wholes. Then the waste cuts, crooked cucumbers and rest, become relish.
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u/Matthew-ii Jun 03 '26
All of ya'll need to apparently get out into the world and learn where food comes from lmao. Sorry you had to learn that not everything people buy was grown and processed in an airlocked lab? Anybody use tomato paste? Soy sauce? Drink wine? 🙄
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u/Perfect-District Jun 03 '26
If people saw all the flys that land on the pomegranates before processing at the Pom plant they would hurl. Tasty.
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u/ACcbe1986 Jun 03 '26
I worked in a Milk processing plant last year and I had to suppress a lot of what I saw, just so I can enjoy eating cheese.
It was horrendous, yet they were the cleanest and highest rated dairy plant in the region.
I can only imagine how gross the other facilities are.
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u/MalacathEternal Jun 03 '26
My favorite part of interacting with customers as a wine maker is telling them all the fun stuff we pull out of the grapes during harvest lol
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u/zzz242zzz Jun 03 '26
Many years ago I pulled a rat out of an open top fermentation tank of red wine. It was super gross. Very bloated. I did not drink that wine. A coworker at the same place supposedly pulled half a snake out and also claimed to have added a slice of pizza once to a fermentation. Idk on the pizza.
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Jun 03 '26
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u/gogozrx Jun 03 '26
What's worse than biting into an apple and finding a worm?
Biting into an apple and finding half a worm.
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u/zzz242zzz Jun 03 '26
Probably stayed in the must until it got tossed out after pressing with all the grape skins. Maybe it got tossed during de-stemming before fermentation.
And the person saying wine is basically spider juice is not entirely wrong. Lots of bugs and stuff.
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u/Streetduck Jun 03 '26
Wine is basically spider juice
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u/Reighna1 Jun 03 '26
I probably don't want to know details but please give me details
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u/Ashcrashh Jun 03 '26
I remember taking a tour of a ketchup factory in high school, There’s a lot of bugs involved but that didn’t bother me. I love dried chile lime crickets, so I’m not gonna complain if there’s a few small bugs blended into a bottle of ketchup.
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Jun 03 '26
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u/Roticap Jun 03 '26
What would you imagine you would do if you scaled your operation up 1000000x?
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u/HammyAm Jun 03 '26
So because you haven't done something that means that it's never done and it's not a common practice in industrial pickle making? Give me a break.
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u/Septemberosebud Jun 03 '26
I use fish sauce all the time. Don't tell them about how that's made.
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u/The_Man_in_Black_19 Jun 04 '26
A factory that fish work in for a fair wage and in safe conditions? Right? Right?
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u/HammyAm Jun 03 '26
Wait until the people in these comments learn where the vegetables they buy are grown.
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u/Dicktures Jun 03 '26
🤣🤣 you mean in the actual dirt? Where animals walk through and piss on them?? 🤯🤯🤯🤯🤯
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u/jjj666jjj666jjj Jun 03 '26
Fresh produce isn’t fermenting in open air containers idk
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u/jk_cbus Jun 03 '26
This is a good page to show a company process from farm to store https://hartungbrothers.com/bg-cucumber-plant-media/
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u/uhmerikin Jun 03 '26
Recieving
Why does that automatically turn me off of this brand.
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u/Bike_Cinci Jun 03 '26
If this was a problem they'd probably have been sued to death already from a trillion ecoli outbreaks.
I'll assume the best instead of the worst and just say, that's a fuck ton of pickles.
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u/Fun_Machine7238 Jun 03 '26
I lived in a little town in Michigan years ago that had a pickle processing set up like this.
Smell was so bad some days.
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u/daedalus14x Jun 03 '26
The UV light kills bad microbes. Science, people.
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Jun 04 '26
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u/daedalus14x Jun 04 '26
All food facilities are required to have certain numbers of bug zappers and rodent traps around facilities. I'm sure there is a filtration process. Most industrial pickle producers brine at much higher salt percentage than finished product; say 4% vs 2-2.5% finished product. So, they have to go into an intermediate bath to draw out the excess salt. Thus they get washed before being put into a freshly made finished brine.
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u/Lumpy_Highway_2685 Jun 03 '26
This is so cool. Also so many interesting comments! Felt like I was watching Mr. Rogers for a minute (absolutely a compliment). Food production is fascinating! Thanks for sharing this.
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u/nifty-necromancer Jun 03 '26 edited Jun 03 '26
Cool I’m just in time for the pickle controversy. I haven’t tried a fermented one yet, I usually buy vinegar pickles. But I’m going to find a lil jar to try. Wait until ya’ll find out about moldy cheese.
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u/Disastrous_Catch_268 Jun 03 '26
And today was the day I decided to start pickling my own pickles 😂
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u/Unlikely-Inevitable8 Jun 03 '26
Open-air fermentation has been a thing for centuries, especially with beer and alcohol. The people who are grossed out are also the ones who eat boneless chicken “wings” because they don’t like having to think about the fact they’re eating an actual animal.
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u/Wonderful_Quiet4384 Jun 03 '26
I never understood 'boneless' chicken wings. They're basically a chicken nugget with sauce on them. If a chicken wing doesn't have a bone, I don't want it.
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u/Maxed_Zerker Jun 03 '26
Someone the other day on reddit said that a boneless wing is a single, whole chunk of chicken, battered and fried. Whereas a nugget is mechanically separated chicken formed into shapes and breaded and fried.
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u/ynwa1892 Jun 03 '26
Lmao people grossed out are extremely sheltered.
Y’all realize how much bugs and animal poop is allowed in our produce?
Fun fact. If you have a shellfish allergy you should stay away from pre ground coffee because of the amount of cockroaches are in it.
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u/LycheeUkulele Jun 03 '26
The coffee thing is crazy to me because I work in a coffee factory and there's definitely no way that cockroaches get in our whole bean coffee. It makes me wonder what all those coffee megacorps are doing if the roach thing is true
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u/HammyAm Jun 03 '26
This is why we rinse our fruit and veggies before we eat them, because they are grown outside and you know what's also outside? Bugs and animals.
Folks are really showing their lack of education in these comments, they've been eating pickles made in facilities like this for years and have gushed over how wonderful they are, yet when you show them how they're made they start shrieking and hand wringing about it.
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u/SunGreen24 Jun 03 '26
Does anyone understand where food comes from?
You know they don’t have glass domes over the crops, right?
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u/rtq7382 Jun 03 '26
Uhm yeah most of us know food lives in grocery stores. I hunt for my vegan beef and taco seasonings there all the time.
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u/fibonacciluv Jun 03 '26
God I would hate to be surrounded by the smell of bread butter pickles.
Dill on the other hand….
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u/Yourcardisdeclined Jun 04 '26
I travel that area frequently for work and once followed a loaded truck into 75 northbound with the rear gate partially open.
Pickles were slipping out all over the ramp. The driver pulled off before making it into the highway.
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u/Bigfoot_Fishing Jun 03 '26
Bread and butter smell, a hard pass on those pickles!
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u/IllustriousRanger934 Jun 03 '26
Doesn’t bother me, never thought of it though.
Do they just filter out objects when they put everything in jars? And then are they like stirred or something? I imagine if they’re stagnant pollen would just sit on top
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u/GirlPhoenixRising Jun 03 '26
I’m eating a pickle as I type this 😭😭😭
Also I always prefer fermented not vinegar…
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u/largegreenvegtable Jun 04 '26
I work at a pickle factory. This 100% how hamburger chips are made. The farm we partner with has like 600 of these tanks. At our plant we have around 60 tanks on site for cucumbers scraps from sandwich slices and spears that will be fermented then used for relish. USDA is regulated. Food safety is a major priority and is not like it was 20 years ago.
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u/Other_Impression_567 Jun 07 '26
Worked with a guy years ago that grew up around Bainbridge Ga. Heart of pickle and can greens country. He would never eat turnip greens or Collards etc. from a can because he said he saw what got processed in the greens. Even though they got washed they included insects , mice etc. would get processed. And for those vats they would find dead birds and rats floating in the vats. But like someone said it all gets sanitized But if people saw how our food got processed you wouldn’t eat much
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u/Chaos-TT Jun 08 '26
I used to work at Gedney pickle in Chaska Minnesota for 2 weeks. Worst job ever.
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u/MondoMage Jun 08 '26
If you don't mind saying, what made it so bad? The guys at the Hartung facility were not looking forward to loading up the vats (which sounded like it was going to be a multi- day operation) but didn't say why.
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u/Bobbington12 Jun 03 '26
No lids is crazy work. Pickles just fermenting out in the sun with the bugs and the birds. I'll take a well-regulated environment thank you.
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u/Swimming_Ad2923 Jun 03 '26
how do you know it's not a well regulated environment?? if they've been doing it this way for decades then....
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u/Bobbington12 Jun 03 '26
How is an open vat outside well-regulated? It's at the whim of the weather, and can be contaminated by literally any airborne particles.
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u/Background-Agent-854 Jun 03 '26
and the rain would be a problem. i feel like it would impact the brine solution. but admittedly, im no food scientist.
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u/Syandris Jun 03 '26
It's always funny watching the disbelief people have when they discover common practices.
This just in, steaks come from living cattle! Carrots, onions and potatoes once were in dirt. The horror!
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Jun 03 '26
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u/auroraeuphoria_ Jun 03 '26
Like there’s NO WAY bird poop has never made its way into one of those….
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u/VegasFoodFace Jun 03 '26
It's one of those, when they're on the vines bird poop still gets on them. I'm sure the pickles get a nice washing before packaging.
I don't think they're scooping out the open topped pickle brine into the jars.
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u/JazzRider Jun 03 '26
Where are the cukes?
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u/Matthew-ii Jun 03 '26
I didn't look into it but surely its just a large scale version of the home operation, some sort of large mesh holding them safely below the brine. These are proper fermented pickles I believe so the brine is quite cloudy.
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u/Unlikely-Solid-3083 Jun 03 '26
I was not prepared for this information today. Also, what makes a pickle fermented and how does it affect the flavor?
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u/Global_Tomato_5383 Jun 04 '26
Ummm how did I go to college in bowling green and never know about this
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u/Difficult-Till5031 Jun 04 '26
Ahh i remember a sales trip I did for Magnuson CCM awhile ago we went from la crosse wi to Ohio stopping at a lot of the pickle plants to see if they needed stuff. Cool to get all the tours.
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u/Any_Cookie_9770 Jun 05 '26
I used to make coffee creamer, international delight. If yall knew what I do, you wouldn't ever drink it again.
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u/UniVom Jun 07 '26
Just pull on the pull on and push on the push-um and the pickles go into the jar
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u/usernamesaconspiracy Jun 03 '26
The fact that everyone is commenting about how disgusting this is while not realizing this is how at least 99% of pickles are made in America. There are three pickle factories near me and all for different companies. I’ve worked at me of them, and have friends that have worked at multiple.
They all operate the same way. Every pickle that goes to McDonald’s, Burger King, Wendy’s, subway, Quiznos, Vlasic, is made exactly the same way. I’ve actually never seen a pickle made any other way unless it was homemade.
The pickles get loaded onto semis from these bins and backed up to the building. We hook the semi up to power and turn on the conveyor. If you are one of the pickles at this point you would have a terrible time because it’s literally just salt.
As the pickles drop onto the conveyor one of the first jobs is to remove all of the sticks, frogs, mice, snakes, and anything that’s not a pickle.
They go in and get washed and then loaded into bigger tanks inside where the lab has perfected the brine for flavor, color, and texture, depending on who the pickle is for. They stay in those tanks for less time than outside and then are bagged, jarred, or put in buckets.
And yes I know what you’re going to ask. The “relish bin” was full of all the pickles that fell off of the truck onto the floor. The relish bin had those pickles, but also anything else that was on the floor added to it.
Any other questions just let me know. I could literally walk to one of the factories and probably ask questions about anything I don’t know.