Producing Sauerkraut

1. Growing White Cabbage 1.1 Seeds White cabbage is a member of the Brassicaceae (or Cruciferae) family. We have been involved in growing and processing cabbage for generations. Until a few years ago, Fritz Masshard, a descendant of Masshard founder Johann Masshard, together with the Wdenswil Research Institute1, cultivated the white cabbage variety called the Waedenswiler. He realized early on that the most profit-yielding variety of cabbage did not necessarily possess the best qualities for making sauerkraut. He made it his goal to find a cabbage with a fruity flavor as well as high levels of valuable nutrients such as sugar, protein and natural vitamin C. White cabbage is a biennial plant, which means that it requires two vegetation periods from germination to seed production. It takes a schooled eye and a great deal of experience to find the right cabbage plants for breeding. Earlier the selected cabbage heads were stored in the companys cellars over the winter. In the spring they were then set out again, at which time they flowered. As with rape-seed, cabbage plants bear pods containing the seeds which are used for sowing. Several years ago, we decided that, rather than produce our own seed, we would work together with other professionals. Since then, the largest cabbage-seed producers have been sending us the newest breeds of cabbage for testing. We not only test the seeds growing qualities in our fields, but also their suitability in the production of sauerkraut. The knowledge gained determines which types are put on the variety list, which is binding for our cabbage producers. Cabbage seeds are very small and it only takes about 250 300 grams of seed to produce 100,000 kg of cabbage. Accordingly, the demands of sowing are high. 1.2 Sowing In January we invite our producers to the traditional cabbage meeting (Kabishck), an important meeting, where the previous growing season is discussed. We make recommendations and suggest guidelines for the current year. In addition, the farmers receive contracts which contain, among other things, information concerning the staggered harvest: Which producers will be delivering their cabbage when to the sauerkraut factory? This is important for producers with regard to variety selection and sowing date.

White cabbage seed

Young cabbage plant

Full-grown white cabbage

1 Known today as Agroscope Changins-Wdenswil Research Station ACW,  http://www.acw.admin.ch

Sowing already begins in February, and there are two means of producing seedlings:  Bare-root planting: In this type of production the seeds are traditionally sown in a temperature-controlled seed bed. The seedlings germinate and by April are approximately 10 to 15 cm tall. Then the seedlings are pricked out by hand and prepared for setting out.  Containerized planting: In this method of production the seedlings are sown in 60 mm thick plastic trays. A tray has up to 320 small holes which are filled with dirt. One seedling is carefully planted in each hole. This type of seedling production also requires a hothouse. 1.3 Plant care In April the first young plants are set out in the fields. For processing cabbage it is important that the plants have enough space a stand of approximately 20,000 plants per hectare (10,000 sq meters) is recommended. The growth period for white cabbage after transplanting ranges from 70 to 130 days, depending on the variety.
Harvesting by hand

White cabbage is a very demanding cultivated plant, and thus it is important that it receive adequate care. Only then can one expect a plentiful harvest of high quality. We support our cabbage producers in all areas of production, e.g. concerning fertilization guidelines and combating weeds organically. 1.4 Harvest At regular intervals, workers check selected cabbage fields to determine the maturity level of the plants. By the end of July or in early August the first varieties are ready for harvest. One hectare of land yields approximately 100,000 kg of high-quality white cabbage. Each head of cabbage is cut and carefully prepared by hand. 2. Production 2.1 Cutting The cabbage is harvested by various producers according to an exact schedule and is delivered to the sauerkraut factory on the appointed day for processing. There the heads of cabbage must pass a quality control check. We primarily check for Cleanliness and diseases Levels of vitamin C and fructose Temperature Afterwards, we determine the exact amount of salt which should be added to each ton of sliced cabbage. The amount is influenced by the temperature outside, dry mass and other criteria.

Preparing heads of cabbage

Right an schedule, cabbage heads are delivered for processing

The actual handling process begins by boring out the core in the middle of the cabbage head. Then the heads are placed in a cutting machine, where they are cut into narrow strips. The knife chosen for slicing plays a major role in producing good sauerkraut. Early varieties of cabbage require a relatively coarse cut, later varieties a fine cut. Our knowledge and experience are crucial to producing excellent sauerkraut. 2.2 Fermentation The sliced cabbage is then transported via conveyor belt into the factory. As in early times, we use pitchforks to move the cabbage into fermenting vats of approx. 18,000 kg and then stomp it down with our feet. It is important that the sliced cabbage be distributed evenly and stomped uniformly in order to press out all the air. The cabbage is then covered and sealed air tight, after which a multi-staged curing process begins. Lactic acid bacteria present in the cabbage and the surrounding air convert the fructose into lactic acid. The sliced cabbage is not as is generally done with fermented food products today sterilized before the fermentation process begins. In contrast to other foods produced using lactic acid fermentation (e.g. yogurt), no additional lactic acid bacteria is added to the sauerkraut. We allow the fermentation process to run its natural course, a procedure which requires absolute sanitariness. Should undesired bacteria such as butyric acid bacteria be prevalent, the sauerkraut will be unfit for consumption. The natural fermentation process preserves the valuable nutrients of the cabbage. As a result, the consumer receives a food product which complies with the current trend towards functional food2. The additional value of our sauerkraut is not in its additives but rather in the natural fermenting process! So our product is as natural and digestible as it can possibly be. Adding salt releases water from the cabbage and raises its dry mass, producing the ideal setting for lactic acid bacteria. Depending on the duration of the fermentation period, the cabbage remains in the fermenting vats anywhere from 10 days to 4 months. Fermenting time depends on the temperature of the cabbage: the colder the cabbage, the slower the fermentation. As soon as the previously-defined desired levels (primarily salt and acid levels) have been achieved, the sauerkraut is removed from the fermenting vat and then moves on to the next stage of production. It takes enormous vat capacity in order to guarantee continual delivery. We can store over 1,300 tons of sliced cabbage in our fermenting vats at one time.
Cutting the cabbages at the factory Sauerkraut after fermentation

Quality control check after packaging

Food products enriched with additional nutrients which supposedly have health promoting qualities

2.3 Cooking After the fermentation process has finished, we decide how the various types of sauerkraut should be further processed. Sauerkraut which is especially mild and fruity is packaged raw in pouches. Other sauerkraut is redeployed for further curing, during which all fructose is eliminated. Most of the fresh sauerkraut, however, is cooked. After leaving the fermenting vats, the sauerkraut arrives at the so-called scratch table. Here we check the sauerkraut once more for possible defects. The cook is the last to decide if the sauerkraut meets our high quality standards. Such competent inspection assures consumers that they are receiving the highest quality sauerkraut. 2.4 Packaging After the cooking process, the warm sauerkraut is put into pouches which are then pasteurized (with few exceptions) to guarantee the designated storage life. During cooking and pasteurizing, we pay particular attention to preserving the nutritional value of the sauerkraut. Consumers should have the pleasure of enjoying the pure and unadulterated taste of Swiss sauerkraut. Our sauerkraut has been produced with love and skill for generations! We wish you an enjoyable meal!

Ready to eat sauerkraut

If you would like to know more about how sauerkraut is produced, call ++41 (0)44 938 30 80 or write to us at: info@swisskraut.ch.