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1. Vanilla is the most labor intensive of all agricultural products.
It is the second most expensive spice in the world, next to saffron.
2. The entire process of vanilla cultivation, pollination and harvesting
is done by hand, without using machinery, chemical fertilizers or pesticides.
3. Vanilla workers, usually women and children who are quick with their hands,
pollinate from 1,000 to 2,000 vanilla orchid flowers per day.
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CURING OF VANILLA BEANS
- Traditional curing methods
- Analysis of improvements to traditional curing methods
- Commercial innovations in curing methods
Curing
Both the vanilla orchid and the ripe vanilla bean lack aroma. It is
only during the curing process that glucovanillin, a vanillin precursor
formed during the ripening of the vanilla fruit, is enzymatically
converted to glucose and vanillin. The longer a bean vine-ripens, the more
concentrated the vanillin and other flavor compounds are after curing.
Higher vanillin indicates higher bean quality, which impacts the beans'
market value. Beans left on the vine split and decrease in quality. Curing
should begin within a week after harvest.
The Mexicans developed the original, labor-intensive, five- to
six-month process for curing green vanilla beans. The "Bourbon" process,
named for the original designation of the island of Reunion, is a result
of slight modifications made by the French. This method, which takes about
four to six months, is currently practiced in Madagascar, Comoros, and
Reunion. Indonesian beans were originally picked while they were still
immature to avoid theft. Although their curing process takes from several
weeks to two months, the Indonesians have begun to adopt Bourbon growing
and curing practices to increase their bean quality.
The curing process varies among growing regions and many bean curers
use a combination of techniques, yet all curing methods involve four
phases that directly affect the amount of vanillin and other flavor
components in the beans:
- Wilting or killing of the beans stops their respiration. Heat is
applied to the pods either by letting them sun-dry, as in the
traditional Mexican method, or by submersing them in hot water for
several minutes, as in the Bourbon process.
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- Sweating the wilted beans involves rapid dehydration and slow
fermentation to develop key flavor components. The beans are alternately
sun-dried during the day and wrapped in boxes at night for several weeks
until the beans acquire a deep chocolate-brown color.
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- Drying the beans very slowly at low temperatures results in a final
moisture level of about 20% to 25%. Over-drying or rapid drying reduces
flavor quality. In the past, Indonesians used wood fires to accelerate
the drying process, which causes the beans to develop a smoky aroma and
flavor.
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- Conditioning is an aging process necessary for flavor development
that involves placing the dried beans into closed boxes for several
months.
McCormick & Co. Inc., Hunt Valley, MD, uses a one- to two-week curing
process in which the beans are chopped and placed into a curing tank for
about 72 hours until they are no longer green. Then they are dried in a
rotary or fluidized dryer, and spread out in a perforated conditioner
until the desired moisture level is achieved.
After curing, the vanilla beans are graded and bundled. Top-grade beans
are oily, smooth, aromatic and very dark brown. The beans are then packed
in boxes and shipped by boat. The beans continue to age during shipping;
it may take several months for them to reach their destinations.
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