Should chlorate residues be of concern in fresh-cut salads?

Chlorine remains the most popular method used by the fresh produce industry for decontamination. However, the occurrence of disinfection by-products (DBP) derived from chlorine-based disinfectants has been highlighted as a problem. After recent reports, chlorate residues in fresh produce are of concern in Europe. This study evaluated the chlorate accumulation in process wash water and the residues in fresh-cut lettuce when sodium hypochlorite was used as a wash aid. At a commercial processing facility, total chlorine was continually added to achieve a free chlorine level of 1-80 mg L−1 for water disinfection as the organic load measured as chemical oxygen demand (COD) increased over time (1000-1500 mg O2 L−1). This resulted in chlorate accumulation (19-45 mg L−1) in the process water. When fresh-cut lettuce was washed in that water, chlorate residues were detected in the lettuce and the concentrations increased linearly with the repeated use of the same process water, reaching concentrations of 4.5-5.0 mg kg−1. To understand the chlorate accumulation in the process wash water, several experiments were performed at a pilot plant scale with different levels of COD and free chlorine. There was a significant (p < 0.001) correlation (R = 0.91) between the total added chlorine and the chlorate accumulation in the process water. We demonstrated that the added chlorine needed to maintain a free chlorine level in the process water was the contributing factor to chlorate accumulation. Chlorate residues in the washed fresh-cut lettuce after rinsing for 1 min in tap water and in commercial bags were below the limit of quantification. This study contributes to the knowledge of chlorate accumulation in the process water when sodium hypochlorite was used as a sanitizer.