Thermal processing is essential for ensuring the safety and shelf stability of semi-preserved foods, yet it often compromises product quality. This study investigated the impact of three thermal schedules on semi-preserved sun-dried tomatoes in olive oil: pasteurization (E1: 90 °C/60 min), mild sterilization (E2: 110 °C/40 min), and high sterilization (E3: 115 °C/25 min). The effects on microbiological safety, physicochemical properties-including color, total phenolic content, antioxidant activity, and oxidative stability-and sensory quality were evaluated. Results showed that increasing thermal intensity significantly improved microbial inactivation, with total mesophilic aerobic counts decreasing from 1.37 × 10³ CFU/g for E1 to 1.6 × 10² CFU/g for E3. However, stronger treatments caused substantial quality losses, including color darkening (L* value decreased from 25.40 to 18.89), a dramatic reduction in total phenolic content (up to 73.79% for E3), and decreased antioxidant activity and oxidative stability. Sensory evaluation clearly favored E1, which scored highest for color, aroma, and texture. Although the mild 90 °C treatment best preserves organoleptic and nutritional qualities, its low sterilizing value (F₀ = 0.046 min) necessitates strict cold-chain management. These findings emphasize the need to balance safety and quality when selecting thermal processing conditions for semi-preserved products.
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