The malaxation step, one of the most important phases of the virgin olive oil (VOO) mechanical extraction process involved in the development of the main quality characteristics of the final product, was carried out at a low temperature (18 °C). The rapid control of malaxer temperature was handled with the same chiller as that of the heat exchanger used in a semi-industrial extraction plant. Low temperature was used during the full olive paste kneading process and also for half of this process, which showed that there was a significant impact on the phenolic and volatile contents of VOO. Trials were conducted on three different cultivars (Canino, Moraiolo and Peranzana), and their phenolic and volatile concentrations showed different quantitative and qualitative effects due to the prolonged use of low temperature after the crushing phase, as a function of the different genetic origins of the olives. The process of phenolic compound solubilization into the oily phase was negatively influenced by the use of low temperature during the entire malaxation period for all the cultivars, whereas the volatile fraction showed an improvement in VOO flavor mainly due to the oil extracted from Canino olives.

The development of innovative technologies in the mechanical extraction process of extra virgin olive oil can improve its quality standards through the modulation of physical, chemical and biochemical processes. Extra virgin olive oil quality and varietal differentiation are influenced by many factors, particularly the extraction. The use of ultrasound technology in the extraction process does not affect the quality, the composition, and the thermal properties of the oil, facilitating its separation from solids, and it allows the release of active compounds from the olive paste, with a positive influence on the phenolic content. In this study, the impact of ultrasound technologies was evaluated on merceological parameters, quality profile, and organoleptic features of extra virgin olive oils extracted from whole and destoned olives of the three main Italian cultivars (i.e., Peranzana, Canino, and Coratina). The parameters analyzed were influenced by both genotype and treatment, in particular, sonication did not lead to significant changes in the nutraceutical profile of the oils. The de-stoned olives were able to determine a great improvement of oil quality both for phenolic and volatile composition with a significant enhancement of health and sensory properties of the product.

A new technology used to reduce the temperature of olive paste was applied to the extra virgin olive oil (EVOO) mechanical extraction process. The performance of a cooling crusher that was able to counteract the thermal increase that occurs during olive fruit grinding was analyzed to evaluate the effects on the development of volatile compounds and the concentration of hydrophilic phenols in the final product. The volatile profiles and phenolic fraction of EVOOs extracted from three different cultivars (Coratina, Peranzana, and Moresca) were positively affected by the use of lower temperatures during the crushing phase. The volatile fractions showed increases in the total aldehydes, mainly related to the concentrations of (E)-2-hexenal, and reductions in the total alcohols, mainly due to 1-penten-3-ol, 1-hexanol and (Z)-3-hexen-1-ol contents. The use of a lower temperature reduced the level of oxidative processes, protecting the phenolic compounds in the Moresca and Peranzana EVOOs by 17.8 and 12.1%, respectively.

The improvement of the extra virgin olive oil (EVOO) extraction process involves the proper management of endogenous enzymes of the olive fruit and all the technological conditions that can affect their activities. Coratina and Peranzana cultivars were processed to assess the influence of different technologies for fruit breaking (crushing and stoning) with and without controlled oxygen addition during this critical phase. The study of volatile compounds revealed that the enzymes that are responsible for their genesis during the technological process were significantly affected by oxygen addition in both the systems of fruit crushing. The results from the stoning technology proved that the quality improvement was a consequence of the prevention of the seed breaking and the oxidation catalyzed by the olive stone enzymes. In Peranzana EVOOs, it was possible to increase the aldehyde concentration up to 97% using stoning technology with a 0.2 L/min oxygen addition compared with traditional crushing. At the same time, non-significant reductions in phenolic compounds were detected when comparing crushing and stoning with and without the addition of oxygen, and similar trends were observed for the two studied cultivars. The sensory analyses confirmed the differences in phenolic and volatile composition detected in the EVOO samples.

In virgin olive oil industries, the technological choices of the production plant affect the biochemical activities that take place in the olives being processed throughout the entire process, thereby affecting the quality of the final product. The lipoxygenase pool enzymes that operated their activity during the first phases of the process need the best conditions to work, especially concerning temperature and oxygen availability. In this study, a system was equipped to supply oxygen in the crusher at a controllable concentration in an industrial olive oil mill at pilot plant scale, and four oxygen concentrations and two cultivars, Coratina and Ogliarola, were tested. The best concentration for oxygen supply was 0.2 L/min at the working capacity of 0.64 Ton/h. Further, using this addition of oxygen, it was possible to increase the compound’s concentration, which is responsible for the green, fruity aroma. The effect on volatile compounds was also confirmed by the sensory analyses. However, at the same time, it was possible to maintain the concentration of phenols in a good quality olive oil while also preserving all the antioxidant properties of the product due to the presence of phenols. This study corroborates the importance of controlling oxygen supply in the first step of the process for process management and quality improvement in virgin olive oil production.

Extra virgin olive oil (EVOO) is prone to oxidative degradation during storage, especially after opening, when exposure to oxygen and light accelerates the depletion of antioxidants and promotes the formation of oxidation products, including hydroperoxides and C₇–C₉ aldehydes associated with rancidity. Packaging materials play a critical role in preserving EVOO quality in real-use conditions. This study comparatively evaluated the effectiveness of three widely used packaging materials: green polyethylene terephthalate (PET), bag-in-box (BB), and chrome-plated tin (CPT) in preserving regulatory, sensory, and health-related qualities of EVOO under simulated household use and storage conditions. Methods: PET, BB, and CPT containers (3 L) were totally filled with the same EVOO and stored at 25 °C under a 12 h light/dark cycle, with 75 mL withdrawn daily for 40 days to mimic consumer use. Every 10 days, regulatory quality indices (free acidity (FA), peroxide value (PV), K₂₃₂, and K₂₇₀), antioxidants, volatile compounds, and sensory attributes were evaluated. Results: Free acidity, K₂₃₂, and K₂₇₀ increased slightly in EVOOs across all containers, while EVOO stored in PET showed a sharp rise in PV, exceeding the legal limit after 30 days. Antioxidant depletion was significantly (p ≤ 0.05) more pronounced in the EVOO stored in PET (44% α-tocopherol and 26% total phenols, respectively) than in BB (1% and 11%) and CPT (5% and 12%). The EVOO stored in PET also showed a reduction in C₅–C₆ aldehydes (−26% and −24% compared to BB and CPT, respectively), alongside an accumulation in C7–C9 aldehydes (+8% and +5%), exhibiting higher loss of C₅–C₆ aldehydes and of C₇–C₉ aldehydes, which is responsible for fruity–green notes and rancid defect, respectively, compared to BB and CPT. Conclusions: Overall, the EVOOs stored in BB, followed by CPT, showed higher oxidative stability than those stored in PET, resulting in prolonged “extra virgin” classification and improved preservation of antioxidant content, volatility profile, and sensory quality during consumer-level storage.