Chemical profile variation in bosana and semidana virgin olive oils using an innovative protoreactor® extraction technology

Extra virgin olive oil (EVOO) quality depends on both cultivar and extraction technology, particularly through their effects on minor bioactive compounds like phenolics and tocopherols. The objective of this study was to evaluate the impact of an innovative pre-conditioning technology (Protoreactor ® ) on the chemical and sensory characteristics of EVOO obtained from Bosana and Semidana cultivars compared with a conventional extraction process. Olives harvested at similar maturity stages were processed using either a traditional malaxation system or a Protoreactor ® -assisted extraction line. Oils were analyzed for standard quality parameters, phenolic profile, α-tocopherol content, and sensory attributes. Free acidity ranged from 0.21 to 0.47% and peroxide values between 7.2 and 9.5 meq O₂/kg. Strong cultivar × process interactions were observed. In Bosana oils, the Protoreactor ® reduced acidity (0.47 to 0.38%) and increased total phenols by approximately 32 mg/kg compared to the traditional process. In contrast, Semidana oils showed higher acidity (0.21 to 0.26%) and a reduction in phenolic content (−68 mg/kg) under Protoreactor ® processing. HPLC-DAD profiling revealed that differences were mainly driven by changes in secoiridoid derivatives (e.g. oleuropein aglycone and ligstroside aglycone). Sensory analysis confirmed these trends: Protoreactor ® processing produced more balanced oils in Bosana but reduced the intensity of organoleptic attributes in Semidana (olive fruitness = 4.2). Overall, the results demonstrate that the effects of innovative extraction technologies cannot be generalized across cultivars. Protoreactor ® processing provided measurable benefits for Bosana but proved less suitable for Semidana under the tested conditions, highlighting the need for cultivar-specific optimization of olive oil extraction technologies.