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Jadilah perubahan, jika ingin melihat dunia adanya…….
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CARILAH ILMU PENGETAHUAN AGAR BISA MENEBAR PEMIKIRAN
MANUFACTURING OF SURIMI Harvest to Frozen Block
Oleh : Bambang Riyanto
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CAPAIAN PEMBELAJARAN DAN KARAKTER YANG DIKEMBANGKAN Kognitif : Mampu menjelaskan sains dan teknologi (K)
ekstraksi, konsentrasi serta pengembangan produk pengolahan berbasis daging ikan lumat (minced fish) atau surimi
Afektif : Mampu bekerjasama dan mengembangan
konsep dan kreativitas (A) dalam pembuatan produk baru yang potensial untuk dikomersialkan dan memberi sumbangan dalam penciptaan kedaulatan pangan protein ikani.
Psikomotorik : Mampu mempraktekkan dan mengaplikasikan (P)
produk bernilai tambah hasil perairan dalam pembuatan produk baru yang potensial untuk dikomersialkan dan memberi sumbangan dalam penciptaan kedaulatan pangan protein ikani.
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• TUTORIAL DAN DISKUSI
• COLLABORATIVE LEARNING (CBL)
• PROJECT BASED LEARNING (PJBL) MODEL PROYEK : KOOPERATIF DAN KOLABORATIF GAGASAN KELOMPOK PENGEMBANGAN PRODUK
STRATEGI/METODE PEMBELAJARAN
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ASSESSMENT KOMPETENSI/KEMAMPUAN DIRI KOGNITIF PERFORMANCE ASSESMENT/ASESMEN KINERJA 1. UJIAN TENGAH SEMESTER 2. QUIS
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ASSESSMENT KOMPETENSI/KEMAMPUAN DIRI AFEKTIF DISKUSI DAN PEMBUATAN RESUME (RUBRIC-DESKRIPTIF DAN HOLISTIK)
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DISKUSI DAN PEMBUATAN RESUME DISKUSI 1. Kualitas surimi sangat tergantung dari bahan baku ikan. Bagaimana
faktor biologi (spesies, musim, kematangan seksual, dan kesegaran) berperanan dalam penentuan kualitas surimi tersebut.
2. Kualitas surimi juga sangat tergantung dari berbagai faktor
pengolahan, Bagaimana faktor-faktor seperti cara penangkapan, penanganan (handling), kualitas air untuk pencucian surimi, time-temperature of processing, teknik pencucian (jumlah pencucian dan rasio), salinitas dan pH, yang sangat berpengaruh terhadap kualitas surimi yang dihasilkan.
3. Teknologi surimi berkembang sejalan dengan dikembangkannya
cryoprotectant, sehingga dapat dilakukan penyimpanan dengan waktu yang relatif lebih lama. Saat ini juga dikembangkan dryoprotectant.
4. Teknologi pengolahan surimi telah menuntut pula akan efisiensi produksi
dan profitabilitas. Apa yang dapat dikembangkan melalui teknologi pembekuan (freezing technology), neural network, automation, digital image analysis, waste water treatment.
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PENILAIAN AUTENTIK (RUBRIK DESKRIPTIF) (85%)
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LINGKARI SALAH SATU PILIHAN NILAI DIMENSI
KONTRIBUSI PADA HASIL TUGAS DAN TUGAS YANG DIBERIKAN 5 A. Sangat Berkontribusi 3 B. Berkontribusi sama dan adil 2 C. Hanya memberi kontribusi yang ada
KEPEMIMPINAN 5 A. Inisiatif dan terlihat memberikan perhatian yang besar dalam
menyelesaikan tujuan bersama 3 B. Bertanggungjawab pada tujuan dan menerima pembagian yang
adil 2 C. Kurang memberikan perhatian dan tidak sesuai dengan arah
tujuan KERJASAMA
5 A. Menghargai pendapat orang lain dan sangat berkontribusi dalam diskusi kelompok
3 B. Menghargai pendapat orang lain dan berkontribusi dalam diskusi kelompok
2 C. Tidak berkontribusi pada diskusi kelompok atau sering gagal berpartisipasi
NILAI TOTAL !
PENILAIAN UNTUK SESAMA ANGGOTA TIM (15%)
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ASSESSMENT KOMPETENSI/KEMAMPUAN DIRI PSIKOMOTORIK 1. PRAKTIKUM
2. MODEL PROYEK : KOOPERATIF DAN KOLABORATIF GAGASAN KELOMPOK PENGEMBANGAN PRODUK
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KOMPETENSI DASAR
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SECTION I SURIMI AND FISH PROTEINS • Historical Review of Surimi Technology and
Market Developments • Surimi Resources and Market
• Manufacture of Surimi : Harvest to Frozen Block
• Surimi Gelation Chemistry • Proteolytic Enzymes and Control in Surimi • Fish Protein Isolate by pH Shift • Stabilization of Proteins in Surimi
INDEX
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SECTION II SURIMI SEAFOOD PRODUCTS • Comminution Process for Surimi and Surimi
Seafood Paste • Manufacture of Crabsticks • Manufacture of Kamaboko, Chikuwa,
Tempura, and Hanpen • Manufacture of Fish Balls • Manufacture of Fish Sausage
INDEX
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SECTION III QUALITY ASSESSMENT/CONTROL, DEVELOPMENT, AND NUTRITION
• Waste Management, Utilization, and Challenges • Food-Grade Coproducts from Surimi Processing • Sanitation and HACCP • Microbiology and Pasteurization • Surimi Paste Preparation, Gel Analysis, and
Rheology • Ingredient Technology for Surimi and Surimi
Seafood. • Color Measurement and Colorants for Surimi
Seafood. • Surimi Seafood Flavors • Application of Sensory Science to Surimi
Seafood . • Research and Product Development. • Nutrition and Health Benefits of Surimi Seafood
INDEX
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PUSTAKA
Jae W Park. 2014. Surimi and Surimi Seafood 3th. CRC Press Taylor & Francis Group. Boca Raton
INTRODUCTION RAW MATERIALS • Fresh • Frozen • Tropical Fish • Fresh Water Fish: Tilapia, Catfish, Carp, Rohu • Biological (Intrinsic) Factors Affecting Surimi Quality
(effect of species, seasonality/sexual maturity, freshness or rigor) • Processing (Extrinsic) Factors Affecting Surimi Quality
(harvesting, on-board handling) PROCESSING TECHNOLOGY AND SEQUENCE • Heading, Gutting, and Cutting • Mincing (Deboning) • Washing and Dewatering. • Refining • Screw Press • Stabilizing Surimi with Cryoprotectants • Freezing • Metal Detection
FRESH SURIMI FISH PROTEIN ISOLATE SURIMI POWDER (DRY SURIMI)
MATERI PERKULIAHAN
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INTRODUCTION
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INDUSTRI DAGING LUMAT (MINCED FISH)
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PROCESSING TECHNOLOGY
• Heading, Gutting, and Cutting • Mincing (Deboning) • Washing and Dewatering. • Refining • Screw Press • Stabilizing Surimi with Cryoprotectants • Freezing • Metal Detection
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PRODUCT DESCRIPTION
Aquatic Product Raw Material: Pacific whiting ( Merluccius spp. ); Pollock ( Theragra chalcogramma )
Raw material harvest Area: Off Oregon coast
Raw material received: Directly from harvester
Finished Product: Frozen surimi Food additives, ingredients, processing aids:
Sorbitol, sugar, polyphosphate, protease inhibitor, water
Shipping: Shipped in the firm's refrigerated trucks
Intended use: Raw material for fully-cooked imitation seafood products
Intended consumers: General public
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FLOW DIAGRAM Receiving Receiving Raw fish received at dock; ingredients received at loading platform
| | Refrigerated storage Dry storage Refrigerated storage at or below 40°F; dry storage at ambient temperature
| | Heading | Mechanical heading equipment
| | Gutting | Mechanical gutting equipment
| | Filleting | Mechanical filleting equipment
| | Deboning | Mechanical deboning equipment
| | Mincing | Mechanical mincing equipment
| | Wash | Wash tanks
| | Dewater | Dewatering screens
| | Wash | Wash tanks
| | Dewater | Dewatering screens
| | Mix | Mixing bin
| | Refine | Refiner
| | Dehydrate | Screw dehydrator
| | Blend <– <–––– Blender
| Form Former
| Freeze Freezer
| Package Packing table
| Frozen Storage Freezer
| Ship Ship in firm's trucks
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BAHAN BAKU
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BENTUK IKAN SEGAR
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BENTUK IKAN BEKU
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BENTUK IKAN SEGAR-KECIL (TROPICAL FISH)
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Scanning Electron Micrographs of Fish Muscle Tissue
After 21 Days of Storage
IKAN BERLEMAK
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Changes in the gel strength of surimi gel prepared from horse mackerel cubed mince by (a)(b)(c) flotation washing with different gas or (d) cold water washing
Contoh Peningkatan Gel Surimi dengan Berbagai Teknik Pencucian untuk Ikan Berlemak
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FRESH WATER FISH: TILAPIA, CATFISH, CARP, AND ROHU
Rohu (Labeo rohita) Common carp (Cyprinus carpio)
Clarias gariepinus Park JW, RW Korhonen, TC Lanier. 1990. Effects of rigor mortis on gel-forming properties of surimi and unwashed mince prepared from tilapia. J Food Sci 55:353–355, 360
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BIOLOGICAL (INTRINSIC) FACTORS AFFECTING SURIMI QUALITY • Effect of Species • Effects of Seasonality/Sexual Maturity • Effects of Freshness or Rigor
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Fish meat easily developing “suwari”
Fish meat showing “suwari” moderate degree
Fish meat showing slight “suwari”
Fish meat having strong “ashi”
p Lizard fish p Flying fish p Jack mackerel
p A kind of croaker p Flat fish
p Shark p Blue marlin
Fish meat having medium “ashi”
p Cutlass fish p Barracuda p Alaska Pollock
p Puffer fish p Argentina senufascuate p Strorptoothed eel
p Dolphin fish p Shark skin flounder
Fish meat having weak “ashi”
p Sardine p Round herring
p Saury p Bonito p Mackerel p Yellow fin tuna
FAKTOR SPECIES
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Jack mackerel
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EFFECT OF SPECIES
LINGKUNGAN PERAIRAN DENGAN FISIOLOGI IKAN
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LINGKUNGAN PERAIRAN DAN
PARASIT PADA IKAN
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EFFECTS OF SEASONALITY/SEXUAL MATURITY
Compositional Properties of Pacific Whiting from April to October (Astoria, Oregon). (A) Moisture Content; (B) Protein Content; (C) Fat Content. Bambang Riyanto 44
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EFFECTS OF FRESHNESS OR RIGOR
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PROCESSING (EXTRINSIC) FACTORS AFFECTING SURIMI QUALITY • Harvesting • On-Board Handling
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Harvesting and On Board Handling
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PROCESSING TECHNOLOGY AND
SEQUENCE
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PROCESSING TECHNOLOGY AND SEQUENCE
• HEADING, GUTTING, AND CUTTING
• Mincing (Deboning) • Washing and Dewatering. • Refining • Screw Press • Stabilizing Surimi with Cryoprotectants • Freezing • Metal Detection
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HEADING, GUTTING, AND
CUTTING
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skinless fillets to skin-on fillets or butterfly-shaped headed and gutted (H&G)
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Hopper ElevatorVMK
50/52/58/60
AutomaticFeeder
VMK 31/32/33
ScalingVMK
26/27/28
DeheadingNobbing
VMK 16/20
Format sizesF30/F45/F60
F75/F90
SexSorting
Round fi sh
Headmeasuring
systemDeheading
Vision-System1 operator up to
6 machines
FishCounter
M130
Belly Gutting
M63
VacuumUnit
CUP 752
TailCutting
FilletingMachineVMK 11
PieceCutting
M50
Belly-CutCleaning
M24
Roe & MilkSorting
Belly opening/cleaning
Paralellknives
Butterfl yfi llet device
Single fi lletDevice
M9
SkinningVMK 42
VMK 440
TitbitMachineVMK 470
Arenco ABDatavägen 57 B, SE- 436 32 AskimSwedenPhone: +46 31 748 03 18Fax: +46 31 748 03 10Web: www.arenco.com
Manual-, semiautomatic and up to 6 machines with only 1 operator.
Processing machines for diff erenttypes of pelagic fi sh.
Sprats - Anchovy - Sardines - Herring - Mackerel - Horse Mackerel - SardinellaBlue Whiting and many more.
VMKStandardMachines
VMKStandard
Equipment
VMKExtra
Equipment
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57
HEADING, GUTTING,
AND CUTTING
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HEADING, GUTTING,
AND CUTTING
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During the gutting and filleting steps, water nozzles, along with a plastic bristle wheel brush, are used to separate the undesirable parts from the fillets of the fish.
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PROCESSING TECHNOLOGY AND SEQUENCE
• Heading, Gutting, and Cutting
• MINCING (DEBONING)
• Washing and Dewatering. • Refining • Screw Press • Stabilizing Surimi with Cryoprotectants • Freezing • Metal Detection
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MINCING (DEBONING)
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Mincing MINCING
(DEBONING)
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Mincing MINCING
(DEBONING)
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Mincing
ROLLER-TYPE MEAT SEPARATOR
MINCING (DEBONING)
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Mincing
ROLLER-TYPE MEAT SEPARATOR
medium orifice size of 3–4 mm
MINCING (DEBONING)
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PROCESSING TECHNOLOGY AND SEQUENCE
• Heading, Gutting, and Cutting • Mincing (Deboning)
• WASHING AND DEWATERING
• Refining • Screw Press • Stabilizing Surimi with Cryoprotectants • Freezing • Metal Detection
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WASHING AND DEWATERING
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88
WASHING AND
DEWATERING
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TARGET : • Maximum gelling or formation of a three-
dimensional gel structure (get a myofibrillar proteins, remove blood, myoglobin, fat, and sarcoplasmic proteins)
• Colorless and odorless surimi Mixing minced meat with cold water (5 oC) and removing water by screening and dehydrator to about 5-10% solid.
WASHING AND
DEWATERING
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WASHING CYCLE • Varies with fish species, freshness of fish, type of
washing unit, and the desired quality of the surimi • Repeated Two or Three times. • The water/mince ratio = 5:1 – 10:1
29.1 kg of waste was = 1 kg surimi
(TM Lin and JW Park. 1995. Study of myofibrillar protein solubility during surimi processing : effects of washing cycles and ionic strength. Presented at the PFT annual meeting, Mexico).
WASHING AND
DEWATERING
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An effective washing process for primary grade surimi processes can now be accomplished with • two washing cycles at water meat ratios of less than 2:1 • with typical wash ratios of 0.9–1.2 parts water in the first
wash and • 0.7–0.8 in a second wash. In comparison, at-sea processors can achieve the same washing effect with less water than shore-based processors due to the difference in fish freshness.
WASHING AND
DEWATERING
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WATER
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Ø Residue Chlorine
Ø Temperature 5 oC or less
Ø Hardness or Mineral Content
Soft water with minimum levels of mineral (Ca++, Mg++, Fe++, Mn++) * Ca++ and Mg++, are responsible for the texture change. * Fe++, Mn++ are responsible for the color change.
Ø pH and Salinity * pH : 6.8 – 7.0
* Salinity NaCl and/or CaCl2 at 0.1 - 0.3 % in the final wash water
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Time/Temperature of Processing
Degradation of myosin heavy chain and actin of Pacific whiting at various postharvest storage conditions.
M, myosin heavy chain; A, actin. Numbers followed by M or A indicate storage temperatures.
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WASHING CYCLE AND WASH WATER RATIO
Target : * Texture, Color and Odor * Remove Sarcoplasmic proteins, blood, fat, and other nitrogenous
compounds * Rising utility costs * Limited water sources * Pollution problems Method * Onshore processors
Water/meat = 4:1 to 8:1 Cycle = 3 X - 4X
* Sea processors Water/meat = 1:1 to 3:1 Cycle = 1 X - 2X
* General Water/meat = 3:1 to 24 :1 ~ 50% of total proteins were lost
TM Lin, JW Park. 1997. Effective washing conditions reduce water usage for surimi processing. J. Aquatic Food Product Tech 6 (2) : 65-79 * Water/Meat Ratio = 2:1 * Wash Time = 10 min * Wash Cycle = 4 X Bambang Riyanto
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TM Lin, JW Park. 1997. Effective washing conditions reduce water usage for surimi processing. J. Aquatic Food Product Tech 6 (2) : 65-79 * Water/Meat Ratio = 2:1 * Wash Time = 10 min * Wash Cycle = 4 X
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pH and Salinity
Electrophoretic patterns of proteins soluble in water (0%, 0.5%, 2.0% NaCl). S, High-molecular-weight standard; lane 1, first washing step (WS) of the first washing cycle (WC); lanes 2–3, the first and second WS of the second WC, respectively; lanes 4–6, the first, second, and third WS of the third WC, respectively; lanes 7–10, the first, second, third, and fourth WS of the four WC, respectively. MHC, Myosin heavy chain; ATN, actin; b-TPM/TNT: b-tropomyosin/troponin-T; a-TPM, a-tropomyosin.
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Leaching or
Washing
WASHING AND
DEWATERING
flotation washing
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Rotary screens are traditionally used to remove free water from the washed meat. These are long horizontal drums made of perforated mesh screens that rotate at set speeds. In virtually all cases, meat is pumped to the interior of the rotating screen and water falls through the screens where it is collected and either discharged or reprocessed. Surimi operators will arrange screens along the length of the rotary screen to optimize water removal, meat retention, and production speed. The operator has several tools to manage meat flow through the screens. Some of the primary controls are the screens themselves, which vary in perforation size, typically from 0.3 to 0.8 mm in diameter, the pitch, or distance from hole center to center, and the speed at which the unit rotates. In some cases, the screen arrangement will vary depending on the species being processed. Operators need to pay close attention to rotary screens to ensure the screens do not “blind” of “foul,” meaning small meat particles settle in the holes, resulting in significantly reduced function of the screens. Other technologies exist for water removal, such as hydro sieves, or wedge-wire screens that use static screens to accomplish water removal.
WASHING AND
DEWATERING
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PROCESSING TECHNOLOGY AND SEQUENCE
• Heading, Gutting, and Cutting • Mincing (Deboning) • Washing and Dewatering.
• REFINING
• Screw Press • Stabilizing Surimi with Cryoprotectants • Freezing • Metal Detection
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REFINING
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Before the final dewatering process in a screw press or decanter, impurities, such as • skin, • pin bones, • scales, and • connective tissues, are removed by the refiner. The proximate composition of refiner discharge of Pacific whiting was 81.4% moisture, 1.9% lipid, 15.4% protein, and 1.0% ash. They also found the majority of protein was stroma proteins derived from connective tissue. This clearly indicates the purpose of the refining process is to separate connective tissues from washed mince (Kim and Park 2005)
Perforation : 0.5 – 1.2 mm
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Conventionally, all manufacturers used a Fukoku refiner until the recent introduction of the Brown refiner (Covina, CA). According to US industry experts, the Brown refiner is designed as a more user-friendly structure in cleaning and adjusting the paddle height. The Brown refiner system also offers models with paddles, which is used in the decanter surimi production process as well as typical drum systems with blades attached that are used for the traditional surimi process. One key advantage to the Brown refiner is the size of the drum and the use of more veins and paddles in the process. By using more paddles, the unit is able to separate connective tissue and proteins easier, thus resulting in lower temperatures in the process.
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REFINING
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Brown refiner (Covina, CA).
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PROCESSING TECHNOLOGIES THAT ENHANCE EFFICIENCY AND PROFITABILITY • Neural Network • PROCESSING AUTOMATION: ON-LINE SENSORS • Digital Image Analysis for Impurity Measurement • Innovative Technologies for Wastewater • Fresh Surimi
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ON-LINE SENSORS
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PROCESSING TECHNOLOGY AND SEQUENCE
• Heading, Gutting, and Cutting • Mincing (Deboning) • Washing and Dewatering. • Refining
• SCREW PRESS
• Stabilizing Surimi with Cryoprotectants • Freezing • Metal Detection
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SCREW PRESS
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The screw press is a compression machine with a 2:1 fixed compression ratio: two parts in, one part out. The desired moisture content out of the screw press is 82% moisture or 18% solids. This results in, with the addition of 9.3 parts dry cryoprotectant additives (typical for Alaska pollock and Pacific whiting) to 100 parts meat, a finished surimi moisture content of 75% (82%/1.093) (M. Burns, personal communication, 2012).
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SCREW PRESS
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PROCESSING TECHNOLOGIES THAT ENHANCE EFFICIENCY AND PROFITABILITY • Freezing Technology (Freezing Capacity and
Freezing Time) • Neural Network • Processing Automation: On-line Sensors • Digital Image Analysis For Impurity Measurement • INNOVATIVE TECHNOLOGIES FOR WASTEWATER • Fresh Surimi
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WATER RECYCLE WITH COUNTERCURRENT WASHING
1st
Wash DEWATER 2nd
Wash
DEWATER DEWATER 3rd
Wash
SURIMI FRESH WATER
WASTE DISCHARGE
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PROCESSING TECHNOLOGY AND SEQUENCE
• Heading, Gutting, and Cutting • Mincing (Deboning) • Washing and Dewatering. • Refining • Screw Press
• STABILIZING SURIMI WITH CRYOPROTECTANTS
• Freezing • Metal Detection
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STABILIZING SURIMI WITH CRYOPROTECTANTS
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The addition of cryoprotectants is important to ensure maximum functionality of frozen surimi because freezing induces protein denaturation and aggregation.
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Moisture : 82-85 % Mixture wit salt (NaCl and CaCl2) : 0.1 – 0.3 %
Streaming (Stabilizing
With Cryoprotectants)
STABILIZING WITH
CRYOPROTECTANTS
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Dewatering STABILIZING
WITH CRYOPROTECTANTS
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Ø Target : Ensure maximum functionality of frozen surimi (prevent to protein denaturation and aggregation during freezing and storaging)
Ø 10 Kg block surimi
* Sucrore and sorbitol = ~ 9% w/w to dewatered fish meat * Sodium tripolyphosphate and tetrasodium pyrophosphate = 0.2-0.3 % (1:1)
is commonly used as both a chelating agent, which inactivates metal ions in surimi, and as a pH adjusting agent. The shifting of the pH to 7.0 also helps to increase transglutaminase activity, which is inherent in the fish, thereby improving gel values. Ø Kneader and Silent Cutter : 2.5 min
temperature 10 oC.
STABILIZING WITH
CRYOPROTECTANTS
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Commercial practices for mixing cryoprotectants (100 kg approximately) using a kneader and a silent cutter are 6 min and 2-½ min, respectively. Inline blending systems reduce the time to 10–12 s. The temperature of the mix must not exceed 10°C because at temperatures greater than 10°C protein functionality could be damaged, particularly for cold water species.
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KNEADER MACHINES
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TARGET Since 1991, with commercial surimi processing of Pacific whiting
- Cryoprotectants - Gel enhancers - Color enhancers
Enzyme inhibitor :
- Beef plasma protein - Egg white - Whey protein concentrates - Potato extracts
Enzyme inhibitors are commonly formulated with sucrose, sorbitol, sodium tripolyphosphate, tetrasodium pyrophosphate, calcium carriers (calcium lactate, calcium sulfate, calcium citrate, or calcium caseinate), sodium bicarbonate, mono- or diglyceride, and partially hydrogenated canola oil
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As a verification step to determine whether cryoprotectants are homogeneously mixed, pH and degrees Brix (°Bx) are measured using surimi after thawing. • 0.3% sodium tripolyphosphate or a mixture (50:50) of sodium
tripolyphosphate and tetrasodium pyrophosphate is used and mixed homogeneously,
• pH of surimi should range between 7.2 ± 0.2.
• Brix 5.6–5.7 should be a target when 4% sugar + 5% sorbitol are added to the measure whether cryoprotectants were homogeneously mixed in the surimi. Sugar and/or sorbitol concentration in an extracted surimi sample solution can be calculated using sugar (%) = 2.04 × oBrix – 2.98,
(One degree Brix is 1 g of sucrose (sugar) in 100 g of solution and represents the strength of the solution as a percentage by weight (% w/w). If the solution contains dissolved solids other than pure sucrose (like fish proteins), then the °Brix only approximates the dissolved solid content. To remove fish proteins from the properly diluted sample solution, 2% trichloroacetic acid solution is added)
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CRYOPROTECTANTS
• Sugar (sorbitol) • Amino acids • Polyls • Methyl amines • Carbohydrate polymers • Synthetic polymers (Polyethylene glycol, PEG) • Other proteins (Bovine serum albumine, BSA) • Organic salt ((potassium phosphate, ammonium sulfate)
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• Lactitol ® (4-O-(b-D-galactopyranosyl)-D-glucitol) It is a sweet tasting sugar alcohol derived from lactose by reduction of the glucose moiety of the disaccharide, and is a value-added product from lactose in whey, a by-product from cheese making. Lactitol is 0.3±0.4 times as sweet as sucrose, and its nutritional caloric utilization is half that of carbohydrates, with a maximum metabolic energy value of 2 kcal/g.
• Palatinit ® • Polydextrose ®
Litesse ® is a modified form of Polydextrose ®, a highly branched polysaccharide which is prepared from dextrose, sorbitol and citric acid
Litesse ® is not sweet and is less bitter, astringent and acidic than polydextrose, and therefore, in most food systems Litesse ® will not require neutralization. The calorie utilization of Litesse ® is 1 kcal/g, which is 25% that of carbohydrates
• Glycerol, • Glucose syrup, • Starch hydrolysate products • Linear oligosaccharides
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MECHANISMS FOR CRYOPROTECTION AND CRYOSTABILIZATION A. Solute Exclusion B. Ligand Binding C. Antioxidants D. Freezing-Point Depression E. Cryostabilization by High Molecular Weight Additives F. Vitrification
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Freezing of surimi is done commercially by incorporation of sucrose (4%), sorbitol (4%) and polyphosphates (0.2%) which protect fish myofibrillar proteins during long periods of frozen storage (Lee, C. 1984. Surimi process technology. Food Technology 38, 69-80.) One disadvantage of the commercial cryoprotectant blend used is the high level of sucrose and sorbitol which impart a sweet taste that may be undesirable to the Western consumer in particular. Yoon and Lee (1990) showed that 4% sucrose plus 4% sorbitol in crystalline or liquid form in red hake (Urophycis chuss) surimi when given as extruded gel products to a sensory panel were judged to be slightly too sweet. (Yoon, K. S. and Lee, C. M. 1990. Cryoprotectant efects in surimi and surimi/mince-based extruded products. Journal of Food Science 55, 1210-1216. In addition, today's consumer is conscious of caloric content, and low calorie cryoprotectants in surimi may be preferred.
GENERAL INGREDIENT • White Fish Meats • Water • Starch • Protein Additives
* Whey Proteins * Egg White Proteins * Beef Plasma Proteins * Soy Proteins * Wheat Gluten and Wheat Flour
• Hydrocolloids * Carrageenan * Konjac * Alginate * Chitosan
• Cellulose • Vegetable Oil • Food Grade Chemical Compounds
* Oxidizing Agents * Calcium Compounds * Transglutaminase * Phosphate * Coloring Agents
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PROCESSING TECHNOLOGY AND SEQUENCE
• Heading, Gutting, and Cutting • Mincing (Deboning) • Washing and Dewatering. • Refining • Screw Press • Stabilizing Surimi with Cryoprotectants
• FREEZING
• Metal Detection
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FREEZING
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In commercial applications, Surimi is formed in a standard 10 kg block extruded into a plastic bag (3–7 mil), which is placed into a stainless steel or aluminum tray for freezing. The latter offers better heat transfer, but the former is better for longevity. Trays are then placed in a contact plate freezer and held for approximately 2–2.5 h or until the core temperature reaches –25°C. Proper loading of trays and plate freezers is critical as the poly bags may become embedded in the surimi.
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FREEZING
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FREEZING RATE OF THREE DIFFERENT FREEZING METHODS FOR SURIMI Bambang Riyanto 153
Microstructure of surimi gels from four species prepared from fresh and frozen fish
Note : (A) Croaker; (B) Lizardfish; (C) Threadfin bream; (D) Bigeye snapper.
FREEZING
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PROCESSING TECHNOLOGIES THAT ENHANCE EFFICIENCY AND PROFITABILITY
• FREEZING TECHNOLOGY (FREEZING CAPACITY AND FREEZING TIME)
• Neural Network • Processing Automation: On-Line Sensors • Digital Image Analysis for Impurity Measurement • Innovative Technologies for Wastewater • Fresh Surimi
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Frozen Mincemeat of Fish (SURIMI)
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PROCESSING TECHNOLOGY AND SEQUENCE
• Heading, Gutting, and Cutting • Mincing (Deboning) • Washing and Dewatering. • Refining • Screw Press • Stabilizing Surimi with Cryoprotectants • Freezing
• METAL DETECTION
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METAL DETECTION
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METAL DETECTION
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• FDA’s Health Hazard Evaluation Board has supported regulatory action against products with metal fragments of 7–25 mm in length
• The most common types of metallic contamination include :
ferrous, copper, aluminum, lead, and various types of stainless steel.
Of these, ferrous metal is the easiest to detect. The following factors also affect the sensitivity of metal detection: • shape of metal, • orientation of metal, • aperture dimension, • position of metal in the aperture, • environmental conditions, • condition of the product (frozen vs. chilled), • operation frequency, and throughput speed .
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NUTRIENT
Water : 76% Protein : 15% Fat : 0.9% Carbohydrate : 6.85% Cholesterol : 0.03%
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CHEMICAL SCORES FOR ESSENTIAL AMINO ACIDS IN SURIMI, BEEF, PORK, CHICKEN AND TURKEY
Source : Holmes, K., ed. (1987) $urimi - It's American Now, pp. V4-V6, Alaska Fisheries Development Foundation
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FRESH SURIMI
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Comparison of fresh and frozen surimi based on textural values of gels. Both frozen and fresh surimi samples were from the same batch and evaluated based on the equal moisture contents (75%). FZ = frozen surimi; FS = fresh surimi. Numbers followed by FZ or FS indicate percent surimi content used in surimi seafood gels.
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BENEFITS OF FRESH SURIMI VS FROZEN SURIMI Pipatsattayanuwong et al. * Lower cost (additives and freezing are not necessary) * No sugar products and also increase the market value * Better gel functionality and can be used at a reduced
level Park and Pipatsattayanuwong * The use of fresh surimi over commercial frozen surimi
could contribute $0.172/kg of finished products to users
* When 50% of frozen and fresh surimi was used in surimi seafood, significantly higher stress (by 25%) and higher strain values (5%).
42.2% fresh surimi is as good as 50% frozen surimi.
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CONTINUOUS PROCESSING
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Electron microscopic image of surimi gels prepared by using different conditions (magnification: 10,000, EHT: 10 kV). • Con: conventional method • Acid: acid-aided process • Alk: alkaline-aided process Bambang Riyanto 174
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SURIMI POWDER/DRY SURIMI
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TERIMA KASIH
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