Manufacturing process of frozen surimi
The birth process of frozen surimi is as follows.
The background is
1) an increase in the catch of walleye pollock
2) an increase in the demand for fish sausage and kamaboko.
At the same time, the development of frozen surimi made from walleye pollock was carried out.
The problem with the initial development was that Alaska pollack meat was easily frozen and denatured (sponged by freezing).
1) Thorough washing of meat
2) Addition of sugars such as sugar
We were able to suppress freezing denaturation through technological development（1960）.
Therefore, long-term storage and mass processing became possible, which had an effect on the stable supply of raw materials for paste products and the development of walleye pollock.
After catching the fish, we have put them into the tank and sorted out after unloading them in the factory.
Then we use fresh fish that have passed in inspection as raw materials for surimi.
After removing head, visceral parts, bones and wastes,fresh lean meat from fish has been separated.
After the soaking process in water tank,blood,water soluble protein , fat ,mineral , etc. are removed from the lean meat of fish. Soaking surimi into water is affective way of deterring a breach-out process of the color.
After the soaking, water is removed unnecessary elements (water soluble protein, fat, mineral, etc)
in water and help to keep fish meat soft in the next process of refiner.
We have eliminated fish skin, bones, blood, etc. by using refiner. Depending on the quality of fish meat,we adjust rotor’s rpm, the gap between rotor bladesand the plate, size of the mesh, etc.
Appropriate operation of refiner could greatly affect the quality of surimi.
After the refiner process, water is removed from the fish meat by screw pressor. Through this process, water value in the fish meat returns to the original value.
After adding sugar, sorbitol to the fish meat, we have mixed it evenly by silent cutter. In the process, additives show the deterrent effect of freezing denaturation and fish meat is completed.
Completed fish meat is filled into 10Kg of poly-bag by filling machine and then put them into freezing pan.
After this process, it has been treated with rapid freezing system and transferred to the box. Products are thoroughly checked by metal detector and keep them into storage for delivery.
As a water soluble globular protein, it is called zymoprotein or chromoprotein.
It is eliminated when soaked in water.
It is insoluble in water, but it dissolves in saline solution. The most important thing is that it has myosin and actin which is related to elasticity of the products.
It is insoluble in water, neutral salt solution, dilute acid, dilute alkali.
It contains elastin, collagen which helps to form vascular tissue or connective tissue in muscle.
The purpose is to remove the sarcoplasmic protein by exposing it to water.
However, at the same time, the umami component is lost.
So seasoning technology is required due to lack of fish flavor Becomes important.
A mixture of myofibrillar protein and extracellular protein is a surimi protein.
To make Kamaboko, which forms supple and smooth elasticity, high-grade surimi containing a large amount of myofibrillar protein is used.
Lower surimi, which has a high proportion of extracellular protein, tends to be less smooth.
The purpose is to prevent freeze denaturation.
Prevents the release of free free water around the protein and bound water bound to the protein.
Usually, 4.0% sugar, 5.0% sorbitol and 0.2-0.3% phosphate are added.
It is important to freeze as soon as possible with a contact freezer to reduce ice crystals.
It also has the meaning of minimizing the biochemical changes (decrease in freshness) of proteins.
It should be stored at -25℃ or lower.
The quality of kamaboko depends on the quality of the frozen surimi that is the raw material.
The quality of frozen surimi is affected by the freshness of the raw fish.
The fresher the salt, the greater the effect of dissolving salt. You can make high quality kamaboko.
The biggest factor that influences the quality of Kamaboko is the quality of the main raw material, surimi.
The quality standards and labeling of surimi are different for each surimi manufacturer, and there is no universal standard.
From the standpoint of the user, the actual quality at the time of use must be judged and a certain product cannot be manufactured.
The point of surimi judgment is to decide the check items and always make the inspection judgment by the same method according to a certain manual.
Accurate judgment is possible by accumulating data.
Offshore and land-based fish, and other fish species such as Alaska pollack and Itoyori, but basically the same method can be used for determination.
1.Accurately judge the standard shown in the display standard and the quality of the actual surimi.
2.The fact is that some surimi with high-grade display has only high-grade non-standard quality such as intermediate jelly strength.
3.Since frozen surimi is the main raw material for paste products, it can be said that what is important when making paste products is not the technology for processing the paste, but the technology for correctly evaluating the quality of the paste itself.
4.Anyone can make a good product by making a surimi product using high quality surimi. On the other hand, if you use poor quality surimi, no matter who does it, you will end up with a poor quality product.
This is the advantage and disadvantage of frozen surimi.
It is important to be able to accurately grasp the quality of the surimi (gel forming ability) at the time of purchase.