freezing lab
TRANSCRIPT
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FROZEN PRAWNS (Shrimp)
RAW MATERIAL
Prawns belonging to the families
Penaeidae (Penaeus, Metapenaeus, Parapenaeopsis) Pandalidae (Heterocarpus)
Solenoceridae (Solenocera crassicornis)
Palemonidae (Macrobrachium rosenbergii, malcolmsonii)
TYPES OF PRODUCTS
1. Whole (Head-on)2. Headless (HL)
3. Easy peel shell-on
4. Fantail round / PUD tail-on
5. Fantail deveined / PD tail-on
6. Butterfly7. Raw peeled or peeled undeveined (PUD)
8. Peeled and deveined (PD)
9. Cooked and peeled (CP)
10. Peeled and cooked (PC)
1. Peeled, deveined and cooked (PDC)1. Whole cooked
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PRE-PROCESS HANDLING
Separate prawns from other fish.
Sort the prawns species wise and size wise.
Wash well in potable water.
Ice it immediately and stock in insulated boxes in alternate layers of
ice & prawn.
Use only clean crushed/flake ice made from potable water.
Height of the iced pack shall not exceed 50 cm.
HANDLING FOR PROCESSINGPrawn is further handled according to the type of product desired.
1. WHOLE PRAWNS:
Discard discolored, bruised, soft shell and hanging head pieces.
Use only absolutely fresh quality material for this type of pack.
Pack uniform size prawn (as per the declared size grade) in apolythene lined or waxed duplex carton.
Pack the prawns in a parallel style. Do not allow cross packing.
Weight of the packed shall be as per the agreement between the
buyer and processor
Add ice cold glaze water to the pack; if needed. Use potable water chlorinated up to 2 ppm level.
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2. HEADLESS:
Remove head portion.
Wash well with potable water
Discard discolored, bruised or soft-shelled pieces.
Pack uniform pieces in polythene lined / waxed duplex cartons.
Pack in a parallel style. Do not allow cross packing.
Add ice cold glaze water, if needed.
3. EASY PEEL SHELL-ON:
Processing is same as of headless. The only difference is that the shell is cut from the top with the help
of a sharp knife or scissor up to the third or forth segment
Remove the alimentary canal completely from meat.
Pack as per the size / grade and weight.
3. FANTAIL ROUND: Proceed as for headless pack.
Head portion and shell are removed except on the last segment.
The tail is left intact.
4. FANTAIL DEVEINED:
Proceed as for fantail round but remove the alimentary canal.
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5. BUTTERFLY:
Proceed as for Fantail deveined, but split open the meat from the
dorsal side and arrange in the required pattern.
6. RAW PEELED OR PEELED UNDEVEINED: Remove head, shell and tail completely.
Wash well in water chlorinated up to 2 ppm. level.
Pack uniform sizes (as per the declared size grade) in polythene-
lined / duplex cartons.
Add ice cold glaze water, if needed.7. PEELED AND DEVEINED:
Proceed as for raw peeled; but remove the alimentary canal
completely from the meat.
8. COOKED AND PEELED:
Immerse prawn in 7-10% (w/v) boiling brine for 7 minutes.
Take out from brine and cool immediately in ice cold water
containing 3-5% salt and chlorinated up to 2 ppm. level.
Proceed further as in the other types
(Note: Cooking conditions may vary depending upon agreement
between buyer and processor).
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9. PEELED AND COOKED:
Remove head, shell and tail.
Wash thoroughly in potable water.
Immerse the meat in 3-5% (w/v) boiling brine for 2-3 minutes.
Take out from brine and cool immediately in ice cold water
chlorinated up to 2 ppm. level.
Proceed further as for cooked and peeled prawns.
10. PEELED, DEVEINED AND COOKED: Proceed as for Peeled and Cooked prawns; but the meat is
deveined before cooking.
11. WHOLE COOKED:
Use only absolutely good quality material for this pack.
Wash the whole undamaged prawn thoroughly in potable water.
Cook in 10% (w/v) boiling brine for 7 minutes.
Take out from brine and cool immediately in ice cold water
chlorinated up to 2 ppm. level.
Proceed, further as for whole prawns frozen.
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FREEZING
Freeze the prawn in cartons in an appropriate type freezer
maintained at -40C till the core temperature reaches - 23C.
GLAZING
Glaze the frozen blocks, if necessary, by pouring sufficient
quantity of ice cold water chlorinated up to 2 ppm level on the
surface after opening the carton.
PACKING OF CARTONS
As per declared weight in waxed corrugated fibre board master
cartons.STORAGE
Store the cartons in cold store maintained at -23C or lower.
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FREEZING OF
CUTTLE FISH
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RAW MATERIALS
Several species of cuttle fish Sepia pharaonis, S. aculeata,
S.thrustoni, S. brevinana, Sepiella inermis, Sepiella lidiolu
TYPES OF PRODUCTS
Cuttle fish is frozen in the following styles. Cuttle fish whole (CFW)
Cuttle fish whole cleaned (CFWC)
Cuttle fish fillets (CFF)
Cuttle fish strips (CFS)
Cuttle fish tentacles (CFTN)
Cuttle fish wings/fins (CFWG)
Cuttle fish head meat / throat meat / tentacle meat (CFTM).
PRE PROCESS HANDLING
Separate cuttle fish from other fish. Sort the cuttle fish size wise.
Discard those with broken ink sacs.
Discard any bruised or damaged or discoloured pieces. Wash well in potable water or clean uncontaminated sea water.
Ice immediately and stock in insulated boxes.
Use only clean crushed/flake ice made from potable water.
Ice and cuttle fish should be in alternate layers. The height of ice pack
shall not exceed 50 cm.
Handle the material carefully during loading/transportation/unloading.
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HANDLING FOR PROCESSING
Depending upon the type of pack desired, handle further as follows:
CUTTLE FISH WHOLE:
Tie the ink sac with twine or clip it. Wash carefully using potable water.
Pack in polythene lined or waxed duplex cartons.
Add ice cold glaze water.
Weight and size grade packed shall be as per the buyers agreement.
it can be individually quick frozen or frozen as shatter packCUTTLE FISH WHOLE CLEANED:
Remove the bone, visceral organ, eyes and beaks. Do not remove
the tentacles.
Eviscerate taking care to avoid breaking of ink sac. Remove the skin
along with the fins. Wash thoroughly in chilled potable water.
Pack in polythene lined waxed duplex cartons for block freezing. Add
ice cold glaze water.
it can be individually quick frozen or frozen as shatter pack
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CUTTLE FISH FILLETS WITH:
The processing is same as for the cuttle fish whole cleaned.
Remove the tentacles and wings also.
Freezing may be block frozen, IQF or shatter pack.
CUTTLE FISH STRIPES :
Follow the same procedure applied for cuttle fish fillets.
Cut the fillets into required size i.e. approx. 1.0-1.5 cm width and
4.0-5.0 cm lengthCUTTLE FISH TENTACLES:
Remove the skin of the tentacles.
Remove the eyes, eyeball and beak
Remove the hanging meat or throat meat
It can be backed as block frozen of IQF.
CUTTLE FISH WINGS:
Remove the skin of the wings.
Trimming of the edges may be done if required.
It can be backed as block frozen of IQF.
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FREEZING
Blocks in contact plate freezer, IQF in IFQ machines at 40C until
the core temperature reaches -23C.
STORAGE
Pack cartons in waxed 5 ply fibre board master cartons and store
in frozen store at -23or below.
Note: Churning cuttle fish in sea water in barrels for 30 minutes gives
rise to improvement in colour and flavour.
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FROZEN SQUID
RAW MATERIALS
Seversal species of squid
Loligo hardwikki
L. indica
L. affinis
TYPES OF PRODUCTS
Squid is frozen in the following styles. Squid whole (SQW)
Squid whole cleaned (SWQC)
Squid rolled pack
Squid tube (SQT)
Squid tentacles (SQTN) Squid fillets
Squid wings/fins
Squid rings (SQRG)
Squid headless/Squid tube skin on
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PRE PROCESS HANDLING
Separate squid from other fish.
Sort the squid species wise (if required) and size wise.
Discard those with broken ink sacs.
Discard any bruised or damaged or discolored pieces.
Wash well in potable water or clean uncontaminated sea water.
Ice immediately and stock in insulated boxes.
Use only clean crushed / flake ice made from potable water.
Ice and squid should be in alternate layers.
The height of Ice pack shall not exceed 50 cm. Handle the material carefully during loading / transportation / unloading.
PROCESSING
Depending upon the type of pack desired, handle further as follows:
SQUID WHOLE
Use only fresh squid with skin and ink sac intact. Tie the ink sac with twine or clip it.
Wash carefully using chilled potable water
Pack squid of uniform size and colour as blocks, shatter pack or IWP.
Weight packed as blocks or shatter pack in polythene lined waxed
duplex cartons shall be as declared or as per the agreement with buyer. Add ice cold glaze water in blocks.
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SQUID WHOLE CLEANED:
Remove the ink sac without detaching the head and tentacles from tube.
Eviscerate.
Remove the skin of the tube, head and tentacles.
Remove eye balls and beak. Wash well in chilled potable water.
Pack as blocks, shatter pack or IQF.
SQUID TUBE:
Remove head and tentacles.
Eviscerate, taking care not to rupture the ink sac. Remove the skin along with the fin.
Wash thoroughly in chilled potable water.
Pack as shatter pack or IQF.
SQUID ROLLED:
Remove head and tentacles. Split open the tube.
Eviscerate, taking care not to rupture the ink sac.
Remove the skin along with the fin.
Wash the fillets well in chilled potable water.
Roll the fillets into tubes.
Pack as shatter pack or IQF.
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SQUID FILLETS:
Remove head and tentacles.
Cut open the tube.
Eviscerate taking care to avoid breaking of ink sac.
Remove the skin along with the fins.
Wash thoroughly in chilled potable water and pack as blocks or IQF.
SQUID RINGS:
Cut the skinned tube as rings.
Wash thoroughly in chilled potable water. Pack as blocks or IQF.
SQUID TENTACLES:
Remove the head and tentacles.
Remove the skin of the tentacles.
Wash thoroughly in potable water and pack as blocks or IQF.
SQUID WINGS/FINS:
Separate the wings/fins from the squid.
Remove the skin from fins and wings.
Wash thoroughly in chilled potable water and pack as blocks.
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FREEZING
Blocks in contact plate freezer, IQF in IFQ machines at - 40C until
the core temperature reaches -23C.
STORAGE
Pack cartons in waxed 5 ply fibre board master cartons and store
in frozen store at -18or below.
Note: Churning squid in sea water in barrels for 30 minutes gives rise
to improvement in colour and flavour.
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FREEZING OF CRAB MEAT
Frozen crab meat is one of the delicacies in advanced countries.
It is used for the preparation of crab salad, crab cakes, crab patties
and other products.
RAW MATERIAL
Live mud crab Scylla serrata
Portunus pelagicus
Use only actively live crabs
Sluggish or dead crabs yield poor quality meat.
PRE PROCESS HANDLING
Wash the crabs thoroughly in running chlorinated water to make free
from dirt.
Take special care of the ventral side.
PICKING THE MEAT
Remove the carapace, claws and legs.
Wash well in chlorinated water.
Remove gills and wash again.
Pick the meat using stainless steel scalpels or knives.
Separate the meat from the claws after breaking them.
Pick the body meat and claw meat separately.
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WASHING
Wash the picked meat once in chlorinated water
Remove any shell pieces, if present.
PACKING
Pack in polythene-lined waxed duplex cartons.
Quantity packed shall be sufficient to yield the declared weight
on thawing.
GLAZING
Add ice cold chlorinated water if needed.
A 1% (w/v) solution containing 9 parts by weight of citric acid and
1 part by weight of ascorbic acid is recommended in place of
water alone.
FREEZING
Freeze the cartons in a plate freezer at - 40C.
STORAGE
Pack the cartons in 5 ply corrugated waxed fibre board master
cartons and store at - 18C or below.
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FREEZING OF FISH & FISH PRODUCTSFish can be frozen into different products known as product styles.
Product style is the description of a product which explains the shape,
size, production method and cooking characteristics of the product.Product styles of fish products are decided according to availability of raw
material, convenience, acceptability and marketing needs. Common
product styles processed from fish are as follows.
FROZEN FISH PRODUCTS:
1. Whole fish or Round Style: Small fishes like sardine, mackerel and
pomfrets are frozen as whole without cutting any part of the body. This is
known as the round style.
2. Semi dress : Bigger fishes like tuna, salmon, shark and seer etc. are
subjected to removal of gills and entrails by making a longitudinal cut in
the abdomen. This is known as semi dress style. Semi dressing before
icing and freezing increases the storage life of the fish as the gills andentrails are the main source of bacterial spoilage in fish.
3. Dressed: In this style, head and entrails are removed from the body of
the fish. This is the common style of processing for fish, chilled or frozen
for retail sale. Dressed fish are also used for further processing into fillets,
or minced meat products. e.g. shark, croakers, pomfrets or any other fish.
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4. Fillets: Fish fillets are pieces of flesh cut away from the sides of the
fish, convenient for cooking and frying. They are free of fins and large
bones with or without skin. Generally fish weighing 2 kg and below are
used for this product. This is the most common product style of chilledand frozen fish used for sale in all the advanced countries. Most of the
Indian fishes can be processed into fillets for sale in India or outside.
5. Steaks: Fish steaks are transverse sections 2.5 3.0 cm thick cut
from either dressed fish or fillets from which all inedible parts except
the central bone have been removed.6. Chopped meat and minced meat: Minced meat is prepared by
mincing the picked meat or fillets of any fish required. Minced meat of
most of the lean fishes is used for preparation and freezing of paste
products. Minced meat is also used as a raw material for sausage
making, cutlets etc.7. Breaded or Breaded and fried products: Certain products like fish
sticks, fish burgers, fish cutlets, prawns etc. are prepared and rolled in
bread crumbs before freezing. These are known as prepared products
ready to be cooked and they are very common in advanced countries
as they are convenient items for cooking.
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Elasmobranches Indian Dog Sharks Scoliodon
Hammer Head Shark Sphyrna zygaena
Guitar fish Rhincobatus djeddenisis
Bony fishes Silver Pomfret Pampus argenteus
Chinese Pomfret Pampus chinensis
Black Pomfret Parastromateus niger
Scombroides Indian Mackerel Rastrelliger kanagurta
Seer Fish / King Fish Scomberomorus guttatus
Tuna Euthynnus affinis,
Thunnus albacares/obesus, Katsuwonus pelamis, Sarda orientalisPerches Snapper Lutjanus sp.
Tiger Perch Tarapon jarbua
Reef Cod Epinephelus malabaricus
Sciaenids Croaker Johnius sp.
Ghol Protonibea diacanthus
Carangids Scad Alepes mate
Horse Mackerel Megalaspis cordyla
White fish Lactarius lactarius
Flat fishes Indian Halibut Psettodes erumei
Sole Cynoglossus macrolepidotus
Sardines Indian Oil Sardine Sardinella longiceps
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OTHERS
Ribbon fishes Lepturacanthus savala
Trichiurus lepturus
Cat fishes Arius maculatus
Hilsa Tenulosa ilisha
Anchovy Anchoviella commersonii
Indian Dog Sharks Scoliodon
Hammer Head Shark Sphyrna zygaena
Guitar fish Rhincobatus djeddenisis
Barracuda Sphyraena jelloIndian Salmon Eleutheronema tetradactylum
Bombay duck Harpadon nehereus
Sea Bass Lates calcarifer
Tilapia Tilapia mossambica
Milk fish Chanos chanos
Pearl spot Etroplus suratensis
Long spine Seabream Argyrops spinifer
Japanese threadfin bream Nemipterus japonicus
Emperor bream Lethrinus fraenatus
Grey mullet Mugil cephalus
Lizard fish Saurida undasqamia