Fish Fish SausageSausageFish raw material Fish raw material International fish groupsInternational fish groups

CodCod HaddockHaddock

HakeHake Pollock Pollock ..

Atlantic hake Atlantic hake

Flounder Flounder

CroakersCroakers

Rake fish ,etc.Rake fish ,etc.

Indian Fish Indian Fish GroupsGroups

Jew fishJew fish

CroakersCroakers

PerchesPerches

AdvantagesAdvantagesThese fishes yields high minceThese fishes yields high mince

Receive additional price from filletingReceive additional price from filleting

Raw materialRaw materialSeasoning materialSeasoning material

Sugar, Sugar, Salt, Salt,

Cloves, Cloves, Pepper, Pepper, Chili, Chili,

Other spices Other spices All as per taste and choiceAll as per taste and choice

PreservativesPreservativesMonosodium glutamate andMonosodium glutamate and

Sodium or Potassium salt of Ascorbic acidSodium or Potassium salt of Ascorbic acid

@ 2g/kg of fish sausage@ 2g/kg of fish sausage

Furyl furamide (AF2) : (2 (2- Furyl), 3( 5- Furyl furamide (AF2) : (2 (2- Furyl), 3( 5- Nitro- 2 furyl – acrylamide )Nitro- 2 furyl – acrylamide )

@ 0.02 g / kg@ 0.02 g / kg

This drug is banned in many countries.This drug is banned in many countries.

Method Method Washing, Eviscerating and Rendering for fish Washing, Eviscerating and Rendering for fish

mincing in mechanical bone separatormincing in mechanical bone separator

Fish preferably filleted before mincing to Fish preferably filleted before mincing to increase the quality increase the quality

Some time along with fish other grinded meat Some time along with fish other grinded meat from poultry and goat is usedfrom poultry and goat is used

Transferring the fish mince for blending into Transferring the fish mince for blending into silent cutter or bowl chopper from the free silent cutter or bowl chopper from the free end end

Add seasoning material and preservativeAdd seasoning material and preservative

Continue blending at least 10-20Continue blending at least 10-20

minutes till the meat is perfectly minutes till the meat is perfectly chopped and homogenised intimately chopped and homogenised intimately with the ingredientswith the ingredients

Use of AF2 is banned instead Use of AF2 is banned instead College of Fisheries College of Fisheries

Mangalore has Mangalore has introduced introduced HTSTHTST ( High ( High temperature temperature short time) short time) technique.technique.

The entire mixture is transferred to stufferThe entire mixture is transferred to stuffer

The grinded homogenised fish meat is stuffed The grinded homogenised fish meat is stuffed into preferable sausage casing Film C into preferable sausage casing Film C Rhyphan or kurahalan casing filmRhyphan or kurahalan casing film

Stuffed sausage in casing is given treatment on Stuffed sausage in casing is given treatment on the lines of the lines of HTSTHTST technique initially at low technique initially at low temperature but late at 80-90temperature but late at 80-90°°C for 1hour C for 1hour preferably (100preferably (100°°C maintains high elasticity of C maintains high elasticity of the product) in the mechanical cooker.the product) in the mechanical cooker.

Cooked sausage in casing are cold Cooked sausage in casing are cold stored at -20stored at -20°°CC

The shelf life of the product is over six The shelf life of the product is over six months or more than a yearmonths or more than a year

Provided cold storage and consumed Provided cold storage and consumed immediately after taken outimmediately after taken out

Characteristics of Characteristics of Rhyphan Rhyphan film casingfilm casing

High weight but strong structureHigh weight but strong structure

Not affected by chemicals as well as Not affected by chemicals as well as on heating and coolingon heating and cooling

Does not permit water and stuffing is Does not permit water and stuffing is easyeasy

Non combustible , tasteless and Non combustible , tasteless and odourless.odourless.

Its only flow is after some months Its only flow is after some months hot gas is free from the film the hot gas is free from the film the product then become fragileproduct then become fragile

Wider use and acceptability due to Wider use and acceptability due to easy availability and eco-friendly easy availability and eco-friendly packagingpackaging

Characteristics of Characteristics of Kurahalon film casingKurahalon film casing

Transparent, shrinkable, water proof Transparent, shrinkable, water proof filmfilm

Melting point is 168°CMelting point is 168°C

Stable in fat, oil and organic solventStable in fat, oil and organic solvent

Extremely hard to break, tear and Extremely hard to break, tear and puncturepuncture

Shrinkablity of film makes very tight Shrinkablity of film makes very tight packaging of sausage materialpackaging of sausage material

Surimi Surimi What is Surimi?What is Surimi?

Surimi is an intermediate product Surimi is an intermediate product produced from fish which because of produced from fish which because of its gel forming ability can be used to its gel forming ability can be used to develop variety of products of develop variety of products of consumer fanciesconsumer fancies

Surimi is myofibrillar protein Surimi is myofibrillar protein concentrate, which readily form gel concentrate, which readily form gel as a result of unfolding and cross as a result of unfolding and cross linking of actomycin the major linking of actomycin the major muscle protein matrixmuscle protein matrix

Surimi is used as raw material for the Surimi is used as raw material for the preparation of seafood analogies but preparation of seafood analogies but in Japan where the technology in Japan where the technology originated.originated.

Surimi is mainly used to prepare the Surimi is mainly used to prepare the traditional Kamaboko products in traditional Kamaboko products in JapanJapan

Method Method Beheading and guttingBeheading and gutting

Head, most of the Head, most of the backbone, viscera like backbone, viscera like

intestine, kidney, perfectly removed while intestine, kidney, perfectly removed while dressing dressing

Mincing Mincing Mincing from the use of Mincing from the use of

meat bone meat bone separator having separator having drums of perforations drums of perforations of 3- of 3-

5mm in diameter. 5mm in diameter.

Filleting before mincing Filleting before mincing adds to the adds to the quality quality

WashingWashing To remove water To remove water soluble nitrogenous soluble nitrogenous

matter and flavour compounds. matter and flavour compounds. Repeated washing also helps in gel Repeated washing also helps in gel forming capacity from muscles. forming capacity from muscles. In series of leaching In series of leaching tanks water tanks water to mince to mince

ratio is 2:1 to 10:1 depending ratio is 2:1 to 10:1 depending on fish freshness avoid overhydrating. on fish freshness avoid overhydrating.

Temperature while washing Temperature while washing should should not exceed not exceed

than 5°Cthan 5°C

RefiningRefining Refining in a high speed Refining in a high speed

rotating rotating spiral, spiral, surrounded by screen having surrounded by screen having perforations which leaves behind any perforations which leaves behind any kind of impurities. kind of impurities. Speed of the refiner controlled not Speed of the refiner controlled not

to lead for heat gain to mince to lead for heat gain to mince

DehydratingDehydrating Water content of mince Water content of mince

is further is further reduced by reduced by device having screw device having screw

pressured, rotating and expelling pressured, rotating and expelling gel dewatered mince from the gel dewatered mince from the surrounded perforations. surrounded perforations. Water content of dewatered Water content of dewatered

mince is periodically checked mince is periodically checked

Gel formation by cookingGel formation by cooking Occurs by the Occurs by the

impartment of heating impartment of heating 80– 80–90°C even at 40 – 50°C and even 90°C even at 40 – 50°C and even at 0°C. at 0°C. The temperature therefore can The temperature therefore can

be set be set as pv choice as pv choice within heating range of within heating range of 40-90°C or the treatment of 2-3% 40-90°C or the treatment of 2-3%

NaCl to mince NaCl to mince

Mixing of CryoprotectantsMixing of Cryoprotectants Sugar-2-4%, Sugar-2-4%,

Sorbitol 4% and Sorbitol 4% and Polyphosphate 0.1-8.3% to Polyphosphate 0.1-8.3% to prevent denaturation of prevent denaturation of

proteins proteins

Freezing Freezing Freezing and Freezing and

gelled fish Surimi gelled fish Surimi mince at -40°C in a large contact mince at -40°C in a large contact

plate freezer to obtain blocks plate freezer to obtain blocks

Packaging Packaging In polythene In polythene

and packed in and packed in master container of corrugated master container of corrugated polythene coated corrugated polythene coated corrugated

paper board paper board

Cold stored at 20˚C in cold Cold stored at 20˚C in cold Room Room

Processing Yield Processing Yield Raw material – 100%Raw material – 100%

Beheading and gutting – 60%Beheading and gutting – 60%

Mincing – 45%Mincing – 45%

Washing – 42%Washing – 42%

Refining – 30%Refining – 30%

Dehydrating or dehydration – 20%Dehydrating or dehydration – 20%

Characteristics of Characteristics of Surimi and Technical Surimi and Technical

datadataAn intermediate myofibrillar proteinAn intermediate myofibrillar protein

Low in calories and cholesterolLow in calories and cholesterol

Odourless , white and neutral tasteOdourless , white and neutral taste

Character valueCharacter valueColour = White grayishColour = White grayish

Moisture = 72-80%Moisture = 72-80%

pH - 6.8 = 7-2%pH - 6.8 = 7-2%

Gelatisation temperature = 40-90 °CGelatisation temperature = 40-90 °C

Protein content = 16- 19%Protein content = 16- 19%

Fat content – 0.5%Fat content – 0.5%

Ash content- 0.5%Ash content- 0.5%

Sucrose- 4%Sucrose- 4%

Sorbitol = 4%Sorbitol = 4%

Polyphosphate = 0.3%Polyphosphate = 0.3%

Surimi can be blended with wide Surimi can be blended with wide range of ingredients to enhance the range of ingredients to enhance the acceptance of popular seafood acceptance of popular seafood cuisines or all together new food cuisines or all together new food products with the mixing of flavour of products with the mixing of flavour of each.each.

Can assumed desired shape due to Can assumed desired shape due to controlled texture.controlled texture.

Premium source of protein having Premium source of protein having rich amino acids composition for the rich amino acids composition for the consumers.consumers.

Quality Maintenance Quality Maintenance and assuring Surimi and assuring Surimi

processingprocessingQuality maintenance through process Quality maintenance through process control and product evaluation control and product evaluation according to standard HACCP or EU according to standard HACCP or EU systemsystem

In India HACCP system since Surimi In India HACCP system since Surimi is exported to Japan where HACCP is exported to Japan where HACCP system is followedsystem is followed

Quality EvaluationQuality EvaluationColour :Colour :

Show white and measured Show white and measured using using whiteness meter whiteness meter

Water content :Water content :

Measured at different stages at Measured at different stages at the required level by using inpared the required level by using inpared moisture metermoisture meter

Gel strength : Gel strength :

Mixing of Surimi with 2-3% NaCl , Mixing of Surimi with 2-3% NaCl , filled in PVC tube of 30mm in filled in PVC tube of 30mm in diameter and 20 cm in length, diameter and 20 cm in length, heated at 90°C for 30 minutes, heated at 90°C for 30 minutes, cooled at 20°C cooled at 20°C

Gel strength of sample 25 mm piece Gel strength of sample 25 mm piece of sample product using of sample product using RheometerRheometer or or Texture meter.Texture meter.

Texture and gel strength using Texture and gel strength using

Folding test : Folding test :

Slice of 5mm thickness cut from the Slice of 5mm thickness cut from the cooked sample and folded in quadrantscooked sample and folded in quadrants

AA –AA – No crack after folding twice No crack after folding twice

A- A- No crack after 1st folding but cracks or No crack after 1st folding but cracks or 22ndnd folding folding

BB- Crack occur gradually or 1st folding - Crack occur gradually or 1st folding

CC- Crack occurs immediately on 1st folding- Crack occurs immediately on 1st folding

DD- Break by finger press even before folding- Break by finger press even before folding

Sensory TestSensory TestExtremely firm – 10Extremely firm – 10

Very firm – 8Very firm – 8

Moderately firm – 6Moderately firm – 6

Slightly soft- 4Slightly soft- 4

Very soft – 2Very soft – 2

Extremely soft – 1Extremely soft – 1

Impurity TestImpurity Test Scoring is done by counting number, Scoring is done by counting number,

black skin, bone residues in a 9 -10 cm black skin, bone residues in a 9 -10 cm field which is prepared by 10 gs in 1mm field which is prepared by 10 gs in 1mm thickness. thickness.

Particles of 2mm length are counted as Particles of 2mm length are counted as 1 and particles under 2mm length are 1 and particles under 2mm length are counted 1/3counted 1/3rdrd..

Fish flakes and Fish flakes and WafersWafers

Fish flakes and wafers are partially Fish flakes and wafers are partially deodourised thin flakes of cooked fish meat deodourised thin flakes of cooked fish meat homogenised with starch and salthomogenised with starch and salt

On frying the wafers swell two – three times On frying the wafers swell two – three times of its initial size and become and crisp and of its initial size and become and crisp and delicious.delicious.

The product utilize the carbohydrate The product utilize the carbohydrate as the main base, with salt, other as the main base, with salt, other ingredients of spices and fish minceingredients of spices and fish mince

Popular product and commercially Popular product and commercially important in south Indiaimportant in south India

Ingredients Ingredients QuantityQuantity

Minced cooked fish 2 kgMinced cooked fish 2 kg

Starch such as corn flour, 1 kg Starch such as corn flour, 1 kg

tapioca and even mashed potatotapioca and even mashed potato

Common salt 5%Common salt 5%

Spicy material As per Spicy material As per taste taste

Refined oil For Refined oil For frying as frying as per per

RequirementRequirement

Water 3-5 litersWater 3-5 liters

MethodologyMethodologyHomogenize the fish meat in one liter of Homogenize the fish meat in one liter of

water for 30 minutes in blender or water for 30 minutes in blender or mixed grindermixed grinder

Add corn flour or Tapioca or any starch , Add corn flour or Tapioca or any starch , salt and spicy material with rest of this salt and spicy material with rest of this water and blend the entire material for water and blend the entire material for

1 hour till it acquire thick semi fluid 1 hour till it acquire thick semi fluid stage. (To avoid over burning instead stage. (To avoid over burning instead of boiling, the material is cooked in of boiling, the material is cooked in

steel chamber for 2-3 minutes)steel chamber for 2-3 minutes)

Spread the homogenized mass in flat Spread the homogenized mass in flat aluminium tray of 3-4 mm. Cool to aluminium tray of 3-4 mm. Cool to

room temperature.room temperature.

After the material become in the form After the material become in the form of film, cut it into desired shapesof film, cut it into desired shapes

Again fully dry the material in sun, or Again fully dry the material in sun, or preferably using electric drier or in preferably using electric drier or in oven at 45 – 50oven at 45 – 50˚̊c till the moisture c till the moisture

content reduce below 10%.content reduce below 10%.

Product of as per shape may be of finger Product of as per shape may be of finger waferwafer

If the other rounded shape in the form of If the other rounded shape in the form of papad is given a liquid homogenized is papad is given a liquid homogenized is spread in small quantity on polythene spread in small quantity on polythene

sheet and dry it in bright sunsheet and dry it in bright sun

The dried product is packed in polythene The dried product is packed in polythene bags and stored in cool and dry place.bags and stored in cool and dry place.

The shelf life of flaked product is of 2 The shelf life of flaked product is of 2 years.years.

Chemical Chemical characteristicscharacteristics

Moisture 5-6%Moisture 5-6%

Protein (dry) 10-12%Protein (dry) 10-12%

Ash 5-7%Ash 5-7%

Fat 1-2%Fat 1-2%

Carbohydrate 73-79%Carbohydrate 73-79%