04b surimi seafood products (crabsticks)

THP 333 Diversifikasi dan Pengembangan Produk Perikanan/Kuliah Ke-3b 1

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Ketika kita berada dalam lorong kegelapan, berjalanlah terus….. Karena cahaya ada di ujung sana

CARILAH ILMU PENGETAHUAN AGAR BISA MENEBAR PEMIKIRAN

SURIMI SEAFOOD PRODUCTS MANUFACTURE OF CRABSTICKS (KANIKAMA/CRAB-FLAVORED STICK)

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.  Bagaimana mekanisme fiberization (slitting) dan bundling

dalam pengembangan filament meat style

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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

MANUFACTURE OF CRABSTICKS (KANIKAMA/CRAB-FLAVORED STICK)

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1.  INTRODUCTION 2.  FILAMENT MEAT STYLE (EXTRUSION TO CUTTING)

2.1 Inspection and Storage of Raw Materials 2.2 Communition and Ingredient Branding 2.3 Cooking and Cooling 2.4 Fiberization (Slitting) 2.5 Bundling 2.6 Color Application and Wrapping 2.7 Cutting

3.  SOLID MEAT STYLE (EXTRUSION TO CUTTING) 2.1 Block (Solid Meat) Formation 2.2 Fiber (Shred) and Binder 2.3 Extrusion and Cooking 2.4 Molding and Cooking

4.  PACKAGING 5.  METAL DETECTION 6.  PASTEURIZATION AND COOLING 7.  REFRIGERATED AND FROZEN STORAGE

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1. INTRODUCTION

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•  Flake type : Mr Sugino of Sugiyo Co. in 1973 •  Stick type : Mr Osaki of Osaki Suisan in 1975

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US SURIMI SEAFOOD MARKET

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STICK

FLAKE

CHUNK

SHRED FLAKE STYLE

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2. PROCESSING METHODS

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PROCESSING METHODS

Sheet Extrusion

First Cooking

Cooling

Slitting

Bundling

Wrapping

Cutting

Comminuting

Color Coextrusion

Surimi

Freezing

Frozen Products

Flake, Stick

Chilled (Refrigerated)

Products

Second Cooking (Color Setting)

Cooling

Film Removal

Metal Detection

Pasteurization

Chilling

Packaging

Cutting

Color Wrapped in Film

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The arrows indicate the production flow

Drum cooker—side view

Molding pumps

Drum cooker

Cooling conveyor

Thin cutting Bundling conveyor

Wrapping cutting

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Molding pumps Cooling conveyor Drum cooker

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Thin cutting Bundling conveyor Wrapping cutting

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FILAMENT MEAT STYLE (EXTRUSION TO CUTTING)

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Sheet Extrusion

First Cooking

Cooling

Slitting

Bundling

Wrapping

Cutting

Comminuting

Color Coextrusion

Surimi

Freezing

Frozen Products

Flake, Stick


Products


Cooling

Film Removal

Metal Detection

Pasteurization

Chilling

Packaging

Cutting


FILAMENT MEAT STYLE

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2.1 RAW MATERIALS

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STORAGE OF RAW MATERIALS

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Changes in thiobarbituric acid reactive substances

in four fish species during frozen storage at – 18 oC for 6 months

Changes in protein solubility in 0.6 M KCl of four fish species during frozen

storage at -18 oC for 6 months.

Changes in formaldehyde content in four fish species during frozen storage

at -18 oC for 6 months.

Changes in Ca2þ-ATPase of natural actomyosin extracted from four fish species during frozen

storage at 218 8C for 6 months.

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Changes in breaking force (A)

and deformation (B) of surimi gels prepared from four

fish species during frozen storage at 218 8C for 6 months.

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Microstructure of surimi gels from four

species prepared from fresh and

frozen fish.

(A)  Croaker

(B)  Lizardfish

(C)  Threadfin

bream

(D)  Bigeye

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TYPICAL INGREDIENTS

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•  starches •  protein additives •  food grade chemicals •  flavorings •  colorings

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Formula for the imitation crab sticks

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2.2 COMMINUTION DAN INGREDIENT BLENDING

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Sheet Extrusion

First Cooking

Cooling

Slitting

Bundling

Wrapping

Cutting

Comminuting

Color Coextrusion

Surimi

Freezing

Frozen Products

Flake, Stick


Products


Cooling

Film Removal

Metal Detection

Pasteurization

Chilling

Packaging

Cutting


FILAMENT MEAT STYLE

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THE TWO MAJOR FUNCTIONS OF COMMINUTION ARE •  to chop (extract) the (salt-soluble)

myofibrillar proteins as much as possible to yield a smooth-textured paste

•  to incorporate (mix) other ingredients into the surimi paste uniformly.

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The maximum solubilization of available myofibrillar proteins is dependent on •  time, •  temperature, and other mechanical functions of the silent cutter, such as •  blade configuration, •  sharpness and/or •  vacuum, and so on.

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2.3. EXTRUSION OF CRABSTICK PASTE AND COOKED SHEET

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Sheet Extrusion

First Cooking

Cooling

Slitting

Bundling

Wrapping

Cutting

Comminuting

Color Coextrusion

Surimi

Freezing

Frozen Products

Flake, Stick


Products


Cooling

Film Removal

Metal Detection

Pasteurization

Chilling

Packaging

Cutting


FILAMENT MEAT STYLE

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COOKED SHEET

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Sheet Extrusion

First Cooking

Cooling

Slitting

Bundling

Wrapping

Cutting

Comminuting

Color Coextrusion

Surimi

Freezing

Frozen Products

Flake, Stick


Products


Cooling

Film Removal

Metal Detection

Pasteurization

Chilling

Packaging

Cutting


FILAMENT MEAT STYLE

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TWO TYPES OF CRABSTICK LINE (a)   Stainless-steel belt cooker (Bibun, Japan) (b)   Drum cooker—side view (Young Nam

Machinery, S Korea)

The arrows indicate the production flow

Stainless-steel belt cooker

Drum cooker—side view Bambang Riyanto 91

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CONTINUOUS FLAT BELT •  radiant heat •  followed by steam heat and then •  radiant heat again. Another common option consists of steam heat followed by radiant heat.

Some machines employ steam heat only. A DRUM COOKER •  Extruder on a large drum that contains high-

temperature steam inside.

•  radiant or steam heat is 90–95°C.

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This short time cooking process induces gelation of the surimi proteins, but is not sufficient to gelatinize (swell) the starch and/or to gel other protein additives.

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Immediately upon completion of this first cooking step, the product is cooled by air at room temperature. Texture development is finalized during a later pasteurization step, which adds rigidity and water-holding properties to the gel

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Extrusion of crabstick paste and cooked sheet

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Crabstick line with ohmic heating

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Crabstick paste is extruded as a thin sheet (1.2–2.2 mm) which is often coextruded with colored paste

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2.4. COLOR COEXTRUSION

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Sheet Extrusion

First Cooking

Cooling

Slitting

Bundling

Wrapping

Cutting

Comminuting

Color Coextrusion

Surimi

Freezing

Frozen Products

Flake, Stick


Products


Cooling

Film Removal

Metal Detection

Pasteurization

Chilling

Packaging

Cutting


FILAMENT MEAT STYLE

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2.5. SLITTING, BUNDLING

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Sheet Extrusion

First Cooking

Cooling

Slitting

Bundling

Wrapping

Cutting

Comminuting

Color Coextrusion

Surimi

Freezing

Frozen Products

Flake, Stick


Products


Cooling

Film Removal

Metal Detection

Pasteurization

Chilling

Packaging

Cutting


FILAMENT MEAT STYLE

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Various factors affecting the bundling (rolling) process (a–d). Tightly rolled stick (e) and stick with a hole in the center (f) Bambang Riyanto 127

Bad cut and good cut as affected by the speed of the wrapping machine and the cutter

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2.6. WRAPPING

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Sheet Extrusion

First Cooking

Cooling

Slitting

Bundling

Wrapping

Cutting

Comminuting

Color Coextrusion

Surimi

Freezing

Frozen Products

Flake, Stick


Products


Cooling

Film Removal

Metal Detection

Pasteurization

Chilling

Packaging

Cutting


FILAMENT MEAT STYLE

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2.7. CUTING

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Sheet Extrusion

First Cooking

Cooling

Slitting

Bundling

Wrapping

Cutting

Comminuting

Color Coextrusion

Surimi

Freezing

Frozen Products

Flake, Stick


Products


Cooling

Film Removal

Metal Detection

Pasteurization

Chilling

Packaging

Cutting


FILAMENT MEAT STYLE

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Degree of slitting that controls fiberization (light, medium, or heavy) is achieved by the shape of cutting teeth.

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http://www.kanekoss.co.jp/

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Kind of the cutting edge There are four main categories. •  Sumiha, •  round blade, •  thin blade, and •  beveled blade. Shape to be cut out with the cutting edge of the shape is as follows.

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Thin blade

corner blade

round blade

Sumiha

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The rope is cut diagonally at a 25–30° angle in 5–8 cm long pieces, tip to tip, as flake. Another shape is the stick (leg) shape that is cut straight at a 90° angle. They are usually cut 3, 5, or 8 inches long. This stick cut is the most popular cutting in countries outside the United States. For filament chunk products, the pieces are cut 1–2 cm long.

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SURIMI CRAB STICKS – JAPANESE STYLE

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SOLID MEAT STYLE (EXTRUSION TO CUTTING)

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Sheet Extrusion

First Cooking

Cooling

Slitting

Bundling

Wrapping

Cutting

Comminuting

Color Coextrusion

Surimi

Freezing

Frozen Products

Flake, Stick


Products


Cooling

Film Removal

Metal Detection

Pasteurization

Chilling

Packaging

Cutting


SOLID MEAT STYLE

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3.2 SECOND COOKING

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Sheet Extrusion

First Cooking

Cooling

Slitting

Bundling

Wrapping

Cutting

Comminuting

Color Coextrusion

Surimi

Freezing

Frozen Products

Flake, Stick


Products


Cooling

Film Removal

Metal Detection

Pasteurization

Chilling

Packaging

Cutting


SOLID MEAT STYLE

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•  cooking for 10–15 min under steam (approximately 95°C) and cooling (typically by fans),

•  the product can be cut into various lengths (chunk or stick) by a wire cutter or guillotine cutter.

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3.3. FILM REMOVAL

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Sheet Extrusion

First Cooking

Cooling

Slitting

Bundling

Wrapping

Cutting

Comminuting

Color Coextrusion

Surimi

Freezing

Frozen Products

Flake, Stick


Products


Cooling

Film Removal

Metal Detection

Pasteurization

Chilling

Packaging

Cutting


SOLID MEAT STYLE

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3.4. CUTING

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Sheet Extrusion

First Cooking

Cooling

Slitting

Bundling

Wrapping

Cutting

Comminuting

Color Coextrusion

Surimi

Freezing

Frozen Products

Flake, Stick


Products


Cooling

Film Removal

Metal Detection

Pasteurization

Chilling

Packaging

Cutting


SOLID MEAT STYLE

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4.1. PACKAGING

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Sheet Extrusion

First Cooking

Cooling

Slitting

Bundling

Wrapping

Cutting

Comminuting

Color Coextrusion

Surimi

Freezing

Frozen Products

Flake, Stick


Products


Cooling

Film Removal

Metal Detection

Pasteurization

Chilling

Packaging

Cutting


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•  Polyester (nylon) •  Polypropylene (PP) •  Polyvinylidene chloride (PVDC) •  Ethylenevinyl alcohol (EVOH) •  Polyethylene (PE) •  Polyester (PET) •  Adhesive.

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•  Roll Stock Vacuum Packaging

•  Stretched Film Packaging

•  Flow Pack Packaging

CRABSTICKS PACKAGING MACHINERY

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4.2. METAL DETECTING

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Sheet Extrusion

First Cooking

Cooling

Slitting

Bundling

Wrapping

Cutting

Comminuting

Color Coextrusion

Surimi

Freezing

Frozen Products

Flake, Stick


Products


Cooling

Film Removal

Metal Detection

Pasteurization

Chilling

Packaging

Cutting


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Ferrous : 2.0–2.5 mm Nonferrous : 2.5–3.0 mm Stainless : 3.0–4.0 mm

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4.3 PASTEURIZATION AND COOLING

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Sheet Extrusion

First Cooking

Cooling

Slitting

Bundling

Wrapping

Cutting

Comminuting

Color Coextrusion

Surimi

Freezing

Frozen Products

Flake, Stick


Products


Cooling

Film Removal

Metal Detection

Pasteurization

Chilling

Packaging

Cutting


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Texture development is finalized during a later pasteurization step, which adds rigidity and water-holding properties to the gel

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The bottom line to control Clostridium botulinum in chilled, vacuum packed products was to pasteurize the product at 85°C internal temperature for a minimum of 15 min in addition to maintaining 2.4% water phase salt and storage temperature at 38°F (3.3°C).

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TEXTURE, MICROBIOLOGICAL, AND COLOR PROPERTIES AS AFFECTED BY HEATING TEMPERATURE AND TIME

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Thermal diffusivity of surimi crabsticks as a function of temperature difference Comparison of simulation data with

experimental values of surimi crabsticks. Thermocouples were placed at 3, 7, and 2 mm from the center for single, double, and triple layer packages, respectively

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Experimental formulae for surimi–starch gels

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4.4. REFRIGERATED AND FROZEN STORAGE

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Sheet Extrusion

First Cooking

Cooling

Slitting

Bundling

Wrapping

Cutting

Comminuting

Color Coextrusion

Surimi

Freezing

Frozen Products

Flake, Stick


Products


Cooling

Film Removal

Metal Detection

Pasteurization

Chilling

Packaging

Cutting


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to obtain an internal temperature of −18°C for a 2.5 lb. package (10°C), it usually takes 60–70 min in a blast or contact freezer and 15–20 min in liquid nitrogen. The freezing rate affects product quality and shelf life. At customary freezer temperatures (−10 to −20°C), about 90% of the moisture freezes out resulting in approximately a 10-fold increase in the concentration of solutes in the remaining free liquid.

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shows how freezing time varies with air velocity. (For this model, it is assumed that a representative commercial freezer is used, in which the blast air temperature is −23°C at the beginning of the freezing cycle and falls rapidly to −32°C) As velocity increases toward 5 m/s, freezing time falls from about 2–1/2 h and begins to level off at 1–1/4 h. It is not a good idea, however, to increase air velocity much past 5 min/s, because more powerful fans begin to contribute a substantial heat load to the system

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TERIMA KASIH

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