Freezing Lab

8/7/2019 Freezing Lab

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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.


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.


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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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.


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

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Freezing Lab