Fish Processing and Value Addition

Fish Processing and Value Addition

• Value addition is the process of increasing the usability, culinary attribute, or economic viability of a food item.
• Value-added fish products include those with added ingredients, coatings, or sauces, or those that provide more convenience to the user.

Global Fish Processing and Marketing

• India is a major exporter of fish and fishery products, with 10.51 lakh tonnes exported in 2016-17, worth Rs. 33,442 crores.
• More than 50 different types of fish and shellfish products are exported to 75 countries around the world.

Chilling of Fish

• Chilling is an effective way of reducing spoilage by cooling the fish as quickly as possible without freezing.
• Immediate chilling of fish ensures high-quality products, and the shelf life of iced fish depends on factors such as species, size, method of capture, and storage conditions.
• A 1:1 fish to ice ratio is ideal for ice storage in tropical countries.

Freezing of Fish

• Freezing is one of the better methods of preserving fresh fish, and can be done using various methods, including:
  • Air freezing: using cold air to freeze the fish
  • Indirect contact freezing: using a cold surface to freeze the fish
  • Liquid immersion freezing: immersing the fish in a cold liquid
  • Cryogenic freezing: using extremely cold gases or liquids to freeze the fish
• Freezing times vary depending on the method used, with cryogenic freezing being one of the fastest methods.

Canning of Fish

• Canning is a method of preserving food by heating it to a high temperature to kill microorganisms, and then sealing it in a sterile container.
• Canned fish products are popular due to their long shelf life and ease of consumption.

Retort Pouch Processing

• Retort pouches are flexible containers made of laminated materials that can be thermally processed like a can, and are shelf-stable for over a year.
• Examples of fish products packaged in retort pouches include oil sardines, mackerel in curry, and seer fish in curry medium.

Other Value-Added Products

• Individually Quick Frozen (IQF) products, such as shrimp, lobster, cuttlefish, and squid, can be packaged in attractive moisture-proof containers and stored at -30°C or below.
• IQF products fetch a higher price than conventional block-frozen products due to their high quality and convenience.### Fish Processing and Preservation
• Flexible pouches manufactured indigenously using CIFT configuration open the way for commercialization of fish curry in retortable pouches.
• Retort pouch provides longer shelf life and does not require refrigeration, energy, expensive methods of distribution and storage.
• No chemical additives are added, as most bacteria are killed by heat sterilization.

Fish Curing

• Traditional methods of processing fish by salting, drying, smoking, and pickling are collectively known as curing.
• Cured fish consumption is more in areas where the availability of fresh fish is limited, namely interior markets and hilly areas.
• In India, roughly 20% of the fish caught is preserved by curing.

Methods of Drying

• There are two methods of drying fish: traditional sun drying and artificial drying.
• Sun drying depends heavily on natural weather conditions, while artificial drying uses mechanical driers for controlled removal of moisture.

Irradiation

• Irradiation treatment involves controlled exposure of food to radiation sources, such as isotopes of cobalt or cesium, to extend shelf life.
• Radiation processes can be applied to fishery products, including radurization, radicidation, and disinfestation.

Battered and Breaded Products

• Battered and breaded products are widely valued for their convenience.
• Production of battered and breaded fish products involves several stages, including portioning, pre-dusting, battering, breading, pre-frying, freezing, and packaging.

Fish Mince and Mince-Based Products

• Fish mince is mechanically deboned fish meat.
• Quality of mince is dependent on the species, season, handling, and processing methods.

Surimi

• Surimi is stabilized myofibrillar protein obtained from mechanically deboned flesh that is washed with water and blended with cryoprotectants.
• Surimi is used to develop a variety of fabricated products like shellfish analogues.

Kneaded Products

• Kneaded products, such as kamaboko, chikuwa, hampen, fish ham, and sausage, are processed using surimi incorporating other ingredients.

Fibreized Products

• Fibreized products, like surimi-based imitation shellfish products, are in great demand.
• Ingredients used in the formulation of fibreized products include surimi, salt, starch, egg white, shellfish flavour, and flavour enhancers.

Accelerated Freeze Drying

• Accelerated freeze-drying is used for the preservation of high-value food products.
• The process involves speeding up the freeze-drying process by modifying the heating mechanism.

Extrusion Technology

• Extrusion technology is used to form shapes by forcing a material through a region of high temperature and/or pressure.
• CIFT has worked on the production of extruded products by incorporating fish mince with cereal flours.

Hurdle Technology

• Hurdle technology is based on the application of combined preservative factors to achieve microbiological safety and stability of foods.
• Hurdles used in food preservation include temperature, water activity, acidity, redox potential, antimicrobials, and competitive microorganisms.

Innovative Packaging Technologies

• Modified Atmospheric Packaging (MAP) is a process that increases the shelf life of fish by enclosing it in an altered atmosphere.
• Active packaging refers to the incorporation of certain additives into packaging systems to alter the packaging atmosphere and maintain it throughout the storage period.
• Intelligent packaging systems monitor the condition of packaged foods and communicate information about quality during transportation and storage.### Factors Influencing Seafood Demand
• Reframing seafood as a healthier substitute to other protein sources
• Targeting individual dietary needs and aspirations through seafood
• Creating seafood experiences that deliver moments of healthy pleasure
• Redefining long-life seafood as a smart shortcut for busy gourmands
• Using preservation technologies to lock in and maximize the benefits of fresh seafood
• Making new trends instantly accessible to all
• Extracting the essence of seafood to reinvent recipes
• Unlocking the power of seafood by pairing with marine and land ‘super foods’
• Diversifying out-of-home and portable solutions by blurring meal and snack formats
• Creating high engagement with seafood through no contact preparation
• Providing universal building blocks that can be easily customized to local tastes

Drivers of Change in the Global Seafood Industry

• Growing disposable incomes in emerging markets
• Rising and more volatile fish prices
• Increasing scope of fishing regulations
• Growth of high-end and premium seafood
• Rising consumer awareness about healthy nutrition
• Growing demand for traceability and transparency
• Increasing desire for convenience
• Depleting wild fish stocks
• Growing exports of cheaper farmed fish from emerging markets
• Rising oil prices
• Growing population: 7 billion mouths to feed
• Rapid aging of the global population
• Growing concern about processed foods and additives
• Stagnant to moderate growth in Europe
• Growing concern about the negative environmental impact of consumption
• Growth of climate change impacts and extreme weather
• Rising levels of sea pollution
• Rise of ‘quantified self’ and data-driven diets
• Development of unconventional protein sources
• Growing development of aquaculture technologies
• Development of marine biotechnology
• Continuing challenge of cold chain distribution from Ireland
• Growing consolidation of the global seafood industry
• Growing resurgence of ‘from scratch’ cooking
• Increasing sophistication of food culture
• The rising popularity of supplements and nutraceuticals
• Growing interest in 'mood food'
• Continuing negative attitudes towards fish preparation
• New retail models combining foodservice
• Growing influence of NGOs
• Growth of fast casual foodservice

Consumer Expectations

• Consumers want a healthy, trusted protein source they can rely on
• They expect seafood to be managed in a way that optimizes health benefits
• They want seafood that will reliably improve their brain health, mood, skin, fitness, etc.

Fish Processing and Value Addition

• Value addition is the process of increasing the usability, culinary attribute, or economic viability of a food item.
• Value-added fish products include those with added ingredients, coatings, or sauces, or those that provide more convenience to the user.

Global Fish Processing and Marketing

• India is a major exporter of fish and fishery products, with 10.51 lakh tonnes exported in 2016-17, worth Rs. 33,442 crores.
• More than 50 different types of fish and shellfish products are exported to 75 countries around the world.

Chilling of Fish

• Chilling is an effective way of reducing spoilage by cooling the fish as quickly as possible without freezing.
• Immediate chilling of fish ensures high-quality products, and the shelf life of iced fish depends on factors such as species, size, method of capture, and storage conditions.
• A 1:1 fish to ice ratio is ideal for ice storage in tropical countries.

Freezing of Fish

• Freezing is one of the better methods of preserving fresh fish, and can be done using various methods, including:
  • Air freezing: using cold air to freeze the fish
  • Indirect contact freezing: using a cold surface to freeze the fish
  • Liquid immersion freezing: immersing the fish in a cold liquid
  • Cryogenic freezing: using extremely cold gases or liquids to freeze the fish
• Freezing times vary depending on the method used, with cryogenic freezing being one of the fastest methods.

Canning of Fish

• Canning is a method of preserving food by heating it to a high temperature to kill microorganisms, and then sealing it in a sterile container.
• Canned fish products are popular due to their long shelf life and ease of consumption.

Retort Pouch Processing

• Retort pouches are flexible containers made of laminated materials that can be thermally processed like a can, and are shelf-stable for over a year.
• Examples of fish products packaged in retort pouches include oil sardines, mackerel in curry, and seer fish in curry medium.

Other Value-Added Products

• Individually Quick Frozen (IQF) products, such as shrimp, lobster, cuttlefish, and squid, can be packaged in attractive moisture-proof containers and stored at -30°C or below.
• IQF products fetch a higher price than conventional block-frozen products due to their high quality and convenience.### Fish Processing and Preservation
• Flexible pouches manufactured indigenously using CIFT configuration open the way for commercialization of fish curry in retortable pouches.
• Retort pouch provides longer shelf life and does not require refrigeration, energy, expensive methods of distribution and storage.
• No chemical additives are added, as most bacteria are killed by heat sterilization.

Fish Curing

• Traditional methods of processing fish by salting, drying, smoking, and pickling are collectively known as curing.
• Cured fish consumption is more in areas where the availability of fresh fish is limited, namely interior markets and hilly areas.
• In India, roughly 20% of the fish caught is preserved by curing.

Methods of Drying

• There are two methods of drying fish: traditional sun drying and artificial drying.
• Sun drying depends heavily on natural weather conditions, while artificial drying uses mechanical driers for controlled removal of moisture.

Irradiation

• Irradiation treatment involves controlled exposure of food to radiation sources, such as isotopes of cobalt or cesium, to extend shelf life.
• Radiation processes can be applied to fishery products, including radurization, radicidation, and disinfestation.

Battered and Breaded Products

• Battered and breaded products are widely valued for their convenience.
• Production of battered and breaded fish products involves several stages, including portioning, pre-dusting, battering, breading, pre-frying, freezing, and packaging.

Fish Mince and Mince-Based Products

• Fish mince is mechanically deboned fish meat.
• Quality of mince is dependent on the species, season, handling, and processing methods.

Surimi

• Surimi is stabilized myofibrillar protein obtained from mechanically deboned flesh that is washed with water and blended with cryoprotectants.
• Surimi is used to develop a variety of fabricated products like shellfish analogues.

Kneaded Products

• Kneaded products, such as kamaboko, chikuwa, hampen, fish ham, and sausage, are processed using surimi incorporating other ingredients.

Fibreized Products

• Fibreized products, like surimi-based imitation shellfish products, are in great demand.
• Ingredients used in the formulation of fibreized products include surimi, salt, starch, egg white, shellfish flavour, and flavour enhancers.

Accelerated Freeze Drying

• Accelerated freeze-drying is used for the preservation of high-value food products.
• The process involves speeding up the freeze-drying process by modifying the heating mechanism.

Extrusion Technology

• Extrusion technology is used to form shapes by forcing a material through a region of high temperature and/or pressure.
• CIFT has worked on the production of extruded products by incorporating fish mince with cereal flours.

Hurdle Technology

• Hurdle technology is based on the application of combined preservative factors to achieve microbiological safety and stability of foods.
• Hurdles used in food preservation include temperature, water activity, acidity, redox potential, antimicrobials, and competitive microorganisms.

Innovative Packaging Technologies

• Modified Atmospheric Packaging (MAP) is a process that increases the shelf life of fish by enclosing it in an altered atmosphere.
• Active packaging refers to the incorporation of certain additives into packaging systems to alter the packaging atmosphere and maintain it throughout the storage period.
• Intelligent packaging systems monitor the condition of packaged foods and communicate information about quality during transportation and storage.### Factors Influencing Seafood Demand
• Reframing seafood as a healthier substitute to other protein sources
• Targeting individual dietary needs and aspirations through seafood
• Creating seafood experiences that deliver moments of healthy pleasure
• Redefining long-life seafood as a smart shortcut for busy gourmands
• Using preservation technologies to lock in and maximize the benefits of fresh seafood
• Making new trends instantly accessible to all
• Extracting the essence of seafood to reinvent recipes
• Unlocking the power of seafood by pairing with marine and land ‘super foods’
• Diversifying out-of-home and portable solutions by blurring meal and snack formats
• Creating high engagement with seafood through no contact preparation
• Providing universal building blocks that can be easily customized to local tastes

Drivers of Change in the Global Seafood Industry

• Growing disposable incomes in emerging markets
• Rising and more volatile fish prices
• Increasing scope of fishing regulations
• Growth of high-end and premium seafood
• Rising consumer awareness about healthy nutrition
• Growing demand for traceability and transparency
• Increasing desire for convenience
• Depleting wild fish stocks
• Growing exports of cheaper farmed fish from emerging markets
• Rising oil prices
• Growing population: 7 billion mouths to feed
• Rapid aging of the global population
• Growing concern about processed foods and additives
• Stagnant to moderate growth in Europe
• Growing concern about the negative environmental impact of consumption
• Growth of climate change impacts and extreme weather
• Rising levels of sea pollution
• Rise of ‘quantified self’ and data-driven diets
• Development of unconventional protein sources
• Growing development of aquaculture technologies
• Development of marine biotechnology
• Continuing challenge of cold chain distribution from Ireland
• Growing consolidation of the global seafood industry
• Growing resurgence of ‘from scratch’ cooking
• Increasing sophistication of food culture
• The rising popularity of supplements and nutraceuticals
• Growing interest in 'mood food'
• Continuing negative attitudes towards fish preparation
• New retail models combining foodservice
• Growing influence of NGOs
• Growth of fast casual foodservice

Consumer Expectations

• Consumers want a healthy, trusted protein source they can rely on
• They expect seafood to be managed in a way that optimizes health benefits
• They want seafood that will reliably improve their brain health, mood, skin, fitness, etc.

Value-Added Seafood Products

• Value-added seafood products are increasingly important for meeting global demands for safe, high-quality seafood.
• Both capture fisheries and aquaculture supply fresh fish and shellfish to markets, but value-added opportunities offer expansion possibilities for the industry.

Advantages of Value-Added Processing

• Creates safer products through improved processing and handling.
• Maintains high-quality characteristics of seafood products.
• Extends shelf life of seafood products.
• Enhances economic return to producers and processors.

New Product Development and Synergy

• Improved safety and new product development create a synergy, increasing the chance of success.
• Quality must not be sacrificed in the process of new product development.

Value-Added Concepts

• Value-added concepts extend beyond processing and packaging to include attributes like sustainability and eco-labelling.
• These attributes are important drivers for maintaining and developing new markets.

Emerging Trends and Opportunities

• There is a growing demand for health-driven products that accommodate seafood products.
• New technologies and the growth of aquaculture provide new market opportunities for a wide range of products.
• Value-added processing will play a crucial role in meeting consumer demands for safe, wholesome, high-quality seafood products.

Value-Added Seafood Products

• Value-added seafood products are increasingly important for meeting global demands for safe, high-quality seafood.
• Both capture fisheries and aquaculture supply fresh fish and shellfish to markets, but value-added opportunities offer expansion possibilities for the industry.

Advantages of Value-Added Processing

• Creates safer products through improved processing and handling.
• Maintains high-quality characteristics of seafood products.
• Extends shelf life of seafood products.
• Enhances economic return to producers and processors.

New Product Development and Synergy

• Improved safety and new product development create a synergy, increasing the chance of success.
• Quality must not be sacrificed in the process of new product development.

Value-Added Concepts

• Value-added concepts extend beyond processing and packaging to include attributes like sustainability and eco-labelling.
• These attributes are important drivers for maintaining and developing new markets.

Emerging Trends and Opportunities

• There is a growing demand for health-driven products that accommodate seafood products.
• New technologies and the growth of aquaculture provide new market opportunities for a wide range of products.
• Value-added processing will play a crucial role in meeting consumer demands for safe, wholesome, high-quality seafood products.

Product Development Phases

• The three phases of product development are interrelated, and changes in one phase affect the other two.
• The simplest methodology in product development is the one-factor-at-a-time method, also known as the trial and error method.

One-Factor-at-a-Time Method

• This method involves changing one ingredient at a time while keeping other variables constant.
• The optimal levels of each variable are determined separately, and then combined to achieve the overall optimal quality.

Disadvantages of One-Factor-at-a-Time Method

• It is laborious and time-consuming.
• It does not provide information about variable interaction effects.
• The achieved optimum may not be the true optimum.

Statistical Experimental Methods

• Statistical experimental methods are used in product development to overcome the drawbacks of the one-factor-at-a-time method.
• These methods provide a more effective way to optimize product development.

Acceptance Tests

• Consumer panels are the best group to use for evaluating the acceptability of a product or range of products.
• Untrained panels of at least 50 people can be used to provide an initial indication of acceptability.

Sensory Evaluation

• Sensory evaluation is an important step in the product development process.
• Trained panels should not be used to evaluate the acceptability or preference of a product.

Functional Foods

• Functional foods are foods that have a component incorporated into them to give a specific medical or physiological benefit.
• Examples of functional foods include those with oat products, wheat bran, and other ingredients that provide health benefits.

Health Claims

• There are three types of health claims: generic, commodity-specific, and product-specific.
• Health claims must be supported by scientific evidence and require approval from regulatory authorities.

Oat Products

• Oats are a functional food that provides a specific health benefit.
• Oats contain insoluble dietary fiber, which can improve colonic function and reduce the risk of colon cancer.
• The FDA has allowed a health claim for the association between consumption of oats and reduced risk of coronary heart disease.

Wheat Bran

• Wheat bran is a functional food that promotes regularity in colonic function and prevents constipation.
• Wheat bran has a protective effect against colon and breast cancers.
• The amount and type of fiber in wheat bran affect its functionality.