PROJECT REPORT NO. 14 DFO - Library I MPO - Bibliotheque

Canada. [Dept. of] . 11111111111111111111111111111111111111111111111111 89839188 Industrial Development Service PROJECT REPORT

DEHYDRATED FISH FLAKE PROJECT

by

David Edwards, Brian Prescott and W.O. McDougall

Industrial Development Service Department of Fisheries of Canada, Ottawa June 1967 DEHYDRATED FISH FLAKE PROJECT

by

David Edwards, Brian Prescott and W.D. McDougall

Opinions expressed and conclusions reached by the author of this report are not necessarily endorsed by the sponsors of this project

This was a project carried out by the Industrial Development Service of the Department of Fisheries of Canada

i

FOREWORD

~his report summarizes the "Dehydrated Fish Flake Projecttt carried out at the Experimental Plant, formerly operated by the Department of Fisheries of Canada at Valleyfield, Newfoundland. It is based on progress reports and a cost analysis prepared by L.E. Deveau and B.F. King of the Industrial Development Service of the Department of Fisheries of Canada'.

SUM1VJARY

The manufacture of fish-potato flakes consists of preparing, cooking and coraminuting of fish and preparing, cooking and ricing of potatoes, after which the two ingredients are blended together with additives, drum-dried and packaged. Manufacture of fish-cereal flakes is similar except that water and cereals are substituted for the cooked potatoes in the blending step. A cost study carried out on the fish-potato flake pilot plant

project showed a cost of ~ 1.03 per pound for the dried product, not including depreciation, taxes or profit. Various types of fish were tried. , both salted and un­ salted, was the species mostly used, although and hake were also felt to have promise as a product for human consumption. Experiments in the fish-cereal process showed that of the varieties tested, which included cod, herring, flounder, whale-meat, capelin and tuna, only tuna could not be processed successfully. High solid, low sugar content potatoes are preferred, . as they give a better yield and .."hiter fish-potato flake. Various types of cereal can be ij used in the fish-cereal process. The main additives used in both types of product are monoglyceride, to tie up the free starch fraction, and an antioxidant to retard rancidity of the product in storage. Other additives bleach and season the product. Recipes have been developed by the Department of Fisheries and tests have been undertaken by FAO. The product holds promise both for human consumption and pet food. iii

Foreword i Summary ii \ PART I - DEHYDhATED FISH POTATO FLAK~ PROJEpT Introduction 1 Processing Method Z a) Fish Preparation b) Potato Preparation c) Blending d) Drum Drying e) Packaging Raw Materiell 5 a) Fish b) Potato c) Additives d) Water Cost and Time Study Recipe Development 10

PART II - DEHYDRATED FISH-CEhEAL FLAKE PROJECT Introduction 13 Processing Method 13 a) Fish Preparation b) Cereal Preparation c) Blending d) Drum Drying e ) Pa ckaging f) Consumer Testing Raw IViaterial 14 a) Fish b) Cereal c} Additives d) \'later Conclusions 16 Appendix I Daily Report Sheet 17 Appendix II Flow Sheet: Dehydrated Fish-Potato Flake Project 1$ Appendix III Preliminary Results of Chilean Food Tests with Fish-Potato Flakes 19 PART 1 - DEHYDRATED FISH-PO'fATO FLAKE PROJECT

INTRODUCTION

This section of the report describes the various aspects of producing a dehydrated fish-potato flake product which reconstitutes with milk or water to form a nutritious food. The dehydrated food project began as a joint federal Department of Agriculture-Department of Fisheries study in 1961. Original studies on a laboratory scale, using a double drum drier with drums of size 7~ inch long x 6 inch diameter were made at Department of Agriculture facilities in Ottawa. It was first attempted to make a dehydrated product consisting of a cooked, comminuted fish only. These attempts were unsuccessful as the product could not be re- hydrated since the water binding capacity of the proteins was lost by heat denaturation. It was found that an acceptable fish product with good rehydration properties could be obtained by incorporating cooked mashed potatoes with the cooked comminuted fish. 1 It was then decided to set up a pilot plant operation on a larger scale. The site chosen was the Department of Fisheries Experimental Fish Processing Plant, Valleyfield, Newfoundland. Development. of the fish-potato flake process was carried out from 1963 to ~965. During this period sa.mples of fresh cod and salt cod-potato flakes were sent to various producers and wholesalers in the food industry in Canada and the United States. Since then samples have been sent. to such countries as India, Chile and Denmark. A pre­ liminary report of the Chilean testing, for which 500 lb of both

1 Asselbergs, E.A.M. and Chan, M.S., "Preparation and Production of Drum Dried Insta.nt Foods", }i'')(ld in Canada, (February 1962), page 21. - 2 - fresh and salt cod flakes \,\rere shipped from ValleyfiE'!ld, is included in Appendix III. Licensing arra.ngements may be made through thE'! holders of the patent on the process, Canadian Patents and Development Limited, Sussex Drive, Ottawa, Ontario. A daily report sheet, with a typical run sh01'm (Appendix I), and a fold-out display of the process (Appendix II) illustrate the method developed.

PROCESSING METHOD a) Fish Preparation

Fish for human consumption is filleted and skinned, giving a yield of approximately one-third of the head-on gut-out cod fish. Pin bones are not removed since they are disintegrated in the comminuter. Depending on the species and maturity of fish and the season, solid content of the raw fillets usually runs from 18~ to 20%. Cod for use· in salt cod-potato flakes is hcc?vy sa.lted skinl'9ss and is put through an extra processing step. It is desalted by soaking in cold fresh water until the salt content is reduced to approxtIl1ately 10~b (dry basis). This takes about .30 hours. Fish in tr.e thawed sta.te, v!hether salt or fresh, is boiled in water for 15 minutes. The weight lo:::;s in cooking is approximately

30~b to 40~~, most of which is ''later. There is, hovlever, a loss of soluble protein. The percentage of solids is between 21% and 2510 after cooking. The fish is then comminuted through 1/8 inch mesh. - 3 -

b) Potato Preparation

Potatoes are peeled, cut into French fry strips and boiled for 6 to 7 minutes. The potatoes are cooled rapidly with 45 0 F air for 6 minutes to a temperature of approximately 720 F to avoid the excessive formation of free sta.rch, which would cause stickiness in the reconstituted product. The potatoes are then riced through a

1/8 inch screen. ~

c) Blending

Thd mixture of riced potato, comminuted fish and additives is then blended for 5 minutes at a slow mixing speed. Ratios of fish: potato have been tried as high as 3:1 and as low as 1/3:1. Although all combinations processed satisfactorily, a ratio of 1:1 was felt to be best since the 3:1 ratio was felt to be too expensive and the 1/3:1 ratio lacked a fish flavour.

d) Drum Drying Operation

Mash with an initial moisture content of 72% to 80% is dried to a moisture content of approximately 6%0 The drum dryer is a single drum type with applicator rolls. The drum is 24 inches in diameter x 48 inches long, steam heated cast iron with variable speed from 0 rpm to 5 rpm. Five 3 inch dia­ meter stainless steel unheated applicator rolls are spaced around the periphery of the drum. Only four were used, however, since the bottom one would not retain the mash very well. Although the space between the applicator rolls and the drum could be varied, it was set at approximately 7/16 inches for all rolls and retained at this throughout the project. A variable speed spreader bar is situated on the top of the drum. - 4 -

Steam pressures on the drum were varied 40 psi to 90 psi. A steam pressure of about 70 psi giving a temperature on the drum sur­ face of 3100F ~ 100F was found to be the most suitable. The mash burned easily with the 90 psi setting, while the productivity was lowered at 40 psi since the speed had to be decreased to ensure proper drying. The speed setting at a particular pressure depends on the moisture content of the incoming ~sh, but at 70 psi is approximately 3.25 rpm to produce a flake with 6~ moisture a In operation the mash is dumped behind the spreader bar either by hand-held scoop or down a chute fed by a screw conveyor from a hopper. The former method was used most of the time since it was more suited to the batch-type pilot plant operation. The mix is transferred, by means of manually operated scraper bars, until each of the four rolls is covered with approximately 3/4 inch of mash. The dried sheet is peeled off the drum with a knife and broken with an auger to approximately 1/2 inch square flakes. If the flakes contain excessive moisture they are dried, before packaging, on a vibrating conveyor with variable intensity infra- red heating. e) Packaging

The flakes were packaged either in 6 oz. size laminated bags (inner lining, polyethylene, aluminum foil core and paper outside) for home consumption or in nitrogen flushed 5 gallon cans for institutional use. Limited testing by the Derartment o.f Agriculture on the product packaged in the 6 oz. bags showed that after 4 to 5 months • storage with temperatures between 900F and lOOoF the product changed from - 5 - white to yellow although there was no flavour deterioration. At these elevated temperatures, flavour deterioration became noticeable at nine months' storage time. Testing at Valleyfield on the product packaged in the 5 gallon container indicated little flavour deterior­ ation after two years although the temperature in this case was in the 60°F to 70°F range.

RAW MATERIAL

Most of the experiments were done using cod since it was locally procurable and also since it is a. widely used food fish. Both fresh and salt cod processed satisfactorily and produced a white product. Salt fish is easier to comminute than fresh since the flesh is firmer. It was also found that fresh fish was easier

to comminute if it had been frozen and tl~wed prior to cooking. Pollock and hake, unsalted, processed as well as cod but both gave a grey proquct. Turbot flake samples were sent to the Fisheries Branch, Dept. of Mines and Natu·ral Resources, Province of Manitoba, for comments. Acceptance was fair. Main complaints were: the strong odour, the bland flavour, and the watery texture. It was felt in Valleyfield that the product would not be acceptable due to high oil content although no specific mention of this was made by the teste.rs. Squid produced a white product with an acceptable taste. The disadvantage of squid was found to be in the low yield and lengthy prepration for cooking, which involved deheading, gutting and skinning. - 6 -

Turbot and herring flakes were felt to be inferior in taste to cod due to the high oil content. Both species processed satis­ factorily, to produce a grey-brown coloured flake. Flounder, capelin, whale and tuna were combined with cereals in the fish-cereal project but not tried with potato. The following observations are based on experience in combining these species with cereal. Flounder formed a slurry instead of a paste when"comminuted and the mixture of flounder and potato would probably not form properly on the applicator rolls of the drum dryer. In the fish­ cereal flake project this problem was overcome by adding less water than usual, a procedure which is impossible with the fish-potato flake process since water is not added to the mash. Capelin would probably process well but is judged to give a colour (dark grey) and an "off" taste.

Whale would probably process well to give a brown fl~ke. Tuna did not produce a mash which would adhere to the appli­ cator rolls when ~ixed with cereal. It is felt that the same would apply when combined with potato. b) Potato High solid, low sugar content potatoes are preferred, as they give a better yield and whiter fIR-lee. Some potato shipments were aged at high relative humidity ($5%) and temperature (700 F) for one­ week periods to reduce the sugar content. However the improvement in the product was not very dramatic. Species such as Ontario Avons and Sebagos of Prince Edward Island and Newfoundland were found acceptable. - 7 - c) Additives Seasonings were added during cooking and during the blending operation and in both cases gave successful results. Other than the basic seasonings of salt, vinegar and pepper, added in an amount depending on the operator's discretion, it is felt that seasonings can be added to taste in the final preparation of the product for the table. Other additives are incorporated while the potato and fish is being blended and are as follows: (Figures in parenthesis following the chemical give the weight in grams added per hundred pounds of """et mash). Monoglyceride (25) in the form of Myverol type 18-00 is added to tie up the free starch fraction to prevent a sticky condition in the reconstituted product. An antioxidant, Witan 4 (20) is used to prevent oxidative rancidi ty due to the formation of free fatty acid from the phos­ pholipid breakdown of fish tissue and potato. Witan 4 is a mixture of 20% butylated hydroxyanisole, 20% butylated hydroxy toluene and 60% vegetable oil. Use of this additive has not been approved by the Food and Drug Directorate, National Health and Welfare Depart­ ment and approval must be obtained for commercial production. Carnation skim milk powder ()O) is added to prevent any grey­ ish tinge of the product from the potato ingredient. Sodium sulphite (9) and sodium bisulphite ()) form sulphur dioxide which bleaches the product slightly. - 8 - d) \'later Water is used in the process during the cooking and comminuting phases. Distilled water was used in Valleyfieldo

Cost and Time Study Calculations are based on 100 lb. of finished product as pro­ duced from a mash of 1:1. that is, 1 part of fish to I part of potato; the mash having moisture content of 80% and the finished

product containing approxi~ltely 6% moisture. The ingredients were fresh cod fillets and "Avon" potatoes. The study was made in 1964. I. RAW MATERIAL QUANTITY UNIT COST -COST A. Fish (gut out, head on) 121$ lb. )00/100 lb. $ )6.50 The conversion factor as established in

the pilot plant from gut out J head on fis h to cooke d , comminuted fish is .2)2.

B. Potatoes )$6 lb. 1.70/100 lb. $ 6.55 The conversion factor from raw potatoes to cooked mashed potatoes is .7).

C. Additives': i) Antioxidant ••••••••••••••••••••••• l1) grams ii) Monog1yceride ••••••••••••••••••••• 141 " iii) Skim milk ••••••••••••••••••••••••• 171 " iv) Sodium Sulphite ••••••••••••••••••• 51 " v) Sodium Bi-sulphite •••••••••••••••• 17 " TOTAL COS'!' .20 - 9 - 2. LABOUR

OPERATION VlAN HOURS UNIT COST COST A. fish processing 7.14 B. potato processing 2.12 C. mixing & conveying .46 D. drying 3.64 E. packaging 7.3 .

20.66 1.25/hr. $25.eO

3. ELECTRICAL ENERGY

OPERATION KW. HOURS A. fish processing 6.91 B. potato processing .3e C. mixing and conveying 1.51 D. drying 5.7e 14.59 0.04/kw hr .59 4. STEAM

OPERATION POUNDS UNIT COST COST A. fish processing 133

B. potato pr~cessing 139 C. drying 506

77e $2.00/1000 Ib $1.56 5. WATER CONSUMPTION

OPERATION fOUNDS A. potato processing 104 (actual) 0004 B. fish processing 1000 .20 (estimated)

5. PACKAGING MATERIAL 267 bags (6 oz. size) .12 ea. ;22.00 Total Cost Per 100 lb. Dry Product $ 103.44 - 10 -

NOTES

1. The above does not include maintenance labour, supervisory labour, overhead, amortization of building and equipment. The product in the pilot plant was produced in 6 oz. packages.

2. The conversion factor from mixed mash at gO~ moisture to 6% dry product, as established in the pilot plant operation is .176. 3. Since this is a pilot plant operation many operations are manually performed which in commercial production could be automated.

Recipes The following recipes were developed by the Information and Consumer Service, Department of Fisheries of Canada for fresh and salt cod. '

JIFFY FISH CAKES Makes 6 cakes

3 ounces fish-potato flakes 1/2 cup finely chopped onion (approximately 3 cups) 1/2 teaspoon salt 1 egg Few grains pepper 1 1/4 cups milk Dry bread crumbs

Combine fish-potato flakes with salt, pepper and onion. Beat egg with milk. Stir into dry mixture. Let stand for 2 minutes. Divide into 6 portions. Form into cakes, 1/2 inch thick. Coat with dry bread crumbs. Pan fry in hot fat over moderate heat until golden brown on both sides. - 11 -

JIFFY SALT COD FISH CAKES

Makes 6 cakes

3 ounces salt cod-potato flakes 1 egg (approximately 3 cups) Few grains pepper 1 cup milk 1/2 cup finely chopped onion Dry bread crumbs

Combine salt cOd-potato flakes with pepper and onion. Beat egg with milk. Stir into dry mixture. Let stand 2 minutes. Divide into six portions. Form into cakes 1/2 inch thick. Coat with bread crumbs. Pan fry in hot fat, over medium heat, until golden brown on both sides.

JIF~Y FISH COCKTAIL BALLS

Makes about 2 dozen balls

3 ounces fish-potato flakes 2 tablespoons chopped parsley (approximately, 3 cups) 1/2 teaspoon salt 1 egg Few grains pepper 1 1/2 cup milk 1/4 cup finely chopped onion Dry bread crumbs

Combine fish-potato flakes with salt, pepper, onion and parsley. Beat egg with milk. Stir into dry mixture. Let stand 2 minutes. Form into balls, about 1 inch in diameter. Coat with bread crumbs. Fry in deep fat at 360oF. until golden brown. - 12 -

JIFFY SURPRISE FISH LOAF

Makes 6 servings

3 ounces fish-potato flakes 2 cups finely diced soft (approximately 3 cups) bread crumbs 1 teaspoon salt 1 egg 1/$ teaspoon pepper 2 cups milk 1/2 cup finely chopped onion 1/4 cup grated Cheddar cheese 1 cup grated Cheddar Paprika

Combine fish-potato flakes with salt, pepper, onion, cheese and bread crumbs. Beat egg with milk. Stir into dry mixture. Let stand 2 minutes. Pour into a greased loaf pan 5" x $" x 2". Top with 1/4 cup grated cheese. Sprinkle with paprika. Bake in moderate oven (350oF.) for 45 minutes. If desired, serve with a cheese or a toma to sauce.

JIFFY FISH PANCAKES

Makes 9 pancakes

3 ounces fish-potato flakes 2 teaspoons baking powder (approximately 3 cups) 1 teaspoon salt 3 eggs 1/4 cup all-purpose flour 2 cups milk

Combine fish-potato flakes with salt, flour and baking powder. Beat eggs with milk. Stir into dry mixture. Mix well. Let stand 2 minutes. Pour 1/) cup at a time into a well greased frying pan.

Fry over medium heat until golden brown on both ~ides. Serve with butter or lemon butter. - 13 -

PART II: .=.;DE;:;.,;;H-=Y~DJiA_ 'l'p;1.J FISH -CEREAL iLAKE PROJEC.1

INTRODUCTION

This section of the report describes the various aspects of producing a dehydrated fish-cereal flake product intended for pet food .. The project began as a result of enquiries late in 1965 from a private company investigating the pet food market. Experimentation was carried out at the Fish Processing Experi­ mental Plant, Valleyfield, Newfoundland, beginning in December 1965. Investigation is now under way by the company to determine whether the production phase of the product will now be undertaken.

PROCESSING METHOD a) Fish Preparation To reduce the loss in yield from filleting it is desirable ta use t -he whole fish in the case o·f he rring 1 the guts· out head em e'od fish,. or c'od fish offal.,

(Cooking and. eomminution of the product was accompliShed :iil' the same' way as for- the fis-h potat·o· project, although the rate of pro-­ d'ue·t.ion: from the comminuter decreased due to' the inclusion' of Dones tI'

«:00king times were varied froml 2'.. 10 minutes ~ depending on species". lbJ); (Cereal Preparation !I!ereals were used in the' ground form .. e' ) ~ Blending Ratios of fish to a 1:-1: ce'real-wate:r mix were successfully- tried from 4,: I to 2 :·3 although the 4: 1 and 3: 2 levels were preferred for taste. - 14 -

Water, cereal, fish and additives are combined in the blender. The mixture is cooked during the blending process. It was found that a ratio of 1:4:3 cooked cereal:fish:potatoes would work. At the end of blending the mixture has a moisture content of

65Yo to 727~. d) Drum Drying

Drum drying is carried out in the same way as for fish-potato flakes except that the steam pressure on the drum is set at 40 psi and the drum speed is set at 3 rpm to 4 rpm depending on the moisture content of the mash. The resultant flakes are 6 to S thousandths of an inch thick and have a moisture content of approximately S%. They are grittier than the fish-potato flake produced from fillets and seem to be more perforated. Both characteristics are probably due to inclu­ sion of bones in the product. e) Packaging

The product, was packed in heat sealed Saran-coated paper bags. f) Consumer Testing

Since the fish-cereal flake product might have application for humans, samples were shipped for testing to the Information and Consumer Service, Department of Fisheries, Ottawa. A dish was pro­ duced using the product. Although rather sticky it was quite tasty and seemed to have promise.

Raw Material a) Fish

~ost experimentation was done with cod and herring. - 15 -

It was found that head on gutted cod and cod offal (less guts), as well as cod fillets could be utilized. Without colouring agents the product varies between white for fillets and grey for offal.

Herr~~ processed satisfactorily to give a light grey flake. Although the product is oily it is quite likely that pets will be attracted by this feature.

Flounder processed satisfactorily to give a yellow flake. Since flounder has a higher moisture content than other varieties used, less water was added during blending to form the proper con­ sistency of mash on the drum.

Whale meat processed satisfactorily to yield a brown flake.

Capelin also processed satisfactorily, yielding a dark grey flake.

Tuna was the only species of those tested which would not pro­ cess satisfactorily, seemingly due to the fibrous nature of the meat.

b) Cereal

Various types of cereal can be blended to proQuce an acceptable flake.

c) Additi~ Monoglyceride and the antioxidant, Wi tS.n 4, were added to the mix while blending, in the same proportions as in the fish­ potato mix. Vita.mins necessary for animal health and colouring were also added. - 16 -

d) Wate..r

As in the fish-potato flake process water is used during cooking and comminuting of the fish. However, water is also added during blending to bring the moisture content up to the 65% to 72~ level required for proper application of the drum dryer.

CONCLUSIONS.

Although the fish flake product has been well accepted in the consumer testing program it seems to be hampered by the fact that it must compete directly with the "convenience" type fish product which is so readily available. Its chief advantage over other , which is long storage life at room temperature, is apparently not important to most Canadian consumers. It may have application in institutional feeding programs, but here cost may be a drawback. On the other hand it would seem to have a good application in areas of the world where long storage life at room temperatures is a necessity and also where it could be added to the normal dishes of the country to increase the protein content of the food. Although all the work towards producing a product for human consumption has been done with a mixture of fish and potato it would seem that the mixture of fish and cooked cereals would be suitable for human consumption. Also the possibility of substitut­ ing other starchy raw materials such as rice or tapioca for the potatoes or cereals should not be excluded. - 17 - DAILY REPOHT SHEET APPENDIX I DRUM DRYING PILOT PLANT EXPERIMENTAL FISH PROCESSING PLANT VALLEYFIELD, NFLD. - Test Run No. C-70 psi. Date: June 12/64 --- NO. I'l'EM DATA UNIT 1. MIXTURE Fish/Potato POTATOES 2. Specific gravity of raw potatoes 3. Percent solid in raw potato % 4. Percent solids in mashed potatoes 17.65 % 5. Quantity of raw potatoes (total) 96 lbs 6. ~uantity peeled and trimmed (total) 68 lbs 7. Quantity after cooling (total) 58 Ibs 8. Steam pressure 40 psi 9. Cooking time 7 mins 10. Quantity mixed - total) 50 lbs II. Cooling time 6 mins 12. Temperature before ricing 72 OF 13. Seasoning Added salt FISH 14. Species and form thawed cod fillet 15. Percent solid (raw fish) % 16. Quantity before cooking (total) 75 lbs 17. Quantity after cooking (total) 50 lbs 18. Cooking time 15 mins 19. Percent solid after cooking (total) 25.20 % 20. Steam pressure 40 psi 21. Quantity mixed - total 50 lbs 22. Seasoning added salt onion pepper MIXING 2.3 • Batches mixed 2 24. Weight per batch 50 lbs 25. Mixing speed 1 1,2,3,4 26. Mixing time 5 mins 27. Percent solid of mash 20.19 % ADDITIVES h 28. Antioxident 20 j , 29. Iv!onoglyceride 25 i grains per 30. Skim milk powder 30 i 100 lbs 31. Sodium sulfite 9 mash 32. Sodium bisulfite 3 DRYING 3.3. Steam pressure 70 psi 34. Drum speed 3.00 rpm 35. Moisture content of flakes 6.0 'Yo 36. Production rate 2.26 Ibs/Hr/Sq.ft. of drum surface 37. Thickness of flake .0095 inches 38. No. of applicator rolls 4 ~J.--2,3 ,4 39. Drum surf_ce temperature 40. Roll clearance on No. 1,2,3,4,5 7/16 inches - 18 - APPENDIX II

, (Please turn over) COMMINUTION OF FISH .

COOKING OF POTATOES OR FISH COOLING HOOD FOR POTATOES (OPTIONAL FO~ FISH) BLENDING OF FISH, POTATOES & ADDITIVES

UNIT FOR RICING POTATOES

FISH PREPARATION FISH COOKING FISH COMMINUTING ADDITIVES SKINLESS FISH FILLETS IN THE THAWED FISH IS BOILED FOR 15. MIN. FISH IS COMMINUTED. MON06LYCERIDE STATE ARE USED. IN THE SAME HETTLE AS BELOW IN A w.]. FITZPATf:lICK AN (lOXIDANT PIN BONES ARE NOT REMOVED. ca . MODEL D COMMINUTER 5HIM MILK POWDER SALT. PEPPER +- VINE6AR ARE ADDED TO TASTE . ....----.1 USING A SCREEN WITH ts" PIA ME TER HOLES. r-, _ SODIUM SULPHITE SODIU M B/SULPHITE

POTATO PREPARATION POTATO COOKING & COOLING POTATO RIC! N6 8LEN DING OF IN6REDIENTS HIGH SOLIDS LOW SU6AR CONTENT POTATOES a) POTATOES ARE BOILED FOR 6 MIN. POTATOES ARE RICED THROU6H FISH AND POTATOES IN A 1:1 RATIO AND ARE PEELED AND CUT INTO r)( J" IN A STAINLESS STEEL PERFORATED A CHISHOLM -RYDER CO. TYPE CRCO. ADDITIVES ARE BLENDED FOR 5 MIN. B 8 BASKET IN A STEAM HEATED KETTLE, COULTER MODEL F RICER t)SIN6 A SCREEN AT II. J SETTING (SLOW 5PEED) ON A FRENCH FRY STRIPS STA/NLESS STEEL MODEL N4-0, CAPACITY WITH '062 INCH DIAM. HOLES . HOBART MANUFACTURING CO . MODEL L 800 32 IMPERIAL GALLONS. STEAM IS SUPPLIED BLENDER USING A FLAT BATTER BEATER. BY A 30 HP NAPANEE BOILER. b) POTATOES ARE COOLED FROM 212°F TO 72° F UNDER 4-5° F AlA IN APPROX, 6 MIN. , (Please turn over)

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"DRY" SIDE OF DRUM DRYER SHOWING CUTTER BLADE PEELING SHEET OF FLAKES FROM J>RUM INTO PAN EQUIPPED WITH BREAKER BAR . FEED HOPPER FOR WET MASH IS SHOWN AT REAR.

VIEWS OF "WET" SIDE OF DRUM DRYER SHOWING MAIN DRUM, APPLICA rOR ROLLS, SCRAPER BARS.

DEHYDRATeD FISH -POTATO FLAKES FOR HOME CONSUMPTION.

PACKAGING LINE FOR 6 -OUNCE BAGS SHOWING VIBRATING HOPPER DRUM DRYING PACKAGING AND FEEDER WITH INFRA -RED LI6HTS THE STEAM PRESSURE ON THE IJRUM IS SET AT 70 PSI FLAKES ARE PACKAGED IN 6 -OUNCE HEAT (TO REMOVE EXCESS MOISTURE), WEI6H (APPRO't 310 0 F SURFACE TEMP). THE MASH,HAVI1V6 SEAL.ED, POLYETHYLENE -ALUMINUM SCALES AND HEAT SEALING UNIT. .. A MOISTURE CONTENT OF 72-75 "10, IS DRIED FOIL - PAPER LAMINATED BAGS FOR HOME TO A FLAKE WITH A 6 % MOISTURE CONTENT CONSUMPTION OR IN NITROGEN FLUSHED EXCESS MOISTURE IS REMOVED By INFRA-RED 5 - GALLON CANS FOR INSTITUTIONAL OR LIGHTING PRIOR TO PACKA6/N6. THE FLAKE 15 RESTAURANT USE. APPROX. IJzH SQUARE BY ·010 INCH THICK. THE DRYER 15 A SINGLE DRUM PILOT PLANT MODEL MADE BY OVERTON MACHINE CO. STEAM IS SUPPLIED BY A 30 HP HI6H PRESSURE NAPA NEE BOILER

FLOW DJAGRAM DEHYDRATED FISH-POTATO FLAKE PROC£S5 APPENDIX II APPEN DIX III - 19 -

,INSTITUTO DE CIENCIA Y TECNOLOGIA DE ALIMENTOS

CASILLA 1004 - FONO 97835 SANTIAGO - CHILE OG/CG cc : Chrono (2) ~i 'ile I~ST/T~-3-7/67/108 Santiago, February 21, 10G7.

Dear Mr. Edwards,

I acknowledge receipt of your letter of Feb. 1'6, in rec;ard to t he tlBO of the fisil-potato-flalces suppl ied by your Dep artment of Pisheries.

The final results ar~ not available yet; some croups are very slow in their actions. ~ e are tryin~ the fish­ potato-flakes for acceptability tests with 5 groups:

A - witll infants, in the Nutrition Division of the Hospital of the U. of Chile;

B - with school children in two sections of the country one in SantiaGO and another one in Chuquicamata;

C - with industrial workers, adults, different cultural patterns, Concepcion;

D - with patients (mostly lung diseases) in the Hospital del Thorax, in Santiago - adults, diff. culturaY patterns;

E - with educated people in the Univ. of Chile, Fac. of Agricultureo

Group D lk

1 - 8chool children, 6-13 years old, made up of 35 male and 45 female (total 80). 'day of prel)aration "charquicun". Acceptability 02% Refused ' 8%

2 - Anoth~r school ~nit, 6-15 years old students, all female (total 70). Way of preparation - pUdding. Acceptability 92% ndfused B% ./.

f:lr. D. ~d\ .... ards , BngineerinG Service Industrial Develo~mcnt Service Department of l"i::;lieries Ott;H'la 8, Canada

PROVECTO DEL GOBIERNO DE CHILE CON LA AVUDA DEL FONDO ESPECIAL V LA FAO DE LAS NACIONES UNIDAS - 20 -

3 - 3rd Ijroup ,school unit, 1-1-17 years old, fehlale (total 58). , i ;:Y ~f preparation II charquicun'l, Acceptability 4~6 2efused 5~~

As you can see, the sm,le dish - IIcharquican .!.~ . which is t:idely used in Chile ShO\iS a I'Llarlced difference .01' acceptability in 1 and 3.

Group C - In this group, mostly made up of industrial workers, 28 male and 32 female, the fish-potato-flal;:es ,,,as admini.stered in different ''lays: puddin~, croquette, added to beans and cream-style.

1'11e results, in general, are as follows:

~xcellent 2Ci~6 Acceptable G3;~ 6 Hefused 12%

(jays of preparat~ - we tried to have the fish-potato-flalces entering the traditional dishes of Chile.

1 - Soups of different kinds ,,,ere prepared with an extra amount of fish-potato-flakes, about 3-4% dry \-leight/volume. '.i.'his '"Iould make the soup thicker and, of course, more nutritious.

2 - Puddin~ - a thick, firm, jelly-like dish made up of fish-potato­ flakes plus water, or water/milk, and seasonin~ (onion, little pepper, garlic, butter). Fish-potato-flalces runs 6-1~' dependinG 011 higher or 10\'ler consistency.

3 - Cream-style - is something like the above puddine;, with mille. Consistency 10\'1er. li'ish-potato-flalces about 3-4%, ,.,/v.

4 - Mixed with beans - fresh beans arc cooked the usual way with portions of squash, carrots, piuientos, seasoning, all to[!'ether. li'ish-potato-flakes ,,,~s added (about 3;'~) to maI~e it thicker. , 5 - IICharquicanl1 - is made up of ground meat, potatoes, carrots, pimientos, seasoning, all cooked together. Fish-potato-flakes entered the dish as an extra inGredient, about 3% w/v.

6 - Croquettes - fish-p6tato-flnkes pl~s some milk or water - 21 -

\'lheat flour, scasoninl:ie F'ish-potnto-fla!~cs runs about 80'% \'Ilv. The croqucttes are fried in vegetable oil.

In gcneral, the most common complaint wao due to the Cod flavor, not very ,'mIl accepted by the Chileans. lie believe that the same product made out with a fish with lower fat content, such as hake - abundant and ci.leap here - ,'lill develop a fish-~)otato-flake with higher, or better, 10o~6 positive acceptabil i ty.

.so far, the results are prom1s1ng; when all the data \'fill be compiled, \'Ii tIl details in tile carryin:j out of tile experiments and on recipes, plus statistical analysis, \'Ie liill be able to send you a complete report.

With kindest regards, I am,

.Sincerely yours, ----- ...... <:.~~- (Q - {,I...\ /"\..--~ ...... (...... / t Otti io Guernelli Pro ect I.lanager , Ii' S T

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