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Unit 6 Whole Fish and Shell Fish Based Unit 7 Moulded Products

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Unit 6 Whole Fish and Shell Fish Based Unit 7 Moulded Products Whole Fish and UNIT 6 WHOLE FISH AND SHELL FISH Shell Fish Based BASED Structure 6.0 Objectives 6.1 Introduction 6.2 Processing of Some Whole Fish Coated Products 6.2.1 Coated Fish Fillets – Preparation 6.2.2 Coated Fish Fingers/ Fish Portions/ Fish Sticks 6.3 Coated Shrimp Products 6.3.1 Coated Shrimp Fantail Round 6.3.2 Coated Butterfly Shrimp 6.3.3 Breaded “Nobashi” 6.3.4 Coated ‘‘Peeled and Deveined Shrimp’’ 6.3.5 Prawn Nuggets 6.4 Coated Products From Squid 6.4.1 Squid Rings 6.4.2 Stuffed Squid 6.5 Coated Products from Mussels, Clams and Oysters 6.6 Let Us Sum Up 6.7 Glossary 6.8 Suggested Further Reading 6.9 References 6.10 Answers to Check Your Progress 6.0 OBJECTIVES After reading this unit, you will be able to: understand the need for product diversification; justify for better product attributes; recognize the demand for ‘ready-to-eat’ or ‘ready-to-use’ products; explain the benefits of coated seafood products; describe the production of various coated products from fish and shell fish; and identify new generation consumer friendly products from fish. 6.1 INTRODUCTION The health benefit associated with fish has resulted in the global demand for fish and fish products considerably. The present day consumers, particularly the urban 5 Types of Products population are showing more and more interest to food products that are available as ready-to-eat or ready-to-cook convenient products. The global demand for these types of products is rapidly increasing. The same is the case with fish products also. The food industry has realized this shift in consumerism, and there has taken place a rapid product diversification to supply a variety of convenience foods. You will be happy to know that the demand for ‘ready-to-eat’ or ‘ready- to-use’ products has led to the development of several products diverse in taste, texture and appearance based on fish. A major group among them commanding high consumer appeal is the battered and breaded products commonly known as coated or enrobed products. The first commercially successful coated product is ‘fish finger or ‘fish stick’. Later, several other products particularly the coated fish fillet, fish portions, fish cakes, fish medallions, fish nuggets, breaded oysters and scallops, crab balls, fish balls, coated shrimp products, coated squid rings etc. became prominent in most of the developed countries with the advent of the fast food trade. Fig. 6.1 gives a view of different ready-to-eat coated fish products Fig. 6.1: Ready-to-eat coated fish products 6.2 PROCESSING OF SOME WHOLE FISH COATED PRODUCTS Now, you will learn in detail the processing of some delicious coated fish products. Coated fish fillet (Fig. 6.2) is an important ready-to-eat/use commercial product prepared from whole fish. Being a ready-to-eat product, it has become a prominent food item in the European markets. Along with fried potato chips, the fried coated fish fillet forms a substitute for lunch for majority of the floating population in Europe. It is available in shopping malls, coffee shops, hotels and hotel - chains like McDonald’s etc. Commercial coated whole fish products are coated fish fillets and fish fingers which are prepared from fishes like cod, haddock, pollock, perch, halibut, plaice, sole, and of late, cat fish from aquaculture sources. In our country, several fishes belonging to perch, sciaenid as well as fresh water fishes have been found suitable for the production of coated products. Fillets from large, medium as well as small fishes are used for this purpose. Generally, lean, white meat fishes are preferred for the preparation of coated fish products. 6 Fig. 6.2: Ready-to-eat coated fish fillet 6.2.1 Coated Fish Fillets Preparation Whole Fish and Shell Fish Based The various stages in the production of coated fish fillet are described below: a) Filleting Now, let us see what is a fish fillet? A fish fillet is a skinless, boneless fish loin cut along the central bone frame and trimmed free of loose or hanging meat. We get two such fillets from a fish. We can prepare skinless, boneless fish fillets manually as well as using filleting machines (Fig.6.3 to 6.8) While fillet yield is 30 to 40% with machine filleting, manual filleting gives better yield. The processing unit should receive the fish in prime quality and properly chilled condition. During filleting also, the fish must be kept in good quality ice; either flake ice or crushed ice. To fillet, keep the fish on the chopping board and cut from behind the pectoral fin down to the main bone and move the knife along the bone frame with minimum loss of meat. Remove the skin along with scales by passing the knife along the skin layer. Also, remove the belly flaps. Trim off any hanging meat from the fillet and make it regular and uniform. Wash the fillets in chilled water and drain (Fig.6.3 to 6.8). Fig. 6.3: Fish filleting Fig. 6.4: Fish filleting in a factory Fig. 6.5: De-skinning a fillet Fig. 6.6: Skinless boneless fillet Fig. 6.7: Filleting by machine Fig. 6.8: A trimmed fillet (center) 7 Types of Products Ingredients To prepare coated fish fillets, the ingredients needed are fish fillets as well as batter. The ingredients needed for a batter are given in Table 6.1 Table 6.1: Ingredients for batter Ingredients Quantity Maida 2 kg Corn flour 200 g Bengal gram 200 g Salt 30 g Guar gum 5 g Turmeric powder 5 g Sodium tripolyphosphate (Food Grade) 10 g The ingredients are mixed evenly and one part of batter powder is mixed with two parts of water to get the required consistency. Preparation Cold Blanching Dip the fillets in 3% brine solution containing 0.1% citric acid for 3-5 minutes depending upon the size grade and then drain off. Pre-dusting The fillets are then pre-dusted with a suitable pre-dust or dry batter mix itself. The excess pre-dust adhered to the substrate is then removed either by shaking or using an air blower. Battering An adhesive type, quick setting batter is usually used. The pre-dusted fillets are then coated with this batter. The excess batter is then removed using a blower. Breading The batter coated fillets are further uniformly coated with breadcrumbs (Fig.6.9) medium size porous crumbs having a relatively large granulation. Pre-frying Fillets are flash fried in hot vegetable oil for 20-30 seconds depending on the size grade of the fillets. The temperature of frying is maintained at 180-200°C. 8 Whole Fish and Freezing Shell Fish Based The fillets are cooled using a fan and then frozen in an IQF freezer preferably a spiral freezer for the required time depending on the size of the fillets. Packaging The frozen coated fillets are immediately packed in thermoformed containers or pouches made of 12µ plain polyester laminated with 118µ LDPE. A specified number of such consumer packs are then packed in master cartons. Storage The packed cartons of frozen coated fillets are stored in a cold storage maintained at -20°C. Fig. 6.9: Breading fish fillet (manual) 6.2.2 Coated Fish Fingers/Fish Portions/Fish Sticks Fish fingers (Fig. 6.10 and 6.11)) are regular sized portions cut from rectangular frozen blocks of fish fillet or fish mince. Blocks are convenient to store, ship and handle. A normal size fish block in commercial practice in Europe is 47.9 cm long, 25.4 cm wide x 6 cm thick weighing 7.5 kg. On the production line, the blocks are subdivided by a series of band saws and subsequently cut into the desired width and shape. Fish fingers are made into different shapes such as rectangular, square, wedge and french cuts. For small-scale units frozen slabs of 1.5 cm thick may be convenient for cutting out fish fingers of uniform size. A typical British fish finger normally weighs about 28 g (1 oz) of which up to 50% of the total weight is contributed by the batter and crumbs. Accordingly, a rectangular piece of 7.5x2.0x1.5 cm weighing about 15 g may give a final weight of 28 g. Food Advisory Committee of the U.K. Government recommends a minimum fish content of 55% for battered and 60% for the fingers coated with breadcrumbs. The frozen fish block is prepared by mixing fish fillet/mince with 0.6% sodium tripolyphosphate and 1% sodium chloride, placing in a frame of convenient size, pressing slightly and frozen to form a solid block of fixed dimension. The frozen 9 Types of Products block is cut into suitable uniform sizes. These pieces are given a coating of pre- dust, batter and breading. The battered and breaded fish fingers are flash fried in oil at 180-200°C for 30 seconds. After cooling, the fingers are frozen preferably in an IQF machine. The frozen fish fingers are packed in thermoformed trays or pouches and stored at20°C. Commercial and retail distribution is in frozen state. Fig. 6.10: Fish finger Fig. 6.11: Coated fish products in consumer pack The fish fingers when fried in vegetable oil develop a golden brown color with attractive appearance and odour. It has been observed that the sensory quality of fish finger developed from the frozen block of fish fillets is superior to that developed from the block of mince.
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