SRAC Publication No. 184

August 2001 VI PR Revised

Processed Catfish Product Forms, Packaging, Yields and Product Mix

Juan L. Silva1,2 and Stuart Dean 2

The channel catfish (Ictalurus live-hauling to replenish other fee- punctatus) industry in the United fishing ponds. As the live-haul States has gone through tremen- market reached a saturation point dous growth during its 35-year in the late 1960s and early 1970s, history. Total water surface established producers moved into acreage for catfish production has processing. In 1998, more than 90 Nuggets Shank fillet increased from about 56,000 acres percent of production was mar- in 1980 to more than 198,000 acres keted through commercial proces- in 2000. The catfish processing sors. More than 297 million industry has also grown dramati- pounds of processed catfish were cally to keep up with rapid consumed in 2000 through vari- changes in supply and demand. ous markets, for a per capita con- Round weight (live weight of fish sumption of more than 1.07 delivered for processing) pounds. Total revenue to proces- processed in 1980 in the U.S. was sors was almost $708 million. Strips/fingers approximately 46.5 million Catfish is now the fourth most pounds. By 2000, this number had popular seafood product in the increased to about 594 million U.S., excluding shrimp. pounds, a 13-fold increase in 20 years. Producer sales (farm value) Product forms for food-size catfish totaled almost $446 million for 2000, at an aver- A traditional product form is the Steaks age price of 75 cents per pound. whole dressed fish. This is a cat- fish that has been deheaded, evis- Initially, catfish processing was cerated, and skinned (headed, developed to help alleviate prob- gutted and skinned, or HGS) with lems associated with overproduc- the tail left intact. The dressed fish tion of farm-raised channel cat- is also further processed into a fish. In the 1960s, most of the variety of cuts or forms, including water acreage was used to pro- (Fig. 1): duce catfish for fee-fishing and for fillets (with belly flap) Dressed/Whole 1Department of Food Science and shank fillets (boneless fillet Figure 1. Product forms for both Technology, Mississippi State University with the belly flap or nugget fresh and frozen farm-raised catfish. 2Food and Fiber Center, Mississippi State removed) University strips/fingers or fillet strips pet foods. It is an advantage to ing to product form and customer (boneless finger-size pieces cut the industry to be able to sell its requirements; however, basic net from shank fillets) solid waste rather than having to weights are 10, 15, 20 and 30 nuggets (belly flap section dispose of it. In addition, a low pounds. The boxed trays are then removed from fillet) temperature enzyme process to placed on pallets and moved into produce hydrolysates from offal a blast freezer for a short period steaks has been studied. of time to achieve the crust freeze. breaded fillets and nuggets They are then held in the cooler heat-set, breaded fillets, por- Packaging for shipment. This form of pack- tions and nuggets aging is more often done now at Catfish products are sold by the point of sale. marinated fillets processors to institutional and retail markets. Most products are Frozen product forms may be smoked (fillets and dressed packaged and delivered fresh (ice- individually quick frozen (IQF) fish) packed), chill-packed, or individu- after injection (or tumbling) with All these forms are marketed ally quick frozen (IQF). phosphates. This is done with spi- fresh and/or frozen. Processors ral or tunnel (cryogenic) freezers The fresh product is packaged in a also sell round-eviscerated catfish or with a blast freeze process. variety of ways to meet specifica- with the head still attached. Most large processors use the IQF tions of the customers. For exam- process. Products sold frozen Specialty products made their ple, whole dressed fish, shank fil- include whole dressed fish, fillets, way into the marketplace in the lets, fillets, steaks, strips and nuggets, strips, steaks and formed late 1980s. Whole dressed catfish nuggets may be packaged in poly- products. and fillets, coated or marinated ethylene on ice in a wax-coated, with flavors and spices such as corrugated box. Fish, especially Breaded products, such as whole lemon-butter, cajun and mesquite, whole dressed fish, may be placed dressed fish, fillets, strips, nuggets can be found in the seafood sec- directly on ice and then covered and formed products, are also tions of many grocery stores. In with ice. When customers request sold frozen. The individually the 1990s, products such as heat- ice pack, the fresh product is frozen products are placed in set, breaded nuggets, strips and placed in wax-coated, corrugated polybags and packed in corrugat- fillets were introduced. Catfish boxes. Drainage holes at the bot- ed boxes with net weights usually gumbo and related products were tom of the side are optional. Dry of 10 and 15 pounds. In some also introduced. Smoked, dressed pack boxes do not have drainage cases, the frozen product is placed fish and fillets have become pop- holes. Depending on the product loose in the corrugated box and ular, although sales are still small form, net weight in the boxes may later packaged in styrofoam trays because of safety hazards associ- be 10, 15, 20 or 30 pounds. for retail outlets. Breaded and ated with these products. However, each box is often pack- other specialty products may also Preformed products such as pat- aged with 1 pound of product per be packaged in 2.5-pound poly- ties and compacted products pound of ice. If the product is bags and 5-pound polybags and (trimmings formed into fillets or going to be placed in a retail pack- placed in 20-pound and 40-pound nuggets) may become popular as age at grocery stores, label inserts master cartons, respectively. These technology is developed. Other are also included in the corrugat- polybagged products are popular products which have been tested ed boxes. with frozen food retail outlets and but are not readily available are food service institutions. Sealed, The chill pack process consists of catfish “corn dog,” sausage, tuna- printed polybags containing lowering the temperature of the and salmon-style canned, sardine- breaded products ranging from 2 product to between 25 and 30 oF style canned, surimi and mince, to 4 pounds are purchased by to form a crust-freezing effect. nuggets with mince formed into wholesale outlets for consumers. Products such as whole dressed patties, salted fillets, catfish roe, Breaded products are also sold, as fish, fillets (including marinated and others. Some by-products are other fish products, in printed fillets), nuggets and strips are also have been used in making cartons in the retail freezer case. often packaged and shipped chill- nonfood items (gelatin, belts, packed and then sold through Another further processed catfish etc.). retail outlets as fresh fish. This item is the enrobed product. This Offal, the by-product of catfish process extends shelf-life and pro- process consists of coating a prod- processing, also should be consid- tects the fish until it is thawed. uct, especially fillets, with a sea- ered when discussing catfish The product is packaged in styro- soning and oil-base mixture and product forms. Offal is sent to foam trays, with soaker pads on then individually freezing it. The rendering plants for further pro- the bottom, and covered with a enrobed fillets are then packed in cessing into fish meal and fish oil polyethylene or PVC film. Trays clear plastic trays that contain (ingredients used in animal feed), are then placed in corrugated individual compartments to keep or it is ground, cooled (or frozen), boxes without ice and stored or the products from touching. Trays and then sold to pet food compa- shipped in cold-storage form. Net are usually packed according to nies as an ingredient for canned weights of the boxes vary accord- fillet size, such as 4, 5 or 7 ounces, and are then placed in a polybag feed regularly when water tem- processor’s cost per pound of in a corrugated box. Normally, peratures are low. Fish harvested marketable product increases there are five trays with a total of in the summer yield higher unless accordingly. This factor, along 20 fillets to the box; however, this fed immediately prior to harvest; with the marketing strategy of the may vary according to the proces- feed in the visceral cavity causes processor and current consumer sor. yield losses. As a fish grows, the demands (the major factor), helps head to body ratio decreases, to determine the product mix for Yields and product mix yielding a higher proportion of individual processors. dressed fish and fillets. A break- Volumes given in the example in The yield from catfish processing down of approximate yields and Figure 2 are based on 10,000 is determined, to a large extent, by product mix of various catfish pounds of live fish converted to the product forms to which the product forms based on the con- several product forms. A live fish processor is keying his marketing version of 10,000 pounds of live dressing yield of 62 percent is strategy. Harvest season and fish catfish to processed products is assumed. As further processing size influence yield also. Fish har- shown in Figure 2. Further pro- occurs, a whole dressed fish is vested in the winter may have cessing of catfish results in lower assumed to yield 70 percent fillets lower yields because fish do not yields and more waste, so the

Live fish 100,000 lbs. Total salable product = 53,010 pounds or 53 percent 38% 62% Total waste = 46,990 pounds or 47 percent

Offal waste Dressed fish 38,000 lbs. 62,000 lbs.

50% 50%

Marketed whole Further processed 31,000 lbs. 31,000 lbs. 5% 95%

For steaks For filleting 1,550 lbs. 29,450 lbs.

10% 90% 30% 70%

Waste Steaks 155 lbs. 1,395 lbs. Waste Fillets 8,835 lbs. 20,615 lbs.

80% 20%

Shank fillets Fillet (w/nugget) 16,492 lbs. 4,123 lbs.

20% 80%

Nuggets Shank fillets 3,298 lbs. 13,194 lbs.

Figure 2. Catfish processing input-output chart illustrating a hypothetical product mix. or 90 percent steaks. Fifty percent increased to 61 percent. In recent References of the whole dressed fish is fur- years, sales of whole catfish have ther processed into fillets, steaks been declining, from 46 percent of Aquaculture Outlook and Situation. and nuggets. Of this amount, 5 total sales in 1986 to 19 percent in National Economics Division, percent is converted to steaks and 2000. On the other hand, sales Economics and Statistics Service, the remaining 95 percent to fillets. have increased for value-added U.S. Department of Agriculture. The amount of fillets can further products such as breaded pieces April 1981. Washington, D.C. be broken down, with 20 percent and nuggets. Aquaculture Outlook. Economic remaining as fillets and 80 per- Research Service, U.S. cent being further processed into Consumption increases Department of Agriculture. nuggets and shank fillets. October 1999. Washington, D.C. Per capita consumption of catfish Thus, from an input of 10,000 products has increased signifi- “Catfish Processing.” National pounds of live fish, a total of cantly over the last decade from Agricultural Statistics Service, 5,301 pounds, or 53 percent of the 0.41 pounds in 1985 to 1.07 Agricultural Statistics Board, U.S. live weight, is converted into sal- pounds in 1999, partly because of Department of Agriculture. able product. The catfish compo- intensive marketing efforts within Washington, D.C. nents of further processed items, the industry. But rapid changes in (http://usda.mainlib.cornell.edu/) such as breaded, marinated, and consumption patterns and an “Catfish Production.” National enrobed product forms, are apparent desire for new and Agricultural Statistics Service, included in the percentages exciting food products have been Agricultural Statistics Board, U.S. throughout the diagram. equally important. This is evi- Department of Agriculture. Sales volume for fresh and frozen denced by the introduction of Washington, D.C. whole dressed fish, fillets and more than 10,000 new food prod- (http://usda.mainlib.cornell.edu/) ucts each year. The catfish indus- other catfish products sold in “Top 10 Seafood and Fish try has recognized these trends 2000 is shown in Table 1. For Products.” Annual Per Capita and has introduced value-added many years, sales of fresh prod- Consumption Report for Seafood products to keep abreast of con- ucts exceeded frozen. In 1985, a Products for 1998, National sumer demands. Some of these turning point in the industry Fisheries Institute. Washington, products (commercial or occurred when the majority of D.C. sales came from frozen products. researched) are gumbo, sausage, In 1987, frozen products repre- corn dog, portion controlled and Silva, J. L. and Ammerman, G. R. sented 52 percent of sales by com- others. Food service/institutional 1993. Composition, lipid changes mercial processors. In 2000, this sales are rising, so product devel- and sensory evaluation of two opment for this industry is criti- sizes of channel catfish during cal for growth. frozen storage. Journal of Applied Aquaculture 2(2):39-49.

Table 1. Sales volume of various product forms sold by U.S. catfish processors in 2000. % Ice pack Frozen Ice pack1 Frozen1 Total sales1 of total % of total % of total Whole dressed2 41,392 13,798 55,190 19 75 25 Fillet3 58,529 119,649 178,178 60 33 67 Other4 16,813 46,975 63,788 21 26 74 Total 116,734 180,422 297,156 100 39 61 Figures are based on data from the USDA, Agricultural Statistics Board “Catfish” 2000 publications. http://usda.mannlib.cornell.edu/ 1Thousand pounds 2Head, viscera and skin removed 3Includes fillets, shank and strip fillets; excludes any breaded product 4Includes all products not already reported, including weight of breading and added ingredients

This publication was supported in part by USDA-CSREES Grant No. 98-38500-5865 from the United States Department of Agriculture, Southern Regional Aquaculture Center. This publication is an update of SRAC Publication No. 184 by the MSU Food and Fiber Center.