surimi, manufacturing, alaska pollock, market, freezing

1. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 1
Jadilah perubahan,
jika ingin melihat dunia
adanya…….
Bambang Riyanto 1
CARILAH ILMU PENGETAHUAN
AGAR BISA MENEBAR PEMIKIRAN
MANUFACTURING OF SURIMI
Harvest to Frozen Block
Oleh :
Bambang Riyanto
Bambang Riyanto 2

2. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 2
CAPAIAN PEMBELAJARAN DAN
KARAKTER YANG DIKEMBANGKAN
Kognitif : Mampu menjelaskan sains dan teknologi (K)
ekstraksi, konsentrasi serta pengembangan produk
pengolahan berbasis daging ikan lumat (minced
fish) atau surimi
Afektif : Mampu bekerjasama dan mengembangan
konsep dan kreativitas (A) dalam pembuatan
produk baru yang potensial untuk dikomersialkan
dan memberi sumbangan dalam penciptaan
kedaulatan pangan protein ikani.
Psikomotorik : Mampu mempraktekkan dan mengaplikasikan (P)
produk bernilai tambah hasil perairan dalam
pembuatan produk baru yang potensial untuk
dikomersialkan dan memberi sumbangan dalam
penciptaan kedaulatan pangan protein ikani.
Bambang Riyanto 3
• TUTORIAL DAN DISKUSI
• COLLABORATIVE LEARNING (CBL)
• PROJECT BASED LEARNING (PJBL)
MODEL PROYEK : KOOPERATIF DAN KOLABORATIF
GAGASAN KELOMPOK PENGEMBANGAN PRODUK
STRATEGI/METODE PEMBELAJARAN
Bambang Riyanto 4

3. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 3
ASSESSMENT
KOMPETENSI/KEMAMPUAN DIRI KOGNITIF
PERFORMANCE ASSESMENT/ASESMEN KINERJA
1. UJIAN TENGAH SEMESTER
2. QUIS
Bambang Riyanto 5
ASSESSMENT
KOMPETENSI/KEMAMPUAN DIRI AFEKTIF
DISKUSI DAN PEMBUATAN RESUME
(RUBRIC-DESKRIPTIF DAN HOLISTIK)
Bambang Riyanto 6

4. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 4
DISKUSI DAN PEMBUATAN RESUME DISKUSI
1. Kualitas surimi sangat tergantung dari bahan baku ikan. Bagaimana
faktor biologi (spesies, musim, kematangan seksual, dan kesegaran)
berperanan dalam penentuan kualitas surimi tersebut.
2. Kualitas surimi juga sangat tergantung dari berbagai faktor
pengolahan, Bagaimana faktor-faktor seperti cara penangkapan,
penanganan (handling), kualitas air untuk pencucian surimi, time-
temperature of processing, teknik pencucian (jumlah pencucian dan
rasio), salinitas dan pH, yang sangat berpengaruh terhadap kualitas
surimi yang dihasilkan.
3. Teknologi surimi berkembang sejalan dengan dikembangkannya
cryoprotectant, sehingga dapat dilakukan penyimpanan dengan
waktu yang relatif lebih lama. Saat ini juga dikembangkan
dryoprotectant.
4. Teknologi pengolahan surimi telah menuntut pula akan efisiensi produksi
dan profitabilitas. Apa yang dapat dikembangkan melalui teknologi
pembekuan (freezing technology), neural network, automation, digital
image analysis, waste water treatment.
Bambang Riyanto 7
PENILAIAN AUTENTIK (RUBRIK DESKRIPTIF) (85%)
Bambang Riyanto 8

5. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 5
LINGKARI SALAH SATU PILIHAN
NILAI DIMENSI
KONTRIBUSI PADA HASIL TUGAS DAN TUGAS YANG DIBERIKAN
5 A. Sangat Berkontribusi
3 B. Berkontribusi sama dan adil
2 C. Hanya memberi kontribusi yang ada
KEPEMIMPINAN
5 A. Inisiatif dan terlihat memberikan perhatian yang besar dalam
menyelesaikan tujuan bersama
3 B. Bertanggungjawab pada tujuan dan menerima pembagian yang
adil
2 C. Kurang memberikan perhatian dan tidak sesuai dengan arah
tujuan
KERJASAMA
5 A. Menghargai pendapat orang lain dan sangat berkontribusi dalam
diskusi kelompok
3 B. Menghargai pendapat orang lain dan berkontribusi dalam diskusi
kelompok
2 C. Tidak berkontribusi pada diskusi kelompok atau sering gagal
berpartisipasi
NILAI TOTAL
!
PENILAIAN UNTUK SESAMA ANGGOTA TIM (15%)
Bambang Riyanto 9
ASSESSMENT
KOMPETENSI/KEMAMPUAN DIRI PSIKOMOTORIK
1. PRAKTIKUM
2. MODEL PROYEK : KOOPERATIF DAN KOLABORATIF
GAGASAN KELOMPOK PENGEMBANGAN PRODUK
Bambang Riyanto 10

6. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 6
KOMPETENSI DASAR
Bambang Riyanto 11
SECTION I
SURIMI AND FISH PROTEINS
• Historical Review of Surimi Technology and
Market Developments
• Surimi Resources and Market
• Manufacture of Surimi : Harvest to
Frozen Block
• Surimi Gelation Chemistry
• Proteolytic Enzymes and Control in Surimi
• Fish Protein Isolate by pH Shift
• Stabilization of Proteins in Surimi
INDEX
Bambang Riyanto 12

7. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 7
SECTION II
SURIMI SEAFOOD PRODUCTS
• Comminution Process for Surimi and Surimi
Seafood Paste
• Manufacture of Crabsticks
• Manufacture of Kamaboko, Chikuwa,
Tempura, and Hanpen
• Manufacture of Fish Balls
• Manufacture of Fish Sausage
INDEX
Bambang Riyanto 13
SECTION III
QUALITY ASSESSMENT/CONTROL,
DEVELOPMENT, AND NUTRITION
• Waste Management, Utilization, and Challenges
• Food-Grade Coproducts from Surimi Processing
• Sanitation and HACCP
• Microbiology and Pasteurization
• Surimi Paste Preparation, Gel Analysis, and
Rheology
• Ingredient Technology for Surimi and Surimi
Seafood.
• Color Measurement and Colorants for Surimi
Seafood.
• Surimi Seafood Flavors
• Application of Sensory Science to Surimi
Seafood .
• Research and Product Development.
• Nutrition and Health Benefits of Surimi Seafood
INDEX
Bambang Riyanto 14

8. THP 333 Diversifikasi dan
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Kuliah Ke-1b 8
Bambang Riyanto 15
PUSTAKA
Jae W Park. 2014. Surimi and Surimi Seafood 3th.
CRC Press Taylor & Francis Group. Boca Raton
INTRODUCTION
RAW MATERIALS
• Fresh
• Frozen
• Tropical Fish
• Fresh Water Fish: Tilapia, Catfish, Carp, Rohu
• Biological (Intrinsic) Factors Affecting Surimi Quality
(effect of species, seasonality/sexual maturity, freshness or rigor)
• Processing (Extrinsic) Factors Affecting Surimi Quality
(harvesting, on-board handling)
PROCESSING TECHNOLOGY AND SEQUENCE
• Heading, Gutting, and Cutting
• Mincing (Deboning)
• Washing and Dewatering.
• Refining
• Screw Press
• Stabilizing Surimi with Cryoprotectants
• Freezing
• Metal Detection
FRESH SURIMI
FISH PROTEIN ISOLATE
SURIMI POWDER (DRY SURIMI)
MATERI
PERKULIAHAN
Bambang Riyanto 16

9. THP 333 Diversifikasi dan
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Kuliah Ke-1b 9
INTRODUCTION
Bambang Riyanto 17
INDUSTRI DAGING LUMAT (MINCED FISH)
Bambang Riyanto 18

10. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 10
Bambang Riyanto 19
Bambang Riyanto 20

11. THP 333 Diversifikasi dan
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Kuliah Ke-1b 11
PROCESSING TECHNOLOGY
• Heading, Gutting, and Cutting
• Mincing (Deboning)
• Washing and Dewatering.
• Refining
• Screw Press
• Stabilizing Surimi with Cryoprotectants
• Freezing
• Metal Detection
Bambang Riyanto 21
Bambang Riyanto 22
PRODUCT DESCRIPTION
Aquatic Product Raw Material:
Pacific whiting ( Merluccius spp. );
Pollock ( Theragra chalcogramma )
Raw material harvest Area: Off Oregon coast
Raw material received: Directly from harvester
Finished Product: Frozen surimi
Food additives, ingredients,
processing aids:
Sorbitol, sugar, polyphosphate, protease inhibitor,
water
Shipping: Shipped in the firm's refrigerated trucks
Intended use:
Raw material for fully-cooked imitation seafood
products
Intended consumers: General public

12. THP 333 Diversifikasi dan
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Kuliah Ke-1b 12
Bambang Riyanto 23
FLOW DIAGRAM
Receiving Receiving Raw fish received at dock; ingredients received at loading platform
| |
Refrigerated storage Dry storage Refrigerated storage at or below 40°F; dry storage at ambient temperature
| |
Heading | Mechanical heading equipment
| |
Gutting | Mechanical gutting equipment
| |
Filleting | Mechanical filleting equipment
| |
Deboning | Mechanical deboning equipment
| |
Mincing | Mechanical mincing equipment
| |
Wash | Wash tanks
| |
Dewater | Dewatering screens
| |
Wash | Wash tanks
| |
Dewater | Dewatering screens
| |
Mix | Mixing bin
| |
Refine | Refiner
| |
Dehydrate | Screw dehydrator
| |
Blend <– <–––– Blender
|
Form Former
|
Freeze Freezer
|
Package Packing table
|
Frozen Storage Freezer
|
Ship Ship in firm's trucks
Bambang Riyanto 24

13. THP 333 Diversifikasi dan
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Kuliah Ke-1b 13
BAHAN BAKU
Bambang Riyanto 25
BENTUK IKAN SEGAR
Bambang Riyanto 26

14. THP 333 Diversifikasi dan
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Kuliah Ke-1b 14
BENTUK IKAN BEKU
Bambang Riyanto 27
BENTUK IKAN SEGAR-KECIL (TROPICAL FISH)
Bambang Riyanto 28

15. THP 333 Diversifikasi dan
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Bambang Riyanto 29
Scanning Electron Micrographs of
Fish Muscle Tissue
After 21 Days of Storage
IKAN
BERLEMAK
Bambang Riyanto 30

16. THP 333 Diversifikasi dan
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Kuliah Ke-1b 16
Changes in the gel strength of surimi gel prepared from horse mackerel cubed mince by
(a)(b)(c) flotation washing with different gas or (d) cold water washing
Contoh Peningkatan Gel Surimi
dengan Berbagai Teknik Pencucian untuk Ikan Berlemak
Bambang Riyanto 31
FRESH WATER FISH:
TILAPIA, CATFISH, CARP, AND ROHU
Rohu (Labeo rohita)Common carp (Cyprinus carpio)
Clarias gariepinusPark JW, RW Korhonen, TC Lanier. 1990. Effects of rigor
mortis on gel-forming properties of surimi and unwashed
mince prepared from tilapia. J Food Sci 55:353–355, 360
Bambang Riyanto 32

17. THP 333 Diversifikasi dan
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Kuliah Ke-1b 17
Bambang Riyanto 33
BIOLOGICAL (INTRINSIC) FACTORS AFFECTING
SURIMI QUALITY
• Effect of Species
• Effects of Seasonality/Sexual Maturity
• Effects of Freshness or Rigor
Bambang Riyanto 34

18. THP 333 Diversifikasi dan
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Fish meat easily
developing
“suwari”
Fish meat showing
“suwari” moderate degree
Fish meat showing
slight “suwari”
Fish meat having
strong “ashi”
p Lizard fish
p Flying fish
p Jack mackerel
p A kind of croaker
p Flat fish
p Shark
p Blue marlin
Fish meat having
medium “ashi”
p Cutlass fish
p Barracuda
p Alaska Pollock
p Puffer fish
p Argentina senufascuate
p Strorptoothed eel
p Dolphin fish
p Shark skin flounder
Fish meat having
weak “ashi”
p Sardine
p Round herring
p Saury p Bonito
p Mackerel
p Yellow fin tuna
FAKTOR SPECIES
Bambang Riyanto 35
Jack mackerel
Bambang Riyanto 36

19. THP 333 Diversifikasi dan
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Kuliah Ke-1b 19
Bambang Riyanto 37
Bambang Riyanto 38

20. THP 333 Diversifikasi dan
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Kuliah Ke-1b 20
EFFECT OF SPECIES
LINGKUNGAN PERAIRAN
DENGAN
FISIOLOGI IKAN
Bambang Riyanto 39
Bambang Riyanto 40

21. THP 333 Diversifikasi dan
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Kuliah Ke-1b 21
LINGKUNGAN
PERAIRAN DAN
PARASIT
PADA IKAN
Bambang Riyanto 41
Bambang Riyanto 42

22. THP 333 Diversifikasi dan
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Kuliah Ke-1b 22
Bambang Riyanto 43
EFFECTS OF SEASONALITY/SEXUAL MATURITY
Compositional Properties of Pacific Whiting from April to October
(Astoria, Oregon).
(A) Moisture Content; (B) Protein Content; (C) Fat Content.Bambang Riyanto 44

23. THP 333 Diversifikasi dan
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Kuliah Ke-1b 23
EFFECTS OF FRESHNESS OR RIGOR
Bambang Riyanto 45
PROCESSING (EXTRINSIC) FACTORS AFFECTING
SURIMI QUALITY
• Harvesting
• On-Board Handling
Bambang Riyanto 46

24. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 24
Harvesting and On Board Handling
Bambang Riyanto 47
Bambang Riyanto 48

25. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 25
PROCESSING TECHNOLOGY
AND
SEQUENCE
Bambang Riyanto 49
PROCESSING TECHNOLOGY
AND SEQUENCE
• HEADING, GUTTING, AND CUTTING
• Mincing (Deboning)
• Washing and Dewatering.
• Refining
• Screw Press
• Stabilizing Surimi with Cryoprotectants
• Freezing
• Metal Detection
Bambang Riyanto 50

26. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 26
HEADING, GUTTING,
AND
CUTTING
Bambang Riyanto 51
skinless fillets to
skin-on fillets or butterfly-shaped headed and gutted (H&G)
Bambang Riyanto 52

27. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 27
Hopper Elevator
VMK
50/52/58/60
Automatic
Feeder
VMK 31/32/33
Scaling
VMK
26/27/28
Deheading
Nobbing
VMK 16/20
Format sizes
F30/F45/F60
F75/F90
Sex
Sorting
Round fish
Head
measuring
system
Deheading
Vision-System
1 operator up to
6 machines
Fish
Counter
M130
Belly
Gutting
M63
Vacuum
Unit
CUP 752
Tail
Cutting
Filleting
Machine
VMK 11
Piece
Cutting
M50
Belly-Cut
Cleaning
M24
Roe & Milk
Sorting
Belly
opening/
cleaning
Paralell
knives
Butterfly
fillet device
Single fillet
Device
M9
Skinning
VMK 42
VMK 440
Titbit
Machine
VMK 470
Arenco AB
Datavägen 57 B, SE- 436 32 Askim
Sweden
Phone: +46 31 748 03 18
Fax: +46 31 748 03 10
Web: www.arenco.com
Manual-, semiautomatic and up to 6
machines with only 1 operator.
Processing machines for different
types of pelagic fish.
Sprats - Anchovy - Sardines - Herring - Mackerel - Horse Mackerel - Sardinella
Blue Whiting and many more.
VMK
Standard
Machines
VMK
Standard
Equipment
VMK
Extra
Equipment
Bambang Riyanto 53
Bambang Riyanto 54

28. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 28
Bambang Riyanto 55
Bambang Riyanto 56

29. THP 333 Diversifikasi dan
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57
HEADING,
GUTTING,
AND
CUTTING
Bambang Riyanto
Bambang Riyanto 58

30. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 30
Bambang Riyanto 59
Bambang Riyanto 60

31. THP 333 Diversifikasi dan
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Kuliah Ke-1b 31
Bambang Riyanto 61
62
HEADING,
GUTTING,
AND
CUTTING
Bambang Riyanto

32. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 32
Bambang Riyanto 63
Bambang Riyanto 64

33. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 33
Bambang Riyanto 65
Bambang Riyanto 66

34. THP 333 Diversifikasi dan
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Kuliah Ke-1b 34
During the gutting and
filleting steps,
water nozzles, along with
a plastic bristle wheel
brush,
are used to separate the
undesirable parts from
the fillets of the fish.
Bambang Riyanto 67
Bambang Riyanto 68

35. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 35
PROCESSING TECHNOLOGY
AND SEQUENCE
• Heading, Gutting, and Cutting
• MINCING (DEBONING)
• Washing and Dewatering.
• Refining
• Screw Press
• Stabilizing Surimi with Cryoprotectants
• Freezing
• Metal Detection
Bambang Riyanto 69
MINCING (DEBONING)
Bambang Riyanto 70

36. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 36
Bambang Riyanto 71
72
Mincing
MINCING
(DEBONING)
Bambang Riyanto

37. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 37
73
Mincing
MINCING
(DEBONING)
Bambang Riyanto
Mincing
ROLLER-TYPE MEAT SEPARATOR
MINCING
(DEBONING)
Bambang Riyanto 74

38. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 38
Bambang Riyanto 75
Bambang Riyanto 76

39. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 39
Bambang Riyanto 77
78
Mincing
ROLLER-TYPE MEAT SEPARATOR
medium orifice size of 3–4 mm
MINCING
(DEBONING)
Bambang Riyanto

40. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 40
Bambang Riyanto 79
Bambang Riyanto 80

41. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 41
Bambang Riyanto 81
Bambang Riyanto 82

42. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 42
Bambang Riyanto 83
Bambang Riyanto 84

43. THP 333 Diversifikasi dan
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Kuliah Ke-1b 43
Bambang Riyanto 85
PROCESSING TECHNOLOGY
AND SEQUENCE
• Heading, Gutting, and Cutting
• Mincing (Deboning)
• WASHING AND DEWATERING
• Refining
• Screw Press
• Stabilizing Surimi with Cryoprotectants
• Freezing
• Metal Detection
Bambang Riyanto 86

44. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 44
WASHING AND DEWATERING
Bambang Riyanto 87
88
WASHING
AND
DEWATERING
Bambang Riyanto

45. THP 333 Diversifikasi dan
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Bambang Riyanto 89
TARGET :
• Maximum gelling or formation of a three-
dimensional gel structure (get a myofibrillar
proteins, remove blood, myoglobin, fat, and
sarcoplasmic proteins)
• Colorless and odorless surimi
Mixing minced meat with cold water (5 oC) and
removing water by screening and dehydrator to
about 5-10% solid.
WASHING
AND
DEWATERING
Bambang Riyanto 90

46. THP 333 Diversifikasi dan
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Kuliah Ke-1b 46
91
WASHING CYCLE
• Varies with fish species, freshness of fish, type of
washing unit, and the desired quality of the surimi
• Repeated Two or Three times.
• The water/mince ratio = 5:1 – 10:1
29.1 kg of waste was = 1 kg surimi
(TM Lin and JW Park. 1995. Study of myofibrillar protein
solubility during surimi processing : effects of washing cycles
and ionic strength. Presented at the PFT annual meeting,
Mexico).
WASHING
AND
DEWATERING
Bambang Riyanto
An effective washing process for primary grade surimi
processes can now be accomplished with
• two washing cycles at water meat ratios of less than 2:1
• with typical wash ratios of 0.9–1.2 parts water in the first
wash and
• 0.7–0.8 in a second wash.
In comparison,
at-sea processors can achieve the same washing effect with
less water than
shore-based processors due to the difference in fish
freshness.
WASHING
AND
DEWATERING
Bambang Riyanto 92

47. THP 333 Diversifikasi dan
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Kuliah Ke-1b 47
WATER
Bambang Riyanto 93
Ø Residue Chlorine
Ø Temperature
5 oC or less
Ø Hardness or Mineral Content
Soft water with minimum levels of mineral (Ca++, Mg++,
Fe++, Mn++)
* Ca++ and Mg++, are responsible for the texture change.
* Fe++, Mn++ are responsible for the color change.
Ø pH and Salinity
* pH : 6.8 – 7.0
* Salinity
NaCl and/or CaCl2 at 0.1 - 0.3 % in the final wash water
Bambang Riyanto 94

48. THP 333 Diversifikasi dan
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Kuliah Ke-1b 48
Time/Temperature of Processing
Degradation of myosin heavy chain and actin of Pacific whiting
at various postharvest storage conditions.
M, myosin heavy chain; A, actin.
Numbers followed by M or A indicate storage temperatures.
Bambang Riyanto 95
96
WASHING CYCLE AND WASH WATER RATIO
Target :
* Texture, Color and Odor
* Remove Sarcoplasmic proteins, blood, fat, and other nitrogenous
compounds
* Rising utility costs
* Limited water sources
* Pollution problems
Method
* Onshore processors
Water/meat = 4:1 to 8:1
Cycle = 3 X - 4X
* Sea processors
Water/meat = 1:1 to 3:1
Cycle = 1 X - 2X
* General
Water/meat = 3:1 to 24 :1
~ 50% of total proteins were lost
TM Lin, JW Park. 1997. Effective washing conditions reduce water usage for
surimi processing. J. Aquatic Food Product Tech 6 (2) : 65-79
* Water/Meat Ratio = 2:1
* Wash Time = 10 min
* Wash Cycle = 4 X
Bambang Riyanto

49. THP 333 Diversifikasi dan
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Kuliah Ke-1b 49
TM Lin, JW Park. 1997. Effective
washing conditions reduce water
usage for surimi processing. J.
Aquatic Food Product Tech 6
(2) : 65-79
* Water/Meat Ratio = 2:1
* Wash Time = 10 min
* Wash Cycle = 4 X
Bambang Riyanto 97
Bambang Riyanto 98

50. THP 333 Diversifikasi dan
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Kuliah Ke-1b 50
pH and Salinity
Electrophoretic patterns of proteins soluble in water (0%, 0.5%, 2.0% NaCl).
S, High-molecular-weight standard;
lane 1, first washing step (WS) of the first washing cycle (WC);
lanes 2–3, the first and second WS of the second WC, respectively;
lanes 4–6, the first, second, and third WS of the third WC, respectively;
lanes 7–10, the first, second, third, and fourth WS of the four WC, respectively.
MHC, Myosin heavy chain; ATN, actin;
b-TPM/TNT:
b-tropomyosin/troponin-T;
a-TPM, a-tropomyosin.
Bambang Riyanto 99
Bambang Riyanto 100

51. THP 333 Diversifikasi dan
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Kuliah Ke-1b 51
Leaching
or
Washing
WASHING
AND
DEWATERING
flotation washing
Bambang Riyanto 101
Rotary screens are traditionally used to remove free water from the
washed meat.
These are long horizontal drums made of perforated mesh screens
that rotate at set speeds. In virtually all cases, meat is pumped to
the interior of the rotating screen and water falls through the screens
where it is collected and either discharged or reprocessed. Surimi
operators will arrange screens along the length of the rotary screen
to optimize water removal, meat retention, and production speed.
The operator has several tools to manage meat flow through the
screens. Some of the primary controls are the screens themselves,
which vary in perforation size, typically from 0.3 to 0.8 mm in
diameter, the pitch, or distance from hole center to center, and the
speed at which the unit rotates.
In some cases, the screen arrangement will vary depending on the
species being processed.
Operators need to pay close attention to rotary screens to ensure
the screens do not “blind” of “foul,” meaning small meat particles
settle in the holes, resulting in significantly reduced function of the
screens.
Other technologies exist for water removal, such as
hydro sieves, or wedge-wire screens that use static screens to
accomplish water removal.
WASHING
AND
DEWATERING
Bambang Riyanto 102

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Bambang Riyanto 107
PROCESSING TECHNOLOGY
AND SEQUENCE
• Heading, Gutting, and Cutting
• Mincing (Deboning)
• Washing and Dewatering.
• REFINING
• Screw Press
• Stabilizing Surimi with Cryoprotectants
• Freezing
• Metal Detection
Bambang Riyanto 108

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REFINING
Bambang Riyanto 109
Before the final dewatering process in
a screw press or decanter, impurities,
such as
• skin,
• pin bones,
• scales, and
• connective tissues,
are removed by the refiner.
The proximate composition of refiner
discharge of Pacific whiting was 81.4%
moisture, 1.9% lipid, 15.4% protein, and
1.0% ash.
They also found the majority of protein
was stroma proteins derived from
connective tissue.
This clearly indicates the purpose of the
refining process is to separate
connective tissues from washed mince
(Kim and Park 2005)
Perforation : 0.5 – 1.2 mm
Bambang Riyanto 110

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Bambang Riyanto 111
Conventionally, all manufacturers used a Fukoku
refiner until the recent introduction of the Brown refiner
(Covina, CA).
According to US industry experts, the Brown refiner is
designed as a more user-friendly structure in cleaning
and adjusting the paddle height.
The Brown refiner system also offers models with
paddles, which is used in the decanter surimi
production process as well as typical drum systems with
blades attached that are used for the traditional surimi
process. One key advantage to the Brown refiner is the
size of the drum and the use of more veins and
paddles in the process. By using more paddles, the unit
is able to separate connective tissue and proteins
easier, thus resulting in lower temperatures in the
process.
Bambang Riyanto 112

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Bambang Riyanto 113
REFINING
Bambang Riyanto 114

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Bambang Riyanto 115
Brown refiner (Covina, CA).
Bambang Riyanto 116

59. THP 333 Diversifikasi dan
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Kuliah Ke-1b 59
PROCESSING TECHNOLOGIES THAT ENHANCE
EFFICIENCY AND PROFITABILITY
• Neural Network
• PROCESSING AUTOMATION: ON-LINE SENSORS
• Digital Image Analysis for Impurity Measurement
• Innovative Technologies for Wastewater
• Fresh Surimi
Bambang Riyanto 117
Bambang Riyanto 118
ON-LINE SENSORS

60. THP 333 Diversifikasi dan
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Kuliah Ke-1b 60
Bambang Riyanto 119
PROCESSING TECHNOLOGY
AND SEQUENCE
• Heading, Gutting, and Cutting
• Mincing (Deboning)
• Washing and Dewatering.
• Refining
• SCREW PRESS
• Stabilizing Surimi with Cryoprotectants
• Freezing
• Metal Detection
Bambang Riyanto 120

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SCREW PRESS
Bambang Riyanto 121
The screw press is a compression machine with a 2:1
fixed compression ratio: two parts in, one part out.
The desired moisture content out of the screw press is
82% moisture or 18% solids. This results in, with the
addition of 9.3 parts dry cryoprotectant additives
(typical for Alaska pollock and Pacific whiting) to 100
parts meat, a finished surimi moisture content of 75%
(82%/1.093)
(M. Burns, personal communication, 2012).
Bambang Riyanto 122

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SCREW
PRESS
Bambang Riyanto 123
Bambang Riyanto 124

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Bambang Riyanto 126

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Bambang Riyanto 128

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Bambang Riyanto 129
Bambang Riyanto 130

66. THP 333 Diversifikasi dan
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Kuliah Ke-1b 66
PROCESSING TECHNOLOGIES THAT ENHANCE
EFFICIENCY AND PROFITABILITY
• Freezing Technology (Freezing Capacity and
Freezing Time)
• Neural Network
• Processing Automation: On-line Sensors
• Digital Image Analysis For Impurity Measurement
• INNOVATIVE TECHNOLOGIES FOR WASTEWATER
• Fresh Surimi
Bambang Riyanto 131
WATER RECYCLE WITH COUNTERCURRENT WASHING
1st
Wash DEWATER
2nd
Wash
DEWATERDEWATER
3rd
Wash
SURIMI
FRESH WATER
WASTE DISCHARGE
Bambang Riyanto 132

67. THP 333 Diversifikasi dan
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Kuliah Ke-1b 67
PROCESSING TECHNOLOGY
AND SEQUENCE
• Heading, Gutting, and Cutting
• Mincing (Deboning)
• Washing and Dewatering.
• Refining
• Screw Press
• STABILIZING SURIMI WITH
CRYOPROTECTANTS
• Freezing
• Metal Detection
Bambang Riyanto 133
STABILIZING SURIMI
WITH CRYOPROTECTANTS
Bambang Riyanto 134

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The addition of cryoprotectants is
important to ensure maximum functionality of frozen
surimi because freezing induces protein denaturation
and aggregation.
Bambang Riyanto 135
Bambang Riyanto 136
Moisture : 82-85 %
Mixture wit salt (NaCl and CaCl2) : 0.1 – 0.3 %
Streaming
(Stabilizing
With
Cryoprotectants)
STABILIZING
WITH
CRYOPROTECTANTS

69. THP 333 Diversifikasi dan
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137
Dewatering
STABILIZING
WITH
CRYOPROTECTANTS
Bambang Riyanto
138
Ø Target :
Ensure maximum functionality of frozen surimi (prevent to
protein denaturation and aggregation during freezing and
storaging)
Ø 10 Kg block surimi
* Sucrore and sorbitol = ~ 9% w/w to dewatered fish meat
* Sodium tripolyphosphate and tetrasodium pyrophosphate
= 0.2-0.3 % (1:1)
is commonly used as both a chelating agent, which inactivates metal ions
in surimi, and as a pH adjusting agent. The shifting of the pH to 7.0 also
helps to increase transglutaminase activity, which is inherent in the fish,
thereby improving gel values.
Ø Kneader and Silent Cutter : 2.5 min
temperature 10 oC.
STABILIZING
WITH
CRYOPROTECTANTS
Bambang Riyanto

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Commercial practices for mixing cryoprotectants
(100 kg approximately) using a kneader and a
silent cutter are 6 min and 2-½ min, respectively.
Inline blending systems reduce the time to 10–12 s.
The temperature of the mix must not exceed 10°C
because at temperatures greater than 10°C
protein functionality could be damaged,
particularly for cold water species.
Bambang Riyanto 139
KNEADER MACHINES
Bambang Riyanto 140

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TARGET
Since 1991, with commercial surimi processing of Pacific whiting
- Cryoprotectants
- Gel enhancers
- Color enhancers
Enzyme inhibitor :
- Beef plasma protein
- Egg white
- Whey protein concentrates
- Potato extracts
Enzyme inhibitors are commonly formulated with
sucrose, sorbitol, sodium tripolyphosphate, tetrasodium
pyrophosphate, calcium carriers (calcium lactate, calcium sulfate,
calcium citrate, or calcium caseinate), sodium bicarbonate,
mono- or diglyceride, and partially hydrogenated canola oil
Bambang Riyanto 141
Bambang Riyanto 142

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As a verification step to determine whether cryoprotectants
are homogeneously mixed, pH and degrees Brix (°Bx) are
measured using surimi after thawing.
• 0.3% sodium tripolyphosphate or a mixture (50:50) of sodium
tripolyphosphate and tetrasodium pyrophosphate is used
and mixed homogeneously,
• pH of surimi should range between 7.2 ± 0.2.
• Brix 5.6–5.7 should be a target when 4% sugar + 5% sorbitol
are added to the measure whether cryoprotectants were
homogeneously mixed in the surimi. Sugar and/or sorbitol
concentration in an extracted surimi sample solution can be
calculated using sugar (%) = 2.04 × oBrix – 2.98,
(One degree Brix is 1 g of sucrose (sugar) in 100 g of
solution and represents the strength of the solution as a
percentage by weight (% w/w). If the solution contains
dissolved solids other than pure sucrose (like fish proteins),
then the °Brix only approximates the dissolved solid content.
To remove fish proteins from the properly diluted sample
solution, 2% trichloroacetic acid solution is added)
Bambang Riyanto 143
CRYOPROTECTANTS
• Sugar (sorbitol)
• Amino acids
• Polyls
• Methyl amines
• Carbohydrate polymers
• Synthetic polymers (Polyethylene glycol, PEG)
• Other proteins (Bovine serum albumine, BSA)
• Organic salt ((potassium phosphate, ammonium sulfate)
Bambang Riyanto 144

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Bambang Riyanto 145
• Lactitol ® (4-O-(b-D-galactopyranosyl)-D-glucitol)
It is a sweet tasting sugar alcohol derived from lactose by reduction of the
glucose moiety of the disaccharide, and is a value-added product from
lactose in whey, a by-product from cheese making.
Lactitol is 0.3±0.4 times as sweet as sucrose, and its nutritional caloric
utilization is half that of carbohydrates, with a maximum metabolic energy
value of 2 kcal/g.
• Palatinit ®
• Polydextrose ®
Litesse ® is a modified form of Polydextrose ®, a highly branched
polysaccharide which is prepared from dextrose, sorbitol and citric acid
Litesse ® is not sweet and is less bitter, astringent and acidic than
polydextrose, and therefore, in most food systems Litesse ® will not require
neutralization. The calorie utilization of Litesse ® is 1 kcal/g, which is 25%
that of carbohydrates
• Glycerol,
• Glucose syrup,
• Starch hydrolysate products
• Linear oligosaccharides
Bambang Riyanto 146
MECHANISMS FOR
CRYOPROTECTION AND CRYOSTABILIZATION
A. Solute Exclusion
B. Ligand Binding
C. Antioxidants
D. Freezing-Point Depression
E. Cryostabilization by High Molecular Weight Additives
F. Vitrification

74. THP 333 Diversifikasi dan
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Kuliah Ke-1b 74
Bambang Riyanto 147
Freezing of surimi is done commercially by incorporation of
sucrose (4%), sorbitol (4%) and polyphosphates (0.2%) which
protect fish myofibrillar proteins during long periods of frozen
storage
(Lee, C. 1984. Surimi process technology. Food Technology 38,
69-80.)
One disadvantage of the commercial cryoprotectant blend used
is the high level of sucrose and sorbitol which impart a sweet taste
that may be undesirable to the Western consumer in particular.
Yoon and Lee (1990) showed that 4% sucrose plus 4% sorbitol in
crystalline or liquid form in red hake (Urophycis chuss) surimi when
given as extruded gel products to a sensory panel were judged to
be slightly too sweet.
(Yoon, K. S. and Lee, C. M. 1990. Cryoprotectant efects in surimi
and surimi/mince-based extruded products. Journal of Food
Science 55, 1210-1216.
In addition, today's consumer is conscious of caloric content, and
low calorie cryoprotectants in surimi may be preferred.
GENERAL INGREDIENT
• White Fish Meats
• Water
• Starch
• Protein Additives
* Whey Proteins
* Egg White Proteins
* Beef Plasma Proteins
* Soy Proteins
* Wheat Gluten and Wheat Flour
• Hydrocolloids
* Carrageenan
* Konjac
* Alginate
* Chitosan
• Cellulose
• Vegetable Oil
• Food Grade Chemical Compounds
* Oxidizing Agents
* Calcium Compounds
* Transglutaminase
* Phosphate
* Coloring Agents
Bambang Riyanto 148

75. THP 333 Diversifikasi dan
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Kuliah Ke-1b 75
PROCESSING TECHNOLOGY
AND SEQUENCE
• Heading, Gutting, and Cutting
• Mincing (Deboning)
• Washing and Dewatering.
• Refining
• Screw Press
• Stabilizing Surimi with Cryoprotectants
• FREEZING
• Metal Detection
Bambang Riyanto 149
FREEZING
Bambang Riyanto 150

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In commercial applications,
Surimi is formed in a standard 10 kg block extruded
into a plastic bag (3–7 mil), which is placed into a
stainless steel or aluminum tray for freezing. The latter
offers better heat transfer, but the former is better for
longevity.
Trays are then placed in a contact plate freezer and
held for approximately 2–2.5 h or until the core
temperature reaches –25°C.
Proper loading of trays and plate freezers is critical as
the poly bags may become embedded in the surimi.
Bambang Riyanto 151
152
FREEZING
Bambang Riyanto

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FREEZING RATE OF THREE DIFFERENT FREEZING METHODS FOR SURIMI
Bambang Riyanto 153
Microstructure of surimi gels from four species
prepared from fresh and frozen fish
Note :
(A) Croaker;
(B) Lizardfish;
(C) Threadfin bream;
(D) Bigeye snapper.
FREEZING
Bambang Riyanto 154

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Bambang Riyanto 155
Bambang Riyanto 156

79. THP 333 Diversifikasi dan
Pengembangan Produk Perikanan/
Kuliah Ke-1b 79
PROCESSING TECHNOLOGIES THAT
ENHANCE EFFICIENCY AND
PROFITABILITY
• FREEZING TECHNOLOGY (FREEZING CAPACITY
AND FREEZING TIME)
• Neural Network
• Processing Automation: On-Line Sensors
• Digital Image Analysis for Impurity Measurement
• Innovative Technologies for Wastewater
• Fresh Surimi
Bambang Riyanto 157
Bambang Riyanto 158

80. THP 333 Diversifikasi dan
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Kuliah Ke-1b 80
Frozen Mincemeat of Fish
(SURIMI)
Bambang Riyanto 159
PROCESSING TECHNOLOGY
AND SEQUENCE
• Heading, Gutting, and Cutting
• Mincing (Deboning)
• Washing and Dewatering.
• Refining
• Screw Press
• Stabilizing Surimi with Cryoprotectants
• Freezing
• METAL DETECTION
Bambang Riyanto 160

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METAL DETECTION
Bambang Riyanto 161
162
METAL
DETECTION
Bambang Riyanto

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• FDA’s Health Hazard Evaluation Board has
supported regulatory action against products with
metal fragments of 7–25 mm in length
• The most common types of metallic contamination
include :
ferrous,
copper,
aluminum,
lead, and
various types of stainless steel.
Of these, ferrous metal is the easiest to detect.
The following factors also affect the sensitivity of metal
detection:
• shape of metal,
• orientation of metal,
• aperture dimension,
• position of metal in the aperture,
• environmental conditions,
• condition of the product (frozen vs. chilled),
• operation frequency, and throughput speed .Bambang Riyanto 163
Bambang Riyanto 164
NUTRIENT
Water : 76%
Protein : 15%
Fat : 0.9%
Carbohydrate : 6.85%
Cholesterol : 0.03%

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Bambang Riyanto 165
CHEMICAL SCORES FOR ESSENTIAL AMINO ACIDS IN
SURIMI, BEEF, PORK, CHICKEN AND TURKEY
Source :
Holmes, K., ed. (1987) $urimi - It's American Now, pp. V4-V6, Alaska
Fisheries Development Foundation
Bambang Riyanto 166

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Kuliah Ke-1b 84
FRESH SURIMI
Bambang Riyanto 167
Comparison of fresh and frozen surimi based on textural values of gels.
Both frozen and fresh surimi samples were from the same batch and
evaluated based on the equal moisture contents (75%).
FZ = frozen surimi; FS = fresh surimi. Numbers followed by FZ or FS
indicate percent surimi content used in surimi seafood gels.
Bambang Riyanto 168

85. THP 333 Diversifikasi dan
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Kuliah Ke-1b 85
Bambang Riyanto 169
BENEFITS OF FRESH SURIMI VS FROZEN
SURIMI
Pipatsattayanuwong et al.
* Lower cost (additives and freezing are not necessary)
* No sugar products and also increase the market value
* Better gel functionality and can be used at a reduced
level
Park and Pipatsattayanuwong
* The use of fresh surimi over commercial frozen surimi
could contribute $0.172/kg of finished products to
users
* When 50% of frozen and fresh surimi was used in surimi
seafood, significantly higher stress (by 25%) and higher
strain values (5%).
42.2% fresh surimi is as good as 50% frozen surimi.
Bambang Riyanto 170

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171
CONTINUOUS PROCESSING
Bambang Riyanto
FISH PROTEIN ISOLATE
Bambang Riyanto 172

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Bambang Riyanto 173
Electron microscopic image of
surimi gels prepared by using
different conditions
(magnification: 10,000, EHT: 10 kV).
• Con: conventional method
• Acid: acid-aided process
• Alk: alkaline-aided process
Bambang Riyanto 174

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Bambang Riyanto 175
Bambang Riyanto 176

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Bambang Riyanto 177
SURIMI POWDER/DRY SURIMI
Bambang Riyanto 178

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Bambang Riyanto 179
Bambang Riyanto 180

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TERIMA KASIH
Bambang Riyanto 181