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01b surimi manufacturing

This document provides an overview of a lecture on surimi and minced fish products. It discusses the raw materials used including various fresh and frozen fish species. It covers the key processing steps to produce surimi from harvest to frozen block, including heading, gutting, mincing, washing, dewatering, refining, adding cryoprotectants, and freezing. It also discusses factors that affect the quality of surimi such as biological factors related to the fish species, season, and freshness, as well as processing factors during harvesting and handling. Diagrams illustrate the processing flow and examples of different fish species and forms used for surimi production.

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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
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
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
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
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
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
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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 9 INTRODUCTION Bambang Riyanto 17 INDUSTRI DAGING LUMAT (MINCED FISH) Bambang Riyanto 18
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 10 Bambang Riyanto 19 Bambang Riyanto 20
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 13 BAHAN BAKU Bambang Riyanto 25 BENTUK IKAN SEGAR Bambang Riyanto 26
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 14 BENTUK IKAN BEKU Bambang Riyanto 27 BENTUK IKAN SEGAR-KECIL (TROPICAL FISH) Bambang Riyanto 28
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 15 Bambang Riyanto 29 Scanning Electron Micrographs of Fish Muscle Tissue After 21 Days of Storage IKAN BERLEMAK Bambang Riyanto 30
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 18 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 19 Bambang Riyanto 37 Bambang Riyanto 38
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 20 EFFECT OF SPECIES LINGKUNGAN PERAIRAN DENGAN FISIOLOGI IKAN Bambang Riyanto 39 Bambang Riyanto 40
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 21 LINGKUNGAN PERAIRAN DAN PARASIT PADA IKAN Bambang Riyanto 41 Bambang Riyanto 42
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 24 Harvesting and On Board Handling Bambang Riyanto 47 Bambang Riyanto 48
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
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
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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 28 Bambang Riyanto 55 Bambang Riyanto 56
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 29 57 HEADING, GUTTING, AND CUTTING Bambang Riyanto Bambang Riyanto 58
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 30 Bambang Riyanto 59 Bambang Riyanto 60
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 31 Bambang Riyanto 61 62 HEADING, GUTTING, AND CUTTING Bambang Riyanto
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 32 Bambang Riyanto 63 Bambang Riyanto 64
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 33 Bambang Riyanto 65 Bambang Riyanto 66
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 36 Bambang Riyanto 71 72 Mincing MINCING (DEBONING) Bambang Riyanto
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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 38 Bambang Riyanto 75 Bambang Riyanto 76
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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 40 Bambang Riyanto 79 Bambang Riyanto 80
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 41 Bambang Riyanto 81 Bambang Riyanto 82
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 42 Bambang Riyanto 83 Bambang Riyanto 84
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 44 WASHING AND DEWATERING Bambang Riyanto 87 88 WASHING AND DEWATERING Bambang Riyanto
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 45 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 52 Bambang Riyanto 103 Bambang Riyanto 104
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 53 Bambang Riyanto 105 Bambang Riyanto 106
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 54 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 55 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 56 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 57 Bambang Riyanto 113 REFINING Bambang Riyanto 114
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 58 Bambang Riyanto 115 Brown refiner (Covina, CA). Bambang Riyanto 116
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 61 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 62 SCREW PRESS Bambang Riyanto 123 Bambang Riyanto 124
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 63 Bambang Riyanto 125 Bambang Riyanto 126
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 64 Bambang Riyanto 127 Bambang Riyanto 128
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 65 Bambang Riyanto 129 Bambang Riyanto 130
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 68 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 69 137 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 70 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 71 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 72 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 73 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 76 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 77 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 78 Bambang Riyanto 155 Bambang Riyanto 156
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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 81 METAL DETECTION Bambang Riyanto 161 162 METAL DETECTION Bambang Riyanto
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 82 •  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%
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 83 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 86 171 CONTINUOUS PROCESSING Bambang Riyanto FISH PROTEIN ISOLATE Bambang Riyanto 172
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 87 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
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 88 Bambang Riyanto 175 Bambang Riyanto 176
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 89 Bambang Riyanto 177 SURIMI POWDER/DRY SURIMI Bambang Riyanto 178
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 90 Bambang Riyanto 179 Bambang Riyanto 180
THP 333 Diversifikasi dan Pengembangan Produk Perikanan/ Kuliah Ke-1b 91 TERIMA KASIH Bambang Riyanto 181

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01b surimi manufacturing

  • 1.
    THP 333 Diversifikasidan 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 Diversifikasidan 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 Diversifikasidan 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 Diversifikasidan 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 Diversifikasidan 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 Diversifikasidan 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 Diversifikasidan 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 Diversifikasidan Pengembangan Produk Perikanan/ 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 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 9 INTRODUCTION Bambang Riyanto 17 INDUSTRI DAGING LUMAT (MINCED FISH) Bambang Riyanto 18
  • 10.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 10 Bambang Riyanto 19 Bambang Riyanto 20
  • 11.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ 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 Diversifikasidan Pengembangan Produk Perikanan/ 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 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 13 BAHAN BAKU Bambang Riyanto 25 BENTUK IKAN SEGAR Bambang Riyanto 26
  • 14.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 14 BENTUK IKAN BEKU Bambang Riyanto 27 BENTUK IKAN SEGAR-KECIL (TROPICAL FISH) Bambang Riyanto 28
  • 15.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 15 Bambang Riyanto 29 Scanning Electron Micrographs of Fish Muscle Tissue After 21 Days of Storage IKAN BERLEMAK Bambang Riyanto 30
  • 16.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ 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 Diversifikasidan Pengembangan Produk Perikanan/ 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 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 18 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 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 19 Bambang Riyanto 37 Bambang Riyanto 38
  • 20.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 20 EFFECT OF SPECIES LINGKUNGAN PERAIRAN DENGAN FISIOLOGI IKAN Bambang Riyanto 39 Bambang Riyanto 40
  • 21.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 21 LINGKUNGAN PERAIRAN DAN PARASIT PADA IKAN Bambang Riyanto 41 Bambang Riyanto 42
  • 22.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ 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 Diversifikasidan Pengembangan Produk Perikanan/ 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 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 24 Harvesting and On Board Handling Bambang Riyanto 47 Bambang Riyanto 48
  • 25.
    THP 333 Diversifikasidan 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 Diversifikasidan 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 Diversifikasidan 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 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 28 Bambang Riyanto 55 Bambang Riyanto 56
  • 29.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 29 57 HEADING, GUTTING, AND CUTTING Bambang Riyanto Bambang Riyanto 58
  • 30.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 30 Bambang Riyanto 59 Bambang Riyanto 60
  • 31.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 31 Bambang Riyanto 61 62 HEADING, GUTTING, AND CUTTING Bambang Riyanto
  • 32.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 32 Bambang Riyanto 63 Bambang Riyanto 64
  • 33.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 33 Bambang Riyanto 65 Bambang Riyanto 66
  • 34.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ 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 Diversifikasidan 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 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 36 Bambang Riyanto 71 72 Mincing MINCING (DEBONING) Bambang Riyanto
  • 37.
    THP 333 Diversifikasidan 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 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 38 Bambang Riyanto 75 Bambang Riyanto 76
  • 39.
    THP 333 Diversifikasidan 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 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 40 Bambang Riyanto 79 Bambang Riyanto 80
  • 41.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 41 Bambang Riyanto 81 Bambang Riyanto 82
  • 42.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 42 Bambang Riyanto 83 Bambang Riyanto 84
  • 43.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ 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 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 44 WASHING AND DEWATERING Bambang Riyanto 87 88 WASHING AND DEWATERING Bambang Riyanto
  • 45.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 45 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 Diversifikasidan Pengembangan Produk Perikanan/ 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 Diversifikasidan Pengembangan Produk Perikanan/ 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 Diversifikasidan Pengembangan Produk Perikanan/ 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 Diversifikasidan Pengembangan Produk Perikanan/ 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 Diversifikasidan Pengembangan Produk Perikanan/ 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 Diversifikasidan Pengembangan Produk Perikanan/ 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
  • 52.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 52 Bambang Riyanto 103 Bambang Riyanto 104
  • 53.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 53 Bambang Riyanto 105 Bambang Riyanto 106
  • 54.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 54 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
  • 55.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 55 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
  • 56.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 56 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
  • 57.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 57 Bambang Riyanto 113 REFINING Bambang Riyanto 114
  • 58.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 58 Bambang Riyanto 115 Brown refiner (Covina, CA). Bambang Riyanto 116
  • 59.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ 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 Diversifikasidan Pengembangan Produk Perikanan/ 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
  • 61.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 61 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
  • 62.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 62 SCREW PRESS Bambang Riyanto 123 Bambang Riyanto 124
  • 63.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 63 Bambang Riyanto 125 Bambang Riyanto 126
  • 64.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 64 Bambang Riyanto 127 Bambang Riyanto 128
  • 65.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 65 Bambang Riyanto 129 Bambang Riyanto 130
  • 66.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ 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 Diversifikasidan Pengembangan Produk Perikanan/ 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
  • 68.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 68 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 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 69 137 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
  • 70.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 70 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
  • 71.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 71 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
  • 72.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 72 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
  • 73.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 73 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 Diversifikasidan Pengembangan Produk Perikanan/ 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 Diversifikasidan Pengembangan Produk Perikanan/ 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
  • 76.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 76 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
  • 77.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 77 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
  • 78.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 78 Bambang Riyanto 155 Bambang Riyanto 156
  • 79.
    THP 333 Diversifikasidan 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 Diversifikasidan Pengembangan Produk Perikanan/ 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
  • 81.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 81 METAL DETECTION Bambang Riyanto 161 162 METAL DETECTION Bambang Riyanto
  • 82.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 82 •  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%
  • 83.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 83 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
  • 84.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ 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 Diversifikasidan Pengembangan Produk Perikanan/ 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
  • 86.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 86 171 CONTINUOUS PROCESSING Bambang Riyanto FISH PROTEIN ISOLATE Bambang Riyanto 172
  • 87.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 87 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
  • 88.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 88 Bambang Riyanto 175 Bambang Riyanto 176
  • 89.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 89 Bambang Riyanto 177 SURIMI POWDER/DRY SURIMI Bambang Riyanto 178
  • 90.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 90 Bambang Riyanto 179 Bambang Riyanto 180
  • 91.
    THP 333 Diversifikasidan Pengembangan Produk Perikanan/ Kuliah Ke-1b 91 TERIMA KASIH Bambang Riyanto 181