Method for processing young sardines and processed young sardines

Abstract

To provide a method for processing young sardines, capable of preventing loss of palate feeling and flavor and deterioration of quality.SOLUTION: The method for processing the young sardines comprises a step of removing foreign matter from the received young sardines, a step of loosening the young sardines after the foreign matter is removed, an IQF freezing step of freezing the loosened young sardines at a temperature of -30°C or lower or a temperature of -30°C or lower in a machine, a step of packing the IQF-frozen young sardines, a step of processing the packed young sardines, and a step of shipping the processed young sardines.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a method for processing whitebait and processed whitebait. [Background technology]

[0002] Figure 3 shows the conventional processing method and distribution of whitebait.

[0003] As shown in the diagram, whitebait is delivered to consumers via primary processors, final processors, and retailers. Here, "whitebait" refers to dried whitebait and boiled whitebait (boiled baby sardines). At each stage, the following processing takes place:

[0004] (1) Production and processing of whitebait by primary processors in the production area Fishermen catch fish, which are the raw ingredients, and processors in the production area boil them in a pot as whitebait. Whitebait is mainly processed by boiling in the production area. Depending on the transportation method, transportation time, shipping policy, etc., whitebait is transported to the final processor via "frozen logistics" or "chilled logistics." In frozen logistics, whitebait is frozen at -18°C or below for long-term storage. In chilled logistics, whitebait is stored at a temperature of around 0°C to 10°C (or -5°C to +5°C) to maintain freshness and be shipped in a short period of time.

[0005] (2) Processing by final processor When whitebait arrives at the processing plant, it is processed to remove foreign matter and be sorted. Any foreign matter (seaweed, small fish, etc.) mixed in with the whitebait is removed by hand or machine, and the whitebait is sorted by size and quality.

[0006] The selected whitebait is packed (processed into packages) or bulk packed depending on the form in which it will be sold to consumers.

[0007] The packed whitebait is slowly frozen (-18°C to -20°C). That is, it is frozen at -18°C to -20°C in a storage freezer. The freezing time is 24 hours or more, and the whitebait is frozen into blocks.

[0008] Frozen shirasu is stored frozen (-18℃ to -20℃) before being shipped. In other words, frozen shirasu is stored in a freezer at -18℃ to -20℃ and then shipped to retailers.

[0009] (3) Sales by Distributors Retailers sell whitebait to consumers. They may sell it after thawing or in a frozen state. Traditionally, frozen whitebait took 12 to 24 hours to thaw. Consumers purchase either thawed or frozen whitebait.

[0010] Regarding the processing of such small fish, the following Patent Document 1 discloses a method for processing small fish with improved shelf life, and a technique for small fish with improved shelf life. [Prior art documents] [Patent documents]

[0011] [Patent Document 1] Japanese Patent Application Laid-Open No. 2010-246498 Summary of the Invention [Problem to be solved by the invention]

[0012] When the above-mentioned retailers or consumers thaw whitebait, 10-20% drips due to slow freezing, resulting in issues such as loss of weight, texture, flavor, and quality. Furthermore, because the whitebait is frozen in blocks, partial thawing is not possible, resulting in losses due to thawing blocks.

[0013] The present invention aims to solve at least one of these problems. [Means for solving the problem]

[0014] In order to achieve the above-mentioned object, according to one aspect of the present invention, a method for processing whitebait that processes whitebait delivered to a processing plant from a primary processor, the whitebait being delivered via frozen or chilled logistics, comprises the steps of removing foreign matter from the delivered whitebait, breaking up the whitebait from which the foreign matter has been removed and then IQF-freezing it in a flash freezer set to a temperature of -30°C or below, or with an internal temperature of -30°C or below, packing the IQF-frozen whitebait, storing the packed whitebait in a frozen state, and shipping the frozen-stored whitebait.

[0015] The processed whitebait is processed by the above-mentioned method for processing whitebait. [Brief explanation of the drawings]

[0016] [Figure 1] FIG. 1 is a diagram showing a method for processing and distributing whitebait in one embodiment of the present invention. [Figure 2] This is a diagram that explains in detail the process from the arrival process at the processing factory in Figure 1 to shipping. [Figure 3] FIG. 1 is a diagram showing a conventional method for processing and distributing whitebait. DETAILED DESCRIPTION OF THE INVENTION

[0017] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0018] Figure 1 is a diagram showing a processing and distribution method for whitebait according to one embodiment of the present invention. The main differences between the embodiment of the present invention and conventional processing and distribution methods are as follows.

[0019] Traditionally, whitebait has been slowly frozen into blocks after boiling or after removing and sorting foreign matter. As shown in Figure 1, the method of this embodiment uses an individual quick freezing technique called IQF (loose). This technique involves breaking down whitebait (i.e., each individual piece is separated from the others, and each piece is individually separated) and quickly freezing them at ultra-low temperatures, significantly shortening the freezing time (approximately 10 minutes, with a range of 8 to 12 minutes being desirable). IQF stands for Individual Quick Frozen, and is a type of flash freezing method. This technique minimizes the destruction of the cell membranes within the whitebait and significantly reduces dripping during thawing. Furthermore, while whitebait could previously only be thawed in blocks, IQF allows for thawing only the amount needed, facilitating portioning and reducing waste.

[0020] Furthermore, because shirasu is small, it can be broken down by the vibrations caused by transporting it on an existing conveyor, making it highly versatile. This is because it can be broken down while being transported by a conveyor. The method of breaking it down can be a method using a conveyor (continuous method), manual breaking down, or by placing it on a tray and breaking it down (batch method).

[0021] The freezing temperature (set temperature or temperature inside the cooling chamber) in IQF is preferably in the range of -30°C to -100°C, and more preferably in the range of -70°C to -80°C.

[0022] Whitebait frozen individually using IQF freezing is packed (packed) or bulk packed for sale. It is then stored frozen. After IQF freezing, whitebait can be stored in existing general freezers, eliminating the cost of installing new low-temperature equipment. After being stored frozen, it is shipped to retailers.

[0023] Retailers can sell frozen packaged whitebait in stores after thawing, or without thawing. According to this embodiment, the thawing time is shortened to about one hour at room temperature, and there is almost no dripping (about 1%). The small amount of dripping prevents deterioration of the taste. In addition, because it is frozen in IQF (loose), it can be thawed and sold in the amount needed, and only the amount needed can be used. In restaurants and other establishments, it can be used in its frozen state, which saves time and makes handling much easier.

[0024] In addition, the quality deterioration due to thawing can be minimized, allowing consumers to be provided with high-quality shirasu.

[0025] That is, the method of this embodiment has the following advantages over conventional methods.

[0026] High quality: By reducing cell membrane destruction, freshness, flavor, and texture are improved.

[0027] Low cost: Cost reduction is possible by shortening freezing time, reducing thawing loss, and reducing equipment installation costs.

[0028] Convenience: You can defrost only the amount you need, making it more convenient to use.

[0029] FIG. 2 is a diagram explaining in detail the process from the arrival at the processing factory in FIG. 1 to the shipment.

[0030] This diagram divides some of the processes involved in the processing and distribution of shirasu into five steps, from STEP 1 to STEP 5, and illustrates the temperature control in each step, the equipment used, the state of the raw materials, and the overall process flow.

[0031] STEP 1: Removal and sorting of raw materials This process involves removing foreign matter and sorting the raw materials (whitebait) after they are received by the raw material feeder. However, this process is not essential for IQF freezing processing, and is performed as an additional step to achieve better quality products.

[0032] The ambient temperature of the raw materials is controlled at 5° C. to 10° C. The raw materials are in an unfrozen state.

[0033] The equipment and facilities used include a conveyor that transports the raw materials fed into the raw material feeder. This conveyor transports the raw materials to the next device (foreign matter removal equipment (color sorter, etc.)). In addition, foreign matter removal equipment (color sorter, etc.) is used. This is equipment that sorts and removes foreign matter other than whitebait (seaweed, small fish, etc.) by color and shape. Removal can also be done visually.

[0034] A visual inspection conveyor is used to send products from the foreign material removal equipment (such as a color sorter) to the next process. This conveyor is used to visually check and remove any foreign materials that the foreign material removal equipment was unable to remove. The visual inspection conveyor is connected to a quick freezer.

[0035] By setting the operating speed (conveying speed) of the above-mentioned transport conveyor and visual inspection conveyor faster than normal, the raw shirasu material can be broken up during transport by the conveyor, resulting in a flow rate of shirasu that is optimal for IQF (bulk) freezing.

[0036] STEP 2: IQF freezing using ultra-low temperature rapid freezing In this process, the whitebait selected in STEP 1 is IQF frozen using an ultra-low temperature quick freezer. The ambient temperature of the raw materials is kept at an ultra-low temperature of -30°C to -100°C, and the raw materials are frozen rapidly. In other words, the freezing temperature is set to -30°C or below. The equipment used is a quick freezer. This is a device for individually quick freezing (IQF) each type of whitebait. After freezing, the whitebait is transported to the next process on a transport conveyor or in temporary storage containers. The transport conveyor is connected to a filling and packaging machine.

[0037] STEP 3: Packing This is the process where IQF frozen shirasu is packed. The set temperature for this process is controlled at 5 to 10°C. The equipment used is a filling and packaging machine. This is a device that fills the shirasu into packs and packages them. Depending on the packaging format, filling may also be done manually. In addition, a transport conveyor is used to transport the packed shirasu to the next process. This transport conveyor is connected to a metal detector and weight checker.

[0038] The metal detector and weight checker are devices that inspect packed shirasu to ensure there are no metal pieces mixed in and that the weight is appropriate. Products that leave the metal detector and weight checker are sent by conveyor to the freezer storage in STEP 4.

[0039] STEP 4: Freeze storage This is the process of storing packaged shirasu in a frozen state. The product is stored at temperatures below -18°C. The frozen storage facility is a warehouse where shirasu is kept frozen.

[0040] STEP 5: Shipping This is the process of shipping frozen shirasu. The temperature must be below -18°C.

[0041] The raw materials are in an unfrozen state up to STEP 1, and in STEPs 2 to 5 they are in a frozen state.

[0042] The processing and distribution process for whitebait shown in this diagram is a system that allows for the efficient production and shipping of high-quality whitebait by controlling the temperature appropriately at each step and using specialized equipment and facilities. In particular, the ultra-low temperature quick freezing technology in STEP 2 plays an important role in maintaining the freshness and quality of the whitebait.

[0043] In step 3, packing processing, the product is packed according to the customer's request. Basically, a fixed amount of frozen shirasu is filled into a bag-shaped container or what is called a tray pack, and then the product is sealed. Filling can be done manually or with an automatic weighing and filling machine. During filling, oxygen is sometimes removed and nitrogen gas or nitrogen carbonate gas is filled in.

[0044] In this embodiment, special freezing (rapid freezing, not slow freezing as in the past) is performed, allowing for distribution within the existing general freezing temperature range. This involves rapidly passing an object through the temperature range of 0°C to -5°C, known as the "maximum ice crystal formation zone," thereby minimizing the destruction of cell membranes within the object during freezing. This, unlike general freezing (slow freezing), allows for a high-quality frozen state (close to the state before freezing). To rapidly pass through the temperature range of 0°C to -5°C, a powerful rapid freezer with a temperature range of -30°C to -100°C is used. Once the object has been rapidly frozen through the 0°C to 5°C range, the quality of the frozen state is high, so subsequent frozen storage does not necessarily require ultra-low temperatures. Storage in commonly used freezers at around -18°C to -20°C is possible.

[0045] Furthermore, according to this embodiment, the thawing time can be shortened to about one hour. The reason for this is as follows: Ordinary frozen shirasu products are frozen into blocks (mainly blocks of 1 kg to 5 kg) by slow freezing. Therefore, although they are thawed slowly using a thawing cabinet (machine) or by natural thawing, it takes about 24 hours (48 hours in winter) for the blocks to completely thaw all the way to the center.

[0046] On the other hand, the frozen shirasu in this embodiment can be thawed naturally in about 1 to 2 hours without using any special equipment such as a thawing cabinet (machine), because the surface area exposed to the outside air is large due to the fact that it is frozen in bulk.

[0047] Furthermore, in this embodiment, dripping is almost completely eliminated (dripping refers to the destruction of the cell membrane caused by the expansion of water within the cell membrane during freezing, resulting in the water leaking out during thawing). As described above, in this embodiment, unlike existing general products, the whitebait is frozen by quickly passing through the maximum ice crystal formation zone of 0°C to -5°C, so the cell membranes within the whitebait are not destroyed. As a result, no dripping due to cell membrane destruction occurs during thawing, making it possible to restore the whitebait to a quality almost equivalent to that before freezing (drip in slow-frozen products using conventional technology is approximately 10% to 20% of the original material, but dripping in this embodiment is almost completely absent to the naked eye, remaining at approximately 1% to 2%).

[0048] This not only brings economic benefits from improved dripping, but also has significance in many areas, such as preserving the deliciousness before freezing, improving ease of handling, and reducing food waste.

[0049] The quick freezer may be one that can freeze at temperatures below -30°C, and the cooling method (gas type using liquid nitrogen or liquid carbon dioxide, mechanical type, etc.) is not limited.

[0050] At least some of the multiple conveyors may be connected. A single conveyor may be divided into different functions and roles depending on its position, achieving the same functions as the multiple conveyors. The conveying speed and time of the conveyor may be adjusted to freeze the raw materials for a predetermined period of time while transporting them on the conveyor.

[0051] The above-described embodiments and modifications should be considered to be illustrative in all respects and not restrictive. The scope of the present invention is defined by the claims, not by the above description, and is intended to include all modifications within the meaning and scope of the claims.

Claims

1. A method for processing whitebait, which processes whitebait delivered to a processing plant from a primary processor, The whitebait is delivered by frozen or chilled logistics, A step of removing foreign matter from the delivered shirasu; After breaking down the shirasu from which the foreign matter has been removed, IQF freezing is performed in a flash freezer with a set temperature of -30 ° C or less or an internal temperature of -30 ° C or less; A step of packing the IQF-frozen whitebait; A step of freezing and storing the packed whitebait; and shipping the frozen and stored shirasu.

2. A processed whitebait product processed by the method for processing whitebait product according to claim 1.

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