Frozen Fish Vacuum Packaging for Albumin Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing processes for packaging cooked fish in solid form result in the release of albumins during heat sterilization, leading to a pasty/lumpy appearance and poor consistency, along with invasive treatments and inefficient production lines.
Innovation Solution
A process involving vacuum packing of frozen fish portions in flexible multilayer packaging, followed by heat sterilization in an autoclave, which minimizes albumin release and preserves muscle integrity by maintaining the fish in a frozen state until sterilization, reducing chemical reactions and maintaining the fish's natural texture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If fish portions are thawed and precooked before packaging to remove albumins, then albumin release during sterilization is reduced, but the production process becomes more complex and time-consuming
Solution Approach 1:
The patent applies preliminary action by freezing the fish portions before packaging. This pre-freezing step prepares the fish in a state that minimizes albumin release during subsequent sterilization, eliminating the need for separate precooking and albumin removal steps. The frozen state is maintained throughout packaging and storage, and only during the final sterilization step does the fish thaw and cook, at which point minimal albumin is released.
2Speed
If fish portions are thawed in water before packaging, then the thawing process is quick, but the fish loses integrity and muscle bundles are damaged
Solution Approach 1:
The patent applies preliminary action by maintaining the fish in a frozen state throughout the packaging process. Instead of thawing the fish before packaging, the frozen portions are directly vacuum-packed and then sterilized. This eliminates the need for preliminary thawing entirely, preserving muscle integrity while still achieving rapid processing through the frozen-state packaging approach.
3Reliability
If fish portions are packaged in rigid metallic containers with filling liquid, then the packaging is robust, but the production line requires more space and time
Solution Approach 1:
The patent applies flexible shells and thin films by using flexible vacuum-packaging materials instead of rigid metallic containers. The flexible packaging allows for compact arrangement on the production line and in storage, reducing the space required. The vacuum sealing provides adequate protection and robustness for the product, eliminating the need for rigid containers while improving production efficiency and reducing packaging volume.
4Reliability
If heat sterilization is performed on packaged fish, then the product achieves commercial sterility and extended shelf life, but substantial albumin is released during the process
Solution Approach 1:
The patent applies parameter changes by maintaining the fish in a frozen state during packaging and storage, and by controlling the sterilization process to heat the frozen portions directly. This parameter change (maintaining frozen state) fundamentally alters the behavior of the fish tissue during sterilization, minimizing albumin release while still achieving commercial sterility. The frozen state acts as a protective parameter that reduces protein denaturation and albumin extraction during the heat treatment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process achieves a commercially sterile, ready-to-use product with minimal albumin presence, improved consistency, and well-defined muscle bundles, while optimizing production line efficiency and extending shelf life.
Implementation Method 1
performing a vacuum (130) inside the packaging filled in with one or more portions of fish in the solid form in the frozen state
Implementation Method 2
heat sterilized in an autoclave, according to known methods, which substantially comprise heating to temperatures around 110°-120°C and maintaining such a temperature for about one hour
Implementation Method 3
maintaining the fish in a frozen state until sterilization, reducing chemical reactions and maintaining the fish's natural texture
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A process for packing products based on portions of fish in the solid form comprises at least the step of introducing (120) one or more portions of raw fish in the solid form in the frozen state into an at least partially flexible packaging; the step of performing mechanical vacuum (130) inside the packaging filled in with one or more portions of fish in the solid form in the frozen state; the step of sealing (140) the package to form a sealed package comprising one or more portions of fish in the solid form still in the frozen state; the heat sterilization step (150) in an autoclave of the sealed package comprising one or more portions of fish in the solid form still in the frozen state, in which the portions of fish remain in the frozen state for all the packing process until the start up of the sterilization step (150), said sterilization step carrying out the cooking of the portions of fish in the solid form still in the frozen state. A package of one or more portions of fish in the solid form (10), cooked during heat sterilization in an autoclave, comprises the portions of fish in the solid form (10) vacuum contained in an at least partially flexible packaging, such portions of fish in the solid form (10) having muscle bundles (12) substantially intact and separable to each other.