Restructured Tuna Product Using Broth Concentrate and Phosphates
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Solution Overview
Problem
The overexploitation of tuna and other high-value marine species has led to a shortage, resulting in prohibitively high prices and a need for value-added tuna products with superior organoleptic characteristics that are more digestible and appealing than natural tuna.
Innovation Solution
A method involving the production of a restructured tuna product using a boiled fish broth concentrate, mixed with frozen raw tuna, phosphates, and vegetable oils, which is then processed into a homogeneous gruel and combined with boiled fish flakes, enhancing texture and flavor while maintaining nutritional quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If natural tuna is used as the product, then the product has authentic fish flavor and nutritional value, but the product has strong flavor on the palate and is less digestible
Solution Approach 1:
The patent applies parameter changes by modifying the physical and chemical properties of tuna through controlled boiling, concentration, and mixing processes. The tuna is boiled to extract juices, concentrated to enhance flavor, and mixed with phosphates and vegetable oils to improve texture and digestibility while maintaining authentic flavor characteristics.
Solution Approach 2:
The patent creates a composite product by combining tuna meat with phosphates, vegetable oils, and concentrated juices. This composite approach enhances the organoleptic properties of tuna, improving its texture, flavor, and digestibility while preserving the authentic fish character through the careful integration of multiple components.
2Ease of operation
If tuna is processed into value-added products, then the product becomes more digestible and appealing, but the production process becomes more complex
Solution Approach 1:
The patent segments the tuna processing into distinct stages: boiling to extract juices, concentrating the juices, mixing with phosphates and vegetable oils, and final product formation. This segmentation allows each step to be optimized independently, improving digestibility while managing process complexity through systematic breakdown of the manufacturing workflow.
3Duration of action of stationary object
If frozen fish is used to produce fish blocks, then the product can be stored and transported, but the product lacks superior organoleptic characteristics
Solution Approach 1:
The patent transforms frozen fish into a processed product with superior organoleptic characteristics by applying controlled thermal treatment, concentration, and mixing processes. These parameter changes enhance flavor, texture, and digestibility while maintaining the ability to store and transport the product in frozen or processed states.
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 method produces a more appealing, digestible, and nutritious tuna product with enhanced organoleptic qualities, suitable for packaged dishes and canned salads, addressing the scarcity and palatability issues of natural tuna.
Implementation Method 1
mixed with frozen raw tuna, phosphates, and vegetable oils, which is then processed into a homogeneous gruel
Implementation Method 2
production of a restructured product consisting of fish meat or muscle, especially tuna muscle
Implementation Method 3
The method produces a more appealing, digestible, and nutritious tuna product with enhanced organoleptic qualities
Data Source
Figure 1
AI summary
Frozen raw fish is introduced into a vacuum cutter where it is mixed with boiled fish broth concentrate, for the purpose of forming a homogeneous paste of frozen raw fish that is kneaded and flaked. In the same cutter it is mixed with food additives, such as phosphates, which act as emulsifiers, and with water in the form of ice, until a homogeneous gruel is obtained. This gruel is mixed with flakes and/or pieces of previously boiled fish. At this stage, two different presentations are possible, whereby it can either be dosed into traditional cans by means of a stuffer and sterilisation following the normal process for manufacturing fish and shellfish preserves, or frozen in moulds with the help of plate cabinets and subsequently subjected to suitable cutting and packing processes with a final sterilising treatment for the preservation thereof.