Surimi Nut Manufacturing via Wide Strip Scarification and Rolling
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Solution Overview
Problem
Conventional surimi sticks lack variety in taste and texture, and no surimi-based product imitating a scallop nut has been marketed, limiting consumer options.
Innovation Solution
A process for manufacturing surimi-based food products in the form of pectinid nuts, such as scallop nuts, by extruding a strip of surimi with a width greater than 160 mm, scarifying, rolling, and cutting to create nuts with a diameter and texture similar to natural scallops, and optionally freezing or crusting for extended storage and flavor retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional surimi sticks are manufactured using narrow strips (1-2 mm thick), then the manufacturing process is simple and production efficiency is high, but the product lacks variety in taste and texture
Solution Approach 1:
The manufacturing process is segmented into distinct stages: extrusion of wide strip, scarification treatment, rolling formation, and cutting. This segmentation allows each step to be optimized independently, enabling complex product forms from simple base materials while maintaining manufacturing efficiency
Solution Approach 2:
The invention transitions from conventional narrow strips to wide strips (greater than 160 mm width), adding dimensional variation to the base material. This dimensional change enables the creation of scallop nut shapes and textures that cannot be achieved with traditional narrow strip configurations
2Manufacturing precision
If scarification depth is increased to achieve fibrous texture similar to natural scallops, then product authenticity is improved, but risk of strip disintegration increases
Solution Approach 1:
The scarification process parameters are precisely controlled, with depth set between 0.2-0.5 mm and spacing between 1-3 mm. These parameter optimizations create the desired fibrous texture while maintaining sufficient structural integrity of the surimi strip throughout processing
Solution Approach 2:
The surimi strip undergoes preliminary cooling and stabilization before scarification, ensuring the material is in optimal condition to withstand the mechanical treatment. This preliminary preparation prevents disintegration during the scarification process while still achieving the desired fibrous texture
3Duration of action of stationary object
If surimi nuts are subjected to freezing or crusting treatment, then storage duration is extended and flavor is retained, but additional processing steps and time are required
Solution Approach 1:
Freezing or crusting treatment is applied as a preliminary step before packaging and pasteurization. This sequencing allows the product to be prepared in advance with extended shelf life, enabling more efficient production scheduling and reduced rush processing later
Solution Approach 2:
The freezing process utilizes phase transition of water in the surimi matrix to preserve the product. This phase change locks in flavor and texture characteristics while extending storage life, with the frozen state serving as a stable intermediate before final pasteurization
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 allows for the creation of surimi nuts with a varied taste and texture close to natural scallops, offering new consumer options and improved storage capabilities while maintaining texture and flavor.
Implementation Method 1
a means for obtaining a strip of surimi with a width greater than 160 mm from a premix, or paste of surimi
Implementation Method 2
a means for scarifying said strip of surimi... During said step of scarifying said strip of surimi, the depth of penetration of the scarification tools into said strip is greater than 0.2 mm
Implementation Method 3
a mechanism for rolling up said strip of scarified surimi in order to form a roll of surimi
Implementation Method 4
a roller cutting mechanism for forming surimi nuts
Implementation Method 5
the method comprises a step of freezing or crusting said surimi nuts... the nuts treated in this way retain all their texture and flavor and can be stored longer
Data Source
Figure 1~3
AI summary
The invention relates to a method for manufacturing a food product based on surimi in the form of pectinid nuts, such as scallops or queen scallops, the method comprising the following steps: - obtaining (S1) a strip (1) of surimi with a width greater than 160 mm from a premix, or surimi paste, - scarification (S4) of said strip (1) of surimi, - rolling (S5) of said scarified strip (1) of surimi to form a surimi roll, - cutting (S2) of the roll to form surimi nuts (2).