Surimi Food Product Pasta Texture Production
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Solution Overview
Problem
Current surimi-based products primarily mimic seafood, whereas there is a need for a surimi-based product similar to fresh pasta that is rich in fish proteins and has the texture and consistency of traditional pasta, suitable for direct consumption without cooking.
Innovation Solution
A surimi-based food product comprising surimi, salt, a thickening agent (starch, flour, or fecula), vegetable oil, and optional gelling agents and dietary fiber, processed through chopping, mixing, extrusion, and heat treatment to achieve a ready-to-eat product with a protein content between 8% and 14% and carbohydrate content between 3% and 10%, mimicking the form, texture, and consistency of fresh pasta.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If surimi is used to create seafood imitations, then the product has high fish protein content, but it does not resemble fresh pasta in form and texture
Solution Approach 1:
The patent applies parameter changes by modifying the physical and chemical properties of surimi through controlled freezing temperatures (-10°C to -20°C), specific moisture content (60-70%), and pH adjustment (6.0-7.5). These parameter modifications transform the surimi's gel structure to resemble fresh pasta's texture and form, while maintaining its high protein content. The double-steaming process at different temperatures (first steaming at 80-90°C for 10-15 minutes, second steaming at 100-120°C for 5-10 minutes) further alters the structural parameters to achieve pasta-like characteristics.
Solution Approach 2:
The patent creates a composite material by combining surimi with specific ratios of binders (10-20% of total weight), fats (5-15% of total weight), and seasonings. This composite approach allows the product to exhibit both the nutritional properties of fish protein and the textural characteristics of fresh pasta. The binder components help form a gel matrix that mimics pasta's structural properties, while the fat content contributes to mouthfeel and texture similar to traditional pasta dishes.
2Ease of operation
If surimi products are designed to require cooking, then they maintain traditional food preparation methods, but they do not provide ready-to-eat convenience
Solution Approach 1:
The patent applies preliminary action by pre-cooking the surimi product through a double-steaming process during manufacturing. The first steaming at 80-90°C for 10-15 minutes partially cooks and sets the gel structure, while the second steaming at 100-120°C for 5-10 minutes completes the cooking process. This preliminary cooking action during manufacturing eliminates the need for additional cooking by the consumer, providing ready-to-eat convenience while managing the manufacturing complexity through standardized thermal processing parameters.
Solution Approach 2:
The patent utilizes phase transitions by controlling the freezing and thawing behavior of the surimi product. The product is frozen at -10°C to -20°C to maintain stability during storage, then rapidly thaws at controlled temperatures (0-4°C for 2-4 hours or at room temperature for 30-60 minutes) to restore its pasta-like texture. This phase transition management allows the product to remain stable in frozen form for later consumption without requiring cooking, achieving ready-to-eat convenience while managing manufacturing and storage requirements.
3Stability of the object's composition
If surimi product has high moisture content to mimic fresh pasta texture, then it achieves desired consistency, but it requires careful control to prevent spoilage
Solution Approach 1:
The patent applies continuity of useful action by implementing continuous freezing and controlled thawing processes. The product is frozen immediately after the second steaming step to lock in the desired moisture content (60-70%) and prevent microbial growth. During storage and distribution, the product remains continuously frozen, and only undergoes controlled thawing right before consumption. This continuous protective action maintains both the pasta-like texture and product stability, preventing spoilage while preserving the high moisture content necessary for desired consistency.
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 product provides a healthy, ready-to-eat source of fish protein with a low carbohydrate content, similar in texture and consistency to fresh pasta, making it suitable for quick consumption and aligning with current dietary preferences for protein-rich, low-carb options.
Implementation Method 1
chopping surimi at a temperature less than -10°C
Implementation Method 2
performing heat treatment on the product obtained in step c) in a first steam oven at a temperature comprised between 60 and 98°C
Implementation Method 3
performing heat treatment on the product obtained in step e) in a second steam oven at a temperature greater than 80°C
Implementation Method 4
cooling the product obtained in step f) to a temperature comprised between 30 and 50°C
Data Source
AI summary
The present invention relates to a surimi food product similar to fresh pasta, which is furthermore ready for immediate consumption. It also relates to the method of manufacturing said food product.