NO339179B1 - Process for the production of stockfish - Google Patents

Process for the production of stockfish Download PDF

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Publication number
NO339179B1
NO339179B1 NO20150483A NO20150483A NO339179B1 NO 339179 B1 NO339179 B1 NO 339179B1 NO 20150483 A NO20150483 A NO 20150483A NO 20150483 A NO20150483 A NO 20150483A NO 339179 B1 NO339179 B1 NO 339179B1
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Norway
Prior art keywords
fish
process according
relative humidity
drying
water content
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NO20150483A
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Norwegian (no)
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NO20150483A1 (en
Inventor
Nordahl Anthonisen
John-Erik Haugen
Jan-Kees Boerman
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Athena Seafoods As
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Priority to NO20150483A priority Critical patent/NO339179B1/en
Publication of NO20150483A1 publication Critical patent/NO20150483A1/en
Publication of NO339179B1 publication Critical patent/NO339179B1/en

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    • AHUMAN NECESSITIES
    • A23FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23BPRESERVING, e.g. BY CANNING, MEAT, FISH, EGGS, FRUIT, VEGETABLES, EDIBLE SEEDS; CHEMICAL RIPENING OF FRUIT OR VEGETABLES; THE PRESERVED, RIPENED, OR CANNED PRODUCTS
    • A23B4/00General methods for preserving meat, sausages, fish or fish products
    • A23B4/03Drying; Subsequent reconstitution
    • AHUMAN NECESSITIES
    • A23FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23LFOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L3/00Preservation of foods or foodstuffs, in general, e.g. pasteurising, sterilising, specially adapted for foods or foodstuffs
    • A23L3/40Preservation of foods or foodstuffs, in general, e.g. pasteurising, sterilising, specially adapted for foods or foodstuffs by drying or kilning; Subsequent reconstitution

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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Food Science & Technology (AREA)
  • Polymers & Plastics (AREA)
  • Health & Medical Sciences (AREA)
  • Nutrition Science (AREA)
  • Wood Science & Technology (AREA)
  • Zoology (AREA)
  • Meat, Egg Or Seafood Products (AREA)

Description

PROCESS FOR THE PRODUCTION OF STOCKFISH
The present invention relates to a process for the production of stockfish, in particular a consistently reproducible process which can be carried out indoors.
Conventionally, stockfish is produced from wild-caught cod, the spring spawning cod caught during a short and intensive fishing period from February to March in Lofoten, Northern Norway, and dried until June on the wooden racks outdoors. The current method of producing stockfish takes 4-5 months and the quality and yield of the product are highly dependent on the weather conditions.
If the weather conditions are not optimal during the outdoor production of stockfish a significant proportion of stockfish product may get downgraded and lost. The extent of the quality failure has increased over the years, and can reach up to 70% downgrading (2014 season) or loss of the stockfish production.
Heavy or prolonged rain is also disadvantageous as it inhibits the drying process and increases the risk of bacterial spoilage or growth of pathogenic bacteria and contributes to the quality fault named "mucoso" which is a degradation of fish tissue.
Rising temperatures increase the risk of "fast-drying" and the inhibition of the maturing process because the bacteria which act in the maturing step and are responsible for the unique taste of this refined seafood product will not be active under dry conditions. Other quality issues related to outdoor production are freezing damage of the fish tissue, oxidation and growth of maggots from fly eggs deposited in the neck region of the fish. In addition, during outdoor drying, stockfish is also prone to contamination with parasites and bacteria from rats, seagulls and other species. All the mentioned outdoor quality issues can simply be avoided by taking the production process indoors.
It is therefore the aim of the present inventors to develop an indoor process for the maturing and drying of stockfish, which produces a product of consistently high quality over a shortened period of time. This is by no means a simple matter since it is necessary to reproduce the effects of the optimal outdoor conditions prevailing in Lofoten in the spring and early summer.
Aranson, in a paper presented at the International Geothermal Conference, Reykjavik, 2003 entitled "the drying of fish and utilization of geothermal energy; the Icelandic experience" describes an indoor process for the drying of fish. The process consists of a primary drying step and a secondary drying step. The primary drying step takes place over about 24-40 hours at a temperature of about 18-25°C, a relative humidity of 20-50% and an air velocity of about 3m/s. In the secondary drying step, which takes about 3 days, the temperature is 22-26°C, the relative humidity is 20-50% and the air velocity is about 0.5-1 m/s. The process is for use with cod heads or small fish rather than for fresh round fish.
In the present invention there is provided an indoor process for the production of a dried fish product the process comprising: i. a maturation step comprising placing a plurality of fresh headed and gutted round fish in a drying chamber and passing air over the fish until the water content of each fish reaches 40-50% by weight; wherein the drying chamber is maintained at a temperature of 5-20°C and a relative humidity of 50-95%; ii. a final drying step comprising adjusting the conditions of the drying chamber to a temperature of 20-40 °C; and relative humidity of 20-50% and passing air over the fish until the water content of each fish reaches 14-20% by weight.
A water content of 14-20% by weight is equal to the water content achieved with natural outdoor drying and so the process is concluded at this stage. Trials conducted on the above described process conditions have shown that the total production time to reach the final product quality can be reduced to 30 days or less, which is considerably shorter than the traditional outdoor process (Figure 1).
We have previously published a report setting out the parameters for an indoor process for the preparation of stockfish (see http:// cordis. europa. eu/ result/ rcn/ 140984 en. html). This earlier process was to consist of two steps. In the first step, fish would be dried for 42 days at 4-8°C, relative humidity of 70-85% and air speed of 0.5-2 m/s until the water content of the fish was about 50% by weight. In the second step the fish would be dried for a further 34 days at a temperature of 10-15°C, relative humidity of 65-75% and air speed of 2.5 m/s. However, this was merely a model based on the known weather conditions in the Lofoten area of Norway and at the time of the publication of the report, no indoor process had been carried out. Surprisingly, it has been found that, using the conditions set out above, the time in which stockfish can be prepared is considerably shorter than that proposed in the model system.
Any fish raw material may be used in the process of the present invention, although suitably the fish is white fish, for example cod, haddock, whiting, hake, pollock, coley or plaice. Other types of white fish may also be used. More suitably, the fish is cod, haddock or whiting, but particularly cod, which is the fish traditionally used in stockfish.
The process of the present invention relates to the drying of headed and gutted round fish, i.e. fish which have had the heads and guts removed but which still have skin and bones. Some processes for drying of fish fillets are known but these have not been successfully applied to round fish.
Any number of fish can be dried in the process, with the maximum size of a batch of fish to be dried being limited by the size of the drying chamber.
The first step of the process is the maturation step. In this step, bacterial growth and biochemical reactions are the dominant processes acting on the fish tissue as it is dried to achieve combined spoilage and biochemical maturation.
During the maturation step, levels of bacteria increase and then reach a maximum steady state plateau (equal amounts of growing and dying of cells). As water is removed from the fish, levels of bacteria start to decline as the reduced water levels in the fish limit bacterial growth. The maturation step may be concluded at any point from when the levels of bacteria have reached the steady state plateau, or are declining.
The levels of bacteria in the fish can be determined indirectly by measuring the emission and levels of volatile compounds/gases, as discussed in more detail below.
As explained above, the maturation step may be concluded at any time from the time at which bacterial levels reach a steady state plateau, and the maturation step may be continued until the bacterial levels are declining (Figure 2). A suitable end point for the maturation step is achieved when the water content of each fish in a batch reaches 40-50% by weight, which will correspond to the end of the bacterial steady-state plateau.
The maturation step is suitably carried out at a relatively low temperature. Suitably, in the maturation step, the temperature of the air is maintained at about 5-15°C, more suitably at about 7-14°C, particularly at 8-12°C.
In some cases, the temperature at the start of the maturation step may be low, for example 5-12°C and may be increased as the amount of water in the fish decreases. For example, the temperature may be raised to about 12-20°C, more usually 14-20°C once the water content of each fish approaches about 55%.
In the maturation step, it is necessary to pass air over the fish continually in order to
remove moisture from the fish. The air flow in step (i) is typically up to about 8 m/s, for example from 1 to 8 m/s or 2-8 m/s. More usually, however, the air flow rate in step (i) will be up to 6 m/s, for example 1-6 m/s, 2-6 m/s, 2.5-6 m/s or 3-6 m/s. In most cases, the air flow rate in this step is up to 5 m/s, such as 1-5 m/s, 2-5 m/s, 2.5-5 m/s or 3-5 m/s.
The relative humidity in the step (i) needs to be high and may be, for example from about 55-95%, 60-95% or, more typically, 60-90%. The relative humidity in the early maturation step is suitably from about 70-95%, more usually 70-90%, it may decrease as the water content of the fish is reduced. Thus in the later part of the maturation step, as the water content of the fish approaches 55%, the relative humidity may be from about 50-65%.
The maturation step is concluded when the water content of the fish is from about 40-50% by weight, for example 45 to 50% by weight and in the period from when the end of the bacterial steady state plateau has been reached.
The water content of the fish during the maturation and drying can be calculated using Formula 1:
where: Mxis weight at day x
Mo is fresh weight at start of process
Wois water content in % of fresh weight at start of process
The average fresh weight water content of the fish (cod) is typically 81 ±1 % determined gravimetrically, and can be used as a starting point water content in the formula, which satisfies the level of precision for the practical purpose of process monitoring and identification of end point of the process corresponding to water content of 14-20 % by weight.
Typically, the maturation step of the process lasts from about 12-20 days.
In the final drying step (ii), the temperature is raised so that it is significantly higher than the temperature in step (i). As mentioned above, the temperature in step (ii) is from 20-40°C but more suitably, the temperature is from about 25-40°C, still more suitably from 30-40°C.
When a higher temperature up to 40°C is used for the second step, it has the advantage of reducing the drying time considerably. At these temperatures, the drying time can be reduced to 6 to 10 days, compared with several weeks for the standard outdoor process or the process suggested in our earlier report (see above).
In the second step, the relative humidity is significantly lower than in the first step and, as mentioned above, is typically about 20-60%, more usually 20-40 %.
The air flow rate may be slightly increased compared to the rate used in the maturation step and is typically up to about 9 m/s, for example 1-9 m/s, 2-9 m/s or 3-9 m/s. More usually, the air flow rate is up to 8 m/s, for example 1-8 m/s, 2-8 m/s or 3-8 m/s. In most cases, the air flow rate is up to 7 m/s such as 1-7 m/s, 2-7 m/s or 3-7 m/s.
The final drying step starts at the bacterial steady state level (Figure 2), or at the end of the plateau corresponding to about 40-50% water content. A suitable end point for the final drying step is reached when the water content of the fish is from about 14 to 20 % by weight, more usually 16-18% by weight and typically about 18% by weight.
The process of the invention may be carried out in a climate controlled industrial drying unit, for example a drying unit, which produces a controlled drying of the fish using a temperature controlled flow of air across the fish. The drying unit may also comprise a dehumidification system and a recirculation system for active removing of moisture, for example using a cooling and evaporation cycle. The recirculation system recirculates the moisture free air back to the drying chamber so that there is continuous recirculation of airwithin the dryer which enables a gradual reduction of the moisture content of the fish. Suitably, the operation of the drying chamber is controlled by a control system which monitors and adjusts the temperature, air speed, relative humidity and moisture removal.
The control system may monitor the weight of the fish by means of gravimetric mass sensors or weighing sensors.
The drying unit may be equipped with logging capabilities to report the measured data that comes from the 2 step indoor process. The reports provide clear information for quality interpretation and quality assurance of the process.
The control unit may also monitor levels of volatile compounds generated during spoilage and maturation of the fish, for example the volatile compounds produced by the bacteria which act on the fish during the maturation step.
Typically, these are volatile compounds such as trimethylamine, dimethyl-disulphide, dimethyl-trisulphide, 3-methyl-1-Butanol, 3-methyl-1-butanal, 2-methyl-1-butanal, 2-methyl-1-propanol, ethanol, acetone, phenol, 2-pentanone and 2-butanone. The levels of these compounds may be used for process monitoring of the production process, since (except trimethylamine) they will be highly correlated with the total bacteria counts in the fish during the maturation step.
The output of the for volatile compounds monitoring typically correlates to spoilage bacteria derived volatile compounds, which show Gaussian shaped curves over the first step process period (Figure 3). This indicates that an increase of bacteria is monitored, and the maturation step is at its highest peak, which is directly related to the top of the Gaussian curve. Figure 2 also shows that in the second step, bacterial activity is ceased.
Bacterial amounts at the end of the Gaussian curve, corresponding to the end of the first process step 1, are comparable to normal low levels at the starting point of the process of the invention.
This volatile compound monitor can act as an indicator of when the maturation step is completed and also of when the bacteria co unt has returned to low levels meaning that process step 2 is complete.
The final product stockfish produced by the method of the invention can be prepared for cooking by rehydration in the same way as traditionally prepared stockfish.
The colour of the skin of the stockfish of the present invention tends to keep it's original colour being darker than that of traditionally outdoor prepared stockfish because of the absence of the bleaching effect of the sun. In addition, the fillet of the indoor dried fish seems to become whiter than that of the traditional outdoor dried fish. This indicates that the fish dried according to the process of the present invention does not have the disadvantage of suffering the thermal stress typically seen in outdoor dried fish. However, the outer skin colour has no relevance for the final sensory quality of the cooked product.
The fish dried according to the process of the present invention was cooked and the appearance and taste compared with that of traditionally dried stockfish. It was found that the flavour and odour of the fish prepared according to the present invention were very similar to the flavour and odour of traditional outdoor dried stockfish.
The invention will now be described in more detail with reference to the following examples and the drawings in which: FIGURE 1 is a plot showing mean weight percentage water content of fish from two indoor drying processes based on weight monitoring compared to traditional outdoor drying. FIGURE 2 shows the temporal distribution of the total bacteria counts (log cfu) from indoor drying of stockfish with process time of 47 days (Trial I, Figure 1). FIGURE 3 is a histogram showing temporal distribution of the major volatile compounds of fish from indoor drying of stockfish with process time of 47 days (Trial I, Figure 1). Days in colour.
Example 1
Two batches of fish (Processes I and IV) were dried using the process conditions set out in Table 1.
FIGURE 1 shows water content of fish from Processes I and IV. The water percentage data shown are based on mean gravimetrically determined weights of the fish at the respective days of drying using the fresh weight of the fish at start of process applied to the Formula 1.
The results for volatile compounds illustrated in Figure 2 are based on Headspace Gas Chromatographic Mass Spectrometry (HS-GC/MS) measurements of 20 gram homogenized fish tissue from a cross section of the central part of the fish of individual fish at respective drying days.

Claims (19)

1. An indoor process for the production of a dried fish product the process comprising: 1. a maturation step comprising placing a plurality of fresh headed and gutted round fish in a drying chamber and passing air over the fish until the water content of each fish reaches 40-55% by weight; wherein the temperature of the drying chamber is 5-15°C; and the relative humidity is 55-95%; and the air velocity is from 1-8 m/s; ii. a final drying step comprising adjusting the conditions of the drying chamber to a temperature of 20-40 °C; and relative humidity of 20-50% and passing air over the fish at a velocity of 2-9 m/s until the water content of each fish reaches 14-20% by weight.
2. A process according to claim 1, wherein the fish is white fish, for example cod, haddock, whiting, hake, pollock, coley or plaice.
3. A process according to claim 2 wherein the fish is cod.
4. A process according to any one of the preceding claims wherein the maturation step is continued until the water content of each fish reaches 40-50% by weight.
5. A process according to any one of the preceding claims wherein the maturation step is carried out at a temperature of 8-12°C.
6. A process according to any one of the preceding claims wherein, in the maturation step, air is passed over the fish at a flow rate of 1-5 m/s.
7. A process according to any one of the preceding claims wherein, in the maturation step, the relative humidity is 60-90%.
8. A process according to any one of claims 1 to 7 wherein, in the maturation step, the relative humidity at the start of the maturation step is 70-90%, and wherein the relative humidity decreases as the water content of the fish is reduced such that when the water content of each fish approaches about 55%, the relative humidity is about 50-65%.
9. A process according to any one of the preceding claims wherein the maturation step lasts from about 12-20 days.
10. A process according to any one of the preceding claims wherein in the final drying step (ii), the temperature is 25-40°C.
11. A process according to claim 10 wherein, in the final drying step, the temperature is 30-40°C.
12. A process according to any one of the preceding claims wherein, in the final drying step, the relative humidity is 20-40 %.
13. A process according to any one of the preceding claims wherein, in the final drying step the air flow rate is 2-7 m/s.
14. A process according to any one of the preceding claims wherein, at the end of the final drying step, the water content of the fish is about 18% by weight.
15. A process according to any one of the preceding claims wherein the drying chamber comprises a parameter controlled industrial drying unit which produces a controlled drying of the fish using a temperature controlled flow of air across the fish.
16. A process according to claim 16 wherein the drying unit further comprises a dehumidification system and a recirculation system for active removing of moisture, for example using a cooling and evaporation cycle.
17. A process according to any one of the preceding claims wherein the operation of the drying chamber is controlled by a control system which monitors and adjusts the temperature, air speed, relative humidity and moisture removal.
18. A process according to claim 17 wherein the control system monitors the weight of the fish by means of gravimetric mass sensors or weighing sensors.
19. A process according to claim 17 or claim 18 wherein the control system monitors levels of volatile compounds generated during the process, wherein the volatile compounds suitably comprise trimethylamine, dimethyl-disulphide, dimethyl-trisulphide, 3-methyl-1-Butanol, 3-methyl-1-butanal, 2-methyl-1-butanal, 2-methyl-1-propanol, ethanol, acetone, phenol, 2-pentanone and 2-butanone. 1. Innendørs metode for fremstilling av et tørket fiskeprodukt, idet fremgangsmåten omfatter:
NO20150483A 2015-04-17 2015-04-17 Process for the production of stockfish NO339179B1 (en)

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Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2213178A1 (en) * 2009-01-28 2010-08-04 Metalquimia, SA Forced convection treatment unit for a meat product cut into slices and method of treatment of a meat product using said unit

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2213178A1 (en) * 2009-01-28 2010-08-04 Metalquimia, SA Forced convection treatment unit for a meat product cut into slices and method of treatment of a meat product using said unit

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
ARASON J., The drying of fish and utilization of geothermal energy; the Icelandic experience, International Geothermal Conference, Reykjavik, Sept. 2003, S08 Paper 076, page 21-31, Dated: 01.01.0001 *

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Owner name: SAFE TRACK FOOD AS, NO