US20020012724A1 - Process for the filleting, treating, packaging, freezing, and thawing of varying types of tuna and other pelagic species - Google Patents

Process for the filleting, treating, packaging, freezing, and thawing of varying types of tuna and other pelagic species Download PDF

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US20020012724A1
US20020012724A1 US08/733,844 US73384496A US2002012724A1 US 20020012724 A1 US20020012724 A1 US 20020012724A1 US 73384496 A US73384496 A US 73384496A US 2002012724 A1 US2002012724 A1 US 2002012724A1
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bag
bags
sashimi
steaks
slabs
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William R. Kowalski
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    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, 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
    • A23L3/00—Preservation of foods or foodstuffs, in general, e.g. pasteurising, sterilising, specially adapted for foods or foodstuffs
    • A23L3/36—Freezing; Subsequent thawing; Cooling
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23B—PRESERVING, e.g. BY CANNING, MEAT, FISH, EGGS, FRUIT, VEGETABLES, EDIBLE SEEDS; CHEMICAL RIPENING OF FRUIT OR VEGETABLES; THE PRESERVED, RIPENED, OR CANNED PRODUCTS
    • A23B4/00—General methods for preserving meat, sausages, fish or fish products
    • A23B4/044—Smoking; Smoking devices
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23B—PRESERVING, e.g. BY CANNING, MEAT, FISH, EGGS, FRUIT, VEGETABLES, EDIBLE SEEDS; CHEMICAL RIPENING OF FRUIT OR VEGETABLES; THE PRESERVED, RIPENED, OR CANNED PRODUCTS
    • A23B4/00—General methods for preserving meat, sausages, fish or fish products
    • A23B4/044—Smoking; Smoking devices
    • A23B4/052—Smoke generators ; Smoking apparatus
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23B—PRESERVING, e.g. BY CANNING, MEAT, FISH, EGGS, FRUIT, VEGETABLES, EDIBLE SEEDS; CHEMICAL RIPENING OF FRUIT OR VEGETABLES; THE PRESERVED, RIPENED, OR CANNED PRODUCTS
    • A23B4/00—General methods for preserving meat, sausages, fish or fish products
    • A23B4/044—Smoking; Smoking devices
    • A23B4/052—Smoke generators ; Smoking apparatus
    • A23B4/0523—Smoke generators using wood-pyrolysis or wood-friction
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23B—PRESERVING, e.g. BY CANNING, MEAT, FISH, EGGS, FRUIT, VEGETABLES, EDIBLE SEEDS; CHEMICAL RIPENING OF FRUIT OR VEGETABLES; THE PRESERVED, RIPENED, OR CANNED PRODUCTS
    • A23B4/00—General methods for preserving meat, sausages, fish or fish products
    • A23B4/06—Freezing; Subsequent thawing; Cooling
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23B—PRESERVING, e.g. BY CANNING, MEAT, FISH, EGGS, FRUIT, VEGETABLES, EDIBLE SEEDS; CHEMICAL RIPENING OF FRUIT OR VEGETABLES; THE PRESERVED, RIPENED, OR CANNED PRODUCTS
    • A23B4/00—General methods for preserving meat, sausages, fish or fish products
    • A23B4/06—Freezing; Subsequent thawing; Cooling
    • A23B4/07—Thawing subsequent to freezing
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23B—PRESERVING, e.g. BY CANNING, MEAT, FISH, EGGS, FRUIT, VEGETABLES, EDIBLE SEEDS; CHEMICAL RIPENING OF FRUIT OR VEGETABLES; THE PRESERVED, RIPENED, OR CANNED PRODUCTS
    • A23B4/00—General methods for preserving meat, sausages, fish or fish products
    • A23B4/06—Freezing; Subsequent thawing; Cooling
    • A23B4/08—Freezing; Subsequent thawing; Cooling with addition of chemicals or treatment with chemicals before or during cooling, e.g. in the form of an ice coating or frozen block
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, 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
    • A23L13/00—Meat products; Meat meal; Preparation or treatment thereof
    • A23L13/40—Meat products; Meat meal; Preparation or treatment thereof containing additives
    • A23L13/42—Additives other than enzymes or microorganisms in meat products or meat meals
    • A23L13/428—Addition of flavours, spices, colours, amino acids or their salts, peptides, vitamins, yeast extract or autolysate, nucleic acid or derivatives, organic acidifying agents or their salts or acidogens, sweeteners, e.g. sugars or sugar alcohols; Addition of alcohol-containing products
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, 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
    • A23L17/00—Food-from-the-sea products; Fish products; Fish meal; Fish-egg substitutes; Preparation or treatment thereof
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, 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
    • A23L27/00—Spices; Flavouring agents or condiments; Artificial sweetening agents; Table salts; Dietetic salt substitutes; Preparation or treatment thereof
    • A23L27/20—Synthetic spices, flavouring agents or condiments
    • A23L27/27—Smoke flavours
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/002—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by condensation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2253/00—Adsorbents used in seperation treatment of gases and vapours
    • B01D2253/10—Inorganic adsorbents
    • B01D2253/102—Carbon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/02—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
    • B01D53/04—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography with stationary adsorbents

Definitions

  • This invention relates to a process for the filleting into steaks and sashimi slabs, treating, packaging, freezing, and thawing of varying types of tuna and other pelagic species including swordfish and marlin.
  • Tuna is an important commodity in the international market, far dwarfing the volume and value of any other species.
  • U.S. National Marine Fisheries Service the total world tuna catch grew from 2.1 million metric tons in 1985 to three million metric tons in 1991 with two-thirds of it being traded in the international market at a value of $4.3 billion for fresh, frozen, and canned tuna.
  • Japan's tuna production has been flat at 700,000 metric tons and their share of the growing global catch has been steadily declining.
  • the first type of fleets are comprised of small boats fishing for high value fresh tuna. These fresh fleets have expanded in the past five to ten years from a few hundred boats to several thousand boats in the Pacific alone primarily managed by Taiwanese, mainland Chinese, and Korean fishing companies. New technology such as gel-ice refrigerant and insulated packing materials, and expanding jet freight capacity from all over the Pacific and other parts of the globe make it possible to deliver fresh high value sashimi grade tuna to Japan. However, because of the high cost of air freight and fluctuating market conditions in Japan, only 30% to 80% of any given catch can profitably go to the Japanese fresh sashimi market. This leaves an ever increasing resource of byproduct (“by-catch”) of 20% to 70% of the catch that can be used as raw material for the process of the invention described herein for distribution to the tuna steaking and sashimi slab markets in the United States.
  • by-catch byproduct
  • the second type of fleets are large super freezer boats that go out for up to three months at a time and freeze the fish whole after catching them. This dramatically expands the geographic fishing area these fleets may cover.
  • the value for frozen sashimi grade tuna is less than fresh, the costs of transporting by surface rather than air are also less.
  • Those whole frozen fish that are graded as acceptable for the sashimi market go to Japan, and those of lower grades are processed while frozen for the U.S. and other steaking markets.
  • such processing has often resulted in unsightly brown freezer burn making the resultant frozen tuna steaks less marketable and marginally profitable as a product distributed to the U.S. market.
  • U.S. Pat. No. 1,977,373 to Birdseye discloses a process where individual fillets are wrapped and boxed before being frozen. This process utilizes a rigid cardboard container rather than a flexible non-permeable plastic barrier bag utilized in the invention described herein.
  • U.S. Pat. No. 2,555,584 to Fairbank discloses a process of packing and orienting meat and poultry foodstuff in a rigid tray with five sides which is then inserted into an envelope.
  • the tray covered on five sides prevents meat and poultry oils from contacting the packing envelope and causing failure in the heat sealing of the envelope.
  • Fish oils do not contaminate a flexible non-permeable plastic barrier bag utilized in the invention described herein, and a four sided spatula shovel is used to pack the bag rather than being part of the package.
  • U.S. Pat. No. 3,593,370 to Lapeyre discloses a method for butchering tuna while frozen, teaching the cutting of the tuna into cross sections and removing the skin and entrails while the cross sectional pieces remain substantially frozen.
  • the invention described herein prefers unfrozen tuna for both the butchering and packing steps.
  • the invention described herein teaches a butchering process whereby the whole tuna is first subdivided into sections parallel with the longitudinal axis, whereas Lapeyre teaches to first subdivide into cross sections transverse to the longitudinal axis.
  • U.S. Pat. No. 3,594,191 to Lapeyre discloses an improved method for commercial processing of tuna for a canned pack where the tuna is subdivided into parts while in a substantially frozen condition. Process steps relating to canning are not relevant to the invention described herein.
  • U.S. Pat. No. 2,920,968 to Grandy discloses the packing of individual frozen seafood articles such as shrimp by sealing each in a plastic strip. The elongated strip is then boxed. The invention described herein first packs then freezes the product.
  • U.S. Pat. No. 2,020,109 to De Meric De Bellefon et al discloses the storage of fresh whole unprocessed fish in hermetically sealed boxes with an optional freezing step of submersing the sealed boxes into a brine.
  • U.S. Pat. No. 3,959,505 to Valiant discloses a process for packing tuna into cylinders for canneries.
  • U.S. Pat. No. 4,812,320 to Ruzek discloses a process for forming and vacuum packing fresh meat products onto a tray.
  • U.S. Pat. No. 5,356,649 to LaMotta et al discusses placing a raw food product on a tray, wrapping the tray, cooking the product, and then freezing the product.
  • the invention described herein does not utilize cooking and the tuna is not packed in tray compartments.
  • U.S. Pat. No. 3,637,405 to Mendelson et al discusses the step of placing poultry on a plastic tray, enclosing the tray in plastic, and aging at specific temperatures for specific times to improve shelf life and tenderness.
  • the aging characteristics of this process refer to mammals and not to fish.
  • U.S. Pat. No. 4,657,768 to Nagoshi discusses a freezing method for perishable foods including preserving fish products in a brine. The invention described herein does not utilize this method.
  • U.S. Pat. No. 4,601,909 to Nagoshi discusses freezing seafood in a brine solution containing a percentage of rapeseed oil to reduce freezing time which is not used in the invention described herein.
  • the process of this invention is to efficiently fillet, treat, package, freeze, and thaw varying types of tuna and other pelagic species.
  • Each whole tuna is first ice brine chilled and then filleted into four loins—left back, right back, left belly, and right belly. A majority of the loins go to the steaking fillet process, while a minority of the loins go to the sashimi slab fillet process.
  • Each loin in the steaking fillet process is then ice brine chilled and filleted manually using a jig, or mechanically using a meat slicing machine, into cross sectional tuna steaks in a preferred range of 3 ⁇ 4′′ to 1′′ thick. Some tuna steaks are larger and some smaller, and all share the common characteristic of two sides being at 90 degrees.
  • tuna steaks are next packed on a four sided spatula shovel area of ⁇ fraction (91/2) ⁇ ′′ by ⁇ fraction (121/2) ⁇ ′′ with the 90 degree cut sides of four steaks aligned with the four corners of the rectangular area, and the interior area of the rectangle “puzzle packed” with tuna steaks of varying size and orientation until a maximum density is achieved.
  • the tuna steak puzzle pack configuration is covered with an absorbent paper towel and placed in a non-permeable barrier bag with the spatula shovel.
  • the shovel is flipped over, tilted up, and removed.
  • the tuna steak puzzle packs are next low pressure vacuum packed, sealed, and placed in an ice brine.
  • Each loin in the sashimi slab process is first cut into loin sections 13′′ in length.
  • Each loin section is filleted longitudinally, slicing slabs in a preferred range of 7 ⁇ 8′′ to 1′′ thick, and parallel to one of the 90 degree cut sides of each loin section, either manually in a jig, or mechanically with a meat slicing machine.
  • Each sashimi slab is dipped in a warm flavor enhancing solution for three minutes, dried, and packed in the spatula shovel to a maximum density in the sashimi slab puzzle pack configuration.
  • the length and thickness of the sashimi slabs are consistent, and the width and angle of the uncut edge vary. These characteristics allow for a configuring process of rotating and flipping the slabs to minimize the open space in a ⁇ fraction (91/2) ⁇ ′′ by ⁇ fraction (121/2) ⁇ ′′ rectangular area on the spatula shovel.
  • the sashimi slab puzzle pack configuration is covered with an absorbent paper towel and placed in a non-permeable barrier bag with the spatula shovel. The shovel is flipped over, tilted up, and removed. The sashimi slab puzzle packs are next low pressure vacuum packed, sealed, and placed in an ice brine.
  • Each puzzle pack is removed from the brine and dried off.
  • a preferred ⁇ fraction (1/16) ⁇ ′′ to 1 ⁇ 8′′ diameter hole is cut into each pack and a gas nozzle is inserted to add a pillow like amount of a varying blend of gases to the bag.
  • Each gas blend varies with the species, the color, and the market to which the product is going.
  • each puzzle pack bag is closed with a clamp, placed on rolling treatment racks, and transferred to cold storage for a preferred treatment period of 4 to 12 hours.
  • Each puzzle pack is next taken to the vacuum packing area and cut open.
  • the paper towel is removed, a permeable plastic membrane backed with absorbent diaper material is added, and the unit is vacuum packed, resealed, and placed in an ice brine.
  • Each puzzle pack is next removed from the brine, dried off, and placed on freezer racks to be taken for high air circulation blast freezing at a preferred range of less than minus 40 degrees Fahrenheit.
  • the seafood product retailer, restaurant, or sushi bar thaws only the number of puzzle packs needed in a cold water and salt solution for approximately forty minutes. Each package is dried, cut open, and the tuna steaks or sashimi slabs are displayed for sale in a store or served in a restaurant.
  • FIG. 1 is a flow chart of the complete process showing the distinct physical areas necessary and the steps performed in each area.
  • FIG. 2 is a full fish description of loin locations.
  • FIG. 3 is a view of the V-shaped jig for manually cutting tuna steaks from tuna loins.
  • FIG. 4 is the tuna steak cutting plan for each tuna loin resulting in varying size tuna steaks.
  • FIG. 5 is a view of the spatula shovel used for configuring the tuna steaks or the sashimi slabs and inserting them into barrier bags.
  • FIG. 6 is an example of a tuna steak puzzle pack configuration.
  • FIG. 7 is a view of the sashimi slab jig with guide bars and cutting board.
  • FIG. 8 is the sashimi slab cutting plan for each tuna loin resulting in varying size sashimi slabs.
  • FIG. 9 is an example of a sashimi slab puzzle pack configuration.
  • FIG. 10 is a view of the gas treating step with a gas nozzle in a puzzle pack barrier bag.
  • FIG. 11 is a view of the gas treatment rolling rack for transport to the cold storage treatment room.
  • FIG. 12 is a view of a tuna steak puzzle pack with permeable plastic membrane vacuum packed.
  • FIG. 13 is a view of the master shipping carton.
  • each tuna is brought fresh to the processing facility joining room where the air temperature is kept within an operability range of 32 to 45 degrees Fahrenheit, a preferred range of 36 to 40 degrees and an optimal temperature of 38 degrees Fahrenheit.
  • Each tuna comes in on crushed ice or in a tote of a brine solution and is placed in a salt brine chilling tank with water, ice, and sufficient salt to keep the solution temperature at an operability range of 28 to 36 degrees Fahrenheit, a preferred range of 30 to 32 degrees Fahrenheit and an optimal temperature of 31 degrees Fahrenheit.
  • each tuna is cut into four loins—left back, right back, left belly, right belly—with skin removed and partial red bloodline remaining at the apex of each loin as a visual clue for freshness. Since the tuna without head and gills has the form of a cylinder tapered at each end, a cross section taken at any point along its length will show each of the four loins as a 90 degree pie shaped sector with the cross sections and the corresponding four pie shaped sectors smaller at the ends and largest in the middle.
  • the loins are next placed in a colder brine solution of water, ice, and sufficient salt to keep the solution temperature at an operability range of 20 to 27 degrees Fahrenheit, a preferred range of 22 to 25 degrees Fahrenheit and an optimal temperature of 24 degrees Fahrenheit.
  • the loins are chilled until the temperature of each loin is in an operability range of 27 to 35 degrees Fahrenheit, a preferred range of 28 to 32 degrees and an optimal temperature of 30 degrees Fahrenheit.
  • the loins are carried in brine totes to the filleting room which is kept within the same operability range, preferred range, and optimal temperature as the loining room.
  • each loin is placed with the 90 degree cut sides down into a food-grade plastic V-shaped jig with slots for slicing with a long thin bread knife or a Japanese tuna knife, or alternatively in a meat slicing machine.
  • Each loin is sliced cross sectionally into an operability range of 5 ⁇ 8′′ to ⁇ fraction (11/8) ⁇ ′′ thick pie shaped tuna steaks and a preferred range of 3 ⁇ 4′′ to 1′′.
  • some tuna steaks are larger and some smaller, and all share the common characteristic of two sides being at 90 degrees.
  • a food-grade plastic four-sided spatula shovel with handle is used for configuring and packing the tuna steaks into tuna steak “puzzle pack” configuration.
  • the inside dimensions of the spatula shovel are ⁇ fraction (91/2) ⁇ ′′ wide by 14′′ long for the bottom side by ⁇ fraction (11/2) ⁇ ′′ high for the back wall and two side walls with a line marked across the interior width at ⁇ fraction (121/2) ⁇ ′′ forward from the back wall.
  • the back wall, two side walls, and the ⁇ fraction (121/2) ⁇ ′′ line form the rectangular area of ⁇ fraction (91/2) ⁇ ′′ by ⁇ fraction (121/2) ⁇ ′′ into which are placed the tuna steaks in puzzle pack configuration.
  • the average ideal weight of a puzzle pack configuration varies with the thickness preferred by the customer with 3 ⁇ 4′′ thick steaks averaging 4.0 lbs, 7 ⁇ 8′′ thick steaks averaging 4.66 lbs, and 1′′ thick steaks averaging 5.33 lbs.
  • the tuna steak puzzle pack configuration in the spatula shovel next has a sterile absorbent paper towel 10′′ by 13′′ placed on top and tucked in along the sides and back wall. Then the spatula shovel with the tuna steaks is slid into a non-permeable barrier bag. The spatula shovel and bag are flipped over with the absorbent towel now on the bottom of the tuna steaks. The spatula shovel is tilted up with the front edge down and it is pulled out of the bag leaving the tuna steaks in the puzzle pack configuration.
  • the tuna steak puzzle packs are next low pressure vacuum packed, sealed and placed in a brine solution of water, ice, and sufficient salt to keep the solution temperature at an operability range of 23 to 30 degrees Fahrenheit, a preferred range of 25 to 27 degrees Fahrenheit and an optimal temperature of 26 degrees Fahrenheit.
  • the tuna steak puzzle packs are carried in brine totes to the gas treatment room.
  • each loin is first cut into a multiple of 13′′ long loin sections with a remainder section less than 13′′ in length. This remainder section may be sliced into less than optimal length sashimi slabs, or alternatively into tuna steaks.
  • each 13′′ loin section is placed in a food-grade plastic jig with two guide bars 24′′ long by 1′′ wide by varying thickness bolted in a counter sunk manner onto a 24′′ long by 15′′ wide food-grade plastic cutting board with 1′′ by 2′′ by 2′′ supporting feet at the corners, or alternatively in a meat slicing machine.
  • One of the guide bars is stationary and the other guide bar is movable with slots for the holding bolts retained by wing nuts under the cutting board.
  • Each 13′′ loin section is placed with one of the 90 degree cut sides down on the cutting board, the other 90 degree cut side adjacent to the stationary guide bar, and the uncut natural tapered side of the loin section adjacent to the movable guide bar.
  • a sashimi slab the thickness of the guide bars is sliced longitudinally from the bottom of the loin section with the cutting edge of a long thin bread knife, or a Japanese tuna knife, traveling parallel to the top of the guide bars.
  • Each sashimi slab is removed and the remaining loin section is replaced in the jig for the next sashimi slab cut. Referring to FIG. 8, the process is repeated until the remaining loin section is below the guide bars.
  • Each sashimi slab has an operability range of 3 ⁇ 4′′ to ⁇ fraction (11/4) ⁇ ′′ thickness and a preferred range of 7 ⁇ 8′′ to 1′′.
  • Each sashimi slab is next placed in a dipping solution which stabilizes the color, enhances the flavor, and firms its texture.
  • the dipping solution is mixed in quantity in the following proportions: 150 liters of boiled or purified water; 15 kilos of baking soda; 4-5 kilos of non-iodized salt; 2-4 drops of smoke oil; and 15-20 granules, or 1-2 drops, resulting in a 10 parts per million solution of chlorine.
  • the dipping solutions maintained at an operability range of 80 to 92 degrees Fahrenheit, a preferred range of 83 to 89 degrees Fahrenheit, and an optimal temperature of 86 degrees Fahrenheit.
  • the sashimi slabs are placed in trays and each tray dipped into a tub of solution for an operability range of 2:00 to 4:00 minutes, a preferred range of 2:30 to 3:30 minutes, and an optimal range of 2:45 to 3:15 minutes. After dipping the slabs are dried with sterile absorbent paper towels.
  • This added step of dipping is viable for sashimi slabs and not for tuna steaks, since the price for the sashimi slabs is higher justifying the additional cost of this step.
  • the enhanced flavor is more noticeable when the sashimi slabs are thawed and eaten raw. The flavor enhancement of this step would not be noticeable for cooked tuna steaks.
  • FIG. 9 we use the spatula shovel previously described in FIG. 5 for configuring and packing the sashimi slabs into a sashimi slab “puzzle pack” configuration.
  • the spatula shovel's back wall, two side walls, and the line parallel to, and ⁇ fraction (121/2) ⁇ ′′ from, the back wall form the rectangular area of ⁇ fraction (91/2) ⁇ ′′ by ⁇ fraction (121/2) ⁇ ′′ into which the sashimi slabs are placed in a sashimi slab puzzle pack configuration.
  • Each sashimi slab has two consistent dimensions of 13′′ in length by a preferred range of 7 ⁇ 8′′ to 1′′ in thickness with three side edges cut at 90 degrees to one another and at 90 degrees to the top and bottom.
  • each sashimi slab that is variable is the natural uncut side of the loin that curves inward and upward from bottom to top resulting in a variable sloping angle of less than 90 degrees. Further, each sashimi slab is wider at one end and narrower at the other due to the curvature of the body of the tuna. Thus, each sashimi slab varies in the slopina angle of the uncut edge and in the width dimension.
  • One of the larger sashimi slabs is selected and placed with its 90 degree sides aligned with the corners of the rectangular area in the spatula shovel.
  • the slab is compressed slightly so that its 13′′ natural length fits within the ⁇ fraction (121/2) ⁇ ′′ of the rectangle.
  • the second piece reverses its orientation with its widest end opposite the widest end of the first slab.
  • the second is flipped over so that the angles of the uncut edges are parallel.
  • This slab is similarly compressed to the ⁇ fraction (121/2) ⁇ ′′ of the rectangle.
  • the process continues with each slab selected, and rotated or flipped as necessary to maximize the utilization of the space and to reduce the contortion of the sashimi slab mating surfaces.
  • the result is the sashimi slab puzzle pack configuration with a weight within an operability range of 4.0 to 6.66 lbs with a preferred range of 4.66 to 5.33 lbs.
  • the average ideal weight of a puzzle pack configuration varies with the thickness preferred by the customer with 7 ⁇ 8′′ sashimi slabs averaging 4.66 lbs, and 1′′ thick steaks averaging 5.33 lbs.
  • the sashimi slab puzzle pack configuration in the spatula shovel next has a sterile absorbent paper towel 10′′ by 13′′ placed on top and tucked in along the sides and back wall. Then the spatula shovel with the sashimi slabs is slid into a non-permeable barrier bag. The spatula shovel and bag are flipped over with the absorbent towel now on the bottom of the sashimi slabs. The spatula shovel is tilted up with the front edge down and it is pulled out of the bag leaving the sashimi slabs in the puzzle pack configuration.
  • the sashimi slab puzzle packs are next low pressure vacuum packed, sealed and placed in a brine solution of water, ice, and sufficient salt to keep the solution temperature at an operability range of 23 to 30 degrees Fahrenheit, a preferred range of 25 to 27 degrees Fahrenheit and an optimal temperature of 26 degrees Fahrenheit.
  • the sashimi slab puzzle packs are carried in brine totes to the gas treatment room referred to in FIG. 1.
  • each of the tuna steak puzzle packs and the sashimi slab puzzle packs is removed from the brine solution and dried with sterile absorbent paper towels.
  • Each non-permeable plastic bag is punctured with a hole of a diameter in an operability range of ⁇ fraction (1/16) ⁇ ′′ to ⁇ fraction (3/16) ⁇ ′′ and a preferred range of ⁇ fraction (1/16) ⁇ ′′ to 1 ⁇ 8′′, a gas nozzle is inserted, and a treatment gas is injected into the bag to a level equal to a soft pillow-like amount sufficient to cover all the edges of each puzzle pack configuration. Then the nozzle is removed and the bag is sealed with a 1′′ wide metal clamp covered with rubber.
  • a blend of gases is used depending on the desired treatment effect for the tuna steak and sashimi slab markets.
  • carbon dioxide, argon, and nitrogen inhibit bacteriological growth and decomposition.
  • Oxygen maintains the natural color of the tuna, and blends including carbon monoxide can be used to improve color.
  • the gas treated puzzle packs are placed on rolling racks with 48 shelves ⁇ fraction (131/4) ⁇ ′′ wide by 32′′ long each holding two puzzle packs.
  • the rack is rolled into the cold storage area referred to in FIG. 1 which is kept at an air temperature in an operability range of 25 to 31 degrees Fahrenheit, a preferred range of 27 to 29 degrees Fahrenheit and an optimal temperature of 28 degrees Fahrenheit.
  • the bags are periodically agitated by slightly moving them or turning them over.
  • the racks are removed from the cold storage and taken back to the gas treatment area where each clamp is removed from each puzzle pack bag, a vacuum nozzle is inserted and the gas is evacuated into the atmosphere outside the treatment room.
  • each puzzle pack bag is taken to the final vacuum packing area where each puzzle pack is placed with the paper towel side up and the tuna steaks or sashimi slabs facing down.
  • Each puzzle pack bag is cut open, the paper towel is removed by hand, and a new pad with a permeable plastic membrane with an absorbent diaper material backing is placed over the top and around the edges of the puzzle pack configuration.
  • This permeable plastic membrane facing the tuna steaks or sashimi slabs is ⁇ fraction (11) ⁇ ′′ wide by 14′′ long by an operability range of 1 ⁇ 8′′ to ⁇ fraction (5/16) ⁇ ′′ thick, and a preferred range of 1 ⁇ 8′′ to 1 ⁇ 4′′ thick. It has the function of absorbing excess moisture after thawing and acts as extra padding around the corners and edges which are most susceptible to bumping and puncturing of the non-permeable barrier bag.
  • the unit is weighed and the weight and lot number are marked on the label and placed inside the bag. Then the bag is placed in a vacuum sealing machine which vacuums the bag, seals it, and trims off any excess plastic.
  • the final vacuum packed puzzle packs are placed back into a brine solution of water, ice, and sufficient salt to keep the solution temperature at an operability range of 23 to 30 degrees Fahrenheit, a preferred range of 25 to 27 degrees Fahrenheit and an optimal temperature of 26 degrees Fahrenheit.
  • the vacuum packed tuna steak puzzle packs with the permeable diaper membrane, and the vacuum packed sashimi slab puzzle packs with the permeable diaper membrane are removed from the brine solution, rinsed and dried with sterile absorbent paper towels.
  • the puzzle packs are next loaded onto freezer racks and rolled into the freezer area where the product is blast frozen with a high circulation rate of cold air in an operability range of less than minus 10 degrees Fahrenheit and an optimal range of less than minus 40 degrees Fahrenheit.
  • the master cartons have inside dimensions of 11′′ wide by 14′′ long by ⁇ fraction (51/2) ⁇ ′′ in height.
  • Each box is waxed or treated with a water resistant coating to prevent deterioration during handling and exposure to air when water rapidly condenses on the outside after removal from frozen storage.
  • packing is done in the carton packing room with an air temperature in the operability range of 20 to 40 degrees Fahrenheit, and a preferred range of 25 to 30 degrees Fahrenheit.
  • Either 4 or 5 units are placed in each carton for an operability range of 20 to 25 total lbs, and an optimal weight of 20 total lbs equal to 5 units averaging 4 lbs each or 4 units averaging 5 lbs each.
  • a foam plastic layer of 11′′ wide by 14′′ long by an operability range of 0.2′′ to 0.4′′ thick, and a preferred range of 0.25′′ to 0.35′′ thick, acts as a cushion between puzzle pack layers and fills any extra space in each carton.
  • the thawing procedure is identical for tuna steak puzzle packs and for sashimi slab puzzle packs.
  • the retailer, restaurant, or sushi bar thaws only enough for immediate sale by preparing a solution of cold water and one tablespoon of salt per gallon of cold water for each tuna steak or sashimi slab puzzle pack to be thawed.
  • the salt prevents discoloring if the meat contacts the solution which is in an operability range of 40 to 50 degrees Fahrenheit, a preferred range of 42 to 48 degrees Fahrenheit, and an optimal temperature of 45 degrees Fahrenheit.
  • This invention can be used to process varying types of tuna species and can similarly be used for other large bodied, pelagic species including marlin and swordfish.

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  • Oil, Petroleum & Natural Gas (AREA)
  • Meat, Egg Or Seafood Products (AREA)
  • Seasonings (AREA)
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  • Coloring Foods And Improving Nutritive Qualities (AREA)
  • Freezing, Cooling And Drying Of Foods (AREA)
US08/733,844 1996-10-18 1996-10-18 Process for the filleting, treating, packaging, freezing, and thawing of varying types of tuna and other pelagic species Abandoned US20020012724A1 (en)

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US08/980,392 US5972401A (en) 1996-10-18 1997-11-28 Process for manufacturing tasteless super-purified smoke for treating seafood to be frozen and thawed

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US08/980,392 US5972401A (en) 1996-10-18 1997-11-28 Process for manufacturing tasteless super-purified smoke for treating seafood to be frozen and thawed

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US20120244262A1 (en) * 2008-02-18 2012-09-27 Mauer James E Method and Apparatus for Forming Unit Portions of Frozen Food Materials
WO2012152964A1 (es) * 2011-05-06 2012-11-15 Disgrossa, S.L. Procedimiento para la obtención de un producto alimenticio a base de pescado
US20130168909A1 (en) * 2010-08-09 2013-07-04 Ad Bank Limited Company Chopping board for sliced raw fish
CN104643157A (zh) * 2015-02-14 2015-05-27 山东海波海洋生物科技股份有限公司 一种速成风味鲍鱼加工工艺
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US20050153035A1 (en) * 2004-01-12 2005-07-14 Winterlab Limited Presentation board for freezing meat product
US20070294370A1 (en) * 2004-06-29 2007-12-20 Fay William F Scheduling and information sharing and distribution system and method
EP1785036A1 (en) * 2005-11-14 2007-05-16 Fortune Frozen Foods, Co Ltd Method of preserving fish
US20070122532A1 (en) * 2005-11-30 2007-05-31 Chun-Hsiung Tsai Method of preserving fish
WO2007066046A1 (fr) 2005-12-08 2007-06-14 Daniel Degage Procede pour la transformation de poissons, en particulier de thonides, et navire-usine adapte pour un tel procede
FR2894434A1 (fr) * 2005-12-08 2007-06-15 Daniel Degage Procede pour la transformation de poissons, en particulier de thonides, et navire-usine adapte pour un tel procede
US20110229614A1 (en) * 2007-08-06 2011-09-22 Tenpoint Manufacturing Corporation Method of treating fish meat
US20120244262A1 (en) * 2008-02-18 2012-09-27 Mauer James E Method and Apparatus for Forming Unit Portions of Frozen Food Materials
US20130168909A1 (en) * 2010-08-09 2013-07-04 Ad Bank Limited Company Chopping board for sliced raw fish
WO2012152964A1 (es) * 2011-05-06 2012-11-15 Disgrossa, S.L. Procedimiento para la obtención de un producto alimenticio a base de pescado
ES2391965A1 (es) * 2011-05-06 2012-12-03 Disgrossa, S.L. Procedimiento para la obtención de un producto alimenticio a base de pescado.
US9095151B1 (en) * 2013-02-08 2015-08-04 Mitsui Foods, Inc. Method for making tuna salad
US20160331004A1 (en) * 2014-01-16 2016-11-17 Gea Food Solutions Bakel B.V. Measurement of dielectric properties during thawing or freezing of a food product
CN104643157A (zh) * 2015-02-14 2015-05-27 山东海波海洋生物科技股份有限公司 一种速成风味鲍鱼加工工艺
EP3667208A1 (en) 2018-12-14 2020-06-17 Keohane Seafood Unlimited Company Process for shelf-life extension of fish
GB2579913A (en) * 2018-12-14 2020-07-08 Keohane Seafood Unlimited Company Process for shelf-life extension of fish
GB2579913B (en) * 2018-12-14 2023-03-01 Keohane Seafood Unlimited Company Process for shelf-life extension of fish
WO2021214800A1 (en) * 2020-04-24 2021-10-28 Lambhusasund Ehf. A method for prolonged storage of fresh food items

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NO20002695D0 (no) 2000-05-26
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WO1999027794A1 (en) 1999-06-10
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DE69827972T2 (de) 2005-05-19
EP1033916B1 (en) 2004-12-01
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US5972401A (en) 1999-10-26
ES2234137T3 (es) 2005-06-16
EP1506712A2 (en) 2005-02-16
AU8688998A (en) 1999-06-16
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EP1506712A3 (en) 2005-02-23
NZ504193A (en) 2003-04-29
CN1283961A (zh) 2001-02-14
KR100432853B1 (ko) 2004-05-24
EP1506712B1 (en) 2007-09-05
CA2308376A1 (en) 1999-06-10
ATE372056T1 (de) 2007-09-15
HK1033077A1 (en) 2001-08-17
JP2001524325A (ja) 2001-12-04
NO317249B1 (no) 2004-09-27
NO20002695L (no) 2000-05-26

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