revalueproject- industry visits
TRANSCRIPT
ReValue Project-Industry Visits
Nutan Kaushik
Amity University, Noida
Project TeamAmity University
Dr. V. K. ModiAmity University , NoidaProject Participants
Dr. Ashutosh SrivastavaAmity University , NoidaProject Participants
Ms. Asha KumariAmity University , NoidaTechnical Assistant and Ph. D. Scholar
Ms. SoumyaAmity University , NoidaJRF
Ms. KhushbooAmity University , NoidaJRF and Ph. D. Scholar
Visit to Mumbai Dockyard
and
Kaiko Surimi-Refrigerated Distributors Private Limited
Fishing Boat
Each compartment has a capacity of 600 kg. Inbuilt compartments ranging from 12-20 in number
They are filled with crushed ice which remains frozen state for approximately 15 days.
Average fishing duration is of 10 days
Basic sorting of fishes according to species of fish are done on boat itself.
Crates used to transport fish
Quality inspection i.e. thumb impression test, bulging of eye, skin colors etc are carried out.
These fish is then loaded in crates in a 3 layer ice pattern where layer of ice and fishes are present in alternation
Crushed ice is used as cooling medium for fish that are transported at short distance (intra-state) and cooling units are installed if fish are to be transported at longer distance (inter-state ).
industry MT11: Refer to response sheet
KW12: Refer to response sheet
KW13: re-written
KW14: Refer to response sheet
RS 15: yes, only head and viscera separated
Pink Perch Deheading/ gutting
Some amount of de-heading i s done at dockyard manually
After which heads are covered with ice and sold to fish meal industry and de-headed fishes are sold to surimi
Refrigerated Distributors Private Limited
Mumbai based Surimi Manufacturing Company
Producer of Kaiko Surimi
Annual Production of 1800 to 2000 tons per year
Mainly for export to Singapore, Japan and Korea
Annual Production of RRM
Product Amount ( tons/ year)Scale 220 – 308Fat 88 – 132Skin & bones 924 – 1012Surimi 1848 – 1970
Wash water is produced at the rate of 20L /hour
Total production of plant is 20 tons per day.
Variety of fishes used for Kaiko surimi production
FISH TYPE COMMON NAME SCIENTIFIC NAMENon Histamine Forming Pink Perch Nemipterus sp
Big eye Priacanthus harmur
Ribbon fish lepuracanthus savala/ Trichiurus lepturus
Lizard fish Saurida sp
Croaker fish Johnius sp.
Barracuda Sphyraena sp.
Reef cod Eplinephelus sp.
Bronze croaker Otolithoides biaurituds
Histamin Forming Sardine Sardinella longiceps
Mamakari Sardinella brachysoma
Figure 1: Flow chart of Surimi processing
Fish from aggregator
Fresh Fish
Deheading/ Degutting
Deheaded/ Degutted fish (Head/ Gut)
Washing I
Fish meal
(Wash water) Washed Fish (Scale)
Washing II
ETP 4°C - 10°C
Demineralization
Washed Fish (Scale)
Deboning/ Meat Separating
Minerals Proteins
(Skin, Bone, Blood) Meat Mince Pesticides Collagen
Water Stirring
Fish meal Meat Mince + water
Chilled water (4°C) Rotary Screen (0.55 mm)
(Wash Water) Washed Mince
(Wash Water) Washed Mince Meat
Salt + Ca Stirring
ETP
Mince meat + Salt mix
Rotary Screen (0.45 mm)
4°C - 10°C
(Wash Water) Washed Meat Mince
Refiner (1.5 mm)
ETP
Refined meat Mince (Finer Parts)
Dehydrator
Fish Meal
Dehydrated meat (Wash Water)
Mixing (Sugar , 6% STPP, 0.3%)
Surimi Mix ETP
Forming & filling
Surimi block (10kg)
Freezing
Frozen surimi
Metal detection
Approved Product
Packaging
Master Carton
Storage -22°C
Shipment
Fish washer
Deboner
Washer (Rotary Screen )
Dehydrator
Contact Plate Freezer Frozen Surimi Block
Rest Raw Material Percentage
Scale 5-7
Fat 2-3
Skin &bone 21-23
Surimi 42-45
Bawa Fishmeal and Oil co.
Mangalore based fishmeal andfish oil producing industry
Production capacity of 550 MTfishmeal per day
• During peak season 600 tonnes of raw material is unloaded daily• Basic Visual Inspection and temperature test is done for acceptance of raw material• Raw material is received from Maharashtra, Goa, Karnataka, Tamil Nadu and Kerala
(a) Location for procurement of raw material (b) Raw material unloaded from trucks
• After metal separation using magnetic separator raw material is loaded on screw conveyor moving towards cooker, where it is subjected to cooking operation.
• Steam heating is used for cooking, which prevents protein from excessive heat denaturation, characteristic of direct heating process.
• Temperature and time combination for cooking process depends on quantity of fish.
Cooker
• Cooked fish are then subjected to pressing in tin screw conveyor type press• Pressing separates liquid fraction from solid fish pulp• The twin screw press produces press cake with a moisture level ranging
between 35- 40%
Screw Conveyor Press
• Press cake obtained after screw press is subjected to drying in steam drier where a temperature of 85°- 90°C is maintained
• Moisture content in fishmeal is reduced to 6-9.5% from 40% in steam drier.• Low moisture content ensures insufficient water level for support of growth of
micro-organisms and halt any chemical degradation• Drying process takes about 40 minutes
Steam Drier
• Sieving is done with sieve of 10 mesh size to obtain uniform size fishmeal particle and separate any impurity
• After sieving cooling is done using air cooler to reduce fishmeal temperature to 30°-35°C
• Fishmeal is added with antioxidant (BHT, TBHQ) as per customer requirement.• Fishmeal is pulverized in a hammer mill based pulverizer and milled into finer size
particles (10 mesh size)
Siever Pulveriser
• A temperature increase of about 10°C is registered after pulverising.• A water cooler is used to reduce the temperature of fishmeal to about 30°C • From water cooler fishmeal is then transferred to silo
Silo Water Cooler
• Total time of production one batch is 60-90 minutes.• Fishmeal is then packed into polypropylene bags of 50 kg unit size • Shelf life is the final product (fishmeal) is about 1 year at room
temperature.• Depending upon protein content in the final product fishmeal is classified
into four grades
Grade Protein Content International market price (USD)
Standard grade 60 1200
Prime grade 62 1250
Super prime grade 65 1350
Premium grade 68 1400
•From press two fractions areobtained i.e. press cake and other ispress liquor.•For the fish oil press liquor afterpressing step is collected in decanterfrom where stick water is sent tooverhead tank for further separationof oil and water•Stick water is pre-heated to atemperature of 80°-85°C usingplate heat exchanger
Decanter
Plate heat exchanger
•After pre-heating stick water is subjected to centrifugation @ 7000 rpmwhich leads to separation of oil and protein water •This fish oil is then inspected, collected, packed and sold.
Product Percentage Uses
Fishmeal 21 Fish feed, Pet food
Fish oil 5-15 Refined fish oil production, Coating material on boats, Cosmetic industry, Pharma-industry
Fish soluble paste 4 Aquaculture
Water 70 Discarded
Products manufactured in Bawa Fishmeal & Oil Co.
Samples from Kaiko Surimi
Fish head (before thawing)
Refiner waste (after thawing)
Skin and bones sample
Surimi sample before drying
Oil from Pink Perch Head and Viscera
Refiner waste oil
Digestion of Industrial samples