e-ITEC Training manual on ‘Quality Assurance of Fish and Fishery Products’ - 2022

INTRODUCTION TO FISH PRESERVATION TECHNIQUES

Zynudheen A.A.
ICAR-Central Institute of Fisheries Technology, Cochin
Email: [email protected]

Fish is one of the healthiest foods available to man and there is an ever-increasing demand for
fish and fishery products. Being a highly perishable commodity, fish require immediate
processing and various options are available for the value addition of fish. Fish processing,
particularly seafood processing and marketing have become highly complex and competitive and
exporters are trying to process more value-added products to increase their profitability. Value
can be added to fish and fishery products according to the requirements of different markets.
These products range from live fish and shellfish to ready to serve convenience products. In
general, value-added food products are raw or pre-processed commodities whose value has been
increased through the addition of ingredients or processes that make them more attractive to the
buyer and/or more readily usable by the consumer. It is a production/marketing strategy driven
by customer needs and perceptions.

Technology developments in fish processing offer scope for innovation, increase in

productivity, increase in shelf life, improve food safety and reduce waste during processing
operations. A large number of value added and diversified products both for export and internal
market based on fish, shrimp, lobster, squid, cuttlefish, bivalves etc. have been identified. This
paper gives an overview of the processing techniques, emerging technologies and the value
added products from fish and shell fish.

Chilling

Chilling is an effective way of reducing spoilage by cooling the fish as quickly as possible
without freezing. Immediate chilling of fish ensures high quality products (Connell, 1995: Huss,
1995). Chilling by use of ice is the most important method employed commercially. The storage
life of fish kept in ice depends on a number factors which include species, size, method of
capture, fat content, breeding conditions, feeding regime and the method of killing. In general,
the keeping quality of non-fatty fish is better than fatty fish in ice storage. The quality and

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 e-ITEC Training manual on ‘Quality Assurance of Fish and Fishery Products’ - 2022

quantity of ice used are important factors in determining the shelf life of iced fish. In tropical
countries, a 1:1 fish to ice ratio is ideal for ice storage. It is recommended to add about 12-20%
extra ice to the fish in order to compensate for water loss from melting and bad handling
(Zugarramurdi et al., 1995). It is generally accepted that some tropical fish species can keep for
longer periods in comparison to fish from temperate or colder waters.

Transportation of live fish and shellfish

Transportation of fish, crustaceans and molluscs in live condition is the best method to ensure
that the consumer is supplied with fresh product. In India, traditional mode of live transport in
open earthen containers and metal containers was practiced (Jhingran, 1975). In terms of the
range of species and the distance shipped, tropical fishes stand first in live fish transport.
Waterless transportation of live fish is also practised for many species where the animals are
kept in moist conditions under optimal cold temperatures.

Freezing

Freezing is one of the better methods to preserve fresh fish. It may be either slow freezing or
quick freezing. Slow freezing is accomplished by placing the product at a low temperature and
allowing it to freeze slowly usually in still air. Quick freezing is accomplished in any one or
combination of the following four methods:

1. Immersion freezing

2. Indirect contact freezing

3. Air blast freezing and

4. Cryogenic freezing

Air freezing

Air blast freezing

Circulating cold air at high speed enables freezing to proceed at a moderately rapid rate and this
method is referred to as air-blast freezing. Air-blast freezing is usually accomplished by placing
the products on a mesh belt and passing it slowly through an insulated tunnel containing air at-18
to -34°C or lower, moving counter current to the product at a speed of I to 20 meter/sec. Air at -

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 e-ITEC Training manual on ‘Quality Assurance of Fish and Fishery Products’ - 2022

29°C and at a speed of 10-12 meter/sec, is often satisfactory, although lower temperatures are
preferred. Air blast freezing is economical and is capable of accommodating products of
different sizes and shapes. It can result in (1) excessive dehydration of unpackaged products if
conditions are not carefully controlled, and this in turn necessitates frequent defrosting of
equipment and (2) undesirable bulging of packaged products which are not confined between flat
rigid plates during freezing. Spiral Belt Freezer and Fluidized Bed Freezing are some of the
commonly used methods in the industry.

Contact Plate Freezing

Fish products can be frozen by placing them in contact with a metal surface cooled by expanding
refrigerants. Double contact plate freezers are commonly used for freezing fish/prawn blocks.
This equipment consists of a stack of horizontal cold plates with intervening spaces to
accommodate single layers of packaged product. The filled unit appears like a multi layered
sandwich containing cold plates and products in alternating layers. When closed, the plates make
firm contact with the two major surfaces of the packages, thereby facilitating heat transfer and
assuring that the major surfaces of the packages do not bulge during freezing. Vertical plate
freezers are also in use especially onboard fishing vessels. Contact plate freezing is an
economical method that minimises problems of product dehydration, defrosting of equipment
and package bulging. In this method the packages must be of uniform thickness. A packaged
product of 3 to 4 cm thickness can be frozen in I to 1.5 hour when cooled by plates at -35°C.
Freezing times are extended considerably when the package contains a significant volume of
void spaces.

Liquid Immersion Freezing

Liquid immersion freezing or direct immersion freezing is accomplished when a product is

frozen by immersing or by spraying with a freezant that remains liquid throughout the process.
This technique is occasionally used for fish and prawns. Liquid immersion freezing can result in
moderately rapid freezing. Freezants used for liquid immersion freezing should be non-toxic,
inexpensive, stable, reasonably inert, and should have a low viscosity, low vapour pressure and
freezing point and reasonably high values for thermal conductivity. Freezants should have a low
tendency to penetrate the product, little or no undesirable effects on organoleptic properties and

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 e-ITEC Training manual on ‘Quality Assurance of Fish and Fishery Products’ - 2022

require little effort to maintain desired standards for sanitation and composition. Aqueous
solutions of propylene glycol, glycerol, sodium chloride, calcium chloride and mixtures of sugars
and salt have been used as freezant.

Cryogenic Freezing

Cryogenic freezing refers to very rapid freezing by exposing food products to an extremely cold
freezant undergoing change of state. The fact that heat removal is accomplished during a change
of state by the freezant is used to distinguish cryogenic freezing from liquid immersion freezing.
The most common food grade cryogenic freezants are boiling nitrogen and boiling or subliming
carbon dioxide.

Individually Quick Frozen Products (IQF)

Lobster, squid, cuttlefish, different varieties of finfish etc. are processed in the individually quick
frozen style. IQF products fetch better price than conventional block frozen products. However,
for the production of IQF products raw-materials of very high quality need to be used, as also the
processing has to be carried out under strict hygienic conditions. The products have to be packed
in attractive moisture-proof containers and stored at –30°C or below without fluctuation in
storage temperature. Some of the IQF products in demand are prawn in different forms such as
whole, peeled and de-veined, cooked, headless shell-on, butterfly fan tail and round tail-on,
whole cooked lobster, lobster tails, lobster meat, cuttlefish fillets, squid tubes, squid rings, boiled
clam meat and skinless and boneless fillets of white lean fish. IQF products can be easily
marketed as consumer packs, which is not possible with block frozen products. This is a distinct
advantage in marketing.

Canning

Canning is a method of food preservation in which preservation is achieved by the destruction

of micro-organisms by the application of heat of food packed in a sealed container. Since the
canned foods are sufficiently cooked products and free from micro-organisms they offer
consumer safety besides being ready to consume. Canning has the unique distinction of being
an invention in the field of food processing/ preservation whereas all other methods can be
considered as adaptation of natural processes or their modifications. Because of their very long

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 e-ITEC Training manual on ‘Quality Assurance of Fish and Fishery Products’ - 2022

shelf life and ready to consume feature canned products have become very popular and a variety
of food stuffs, both plant and animal origin and their combinations are produced and distributed.

Unit Operations in a canning process are:

1. Selection and preparation of raw material.

2. Pre-cooking / blanching

3. Filling in to containers.

4. Addition of liquid medium

5. Exhausting

6. Seaming

7. Heat Processing / Retorting

8. Cooling

9. Drying, warehousing, labelling and casing

Retort Pouch Processing is an improvement over the conventional canning process. Reportable
flexible containers are laminate structures that are thermally processed like a can, are shelf stable
and have the convenience of keeping at room temperature for a period of more than one year
without refrigeration. The most common form of pouch consists of a 3 ply laminated material.
Generally it is polyester / aluminium foil / cast polypropylene. See-through pouches made of
polyester/aluminium oxide or silicon dioxide/nylon/cast polypropylene is also available. The
manufacture of retort pouch packs involves a series of lengthy operations viz., filling, air
removal, sealing, traying and heat processing in an over pressure autoclave

Curing

The traditional methods of processing fish by salting, drying, smoking and pickling are
collectively known as curing. Cured fish consumption is more in areas where the availability of
fresh fish is comparatively limited, namely interior markets and hilly areas. This is also the
cheapest method of preservation, since no expensive technology is used. In India roughly 20 %
of the fish caught is preserved by curing. Considerable quantities of cured fish are also
exported, mainly to Singapore, Sri Lanka and to the Middle East. Simple sun drying was the
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 e-ITEC Training manual on ‘Quality Assurance of Fish and Fishery Products’ - 2022

widely practised traditional method of fish preservation. By this, preservation was achieved by
lowering of water content in the fish, thereby retarding the activity of bacteria and fungi. The
heat was able to destroy the bacteria to a certain extent. Later on, a combination of salting and
drying or salting, smoking and then drying were developed.

Salting

This is one of the oldest methods of preservation of fish. Salting is usually done as such or in
combination with drying or as a pretreatment to smoking. During salting osmotic transfer of
water out of the fish and salt into the fish takes place, which effect fish preservation. It is based
on different factors like diffusion and biochemical changes in various constituents of the fish.
Salting amounts to a process of salt penetration into the fish flesh. Penetration ends when the salt
concentration of the fish equals that of the surrounding medium. Loss of water during salting
limits bacterial growth and enzyme activity, thus preserving the fish. The high salt content
prevents the growth of normal spoilage microflora in the fish; but halophiles, which can survive
12-15% of salt, will survive.

Smoking

Smoke curing is another traditional method of preservation of fish. It is generally a combination

of salting, smoking and drying. Smoking is usually done in a specially designed kiln or a room.
The source of smoke is wood, sawdust or coconut husk, depending on the particular flavour
required. The fish that is salted and partially dried is used for smoking. Smoking can be done at
0
temperatures below 35 C (cold smoking) or at higher temperature (hot smoking). Liquid
smoking by immersion in smoke liquor and electrostatic smoking is also practised in different
countries. Masmin, Dried Squid, Dried Jelly Fish, Dried Bombay duck etc are Some
commercially important dried aquatic products

Irradiation

Irradiation treatment involves controlled exposure of the food to radiation sources such as
isotopes of cobalt (60Co) or cesium (137Cs), which emit gamma rays, and also X-rays and electron
beams (Lagunas-Solar, 1995). Radiation processes that can be applied to fishery products include
radurization (pasteurization of chilled fish), radicidation (sanitization of fresh and frozen

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 e-ITEC Training manual on ‘Quality Assurance of Fish and Fishery Products’ - 2022

products including fish mince by elimination of non-spore forming pathogenic bacteria) and
disinfestation.

Radurization of fresh fish at 1 to 3 kGy reduces initial microbial loads by 1 to 3 log cycle,
essentially reducing spoilage causing bacteria and extends their chilled storage life 2-3 fold. The
treatment is effective for the extension of shelf life of most of the marine and freshwater fish
species.

Battered and Breaded Products

The most prominent among the group of value added products is the battered and breaded
products processed out of a variety of fish and shellfish. Battered and breaded products offer a
‘convenience’ food widely valued by the consumer. These are products, which receive a coat or
two each of a batter followed by coating with breadcrumbs, thus increasing the bulk and
reducing the cost element. The pick-up of coating can be increased by adjusting the consistency
of the batter or by repeating the coating process. By convention, such products should have a
minimum fish component of 50%. Coated products viz., fish fingers, squid rings, cuttlefish balls,
fish balls and prawn burgers form one of the major fish and shellfish based items of trade by the
ASEAN countries.

The first commercially successful coated product is ‘fish finger; or ‘fish stick’. Later several
other products particularly the coated fish fillet, fish portions, fish cakes, fish medallions, fish
nuggets, breaded oysters and scallops, crab balls, fish balls, coated shrimp products, coated squid
rings etc. became prominent in most of the developed countries with the advent of the fast food
trade. The present day production of coated seafood items involve fully automated batter and
breading lines which start from portioning and end with appropriate packaging of the product

Fish Mince and Mince Based Products

Mechanically deboned fish meat is termed as fish mince. Fish mince is more susceptible to
quality deterioration than the intact muscle tissue since mincing operation cause disruption of
tissue and exposure of flesh to air, which accelerates lipid oxidation and autolysis. The quality of
the mince is dependent on the species, season, handling and processing methods. Also, low bone
content in the mince (01-0.4%) is desirable for better functional and sensory properties. Fish
mince is a major source of raw material for the preparation traditional products such as patties,
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 e-ITEC Training manual on ‘Quality Assurance of Fish and Fishery Products’ - 2022

balls, wafers, loaves, burgers, fish fingers, dehydrated fish minces , cutlets and pickled products
The mince from different species could be combined to prepare composite fillets

Surimi

Surimi is stabilized myofibrillar protein obtained from mechanically deboned flesh that is
washed with water and blended with cryoprotectants (Park, 2005). Washing not only removes fat
and undesirable matters such as blood, pigments and odoriferous substances but also increases
the concentration of myofibrillar protein, the content of which improves the gel strength and
elasticity of the product. This property can be made use of in developing a variety of fabricated
products like shellfish analogues. India produces about 40.000 MT of surimi per annum, 70% of
which comes from thread fin bream.

Kneaded products

Several kneaded products like kamaboko, chikuwa, hampen, fish ham and sausage are processed
using surimi incorporating other ingredients. The ingredients used in most of these preparations
are identical; however, the classification is principally based on the manufacturing process
involved. The ingredients employed other than surimi include salt, monosodium glutamate,
sugar, starch, egg white, polyphosphate and water. The method of processing all these products
involves grinding together of the various ingredients to a fine paste and some sort of heat
treatment at some stage.

Fibreized products

Fibreized products are in great demand among the surimi based imitation shellfish products. The
ingredients used in the formulation of fibreized products includes, besides surimi, salt, starch,
egg white, shellfish flavour, flavour enhancers and water. All the ingredients are thoroughly
mixed and ground to a paste. The paste is extruded in sheet on the conveyor belt and is heat
treated using gas and steam for partial setting. A strip cutter subdivides the cooled sheet into
strings and is passed through a rope corner. The rope is coloured and shaped. The final product
is formed by steam cooking the coloured and shaped material.

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 e-ITEC Training manual on ‘Quality Assurance of Fish and Fishery Products’ - 2022

Fish sausage

Fish sausages are surimi or fish mince mixed with additives, stuffed in suitable casings and heat
processed. The surimi or fish mince is mixed with salt (3-4%), sugar (2-3%), sodium glutamate
(0.3%) starch and soy protein in a silent cutter and stuffed in casings by an automatic screw
stuffer. The stuffed sausage is heated in hot water at 85-90°C for 40-60 min. After heating, it is
cooled slowly to avoid shrinking of the tube and then stored at refrigerated temperature. The
production of fish sausage in India is rather insignificant, although market potential for this
product is good (Hassan & Mathew, 1999). Sausages prepared from rohu mince treated with
potassium sorbate had a shelf life of 16 days at refrigerated temperatures (Sini et. al., 2008).

Accelerated Freeze Drying, High Pressure processing, Enzyme treatment, Extrusion technology,
Pulsed light technology, Hurdle technology etc. are some of the emerging technologies for value
addition of fish which are being practices by the industry to certain extent.

Fish processing and value addition has evolved over the years as an important sector in Indian
Agriculture. Fish and fishery products earn maximum foreign exchange in the category of
agricultural produce exported from India. This sector has immense scope for development
through diversification and generation of employment for the skilled and unskilled workforce of
the country.

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