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