Continuous on-board processing of seafood after fishing on the sea

Abstract

The present invention relates to a continuous on-board drying method for Antarctic krill and a continuous on-board processing method of shelled Antarctic krill. The drying method includes the following steps: 1) subjecting fishing materials to cleaning, sorting, and dewatering with a vibrating screen; 2) rapidly heating the krill to the temperature of up to 70? C. using infra-red rays; 3) hot-air drying; 4) impurity removal by vacuum; 5) cooling to obtain dried krill. The processing method includes the following steps: a) subjecting fishing materials to cleaning, sorting, and dewatering with a vibrating screen; b) rapidly heating the krill to the temperature of up to 70? C. using infra-red rays; c) hot-air drying; d) subjecting the dried krill to shelling treatment to separate shell from meat, to obtain shelled krill; e) impurity removal by vacuum to obtain shelled krill product. The methods in the present invention are highly efficient, energy saving, green and environmental protection, and the krill products have high quality and safety.

Claims

1. A method of continuous on-board processing of seafood after fishing on the sea, comprising the following steps: 1) after fishing of seafood materials, cleaning the seafood materials with seawater of 0?10? C., wherein the seafood materials are fish or shrimp; 2) cooking the fish or shrimp for 2?8 min in a cooking soup comprising a quality improver, wherein the solid-liquid ratio is 1 kg: 8?20 L, and the cooking soup comprising the quality improver comprises salt 0?6% (w/w), edible alcohol 0.1?3% (w/w), glucono-delta-lactone 0.05?0.5% (w/w), tea polyphenol 0.02?0.2% (w/w), perilla juice 0.01?0.1% (w/w), sodium hexametaphosphate 0.05?0.25% (w/w), and water; during the cooking, the cooking soup is replaced at a fixed time, and the replaced cooking soup is heat processing wastewater, which should be treated to become more suitable for environment; 3) putting the cooked fish or shrimp onto a vibrating screen, leaching and dewatering the cooked fish or shrimp; 4) putting the processed fish or shrimp evenly onto conveyor belt to go into a multilayer hot-air drying cabinet, and drying the processed fish or shrimp until the moisture content of the fish or shrimp falls below 40% (w/w); 5) removing impurities mixing in the dried fish or shrimp obtained in step 4) by vacuum; 6) cooling the fish or shrimp obtained in step 5) by cold wind to decrease the temperature to not more than 10? C., thereby obtaining dried fish or shrimp product.

2. The method according to claim 1, further comprising a step as follows: 7) screening: the dried fish or shrimp product is screened according to the shape size.

3. The method according to claim 2, further comprising a step as follows: 8) the screened dried fish or shrimp is subjected to packaging according to its specifications and then to storing at room or cold temperature.

4. The method according to claim 1, which is characterized in that: the drying includes the following three stages: stage one: the drying temperature is controlled between 50? C. and 60? C., the drying air velocity is between 1.2 m/s and 3.5 m/s, and the drying time is between 5 min to 15 min; stage two: the drying temperature is controlled between 65? C. and 75? C., the drying air velocity is between 0.8 m/s and 2.3 m/s, and the drying time is between 10 min and 25 min; stage three: the drying temperature is controlled between 55? C. and 65? C., the drying air velocity is between 0.5 m/s and 2.0 m/s, and the drying time is between 8 min and 15 min.

5. The method according to claim 1, which is characterized in that: in step 5), the relative vacuum degree is ranging from ?15 kPa to ?80 kPa.

6. The method according to claim 1, further comprising the treatment of the replaced cooking soup produced in step 2), which is carried out as follows: (a) the replaced cooking soup (i.e., the cooking wastewater) produced in step 2) is cooled down to 0?70? C., the cooled cooking wastewater is subjected to filtration or centrifugation to remove the suspended substances, then a flocculant is added and stirred for 5?60 min, and then the resulted floccule is removed by filtration or centrifugation; wherein the flocculant is diatomite, and the addition amount of the diatomite is 50?1000 mg/L; (b) microfiltration treatment: a microfiltration membrane with aperture of 0.1?2 ?m is used for filtration of the cooking wastewater obtained in step (a), and a permeate solution a is obtained; (c) ultrafiltration treatment: a ultrafiltration membrane with aperture of 10000?100000 Da is used for filtration of the permeate solution a, and a permeate solution b is obtained; (d) purification treatment: the permeate solution b is subjected to one of the following treatments: {circle around (1)} nanofiltration treatment: the permeate solution b flows into a nanofiltration membrane device with aperture of 90?1000 Da, and is subjected to filtration under conditions of 0.5?2 MPa and 0?70? C. to obtain a permeate solution c, and the solution c can be recycled or discharged directly; {circle around (2)} reverse osmosis treatment: the permeate solution b flows into a reverse osmosis device, and is subjected to reverse osmosis treatment under conditions of 1?6 MPa and 0?70? C. to obtain a permeate solution d, and the solution d can be recycled or discharged directly.

7. The method according to claim 6, which is characterized in that: in step (d), if the salt content of the solution before reverse osmosis treatment is over 2.5%, the solution has to be subjected to electrodialysis treatment, and then subjected to reverse osmosis treatment; the electrodialysis device consists of 8 cation and 7 anion membranes placed at regular intervals, and the cation and anion membranes are cation membrane CMX and anion membrane AMX, respectively.

8. The method according to claim 7, which is characterized in that: a prediction model for the desalting ratio by electrodialysis treatment is as follows: $P=1-{\left(\frac{?e-\frac{?{\mathrm{Et}}^{5\text{/}3}{Q}^{2\text{/}3}}{N}}{?-?+?e-\frac{?{\mathrm{Et}}^{5\text{/}3}{Q}^{2\text{/}3}}{N}}\right)}^2$ wherein ? is obtained by SPSS software regression fitting, and can be calculated with flow rate, voltage and feed concentration according to the following formula:
?=1.766?10.sup.?7C.sub.0+2.213?10.sup.?7E+1.476?10.sup.?7Q?7.657?10.sup.?6 C.sub.0 is feed concentration (mol/m.sup.3); ? is ionic limiting molar conductivity of NaCl solution; ? is molar conductivity of NaCl; Q is flow rate (m.sup.3/h); t is time for electrodialysis treatment (h); E is dc voltage (V); N is the number of pairs for cation and anion membrane; e is mathematic constant, and the value is 2.71828.

9. The method according to claim 6, which is characterized in that: in step (a), the pH of cooking wastewater is adjusted to 4.0?5.5 before the addition of the flocculant.

10. The method according to claim 6, which is characterized in that: in step (b), the membrane for microfiltration is ceramic microfiltration membrane with aperture of 0.22 ?m, and the running pressure and temperature are 0.2 MPa and 20?50? C., respectively; in step (c), the aperture of the ultrafiltration membrane is 50000 Da, and the running pressure and temperature are 0.6 MPa and 20?40? C., respectively; in step (d), the aperture of the nanofiltration membrane is below 200 Da, and the running pressure and temperature are 1.5 MPa and 20?40? C., respectively; in step (d), the membrane for reverse osmosis treatment is cellulose triacetate membrane with aperture of 5?10 nm, and the running pressure and temperature are 2.5 MPa and 20?40? C., respectively.

Description

(1) FIG. 1 describes the flow chart of the method of continuous on-board processing of seafood after fishing on the sea.

DETAILED DESCRIPTION

(2) The present invention is further described with examples together with the FIGURE. However, the protection range of the present invention is not limited to the examples.

(3) The electrodialysis device adopted in the present invention consists of a membrane stack of 8 cation and 7 anion membranes placed at regular intervals. Both of the cation membrane CMX and anion membrane AMX are provided by Zhejiang Circle-tech Membrane Technology Co., Ltd.

Example 1

(4) Referring to FIG. 1, a continuous on-board processing of fish or shrimp after fishing on the sea is executed as follows:

(5) 1) Cleaning and sorting of fishing shrimp: The fresh and live shrimp is cleaned by seawater, sorted. The temperature of seawater is controlled between 0? C. to 10? C.

(6) 2) Cooking: 2000 L of cooking soup containing a quality improver are put into a cooking tank. The cooking soup containing the quality improver is composed of edible alcohol (2 kg, produced by Jiangsu Donghai Shuntai Alcohol Co. Ltd.), glucono-delta-lactone (1 kg), tea polyphenol (4 kg), perilla juice (2 kg, produced by Zhejiang Shizi Bio-tech Co. Ltd.), hexametaphosphate (5 kg), and water. The cooking soup in the tank is heated until the temperature is up to 90? C. The shrimp is added into the tank to cook for 6 min, with the purpose of inactivation of enzyme (mainly endogenous proteases), reduction of microorganism, and meat dewatering. The solid-liquid ratio is controlled at 1:10. The cooking soup is replaced with new one every 2 hours. The replaced cooking soup (i.e., heat processing wastewater) should be treated to become more suitable for environment.

(7) 3) After leached on a stainless steel net, the cooked shrimp is put onto a vibrating screen with a vibrating frequency of 750 r/min, to remove the water droplets on the shrimp.

(8) 4) Drying: the shrimp is put evenly onto conveyor belt to go into a 7-layer hot-air drying cabinet for gradually drying: stage one: the drying temperature is controlled at 60? C., the drying air velocity is 2.6 m/s, and the drying time is 5 min; stage two: the drying temperature is controlled at 65? C., the drying air velocity is 1.0 m/s, and the drying time is 25 min; stage three: the drying temperature is controlled at 60? C., the drying air velocity is 0.8 m/s, and the drying time is 15 min.

(9) 5) Impurity removal by vacuum: Impurities such as small antennas mixing in dried shrimp are removed by vacuum at a relative vacuum degree of ?15 kPa.

(10) 6) Cooling: the shrimp is put into a cooling cabinet at ?5? C. for 3 min. The temperature of the shrimp decreased rapidly to 0?10? C. The dried shrimp product is obtained.

(11) 7) Screening: The dried shrimp product is screened according to the shape size.

(12) 8) Packaging and storage: the screened dried shrimp is subjected to packaging according to its specifications and then to storing at ?18? C.

(13) The dried shrimp obtained according to the method mentioned above displays natural colour, uniform texture, and original flavor and taste.

Example 2

(14) 1) 200 kg of clove fish are cleaned by seawater, and sorted. The temperature of seawater is controlled between 0? C. and 10? C.

(15) 2) 1000 L of cooking soup containing a quality improver are put into cooking tank. The cooking soup containing the quality improver is composed of salt (60 kg), edible alcohol (2 kg, produced by Jiangsu Donghai Shuntai Alcohol Co. Ltd.), glucono-delta-lactone (4.5 kg), tea polyphenol (200 g), perilla juice (1 kg, produced by Zhejiang Shizi Bio-tech Co. Ltd.), hexametaphosphate (500 g) and water. The cooking soup in the tank is heated until the temperature is up to 100? C. The clove fish (200 kg) is added into the tank to cook for 2 min. The cooking soup is replaced with new one every 2 hours. The replaced cooking soup (i.e., heat processing wastewater) should be treated to become more suitable for environment.

(16) 3) After leached on a stainless steel net, the cooked clove fish is put onto a vibrating screen with vibrating frequency of 750 r/min, to remove the water droplets on the clove fish.

(17) 4) Drying: the clove fish is put evenly onto conveyor belt to go into a 7-layer hot-air drying cabinet for gradually drying: stage one: the drying temperature is controlled at 60? C., the drying air velocity is 1.5 m/s, and the drying time is 5 min; stage two: the drying temperature is controlled at 75? C., the drying air velocity is 2.0 m/s, and the drying time is 10 min; stage three: the drying temperature is controlled at 60? C., the drying air velocity is 2.0 m/s, and the drying time is 12 min. The moisture content of the final dried clove fish is controlled not more than 40%.

(18) 5) Impurity removal by vacuum: Impurities mixing in the dried clove fish are removed by vacuum at a relative vacuum degree of ?80 kPa.

(19) 6) Cooling: the clove fish is put into a cooling cabinet at ?5? C. for 3 min. The temperature of the clove fish decreased rapidly to 0?10? C. The dried clove fish product is obtained.

(20) 7) Screening: The dried clove fish product is screened according to the shape size.

(21) 8) Packaging and storage: the screened dried clove fish is subjected to packaging according to its specifications and then to storing at ?18? C.

(22) The dried clove fish obtained according to the method mentioned above displays natural colour, uniform texture, and original flavor and taste.

Example 3

(23) 1) 250 kg of acete chinensis with 2 cm length are cleaned by seawater, and sorted. The temperature of seawater is controlled within 0?10? C.

(24) 2) the acete chinensis is brought into cooking tank with a bucket elevator. 2000 L of cooking soup containing a quality improver is put into cooking tank. The cooking soup containing the quality improver is composed of salt (50 kg), edible alcohol (6 kg, produced by Jiangsu Donghai Shuntai Alcohol Co. Ltd.), glucono-delta-lactone (5 kg), tea polyphenol (2 kg), perilla juice (1 kg, produced by Zhejiang Shizi Bio-tech Co. Ltd.), hexametaphosphate (5 kg), and water. The cooking soup in the tank is heated to 98? C. and maintained for 4 min. The cooking soup is replaced with new one every 2 hours. The replaced cooking soup (i.e., heat processing wastewater) should be treated to become more suitable for environment.

(25) 3) After leached on a stainless steel net, the cooked acete chinensis is put onto a vibrating screen with vibrating frequency of 750 r/min, to remove the water droplets on the acete chinensis.

(26) 4) the acete chinensis is put evenly onto conveyor belt to go into a 7-layer hot-air drying cabinet for gradually drying: stage one: the drying temperature is controlled at 60? C., the drying air velocity is 2.5 m/s, and the drying time is 15 min; stage two: the drying temperature is controlled at 70? C., the drying air velocity is 2.0 m/s, and the drying time is 20 min; stage three: the drying temperature is controlled at 60? C., the drying air velocity is 1.5 m/s, and the drying time is 15 min. The moisture content of the final dried acete chinensis is 22%.

(27) In the present example, the steps 5) to 8) are the same to Example 1.

(28) The dried acete chinensis obtained according to the method mentioned above displays natural colour, uniform texture, and original flavor and taste.

Example 4

(29) 1) 300 kg of clove fish with 2 cm length are cleaned by seawater, and sorted. The temperature of seawater is controlled between 0? C. and 10? C.

(30) 2) 3000 L of cooking soup containing a quality improver are put into a cooking tank. The cooking soup containing the quality improver is composed of salt (9 kg), edible alcohol (15 kg, produced by Jiangsu Donghai Shuntai Alcohol Co. Ltd.), glucono-delta-lactone (6 kg), tea polyphenol (3 kg), perilla juice (2.4 kg, produced by Zhejiang Shizi Bio-tech Co. Ltd.), hexametaphosphate (3 kg), and water. 300 kg of clove fish with 2 cm length are put into the cooking soup in the tank. The cooking soup is heated to 95? C. and maintained for 4.5 min. The cooking soup is replaced with new one every 2 hours. The replaced cooking soup (i.e., heat processing wastewater) should be treated to become more suitable for environment.

(31) 3) After leached on a stainless steel net, the cooked clove fish is put onto a vibrating screen with vibrating frequency of 750 r/min, to remove the water droplets on the clove fish.

(32) 4) The clove fish after dewatering is put evenly onto conveyor belt to go into 7-layer hot-air drying cabinet, the drying parameters are controlled as follows: stage one: the drying temperature is controlled at 60? C., the drying air velocity is 1.2 m/s, and the drying time is 8 min; stage two: the drying temperature is controlled at 70? C., the drying air velocity is 2.2 m/s, and the drying time is 15 min; stage three: the drying temperature is controlled at 60? C., the drying air velocity is 2.0 m/s, and the drying time is 15 min.

(33) In the present example, the steps 5) to 8) are the same to Example 2.

(34) The dried clove fish obtained according to the method mentioned above displays natural colour, uniform texture, and original flavor and taste.

Example 5

(35) During the processing mentioned above, a huge number of cooking wastewater is produced. The cooking wastewater contains abundant nutrients and flavor compounds such as polypeptides, amino acids, carbohydrates, and nucleic acids.

(36) 1) Cooling and removal of suspended substances: An aliquot of 2000 L of cooking wastewater from shrimp in Example 1 is cooled down to 55? C., and then filtrated by a cloth bag.

(37) 2) Flocculation and precipitation: The pH of the filtrated cooking wastewater is adjusted by citric acid or acetic acid to 5.5. Then 800 g of flocculant (i.e. diatomite, produced by Kunming Shuixiao Sci-tech Co. Ltd.) are added. The waste is stirred for 8 min and standing for 10 min until the floccule appears.

(38) 3) Centrifugation and separation: The precipitate is obtained by centrifugation separation with a centrifuge (DBSDH5, Yixing Haide Separation Machinery Co. Ltd.). The supernatant is cooking wastewater after pre-treatment, with the salt content of 1.44 g/100 mL, the amino acid nitrogen content of 20.15 mg/100 mL, and the soluble protein content of 1.46 mg/100 mL.

(39) 4) Microfiltration separation: The ceramic membrane with aperture of 0.22 ?m is used for microfiltration membrane. 1800 L of the cooking wastewater after pre-treatment is subjected to microfiltration with the running pressure and temperature of 0.2 MPa and 25?30? C., respectively. The permeate solution after microfiltration treatment flows into the ultrafiltration device.

(40) 5) Ultrafiltration separation: The ultrafiltration membrane with aperture of 50000 Da is used, and the running pressure and temperature of 0.6 MPa and 25?30? C., respectively. The permeate solution after ultrafiltration treatment flows into the nanofiltration device.

(41) 6) Nanofiltration separation: The nanofiltration membrane device with aperture of 90 Da is used for nanofiltrate the permeate solution after ultrafiltration treating, and the operation pressure and temperature are 1.5 MPa and 25?30? C., respectively. The permeate and retention solutions are obtained. The retention solution has the salt content of 1.67 g/100 mL, the amino acid nitrogen content of 152.4 mg/100 mL, and the soluble protein content of 10.77 mg/100 mL. Compared with the cooking wastewater after pre-treatment, the cooking wastewater is concentrated by around 7 times. The treated permeate solution can be reused for shrimp cooking, to achieve recycling usage standard.

Example 6

(42) 1) Cooling and removal of suspended substances: 2000 L of cooking wastewater from clove fish in Example 2 are cooled down to 40? C., and then filtrated by a cloth bag.

(43) 2) Flocculation and precipitation: The pH of the filtrated cooking wastewater is adjusted by citric acid to 4.8. Then 800 g of flocculant (diatomite, produced by Kunming Shuixiao Sci-tech Co. Ltd.) are added. The wastewater is stirred for 8 min and standing for 10 min until floccule appears.

(44) 3) Centrifugation and separation: The precipitate is obtained by centrifugation separation with a centrifuge (DBSDH5, Yixing Haide Separation Machinery Co. Ltd.). The supernatant is cooking wastewater after pre-treatment, with the salt content of 3.22 g/100 mL, the amino acid nitrogen content of 32.71 mg/100 mL, and the soluble protein content of 4.1 mg/100 mL.

(45) 4) Microfiltration separation: The ceramic membrane with aperture of 0.22 ?m is used for microfiltration separation. 1800 L of the cooking wastewater after pre-treatment are subjected to microfiltration with the running pressure and temperature of 0.2 MPa and 25?30? C., respectively. The permeate solution after microfiltration treatment flows into the ultrafiltration device.

(46) 5) Ultrafiltration separation: The ultrafiltration membrane with aperture of 50000 Da is used, and the running pressure and temperature are 0.6 MPa and 25?30? C., respectively. The permeate solution after ultrafiltration treatment flows into the electrodialysis device. The permeate solution after ultrafiltration has the salt content of 3.50 g/100 mL, the amino acid nitrogen content of 128.53 mg/100 mL, and the soluble protein content of 16.5 mg/100 mL. Compared with the cooking wastewater after pre-treatment, the cooking wastewater is concentrated by around 4 times.

(47) 6) The permeate solution after ultrafiltration is subjected to electrodialysis treatment. The parameters for electrodialysis treatment are as follows: temperature 20? C., current 3 A, flow rate 40 L/h. According to the prediction model for the desalting ratio, the desalting ratio is 85.3%. In the practical desalted solution after electrodialysis treatment, its salt content is 0.49 g/100 mL, and the desalting ratio is 86%. The result indicates the present invention of the prediction model for the desalting ratio can accurately predict the desalting ratio.

(48) The desalted solution flows into reverse osmosis device, which adopts cellulose triacetate (CTA) membrane (produced by Japanese Toyobo Co. Ltd.) with aperture of 5?10 nm, and the running pressure and temperature of 2.5 MPa and 26? C., respectively. The permeate and retention solutions are obtained. The retention solution has the salt content of 2.83 g/100 mL, the amino acid nitrogen content of 190.53 mg/100 mL, and the soluble protein content of 13.2 mg/100 mL. Compared with the cooking wastewater after pre-treatment, the cooking wastewater is concentrated by around 6 times. The treated permeate solution can be discharged directly and reused.

Example 7

(49) 1) Cooling and removal of suspended substances: 2000 L of cooking wastewater from clove fish in Example 4 are cooled down to 25? C., and then filtrated by a cloth bag.

(50) 2) Flocculation and precipitation: The pH of the filtrated cooking wastewater is adjusted by acetic acid to 4.0. Then 800 g of flocculant (diatomite, produced by Kunming Shuixiao Sci-tech Co. Ltd.) are added. The wastewater is stirred for 8 min and standing for 10 min until floccule appears.

(51) 3) Centrifugation and separation: The precipitate is obtained by centrifugation separation with a centrifuge (DBSDH5, Yixing Haide Separation Machinery Co. Ltd.). The supernatant is cooking wastewater after pre-treatment, with the salt content of 3.8 g/100 mL, the amino acid nitrogen content of 41.25 mg/100 mL, and the soluble protein content of 3.4 mg/100 mL.

(52) 4) Microfiltration separation: The ceramic membrane with aperture of 0.22 ?m is used for microfiltration. 1800 L of the cooking wastewater after pre-treatment are subjected to microfiltration with the running pressure and temperature of 0.2 MPa and 25?30? C., respectively. The permeate solution after microfiltration treatment flows into the ultrafiltration device.

(53) 5) Ultrafiltration separation: The ultrafiltration membrane with aperture of 50000 Da is used, and the running pressure and temperature are 0.6 MPa and 25?30? C., respectively. The permeate solution after ultrafiltration has the salt content of 3.8 g/100 mL, the amino acid nitrogen content of 40.6 mg/100 mL, and the soluble protein content of 3.1 mg/100 mL.

(54) 6) The permeate solution after ultrafiltration is subjected to a combined technology of electrodialysis and reverse osmosis treatment. The permeate solution after ultrafiltration treatment flows into the electrodialysis device. The parameters for electrodialysis treatment are as follows: temperature 20? C., current 3 A, flow rate 300 L/h. According to the prediction model for the desalting ratio, the desalting ratio is 86.2%. In practical desalted solution after electrodialysis treatment, its salt content is 0.54 g/100 mL, and the desalting ratio is 85.7%.

(55) The desalted solution flows into a reverse osmosis device, which adopts cellulose triacetate (CTA) membrane (produced by Japanese Toyobo Co. Ltd.) with aperture of 5?10 nm, and the running pressure and temperature of 2.5 MPa and 20? C., respectively. The permeate and retention solutions are obtained. The retention solution has the salt content of 3.6 g/100 mL, the amino acid nitrogen content of 276.8 mg/100 mL, and the soluble protein content of 21.56 mg/100 mL. Compared with the cooking wastewater after pre-treatment, the cooking wastewater is concentrated by around 6.6 times. The treated permeate solution can be discharged directly.