ReValue Project- Industry Visits. Nutan Kaushik Amity University, Noida

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Martin Rodgers
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1 ReValue Project- Industry Visits Nutan Kaushik Amity University, Noida

2 Project Team Amity University Dr. V. K. Modi Amity University, Noida Project Participants Dr. Ashutosh Srivastava Amity University, Noida Project Participants Ms. Khushboo Amity University, Noida JRF and Ph. D. Scholar Ms. Soumya Amity University, Noida JRF Ms. Asha Kumari Amity University, Noida Technical Assistant and Ph. D. Scholar

3 Visit to Mumbai Dockyard and Kaiko Surimi-Refrigerated Distributors Private Limited

4 Fishing Boat

5 Basic sorting of fishes according to species of fish are done on boat itself. Inbuilt compartments ranging from in number Each compartment has a capacity of 600 kg. They are filled with crushed ice which remains frozen state for approximately 15 days. Average fishing duration is of 10 days

6 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 Crates used to transport fish 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 (interstate ). 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

7 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

8 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

9 Annual Production of RRM Product Amount ( tons/ year) Scale Fat Skin & bones Surimi Wash water is produced at the rate of 20L /hour Total production of plant is 20 tons per day.

10 FISH TYPE COMMON NAME SCIENTIFIC NAME Non Histamine Forming Pink Perch Nemipterus sp Big eye Ribbon fish Priacanthus harmur lepuracanthus savala/ Trichiurus lepturus Lizard fish Croaker fish Barracuda Reef cod Bronze croaker Saurida sp Johnius sp. Sphyraena sp. Eplinephelus sp. Otolithoides biaurituds Histamin Forming Sardine Sardinella longiceps Mamakari Sardinella brachysoma Variety of fishes used for Kaiko surimi production

11 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

12 (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

13 Deboner Fish washer

14 Dehydrator Washer (Rotary Screen )

15 Contact Plate Freezer Frozen Surimi Block

16 Rest Raw Material Percentage Scale 5-7 Fat 2-3 Skin &bone Surimi 42-45

17 Bawa Fishmeal and Oil co. Mangalore based fishmeal and fish oil producing industry Production capacity of 550 MT fishmeal per day

material is received from Maharashtra, Goa, Karnataka, Tamil Nadu and Kerala

18 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.

19 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

$Cooked fish are then subjected to pressing in tin screw conveyor type press Pressing separates liquid fraction from$

20 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.

21 Press cake obtained after screw press is subjected to drying in steam drier where a temperature of 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

Fishmeal is added with antioxidant (BHT, TBHQ) as per customer requirement.

25 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 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

26 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

27 Total time of production one batch is 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 Prime grade Super prime grade Premium grade

$From press two fractions are obtained i.e. press cake and other is press liquor.$ stick water is sent to overhead tank for further separation of oil and water Stick water

stick water is sent to overhead tank for further separation of oil and water Stick water

28 From press two fractions are obtained i.e. press cake and other is press liquor. For the fish oil press liquor after pressing step is collected in decanter from where stick water is sent to overhead tank for further separation of oil and water Stick water is pre-heated to a temperature of C using plate heat exchanger Decanter Plate heat exchanger

After pre-heating stick water is subjected to centrifugation @ 7000 rpm which leads to

29 After pre-heating stick water is subjected to 7000 rpm which leads to separation of oil and protein water This fish oil is then inspected, collected, packed and sold.

30 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.

31 Samples from Kaiko Surimi

32 Fish head (before thawing)

33 Refiner waste (after thawing)

34 Skin and bones sample

35 Surimi sample before drying

36 Oil from Pink Perch Head and Viscera

37 Refiner waste oil

38 Digestion of Industrial samples

YEDENT AGRO GROUP OF COMPANIES PROCESSING OF SOY BASED PRODUCTS FOR HUMAN FOODS AND POULTRY FEEDS

YEDENT AGRO GROUP OF COMPANIES PROCESSING OF SOY BASED PRODUCTS FOR HUMAN FOODS AND POULTRY FEEDS 1. SOYA EXTRUSION AND PRESSING PROCESS EQUIPMENT 1. The Pre Cleaner 2. The Course Mill 3. The Extruder