canada. fisheries service industrial development branch project...
TRANSCRIPT
Canada. Fisheries Service Industrial Development Branch
PROJECT REPORT
Ottawa/Hull 1972
SPECIALTY FISH PRODUCT DEVELOPMENT
IN NEWFOUNDLAND 1971
prepared by
Louis Lipton Haniff Madakia
for
Industrial Development Branch Fisheries Service
Environment Canada
acting in cooperation with
The Newfoundland Fisheries Development Authority
w. D. McDougall Project Supervisor
Opinions expressed and conclusions
reached by the author are not necessarily endorsed
by the sponsors of this project.
The Authors at a Product Development luncheon Show
( l. lipton (l), H. Madakia (R) )
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ii
ABSTRACT
As part of a program to improve the fishing
industry in Newfoundland, 24 new recipes for the
manufacture of foodstuff suited to the retail market
have been developed. These items have been well
accepted at luncheon shows in Newfoundland, in Prince
Edward Island, and in Ottawa and trial orders were
placed by major buyers.
iii
ACKNOWLEDGEMENTS
The entire project could not have been carried out as ef
fectively as it was, without the cooperation of many interested people.
Mr. Rupert Prince, of the Newfoundland Fisheries Development
Authority and Mr. Marvin Barnes, Newfoundland representative of the
Industrial Development Branch, Fisheries Service, Environment Canada
made all the facilities of their respective organizations available as
needed.
Miss Catherine O'Brien, Consumer Consultant in the St. John's
office of the Fisheries Service, Environment Canada was always ready
to assist us.
The Fisheries College in St. John's was most generous in al
lowing us to use the plant set up there for preparing samples with the
newly created recipes.
Bonavista Cold Storage Co. Ltd., Bonavista was most helpful
in permitting the use of plant facilities.
Above all, we are indebted to Mr. Wally MacDougall of the
Industrial Development Branch, Fisheries Service, Environment Canada
(Ottawa) who offered valuable encouragement and assistance in every
form.
We wish to express our sincere thanks to all the above, to
the members of their staffs and to the many other people who provided
assistance.
iv
Introduction
Summary
Product Development
Re.UEeA
1. Fish Stock
2. Stuffed Crab Shell
3. Crab Meat Puffs
4. Au Gratin Sauce
5. Shrimp Au Gratin
6. Crab Au Gratin
7. Scallop Au Gratin
8. Cod Au Gratin
9. Salt Cod Au Gratin
10. Shrimp Scampi on Bed
11. Shrimp Fried Rice
12. Chowder Concentrate
13. Fish Chowder
14. Seafood Chowder
15. Salmon Chowder
16. Shrimp Chowder
TABLE OF CONTENTS
of Rice
v
1
2
3
7
8
9
10
11
12
13
14
15
16
17
18
19
19
19
19
Table of Contents Cont'd
Page
17. Lobster Chowder . . . . 19
18. Stuffed Squid · · 20
Lemon Butter Sauce 21
19. Stuffed Baby Flounder . . · · . 22
20. Egg Milk Batter · . . . . . . . · · 23
21. Breading . . · .. . . . . . · • 24
22. Deep Fried Cod Strips . . . . . 24
23. Marinated Squid 25
24. Chips . . . · · 26
vi
INTRODUCTION
At the present time a large part of the Newfoundland fish
catch is sold in the form of frozen fillets with minimum processing
requirements.
During 1971 Environment Canada and the Newfoundland Fisheries
Development Authority carried out a "fish product development" program
in an effort to increase the value of the catch and the number of jobs
available in the processing and related industries (e.g. packaging,
advertising, transportation), and to generally assist in diversifying
the fishing industry.
Several new products were developed using the fish available
in Newfoundland waters. Some of the ingredients utilized were by
products normally discarded or utilized in fish meal.
- 1 -
SUMMARY
The program was directed mainly to the development of frozen
products for several reasons:
1. most plants in the area are equipped with freezing
facilities
2. the frozen product is better tasting than the canned and
is very similar to the fresh product
3. the market for prepared frozen products is steadily growing
and all kinds of consumers are receptive to such new items.
The recipes prepared resulted in specialty foods which could
be mass produced to be sold at popular prices. In addition to super
market products which will find their way into the average home, the
program also developed products suitable for institutional and restaurant
trade, airline and railroad service and in-plant feeding.
A survey of several plants was made in order to determine the
catch distribution and the equipment available to each. The results
were used in selecting the products each plant was best able to produce.
Thus, recipes and procedures were tailor-made to each situation. Sample
batches of all new products were prepared for evaluation in Canada and
in the United States.
In Canada, eight luncheon shows were arranged to introduce
the products to potential customers.
- 2 -
Fish Steaks on a bed of Lumpfish Caviar trimmed with Smoked Char Slices
PRODUCT DEVELOPMENT
Most of the work was carried out at the Bonavista Cold Storage
Limited Plant in Bonavista. Some work utilizing vacuum packaging
techniques, was carried out at the Department of Fish Technology,
Fisheries College, St. John's.
The facilities of the test kitchen, Information and Consumer
Branch, Fisheries Service, Environment Canada, St. John's were also
utilized in the product development.
About 20 products were developed utilizing raw materials such
as scallop, shrimp, crab, lobster, cod, flounder, salmon, halibut, and
lumpfish roe. Some work was also carried out on suitable packaging
materials and convenient packaging for the products. Vacuum pack
'boil in bag' products were produced at the Fisheries College.
Fish frames were used as a principle ingredient. These are
the principle by-product from filleting lines and are presently used
for reduction to fish meal. A quantity of fish stock was prepared and
frozen for future use.
Lumpfish roe was processed into lumpfish caviar in 2 oz. and
3 oz. jars and also as bulk fresh lumpfish caviar. The caviar was dyed
black or red and the jar lumpfish caviar was later pasteurized in St.
John's and stored in a chill room. For details of the process, refer
to Technical Report No. 7 (1).
- 3 -
Processing Lumpfish Caviar - A Progress Report of Work in 1970 by
A.B. Dewar, Louis Lipton and G.E. Mack, of the Applied Research and
Development Laboratory, Inspection Branch, Canada Department of Fisheries
and Forestry, Maritimes Region, Fisheries Service, Halifax, N.S.,
March 1971.
The chowders were prepared next, in frozen concentrate form,
to be diluted by the consumer. They were:
(i) Fish chowder from any species of raw groundfish
(ii) Seafood chowder from a mixture of shrimp, salad crabmeat and fish
(iii) Salmon chowder from salmon
(iv) Shrimp chowder from pink shrimp
(v) Lobster chowder from lobster
The chowders were packed in 1/2 lb. and 1 lb. boil-in bags,
sealed and quick frozen.
The next products developed were the Au Gratins. They were:
(i) Shrimp Au Gratin
(ii) Crab Au Gratin
(iii) Scallop Au Gratin
(iv) Fresh Cod Au Gratin
(v) Salt Cod Au Gratin
- 4 -
The Au Gratin are packed in aluminum trays of two sizes, 1/2 lb.
and 1 lb., with a see-through plastic lid and are quick frozen. All the
customer has to do is to remove the plastic lid and place the frozen
Au Gratin tray in the oven to heat it before use.
Until the present time the plants processing snow crab in
Newfoundland were throwing away the shell (carapace) of the crabs. We
developed a product called stuffed crab shell. The shells are thoroughly
cleaned and sterilized before being filled with stuffing made from salad
crab meat and filler and are then quick frozen. They are packed 36
shells to a carton or 2 shells per tray for the supermarket trade. The
other product developed from salad crab meat was crab meat puffs; the
crab mixture is rolled into balls which may be frozen raw or deep fried
and then frozen. The balls are packed in 1 lb. poly bags or in aluminum
trays for the "heat and eat" trade if they have been pre-cooked.
Two seafood sauces were prepared utilizing shrimp, squid,
salad crabmeat and fish; they are seafood sauce with cream and seafood
sauce with tomato sauce.
A product called stuffed "Baby" flounder was prepared from
small flounder. It consists of stuffing between fillets. These are
dipped in batter and breaded and are quick frozen raw. The stuffed
"Baby" flounder is packed in aluminum trays and could be "baked or fried"
during processing or, by the consumer, during preparation for serving.
Pink shrimp caught in Newfoundland waters were prepared in
two forms:
(i) Shrimp scampi on a bed of rice
(ii) Shrimp fried rice.
- 5 -
The Shrimp scampi is packed in aluminum trays with transparent lid and
the shrimp fried rice in 1/2 pound and 1 pound size 'boil-in bags' which
are then sealed. Both products are quick frozen.
Two different squid recipes were prepared:
(i) Stuffed squid
(ii) Marinated squid
The stuffed squid is packed in aluminum trays and quick frozen, and the
marinated squid is packed in jars and kept refrigerated.
Packed 'portion control' halibut and salmon steaks in boil-in
bags from 4 to 12 ozs.were prepared, vacuum sealed and quick frozen.
Cod strips, cod cheeks, cod tongues, and capelin were prepared in heat
and serve form. These products were dipped in egg-milk batter and rolled
in breading prior to deep frying. They were then quick frozen.
With more research and development, the recipes presented here
and the technology used can be modified or improved to give better and
more attractive products. Some of the recipes, as presented here, are
small batches or test formulations. They may be used as the basis of a
commercial operation. Since the recipes are bland, they can be adjusted
to suit the particular flavor or characteristic the producer wishes to
emphasize.
No attempt was made to determine the exact cost of production
of the various recipes discussed in this report, as the objective of the
work was to determine whether or not high quality food products could be
achieved in a frozen package acceptable to the consumer.
- 6 -
Recipe No.1 - Fish Stock
The following ingredients are placed in a 50 gallon steam
-jacketed kettle.
125 lb. fish frames
1/2 lb. salt
1/4 lb. pepper
*Fish frames, with gills and eyes removed, are thoroughly washed.
These and the other ingredients are then placed in the kettle. Water is
added to 6 inches below the top of the kettle. Bring to low boiling
point and cook for 2 hours. Shut off the steam and let the mixture
settle for 15 minutes. Skim the froth from the top and discard it.
Thoroughly strain the mixture. The liquid so obtained is the stock.
The fish stock can be packaged for sale or utilized for the
recipes in this report. The remains of the fish frames could be used in
a fish meal plant.
*Fish frames are the parts of the fish left after the fillets have been
removed.
- 7 -
Stuffed Crab Shell
Recipe No. 2 - Stuffed Crab Shell
8 lb. of (fine) bread crumbs or 2 tblsp. pepper cracker crumbs
2 tblsp. onion powder 5 lb. of margarine
2 tblsp. celery seed 1 1/4 lb. corn flake crumbs
2 tblsp. parsley flakes 10 lb. salad crab meat
2 tblsp. Italian seasoning 3 tblsp. monosodium glutamate
1 tblsp. garlic powder 6 u.s. qt. fish stock
1 tblsp. cayenne pepper 1 tblsp. oregano
1 tblsp. paprika 4 tblsp. salt
Melt the margarine in a pot and add the fish stock. Place
the bread crumbs and corn flake crumbs in a bowl or mixer, add the
spices and mix thoroughly. Blend the salad crab meat into the dry
mixture. Slowly add the liquid to the dry mixture.
Clean the carapaces and fill with stuffing (4 oz.). Sprinkle
the stuffing surface with parsley flakes and paprika. Freeze!
- 8 -
Crab Meat Puffs
Recipe No.3 - Crab Meat Puffs
5 lb. salad crab meat
4 lb. bread or cracker crumbs
10 oz. corn flake crumbs
1 lb. margarine
3 u.s. qt. fish stock
2 tblsp. salt
2 tblsp. parsley flakes
1 tblsp. pepper
1 tblsp. paprika
1 tblsp. monosodium glutamate
1 tblsp. Italian seasoning
1/2 tblsp. garlic powder
1 tblsp. onion powder
1/2 tblsp. cayenne pepper
1/2 tblsp. oregano
Melt the margarine in pot, add fish stock to it. Place the
bread crumbs and corn flake crumbs in a bowl or mixer, add all the
spices and mix thoroughly. Blend in all salad crab meat. Slowly add
the liquid mixing it with the other ingredients. Continue mixing
until an even consistency is attained.
Roll the mixture into balls, 16 to 20 balls to a pound.
Freeze them. 3 u.S. quarts = 2 1/2 Imp. quarts = 2 Litres.
- 9 -
Au Gratins
Recipe No.4 - Au Gratin Sauce
3 U.S. gal. fish stock
3 lb. cheddar spread
2 tblsp. onion flakes
2 tblsp. pepper
2 tblsp. salt
2 tblsp. parsley flakes
2 tblsp. monosodium glutamate
3 cups mushrooms
1 tblsp. garlic powder
1 tblsp. Italian seasoning
1 tblsp. oregano
1 tblsp. all-purpose mixed spices
1/2 tblsp. cayenne pepper
1 lb. margarine
1 lb. corn starch
1 tblsp. cream of tarter
1 1/2 lb. all-purpose flour
Place all the above ingredients except the corn starch, flour,
and cream of tartar in 2 gallons of fish stock in a pot. Bring the
mixture to a boil and let it simmer.
Prepare the thickening agent by mixing the all-purpose flour,
corn starch, and cream of tartar in a high speed beater.
Add the remaining gallon of cold fish stock to the thickener.
Mix slowly until a smooth batter is obtained. It should be thick enough
to flow smoothly.
Add the batter to the seasoned stock, stirring constantly,
until liquid thickens.
- 10 -
Recipe No.5 - Shrimp Au Gratin
3 u.s. gal. au gratin sauce (Recipe No.4)
5 lb. cooked, peeled, deveined pink shrimp
Parsley flakes
Paprika
The deveined pink shrimp is put into the pot of simmering
Au Gratin sauce and the mixture is stirred gently. When the mixture
is thoroughly blended, it is poured into a container of the desired size.
Add cheddar cheese to cover the surface of the product, sprinkle with
parsley flakes and paprika for decoration. Cover and freeze.
- 11 -
Recipe No.6 - Crab Au Gratin
3 U.S. gal. au gratin sauce (Recipe No.4)
5 lb. cooked crabmeat
Shredded cheddar cheese
Parsley flakes
Paprika
Add the cooked crabmeat to the pot of simmering Au Gratin
sauce. Stir gently. When the mixture is blended, pour it into a
container of desired size. Place 3 whole crab legs on top before
adding the shredded cheddar cheese to cover the surface of the product.
Sprinkle parsley flakes and paprika for decoration. Cover and freeze.
- 12 -
Recipe No.7 - Scallop Au Gratin
3 u.s. gallons au gratin (Recipe No.4)
5 lb. scallops
Cheddar cheese
Parsley flakes
Paprika
The scallops are parboiled for 5 minutes. They are then gently
stirred into simmering Au Gratin Sauce. When the mixture is thoroughly
blended, it is poured into a container of the desired size. To the
filled container, add shredded cheddar cheese to cover the surface of
the mixture. Sprinkle with parsley flakes and paprika for decoration.
Cover and freeze.
- 13 -
Recipe No.8 - Cod Au Gratin
3 u.s. gallons au gratin sauce (Recipe No.4)
5 lb. cod fillets
Shredded cheddar cheese
Parsley flakes
Paprika
The cod is parboiled for 5 minutes and then put into the pot
of simmering Au Gratin sauce. Stir gently. When these are thoroughly
blended pour the mixture into a container of suitable size. To the filled
container, add shredded cheddar cheese to cover the product. Sprinkle
with parsley flakes and paprika for decoration. Cover and freeze.
- 14 -
Recipe No.9 - Salt Cod Au Gratin
3 u.S. gallons au gratin sauce (Recipe No.4)
5 lb. salt cod
2 cans evaporated milk
Shredded cheddar cheese
Parsley flakes
Paprika
Soak 5 lb. of the salt cod overnight in fresh water. Dice or
shred the freshened salt cod and put it into the pot of simmering
Au Gratin sauce. Add 2 cans of evaporated milk and stir gently. When
blending is complete, pour the mixture into container of the desired size.
Cover the mixture with shredded cheddar cheese. Garnish with parsley
flakes and paprika. Cover and freeze.
- 15 -
Shrimp Scampi on a Bed of Rice
Recipe No. 10 - Shrimp Scampi on Bed of Rice
5 lb. converted rice 2 tblsp. garlic powder
7 lb. cooked, peeled pink shrimp 1 tblsp. onion flakes
3 cups mushrooms 1 tblsp. pepper
3 lb. margarine 2 tblsp. salt
1 tblsp. monosodium glutamate 2 tblsp. arrowroot
Parsley flakes 6 oz. sherry
Paprika
Boil 5 lb. of converted rice. Wash and drain it thoroughly.
Melt margarine, add all spices and 6 oz. of sherry. Blend. Add the
shrimp.
Half fill a container with cooled drained rice, and pour
the scampi sauce over the riee. Sprinkle with parsley flakes and
paprika.
- 16 -
Shrimp Fried Rice
Recipe No. 11 - Shrimp Fried Rice
2 1/2 lb. shrimp 2 tblsp. pepper
10 lb. converted rice 2 tblsp. onion flakes
3 cups mushrooms, 2 tblsp. monosodium glutamate sterns and pieces, drained, chopped
1 tblsp. oregano 4 oz. salt
1 tblsp. garlic powder 14 oz. soya sauce
1 tblsp. Italian seasoning 2 tblsp. gravy browning
Boil 10 lb. of rice. Wash and drain it thoroughly. Place
the rice in a mixing bowl. Add the spices and mushrooms to the cooked
rice. Mix thoroughly and gently. Add the gravy browning and soya
sauce and mix again. Add the shrimp and mix again. Place in vacuum
pack bags from 1/2 lb. up. Vacuum seal and freeze.
- 17 -
Recipe No. 12 - Chowder Concentrate
3 1/2 gals. fish stock (Recipe No. 1) 1 lb. corn starch
20 lb. peeled, diced raw potatoes 6 oz. salt
12 medium size onions, diced 4 oz. pepper
2 stalks of thinly sliced celery 4 cans of evaporated milk (6 oz.)
1 1/2 lb. all-purpose flour 1 1/2 lb. margarine
Add the vegetables, spices, flour and corn starch to the pot
of fish stock. Let the mixture boil for 15 minutes. Then add the
evaporated milk and margerine.
Prepare the thickening agent by lending 1/2 lb. of all-purpose
flour with 1 lb. corn starch. Use a high speed beater. Add 1 qt. cold
fish stock slowly until a smooth batter is obtained. It should be thick
enough enough to flow smoothly. Add batter to the pot of boiling liquid,
stirring until the liquid thickens.
Chill the cooked chowder thoroughly. Fill the vacuum pack
bags (from 16 oz. up) and freeze.
- 18 -
Recipe No. 13 - Fish Chowder
1 batch concentrated chowder (Recipe No. 12)
1 batch thickener
10 lb. of any species of ground fish
Prepare the chowder concentrate (Recipe No. 12) but before adding the
thickener, add the ground fish. Cook slowly for a further 10 minutes,
then add thickener slowly until a thick texture is obtained.
Recipe No. 14 - Seafood Chowder
Use Recipe No. 13, replacing the ground fish with 10 lb. mixed shrimp,
salad crab meat, and fish.
Recipe No. 15 - Salmon Chowder
Use Recipe No. 13, replacing the ground fish with 10 lb. of salmon.
Recipe No. 16 - Shrimp Chowder
Use Recipe No. 13, replacing the ground fish with 5 lb. of broken pieces
of shrimp.
Recipe No. 17 - Lobster Chowder
Use Recipe No. 13, replacing the ground fish with 3 lb. lobster meat.
- 19 -
Stuffed Squid
Recipe No. 18 - Stuffed Squid
Stuffing:
1 lb. hard bread crumbs
1 lb. any edible fish species
1 qt. (American) fish stock
1/2 lb. margarine
1/8 tsp. paprika
1 tblsp. salt
1/2 tblsp. pepper
1 tblsp. monosodium glutamate
1 tsp. parsley flakes
1 tsp. oregano
Meat tenderizer
Melt the margarine in the fish stock. Blend all the spices
and the fish with the hard bread crumbs. Then, slowly pour the liquid
into blended crumbs and mix thoroughly. The stuffing is now ready to
use.
Remove the tentacles and clean the squid thoroughly. Place
the cleaned squid into a meat tenderizer solution as directed by the
manufacturer (1/4 lb. of meat tenderizer powder to 6 qt. of water)
for 10 minutes. Remove the squid from the water, drain, and fill it
with the stuffing.
Place the stuffed squid in the container. Pour lemon butter
sauce* over the squid. Sprinkle with paprika and freeze.
- 20 -
*Lemon Butter Sauce
5 lb. margarine
1/4 lb. cream of tartar
2 oz. lemon juice
1/2 tsp. garlic powder
1/2 tsp. onion powder
1 tsp. salt
1 tsp. pepper
Melt the margarine and add the spices
- 21 -
Recipe No. 19 - Stuffed Baby Flounder
Stuffing:
1 lb. hard bread
1 lb. any edible
1 qt. (American)
1/8 tsp. paprika
1/2 lb. margarine
crumbs
fish species
fish stock
1 tblsp. salt
1/2 tblsp. pepper
1 tblsp. monosodium glutamate
I tsp. parsley flakes
1 tsp. oregano
Melt the margarine in fish stock. Blend all the spices and
the fish with the hard bread crumbs. Then, slowly pour the liquid into
the dry mixture and mix thoroughly.
Place the above stuffing between fillets. Then, dip the
stuffed baby flounder in egg-milk batter (see Recipe No. 20). Then,
bread, refer to breading recipe, Page 22, and freeze raw.
- 22 -
Recipe No. 20 - Egg Milk Batter
1 doz. eggs
1/2 lb. all purpose flour (sifted)
2 cans evaporated milk
2 tsp. corn starch
6 oz. oil.
Beat the eggs at a very high speed, blend with oil, milk,
then add flour and corn starch.
- 23 -
Recipe No. 21 - Breading
2 lb. fine milled hard bread 1 tsp. cayenne pepper
1 lb. extra fine corn flour 1 tblsp. allspice finely ground
1 lb. corn flake crumbs 2 tblsp. onion powder
1/2 lb. all purpose flour 1 tblsp. ground Italian seasoning
8 oz. corn starch 1 tblsp. paprika
1/4 lb. salt 2 tblsp. monosodium glutamate
2 tblsp. pepper 1 tsp. garlic powder
1 tsp. ground oregano
Mix all the above ingredients absolutely thoroughly.
Recipe No. 22 - Deep Fried Cod Strips
a) Cod Strips
b) Cod Cheeks
c) Cod Tongues
d) Capelin
Dip any of the above in egg-milk batter and roll in Breading,
(Recipe No. 21) and deep fry. Pack and freeze.
- 24 -
Recipe No. 23 - Marinated Squid
20. lb. of Squid
Pickling Solution
2 lb. sugar
1 qt. (American) white vinegar or cider vinegar
4 medium size onions, thinly sliced
1 tblsp. pickling spices
1 qt. water
Meat tenderizer
Place the squid into a meat tenderizer solution as directed
by the manufacturer (1/4 lb. of meat tenderizer powder to 6 qt. of
water) for 5 minutes. Remove and wash in hot water.
Cut the squid into pieces and place in pickling solution and
let stand for 3 days in the cooler. Pack in jars and keep refrigerated.
- 25 -
Recipe No. 24 - Chips
2 lb. tapioca flour
2 lb. fish
8 oz. cold water
1 egg
2 tblsp. salt
1 tsp. pepper
Beat the egg, water and spices thoroughly. Mince or grind
(extra fine) 2 lb. of any edible fish. Mix fish and flour thoroughly,
then slowly add the liquid and mix until the mixture is slightly moist.
Form into 1/2 lb. logs (1 1/2 inches diameter). Wrap in boil-in bags,
seal and place in retort at 2400 F. for 20 minutes. After cooking place
the logs in a refrigerator until the contents are sufficiently firm to
permit slicing. Slice into thin chips and dry thoroughly at 1000 - 2000 F.
maximum. Place the chips in plastic bag, and seal. Keep refrigerated.
The chips are deep-fat fried at 3500
- 3750
F. for about 10
seconds, or until they puff. The chips should swell about 3 times the
original size on frying.
- 26 -