Ice fraction assessment by near-infrared spectroscopy enhancing automated superchilling process lines

The objective of the current study was to analyze and develop some important automation steps in a superchilling process line. In order to control the product quality there is a need for online measurements of ice fraction and distribution in inhomogeneous products. Moreover, automatic handling of such superchilled products is currently commercially unavailable. The current study presents a new method for monitoring and handling superchilled product of varying form and consistency. Observation of the shift in the water absorption peak, measured by near-infrared spectroscopy (NIR) transflection mode, was used to determine the ice level in superchilled salmon, scanning approximately 1.5 cm into the fillets. The salmon fillets were stored on ice at 0 °C for 5–7 days before superchilling at −24 °C to target ice contents of 10%, 15% and 30%. Online NIR measurements of ice fraction showed promising results, with a low prediction error of 2.5%. The storage study confirmed former quality results with a microbiological shelf life of 15–17 days with only minor differences in values for drip loss and water-holding capacity between superchilled and chilled samples.     

A study of the ice crystal sizes of red muscle of pre-rigor Atlantic salmon (Salmo salar) fillets during superchilled storage

Pre-rigor salmon fillets were superchilled in an impingement freezer and stored at −1.7 ± 0.3 °C for 29 days. The objective of this work was to study the ice crystal sizes in red muscle of pre-rigor salmon fillets that were partially frozen at fast (−30 °C, 227 W/m² K, 2.1 min) which is referred to as process F and slow (−20 °C, 153 W/m² K, 4.2 min) which is referred to as process S during superchilled storage. It was observed that the size of intracellular ice crystals in pre-rigor muscles at faster superchilling rate was significantly (p < 0.05) smaller than that at slower superchilling rate. The size of ice crystals formed in pre-rigor muscle was significant (p < 0.05) smaller than that formed in post-rigor muscle. It was also observed that the size of intracellular ice crystals formed in pre-rigor red muscles was significant smaller than that in white muscle. In addition, a large number of small ice crystals are formed within the muscle during partial freezing of pre-rigor muscle compared to post-rigor muscle. Future research should focus on tests of the quality parameters separately in red and white muscles (pre- and post-rigor) during superchilled storage of food products in order to understand more about their characteristics (quality and shelf life).     

A study of the ice crystals in vacuum-packed salmon fillets (Salmon salar) during superchilling process and following storage

The aim of this work was to study the microstructure of vacuum-packed salmon fillets superchilled in an impingement freezer at −30 °C (air temperature) and 227 W/m² K (surface heat transfer coefficient, SHTC) for 2.1 min prior to storage at a superchilling storage temperature of −1.7 ± 0.3 °C for 28 days. The microstructure of vacuum-packed salmon fillets were analysed at the surface, mid-centre and centre layers. Significant differences were observed between the ice crystals formed at the surface, mid-centre and centre layers. The size of ice crystals at the centre of the superchilled fillets was 3 times larger than those at the surface layer. Significant differences were observed between the size of ice crystals formed during the superchilling process and following storage. The results further indicated that, after temperature equalisation (1 day of storage) the growth of the intracellular ice crystal was not significant at (P < 0.05) at any storage time.     

Quality changes during superchilled storage of cod (Gadus morhua) fillets

Superchilling is a method with potential for extending the shelf life of food products by partial freezing. For centuries, Atlantic cod (Gadus morhua) has been the most important commercial species in the North Atlantic fisheries and is now regarded as a very promising species in cold water fish farming. In the present work, superchilled storage at −2.2 °C of fillet portions of farmed cod was investigated. Superchilled cod showed increased shelf life with respect to reduced growth of sulphide producing bacteria compared to ice chilled. Drip loss was lower in superchilled cod. However, liquid loss by low-speed centrifugation was higher in superchilled cod fillets compared to ice chilled. This can be explained by freeze denaturation of muscle proteins, which is supported by the lower extractability of salt soluble proteins. There is a need for process optimization to minimize protein denaturation.     

Quality changes during superchilled storage of pork roast

Quality parameters (sensory, physical, biochemical and microbiological) of superchilled vacuum packed boneless pork roasts were studied during storage for 16 weeks. Superchilling of vacuum packed pork roast at a temperature of −2.0 °C improved shelf life significantly compared to traditional chilled storage at +3.5 °C. Superchilled pork roasts maintained good sensory quality and low microbiological counts during the whole storage period. The drip loss in superchilled samples was lower and showed less variation than in the references and the temperature abused roasts. The consequences of an interrupted cold chain during storage were also investigated. Superchilled samples with temperature abuse resembled chilled samples with respect to drip loss and microbial levels. To take advantage of all the benefits of superchilling and successfully implement the process in the food industry a stable, controlled temperature during storage is critical.     

The combined effect of superchilling and modified atmosphere packaging using CO2 emitter on quality during chilled storage of pre‐rigor salmon fillets (Salmo salar)

BACKGROUND: Pre‐rigor fillets of Atlantic salmon were either superchilled or chilled prior to packaging in air or in modified atmosphere (MAP, 60% CO₂/40% N₂) with a CO₂ emitter, in 5.3 L high‐density polyethylene trays with three to four layers of fillets (3.0–3.7 kg). All samples were stored at 0.1 °C for 28 days. RESULTS: Fillets stored in MAP had significantly lower bacterial growth compared to fillets stored in air, and MAP superchilled bottom fillets had lower bacterial counts compared to the corresponding chilled fillets. Samples superchilled prior to refrigerated storage in air had similar bacterial growth to ordinary chilled samples. Faster fillet softening during storage and higher liquid loss were observed in superchilled MAP samples. CONCLUSION: Combining short‐term superchilling and MAP with a CO₂ emitter prolonged the shelf‐life of pre‐rigor salmon fillets, which can improve sustainability throughout the value chain. The superchilling method needs to be optimized to avoid negative effects on texture and liquid loss. Copyright © 2009 Society of Chemical Industry     

A histological study of the microstructure sizes of the red and white muscles of Atlantic salmon (Salmo salar) fillets during superchilling process and storage

Atlantic salmon (Salmo salar) fillets were partial frozen in an impingement freezer at −30 °C and 227 W/m2.K for 2.1 min prior to storage at a superchilling storage temperature of −1.7 ± 0.3 °C for 28 days. The aim of this article is to study the microstructure of the red and white muscles during superchilling process and during superchilled storage. The histology and microscopic analysis of the red and white muscles were carried out. It was found that the size of the ice crystals formed in the red muscles was smaller than those formed in the white muscles. The equivalent diameters of the intracellular ice crystals obtained upon superchilling (day 0) were 17 ± 2 and 29 ± 1 μm for the red and white muscles, respectively. Significant differences were initially observed between the size of the ice crystals formed during the superchilling process and after 1 day of storage. However, after temperature equalisation (day 1), there was no significant change in the size of the ice crystals.     

Effects of −1.5 °C Super-chilling on quality of Atlantic salmon (Salmo salar) pre-rigor Fillets: Cathepsin activity,muscle histology,texture and liquid leakage

The aim of this study was to evaluate the impact of super-chilling on the quality of Atlantic salmon (Salmo salar) pre-rigor fillets. The fillets were kept for 45 min in a super-chilling tunnel at −25 °C with an air speed in the tunnel at 2.5 m/s, to reach a fillet core temperature of −1.5 °C, prior to ice storage in a cold room for 4 weeks. Super-chilling seemed to form intra- and extracellular ice crystals in the upper layer of the fillets and prevent myofibre contraction. Lysosome breakages followed by release of cathepsin B and L during storage and myofibre–myofibre detachments were accelerated in the super-chilled fillets. Super-chilling resulted in higher liquid leakage and increased myofibre breakages in the fillets, while texture values of fillets measured instrumentally were not affected by super-chilling one week after treatment. Optimisation of the super-chilling technique is needed to avoid the formation of ice crystals, which may cause irreversible destruction of the myofibres, in order to obtain high quality products.     

Relevance of calpain and calpastatin activity for texture in super-chilled and ice-stored Atlantic salmon (Salmo salar L.) fillets

The aim of the present experiment was to measure the protease activities in ice-stored and super-chilled Atlantic salmon (Salmo salar) fillets, and the effect on texture. Pre-rigour fillets of Atlantic salmon were either super-chilled to a core temperature of −1.5 °C or directly chilled on ice prior to 144 h of ice storage. A significantly higher calpain activity was detected in the super-chilled fillets at 6 h post-treatment compared to the ice-stored fillets and followed by a significant decrease below its initial level, while the calpastatin activity was significantly lower for the super-chilled fillets at all time points. The cathepsin B + L and B activities increased significantly with time post-treatment; however, no significant differences were observed at any time points between the two treatments. For the ice stored fillets, the cathepsin L activity decreased significantly from 6 to 24 h post-treatment and thereafter increased significantly to 144 h post-treatment. There was also a significantly lower cathepsin L activity in the super-chilled fillets at 0 h post-treatment. No significant difference in breaking force was detected; however, a significant difference in maximum compression (F_max) was detected at 24 h post-treatment with lower F_max in the super-chilled fillets. This experiment showed that super-chilling had a significant effect on the protease activities and the ATP degradation in salmon fillets. The observed difference in F_max may be a result of these observed differences, and may indicate a softening of the super-chilled salmon muscle at 24 h post-treatment.     

Changes in water holding capacity and drip loss of Atlantic salmon (Salmo salar) muscle during superchilled storage

Changes in water holding capacity and drip loss of Atlantic salmon (Salmo salar) fillets during superchilled storage were studied. Due to the significant differences in ice crystal sizes observed in our previous study, the liquid loss (LL) was analysed separately, at the surface and centre of the superchilled samples. No significant differences were found in LL between surface and centre parts of the superchilled samples. No significant difference in the LL was observed from surface samples between 1 and 14 days of storage. There was a significant difference in the LL at day 1 of the centre samples, but no significant differences were observed between 3 and 14 days of storage. In contrast, the LL was significantly decreased at day 21 both at the centre and the surface of the superchilled samples. No significant difference (p < 0.05) was found in drip loss between 1 and 14 days of storage for the superchilled samples. A significant increase in drip loss for the superchilled samples was observed at day 21. These findings are significant for the industry because it provides valuable information on the quality of food in relation to ice crystallisation/recrystallisation during superchilled storage.     

Effect of high-pressure versus conventional thawing on color, drip loss and texture of Atlantic salmon frozen by different methods

Atlantic salmon (Salmo salar) samples were frozen by conventional air freezing, plate freezing and liquid nitrogen (LN) freezing, and subjected to different thawing treatments: water immersion thawing (WIT) (4°C and 20°C) and high-pressure thawing (HPT) at 100, 150 and 200 MPa with water (containing 2 g oil/100 g) as pressure medium at 20°C. Temperature and phase change behavior of fish samples were monitored during freezing and thawing. The phase change point of frozen salmon was lowered to −14°C, −19°C and −25°C for the HPT processes at 100, 150 and 200 MPa, respectively. These phase change temperatures were lower than for pure ice at the same pressures possibly due to the presence of solutes in salmon. The HPT times were 22.6±1.4, 18.1±1.4 and 17.0±1.3 min at 100, 150 and 200 MPa, respectively, as compared with 26.6±2.1 and 94.3±3.4 min for the WIT process at 20°C and 4°C, respectively. Employing pressures above 150 MPa caused noticeable color changes in salmon during the HPT process and the product texture was significantly modified during HPT at 200 MPa. Different freezing rates prior to thawing resulted in differences in drip loss in salmon samples, but they did not induce specific color and texture changes. A significant (P<0.05) reduction of drip loss by the HPT process was observed only for the LN frozen samples in which mechanical cracking occurred and much of the drip appeared after WIT process. Drip loss formed during pressure thawing seems to be a complicated process, for which further studies are needed.     

Superchilled,chilled and frozen storage of Atlantic mackerel (Scomber scombrus) fillets – changes in texture,drip loss,protein solubility and oxidation

Changes in quality characteristics in relation to protease activity and protein oxidation in chilled, superchilled and frozen mackerel fillets during storage were studied. The solubility of sarcoplasmic proteins was quite stable in mackerel samples for all storage experiments, whereas the solubility of myofibrillar proteins decreased in both superchilled and frozen samples. A significant correlation (r = 0.983, P < 0.05) between the increased activity of cathepsin B+L in chilled fillets and softening of the fish flesh during storage was revealed. Contrary with chilled samples, the texture of superchilled mackerel fillets became tougher along the storage period, which can be explained by a higher rate of myofibrillar oxidation (r = 0.940, P < 0.05). The hardness and drip loss decreased slightly at the end of frozen storage. Superchilling preserved the quality of mackerel fillets with the least side effects in relation to protein solubility, drip loss and softening of the fish tissue as compared to chilled and frozen storage.     

Rancidity development in frozen pelagic fish: Influence of slurry ice as preliminary chilling treatment

The slurry ice technology has shown profitable advantages when employed instead of traditional flake ice for the manufacture of chilled aquatic species. The present work is aimed at evaluating the effect of slurry ice as a preliminary treatment prior to frozen storage. For it, specimens of a small pelagic fatty fish species (sardine; Sardina pilchardus) were stored in slurry ice for 2, 5 and 9 days, then subjected to freezing (-80 °C; 24 h) and finally kept frozen (−20 °C) during 1, 2 and 4 months. At such times, rancidity development in frozen sardine was measured by sensory (odour, skin, colour and flesh appearance) and biochemical (lipid hydrolysis and oxidation) analyses and compared to a control batch previously chilled in flake ice. Sensory analysis indicated an extended shelf-life time for frozen sardine that was preliminary stored under slurry ice for 2, 5 or 9 days, as compared to their counterparts subjected to flake icing. Sensory results were corroborated (P<0.05) by biochemical lipid oxidation indices (thiobarbituric acid reactive substances and the fluorescence formation). The present work opens the way to the use of slurry ice instead of flake ice as preliminary treatment of fish material prior to the frozen storage.     

Effect of freezing on the physicochemical, textural and sensorial characteristics of salmon (Salmo salar) smoked with a liquid smoke flavouring

This study reports the effect of different refrigeration/freezing treatments on the physicochemical, textural and sensorial properties of farmed Atlantic salmon (Salmo salar) treated with a commercial liquid smoke flavouring. Observations were made on three groups of fillets - group RFS: salted, smoked and stored at 4 °C; group BFS: frozen at −25 °C for 24 h, thawed, salted, smoked and stored at 4 °C; and group AFS: salted, smoked and frozen at −25 °C for 24 h and stored at −18 °C - over a period of 45 days. Scores (on a scale of 1-9) were provided for different sensorial attributes by a panel of 10 trained tasters. Sixty percent of the panellists consistently preferred the AFS fillets. The maximum shelf life associated with each treatment was defined as the last sampling day on which a mean score of ≤5 was awarded for the fillet sensorial attributes by ≥50% of the panellists. Freezing the salmon for 24 h before smoking (BFS) did not increase its shelf life (30 days) over that of refrigerated smoked salmon (RFS). In addition, the former treatment had a negative effect on the adhesiveness, cohesiveness, smoke odour intensity and colour intensity of the flesh. However, maintaining the fish frozen at −18 °C (AFS) increased its shelf life (>45 days) and invested the flesh with greater firmness, cohesiveness and colour intensity.     

Superchilling of rested Atlantic salmon: Different chilling strategies and effects on fish and fillet quality

Rested Atlantic salmon was superchilled in seawater slurry (−1.93 ± 0.27 °C). The chilling efficiencies of slurry and crushed ice were compared. The feasibility of using slurry to produce subzero core temperatures before packing was also evaluated. Simulated transport to market, with or without ice after initial superchilling (1 day), was also studied. Fish quality (Quality Index, fillet colour, pH, water content, water-holding capacity, hardness and bacterial loads) was evaluated at arrival to ‘market’ and after keeping the fish ‘in the market’ for 1 week. The results were compared with continuous ice (control) or slurry storage. In terms of quality, pre-chilling in slurry and continuous storage in slurry were evidently not advantageous over traditional ice storage, as evaluated after 4 days. After 11 days, both advantages and disadvantages of continuous superchilling were observed. Notably, subsequent ice storage of superchilled fish resulted in increased bacterial load and inferior fillet hardness.     

Effect of Modified Atmosphere Packaging and Superchilled Storage on the Microbial and Sensory Quality of Atlantic Salmon (Salmo salar) Fillets

ABSTRACT: Fresh Atlantic salmon fillets packaged under modified atmosphere (MA) (CO²:N² 60:40) and air was stored at superchilled (-2 °C) and chilled (+4 °C) temperatures. Changes in sensory scores, microbial growth, headspace gas composition, water loss, and pH were monitored during 24 d of storage. The superchilled MA packaged salmon maintained a good quality, with negligible microbial growth (<1000 colony-forming units [CFU]/g) for more than 24 d based on both sensory and microbial analyses (aerobic plate count, H2S-producing, and psychrotrophic bacteria). Superchilled salmon in air had a 21-d sensory shelf life, whereas MA and air-stored fillets at chilled conditions was spoiled after 10 d and 7 d, respectively.     

Physicochemical changes in ω − 3-enhanced farmed rainbow trout (Oncorhynchus mykiss) muscle during refrigerated storage

Physicochemical changes of ω − 3-enhanced farmed rainbow trout (Oncorhynchus mykiss) fillets developed by dietary modification with flaxseed oil and α-tocopheryl acetate (α-TA) were determined during storage at 2 °C. Trout were fed experimental diets for 120 days followed by processing to obtain boneless skinless fillets. The dietary modification increased concentration of total ω − 3 fatty acids in the fillets, which enhanced chances for lipid oxidation during storage. The fillets were vacuum or non-vacuum packed and stored at 2 °C for 10 or 12 days. Dietary α-TA resulted in higher (P < 0.05) concentration of α-tocopherol in fillets during storage; however, it did not retard (P > 0.05) lipid oxidation. Vacuum packaging resulted in much lower (P < 0.05) TBARS and higher (P < 0.05) retention of α-tocopherol during storage than non-vacuum packaging. However, α-tocopherol unlike vacuum packaging better protected ω − 3 FA in the fillets during storage.     

Effect of superchilled storage on the freshness and salting behaviour of Atlantic salmon (Salmo salar) fillets

The aim of this work has been to evaluate the effect of superchilled storage compared with ice and frozen storage on the quality of raw material and subsequent behaviour during processing of lightly salted salmon (Salmo salar), as the first step of smoked salmon production. Physicochemical parameters used as quality indicators were α-glucosidase activity, protein denaturation and degradation (as changes in protein solubility, SDS–PAGE and free amino acids), texture attributes, and mass transfer phenomena during salting. The results obtained for the raw material within the storage range studied (until 16 days) allowed us to conclude that salmon superchilled for 9 days behaved as salmon stored on ice for 2 days with regard to hardness, protein solubility and free amino acids. In general, salting minimises the effect of the different storage methods. Superchilling for 9 days obtained the highest process yield, indicating that this method is a good way to preserve freshness of the raw material before processing.     

VIS/NIR spectroscopy for non-destructive freshness assessment of Atlantic salmon (Salmo salar L.) fillets

Visible/near-infrared spectroscopy has been evaluated for use in freshness prediction and frozen-thawed classification of farmed Atlantic salmon fillets, where fresh samples were stored as whole fish in ice. A handheld interactance probe for performing rapid measurements of single fillets and an imaging spectrometer for online analysis at an industrial speed of one fillet per second, have been used. Freshness as storage days in ice is predicted with an accuracy of 2.4 days for individual fillets, whereas frozen-thawed salmon fillets are completely separated from fresh fillets. The prediction results are comparable to previous results using the Quality Index Method with trained panelists. The region between 605 and 735 nm, which excludes interference by carotenoids and water, is appropriate for both frozen-thawed classification and freshness prediction of salmon fillets. The results indicate that the spectral changes are explained mainly by oxidation of heme proteins during the freeze–thaw cycle and during chilled storage in ice.     

Combined effects of freezing rate, storage temperature and time on bread dough and baking properties

This study compares the effects of freezing temperature and rate as well as storage temperature and time on the quality of frozen dough. Yeasted bread dough was frozen using four freezing rates (19-69 °C/h), then stored at −10, −20, −30, or −35 °C for up to 180 days. Dough strength diminished with longer storage time and higher storage temperatures. Cryo-SEM showed that dough stored at −30 and −35 °C had the least damaged gluten network. NMR studies showed that more rapidly frozen dough, and that stored at lower temperatures had lower transverse relaxation (T₂) times (9-10 ms). However, dough stored at −20 °C displayed the highest yeast activity among samples. Bread loaf volume decreased with storage time, and bread made from dough stored at −20 °C showed the highest loaf volume. Breads produced from −30 and −35 °C stored dough displayed less change in the texture profile during storage as well as less change in T₂ values. Response surface analysis showed that optimal properties occurred at freezing rates of around 19-41 °C/h and storage temperatures of −15 to −20 °C.