IE69463B1 - Fish processing - Google Patents

Abstract

Frozen fish fillets are tempered in step 2 and then separated in step 3 into individual fillets. Larger sized fillets are cut in step 4 and are then coated in step 5 with a light batter. A pre-dust is applied in step 6 and in step 7 a batter coating is applied over the pre-dust. The battered fillet is coated with crumb in step 8 and fried in step 9 prior to chilling in a spiral freezer 10. Frozen fillets from the freezer 10 are discharged through an outlet 11 to one of a plurality of weighing stations 15.

Description

Fish Processing The invention relates to a process for preparing coated cooked and frozen fish.

However, there are various problems in preparing coated cooked and frozen fish fillets. For example, one of the difficulties is because the fillets are processed from a frozen form, globules of ice tend to lie on the surface of the fish which in processing may vaporise causing local lifting of any coating applied to the fish which in turn causes small localised irregularities in the coating.

Another difficulty is in providing a system for processing frozen blocks of fish. There are difficulties in separating individual fillets from the block when it still maintains the fillet frozen.

Further there are problems in handling large quantities of coated, cooked and frozen fish fillets for packaging.

This invention is directed towards providing an improved process for preparing coated, cooked and frozen fish fillets which will overcome at lease some of these difficulties.

According to the invention there is provided a process for preparing coated cooked and frozen fish fillets comprising the steps of:loading individual frozen fillets of fish onto a conveyor; applying a first coating to the frozen fillets; applying a pre-dust to the pre-coated fillets; applying a batter to the dusted fillets applying crumb material to the battered fillet cooking the coated fillet; freezing the cooked fillets; loading the frozen coated cooked fillets from the freezer to one of at least two separate weighing stations; directing the weighed fillet to a desired one of a plurality of bagging stations associated with the weighing station; loading filled bags from the bagging stations to a common output conveyor; applying a code to each bag; loading a pre-ser number of bags into a box, and palletising a plurality of boxes of frozen fish fillets.

In a particularly preferred embodiment of the invention the first coating comprises a light batter.

In one embodiment of the invention the crumb comprises a breaded material.

In one embodiment of the invention the fish fillets are first cooked in oil at a temperature of at least 185°C for a period of at least 15 seconds. Typically the fillets are cooked in oil at a temperature of approximately 190°C for a period of approximately 30 seconds.

In a particularly preferred embodiment of the invention ‘ the process includes the steps prior to application of a first coating, of cutting fillets of fish above a desired * size to form fish fillet pieces of generally triangular 5 fish shape.

In one embodiment of the invention the process includes the step of providing a vertical wall forming means on at least one side of a pallet to be loaded with boxes of bagged fish fillets.

Preferably a vertical wall forming means is provided on two adjacent sides of a pallet. In the particularly referred arrangement the vertical wall forming means comprises a jig of angle configuration having a first plate member and a second plate member extending substantially at right angles to the first plate member.

In one embodiment of the invention the process includes steps of tempering blocks of frozen fish fillets and applying a pressure force to the tempered blocks to separate the individual frozen fillets of fish from the block for processing.

In one case the frozen blocks of fish fillets are tempered for a period of at least 12 hours at a temperature of between -5°C and -10°C. Preferably the blocks are tempered at a temperature of approximately -8°C for a period of approximately 48 hours.

In one embodiment of the invention the process includes * steps of separating layers of frozen blocks of fillets during tempering. Preferably the layers are separated by pallets which facilitate air circulation between the blocks, during tempering.

In one case the pressure force is applied by a ram means.

* The invention also provides frozen cooked fillets of fish, whenever prepared by the process of the invention. £ The invention will be more clearly understood from the following description, given by way of example only with reference to the accompanying drawings in which:Fig. 1 is a schematic block diagram of the process of the invention; Fig. 2 is a diagrammatic side view of one step in the process of the invention; Fig. 3 is a plan view of another step in the process of the invention; Fig. 4 is a plan view of a further step in the process of the invention Figs. 5 and 6 are respectively perspective and plan views of a further step in the process of the invention.

Referring to the drawings and initially to Fig. 1 thereof, coated cooked and frozen fish fillets are prepared by a process which comprises the following steps. In some cases the frozen fish fillets are in a block 1 of ice containing a number of individual fillets. To assist in separating the individual fillets from the block, the * blocks are first tempered for a period of at least 12 hours, preferably approximately 48 hours at a temperature of between -5eC and -10°C, most preferably approximately 8°C.

In the tempering step 2 layers of frozen blocks are separated, for example by means of pallets interleaved between the blocks to facilitate air circulation between the blocks during tempering. After tempering they are separated in step 3 by applying a pressure force to the tempered blocks which separates the individual fillets in the block. Larger sized fillets of fish above a desired size are cut in step 4 by a band saw to form fish fillet pieces of generally triangular fish shape. The fillet pieces then pass through a first coating step 5 in which they are immersed in a light batter or wash which vaporises any ice present on the surface of the fish fillet piece. This is particularly important as we have found that if ice is present on the surface of the fish during cooking, it flashes off causing a localised lifting of the coating on the fish and an unsatisfactory product.

In step 6 a pre-dust material is applied to the pre-coated fish fillet and in step 7 a batter coating is applied over the pre-dust. The battered fillet is then passed through a crumbing station 8 where fine pieces of breaded material are applied to the batter. The battered and crumbed fish fillets then pass to a frying stage 9 in which the fillets are fried in hot oil at a temperature of at least 185°C, most preferably approximately 190°C, for a period of at least 15 and most preferably, approximately 30 seconds. The fried fillets are then delivered to a spiral freezer 10 from which they are discharged through an outlet 11. From the outlet 11 the fillets pass down a chute 12 having diverters 13 for diverting the individual fillets into one of a number, in this case three, separating weighing stations 15.

Each of the weighing stations 15 has a plurality of associated bagging stations 19 to which the fillets of fish are directed in accordance with the weight required to fill a particular bag. Filled bags from the bagging stations 19 are then lead to a common output conveyor and r a batch code is applied in step 20. A number of bags are loaded in step 25 into boxes which are check weighed in t step 26 and palletised in step 27.

Referring to Fig. 2 tempered blocks 1 of frozen fish fillets are inserted between a fixed jaw 30 and a movable jaw 31 of a crushing machine and a ram 32 is extended down to force the jaw 31 downwardly to crush the blocks of frozen fillets separating the individual fillets in the block. The crushed blocks are then passed to a sorting table 35, and plastic outer coating on the block is removed and the individual fillets are separated and passed through one of two band saws 36 which automatically cut larger fillets of fish into smaller generally fillet shaped pieces. Fillets to be cut are presented to the band saws 36 between a pair of spaced - apart marked indicators 37 associated with each band saw 36, the positioning of the fish relative to the indicators 37 determining the angle at which the fish fillet is cut.

Referring particularly to Figs. 5 and 6, in the palletising step 27 an empty pallet 50 is first placed in a palletizing area adjacent to a jig 60 which in this case is of angle configuration and comprises a first plate member 61 and a second plate member 62 extending at right angles to the first plate member 62. The jig 60 defines vertical walls on two adjacent sides of the pallet 50 during stacking of boxes on the pallet. The jig 60 greatly increases the efficiency of palletization as the boxes can be more quickly palletised. When a pallet 50 is full it is mounted on a turn table 65 and is automatically wrapped in plastic film material by an automatic wrapping machine 66.

Claims (17)

1. A process for preparing coated cooked and frozen fish fillets comprising the steps of:loading individual frozen fillets of fish 5 onto a conveyor; applying a first coating to the frozen fillets; applying a pre-dust to the pre-coated fillets; 10 applying a batter to the dusted fillets; applying crumb material to the battered fillets; cooking the coated fillet; freezing the cooked fillets; 15 loading the frozen coated cooked fillets from the freezer to one of at least two separate weighing stations; directing the weighed fillet to a desired one of a plurality of bagging stations associated 20 with the weighing station; loading filled bags from the bagging stations to a common output conveyor; applying a code to each bag; loading a pre-set number of bags into a box, and r palletising a plurality of boxes of frozen £ fish fillets.

2. A process as claimed in Claim 1 wherein the first coating comprises a light batter.

3. A process as claimed in Claim 1 or 2 wherein the crumb comprises a breaded material.

4. A process as claimed in any preceding claim wherein the fish fillets are first cooked in oil at a temperature of at least 185°C for a period of at least 15 seconds.

5. A process as claimed in Claim 4 wherein the fillets are cooked in oil at a temperature of approximately 190°C for a period of approximately 30 seconds.

6. A process as claimed in any of Claim 1 to 5 wherein the process includes the step, prior to application of a first coating, of cutting fillets of fish above a desired size to form fish fillet pieces of generally triangular fish shape.

7. A process as claimed in any preceding claim wherein the process includes the step of providing λ a vertical wall forming means on at least one side of a pallet to be loaded with boxes of bagged fish fillets.

8. A process as claimed in Claim 7 wherein a vertical wall forming means is provided on two adjacent sides of a pallet.

9. A process as claimed in Claim 8 wherein the vertical wall forming means comprises a jig of angle configuration having a first plate member and a second plate member extending substantially at right angles to the first plate member.

10. A process as claimed in any preceding claim including the step of tempering blocks of frozen fish fillets and applying a pressure force to the tempered blocks to separate the individual frozen fillets of fish from the block for processing.

11. A process as claimed in Claim 10 wherein the frozen blocks of fish fillets are tempered for a period of at least 12 hours at a temperature of between -5°C and -10°C.

12. A process as claimed in Claim 11 wherein the blocks are tempered at a temperature of approximately -8°C for a period of approximately 48 hours.

13. A process as claimed in any of Claims 10 to 12 wherein the process includes step of separating layers of frozen blocks of fillets during tempering.

14. A process as claimed in Claim 13 wherein the layers are separated by pallets which facilitate air circulation between the blocks, during tempering.

15.

16.

17. A process as claimed in any of Claims 10 to 14 wherein the pressure force is applied by a ram means. A process substantially as hereinbefore described with reference to the accompanying drawings. Frozen cooked fillets of fish whenever processed by a process as claimed in any preceding claim.