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Frozen shrimp processing technology
When there are few refrigeration machinery and refrigeration equipments, shrimps that are harvested are processed into raw and cooked products, except for fresh food. With the development of the times, the backward processing methods of the past Has been eliminated by history, now basically all use of frozen processing methods. The frozen shrimp processing technology is introduced as follows: 1. Pre-work preparations. i. According to the provisions of the shrimp processing capacity equipped with appropriate processing personnel, and physical examination and technical training to learn the processing specifications, standards and related precautions. Ii. Cleaning, refurbishing, scrubbing and disinfecting equipment and equipment required for processing. Iii. Inspect the changing facilities, showers, toilets, and disinfection facilities to meet the requirements. Fully equipped work clothes, caps, sleeves, rubber shoes, aprons and other clothes. Iv. Perform hygienic inspection of process water to ensure adequate water supply and meet sanitary requirements. v. Perform necessary flushing of the cooling boxes in the quick-freezing room, sanitize the cold rooms, and commission the refrigeration machinery and equipment to ensure smooth production. Vi. Sanitize the processing room and packing room. Fly-flying, insect-proof, ventilation, lighting and other facilities in the workshop must be fully equipped, and the water pipelines must be unblocked. Vii. Prepare adequate and qualified packaging materials and labels. 2. Process flow i. Process of leading prawn: raw shrimp preservation → raw shrimp rinsing → sorting selection → graded specification → washing → water control → weighing → wobble plate → pre-freezing inspection → warehousing quick freezing → making frozen quilt ( Divide into water twice) → remove plate → glazing → temperature measurement before packing → packing → inspection → refrigerate. Ii. Process flow for prawn: Raw shrimp preservation → Raw shrimp rinsing → Sorting selection → Steamed breading → Washing shrimp (adding ice) → Sorting (plus ice) → Washing → Water control → Weighing → Wobble plate → Irrigation ( Ice water)→turning water control→freezing semi-finished products inspection→incoming quick freezing→making ice quilt (divided into two irrigations)→disengaging (watering method)→icing clothes→pre-packaged temperature measurement→packaging→inspection→refrigeration. Iii. Shrimp shrimp prawn process flow: Raw shrimp preservation → Raw shrimp rinsing → Sorting selection → Peeling → Goal gland → Washing → Water control → Weighing → Wobble plate → Irrigation (ice water) → Turning water control → Freezing semi-finished products Inspection → Quick freezing into storage → Making ice quilt (two times of watering) → Taking off (watering method) → Ice glazing → Temperature measurement before packing → Packaging → Inspection → Refrigeration. 3. Acceptance and storage of raw shrimp: After each batch of shrimp enters the factory, quality, hygiene, ice-melting and packing conditions should be promptly inspected. Raw material shrimp that meets the requirements should be processed in a timely manner in order to be processed on the same day as shrimp. , The first time there is no backlog. Raw shrimps that cannot be processed in time should be actively taken fresh-keeping measures, such as timely access to a fresh-keeping store at 0-4°C, or a ratio of 1:3 with shrimp ice, and crushed ice with a diameter of no more than 3 cm. Ice cubes should be clean and spread evenly. Shrimp should be protected against fly maggots, light, rain, air drying and other pollution. 4. Rinsing of Raw Shrimp: The raw shrimp is rinsed with clean water that meets hygiene standards to remove crushed ice, sediment, seaweed and other contaminants from raw shrimp. 5. Classification and selection: After washing the shrimp, should be selected first to take the lead shrimp, after processing to the head shrimp, and then processing the shrimp, shrimp ball production, sorting, the raw shrimp should not be backlog too much. When the temperature is high, add ice to keep it fresh. The selected shrimp body is placed in a clean container. 6. Processing: According to the classification of shrimp, respectively, processing. i. Shrimp processing: The raw materials for the leaded prawn selected according to the specifications should be carefully washed, and the last water must be cleaned to avoid turbidity and prevent the occurrence of “red shrimp†and “mixed shrimpâ€. To gently wash gently, do not damage the shrimp. Wash the shrimp into a leaking container and control the water for 5 minutes to be weighed. Ii. Shrimp processing: 1) Steamed bread: Wash the clean raw shrimp. When you go to the head, pinch the head and chest of the shrimp and the abdomen with your thumb and forefinger, respectively, and pull them away in the opposite direction. Use force to adapt to prevent the shrimp head from bringing out the meat, but not to bring out the first quarter of the shrimp shell. 2) Washing: It is better to wash until the flesh meat is white, without any impurities. When washing, round Romanian baskets were used to rotate left and right to allow full washing. The washing tanks were arranged using a "flowing water three-barrel bucket". Ice was added to the water and the temperature was lowered to 0-5 °C. 3) Grading: According to the specifications of the squid shrimps, the grading should be carried out. The grading should not be mixed. There should be no excessive backlog on the workbench. When the temperature is high, ice should be added to cool down. 4) After the grading shrimp is cleaned again, put it in a clean sieve tray for 5 minutes to be weighed. Iii. Shrimp processing: 1) Raw shrimps that do not meet the standard for export squid can be used as raw materials for frozen shrimps. Processed shrimps were first stripped of the shells to remove intestinal glands or more than 71 unintestinal glands per 454 grams (one pound). When going to the intestine glands, hold the shrimp in the left hand to bring it back up. Hold the knife in the right hand and cut a small incision along the midline of the back. Then use a knife tip to remove the exposed glands. 2) The shrimps with the bowel glands removed will be washed in ice water and graded according to shrimp specifications. 3) After the grading, the shrimps are washed once and placed in a sieve tray to control the water for 10 minutes and weighed. Iv. Shrimp ball processing: Where freshness meets requirements, incomplete shrimp can be used as frozen shrimp ball raw materials. When processing, first remove the shrimp shell and intestinal glands, remove the sediment and poor quality of meat, the shape is not limited, but not less than two sections of the abdomen, clean in ice water, placed in the sieve tray control water for 10 minutes, you can weigh . 7. Weighing: After the water is to be controlled, it is weighed according to different types and specifications. Weighing requirements: (1) It is necessary to appoint a special person to overweight and to be responsible for weighing and weighing. Semi-finished products before quick freezing should be sampled. (2) Weighing must be accurate, so that the amount of water can be customized according to production and processing conditions. In principle, the required net weight must be met after thawing. (3) The weighed shrimp should be immediately filled in a clean iron plate and attached with two grade specification labels. 8. Wobble plate (1) wobble plate mode: 1) Take the lead shrimp: straight body pendulum, arranged in layers, head outward, tail cross, the lower anticline down, the upper anticline up. The surface is flat and beautiful, but it is dense or thin. 2) Shrimp prawn: sideways, weighs less than 30 tiers per 454 g. The prawn neck is turned outwards, the tails are crossed, the lower anticline is downward, the upper one is anticline upwards, and 31-40 are only placed on the lower layer. There are three rows of the upper and lower floors. The lower pendulum method: the first side of the plate is placed at the same time in two rows, the tails are crossed, and the third row of tails is placed on the middle row of necks. Upper pendulum method: first by the side of the plate placed in a row, the neck outward, and then put the second and third rows at the same time, the tail cross, the second row of the neck pressure on the tail of the first row; 41 The above is not arranged, as long as it can be flattened. 3) Shrimp: yaw, shrimp flat slightly curved shape, each 454 g is said to be less than 30 within the layered pendulum; 31-40 only placed two layers; 41 or more are not arranged, as long as the equipment is flat You can. 4) Shrimp ball: no matter how many, no arrangement, according to the requirements of a small plate or small box to make it smooth. (2) Wobble requirements: 1) The used iron pan should be washed before use and placed in 3% potassium permanganate solution for 3-5 minutes, or in 5-10% of available chlorine (bleach) solution Soaking disinfection. After removing it, rinse it with clean water and use it. 2) Before placing the plate, place the oversized shrimp into a small dish, add ice water, and wash it with a side plate to further remove impurities. Therefore, this type of wobble plate method is called water pendulum. 3) When swinging the plate, the front of the label on the bottom of the shrimp plate and the upper two sides of the shrimp plate are attached to the front of the label (shrimp ball is also attached with a label), so that the grade specification can be identified after the finished product. 4) In the wobble plate process, if shrimps with unsatisfactory quality are found to be replaced, the shrimps to be replaced must be equivalent to the weight of the shrimps being replaced. 5) Every time a plate of shrimp is placed, take an empty plate and put it on it. Apply a little pressure and make it flat and tight. 6) Place the plate of shrimp in the clear water (water temperature is controlled below 5°C). When watering, use one hand to press on the top of the shrimp. The water first falls on the hand and then flows into the pan to avoid directly adding water to flush the shrimp and the label. Then, each group of four shrimps (a group of shrimp shrimp balls in every 3 dishes) ), Deck stacking, pressing an empty plate above, and immediately turn over the water for 5 minutes (shrimp and shrimp ball control water for 10 minutes), the purpose of irrigation is to further wash, to avoid the emergence of red shrimp and mixed bottom shrimp . 7) Before the shrimp plate is put into the quick-freezing room, stainless steel inserts shall be used to slit along both sides of the inner wall of the long side of the iron plate to shape it and facilitate the penetration of water when ice is poured on. After marking, put it gently on the shelf to prevent the gap from closing. 8) Inspection of semi-finished products before freezing: The inspection personnel shall conduct random inspection according to the specified 5% sample proportion. Inspection items include: quality, weight, specifications, hygiene, arrangement and appearance. Where it is found that it does not meet the above requirements, it shall be promptly corrected, and the unqualified semi-finished products shall be immediately reworked. The inspection results should be well documented for future reference. 9. Frozen i. Semi-finished products that have been tested and put on shelves should be immediately sent to the quick-freezing room. Before entering the semi-finished products, the temperature in the quick-freezing room must fall below -15°C. There must be full-time inspectors when entering the frozen area to carry out disk-by-tray inspections. Flattening should be done so as not to affect the shape. Freezing operating temperature requirements below -25 °C. Ii. If it is more than one hour, it must be re-inspected if it has not yet entered the quick-freezing room. Semi-finished products that cannot be promptly frozen in special circumstances may be placed in a pre-cooling room below -8°C for preservation, but generally it shall not exceed 2 hours. Iii. For shrimp that has entered the quick-freezing room, it is necessary to add clean fresh water at appropriate and timely intervals to make ice quilts. It is better to use two irrigation methods. The thickness of the ice quilt should be just over the shrimp body. The first addition of water is performed when the temperature of the shrimp body reaches -6-8°C, and the amount of water added is similar to that of the upper body of the submerged oil. This time, the water is mainly made of bottom ice and edge ice. The first time to add water, to control the body temperature of the shrimp is an important key, when the temperature is too high, add water, easy to float the shrimp, resulting in ice is too thick, and will extend the freezing time, affect the quality of shrimp, reduce the freshness When the temperature is too low, add water. When the water comes into contact with the shrimp body, the ice will not be able to permeate and it will cause the bottom ice to appear beehive. The second time the water is added is 2-3 hours before the quick-freezing, and the amount of water added must be the degree of submerged shrimp. The purpose of adding water is to fully cover the flattening of the shrimp and ice. The timing of the second addition of water is also important. Adding water too early will often cause the top ice to be uneven. Too late to add water will cause the ice to be frozen insufficiently, which will affect the quality and appearance. In short, the production of the ice bedding requires a smooth surface, attractive appearance, and good transparency. Iv. The shorter the shrimp's freezing time, the better. Usually it is less than 12 hours. When the center temperature of the shrimp block reaches -18°C, it can be released and released. 10. Stripping, ice glazing i. After freezing, the frozen shrimps should be removed in time. It is advisable to remove the water from the dish. It should not be used to remove water. The operation time should not be too long. The water temperature should not be too long. Too high (generally no more than 20 °C is good) to prevent the ice from being melted, and be careful when placing the dish so as not to damage the ice bedding and the iron plate. Ii. Frozen block ice is bad, it must be frozen or corrected again in water, malformed blocks, contain foreign impurities, and sanitation should be removed. Severe red shrimp, mixed bottom shrimp and crushed shrimp should be returned to the processing workshop. Processing. Iii. The frozen block before packaging must be provided with a galvanized coat. The operation of the glazing coat in the cold store is generally performed simultaneously with the removal of the plate. The method of adding ice-plating is best for the over-water method. The water temperature should be 0-4°C and the immersion time should be 3-5 seconds. After freezing the ice coating, the temperature of the center must not rise above 3 degrees. Use water for hygiene to increase the transparency of the ice. 11. Packaging i. Packaging materials: For export products, packaging materials that are designed and processed by exporting business units should be used and packaged according to the standard. Domestically produced products can be properly packaged according to customer's opinion. Ii. Any packaging paper, label, etc. directly in contact with the shrimp body shall not contain fluorescent substances (harmful to human body).