Summary materials of typical experiences and practices in the deep processing of agricultural products

1.
Brief introduction of the basic situation

Yasui Food Group Co.
, Ltd.
was established in December 2001, the company is mainly engaged in the research and development, production and sales of quick-frozen hot pot products (mainly quick-frozen surimi products, quick-frozen meat products) and quick-frozen noodle and rice products, quick-frozen dish products and
other quick-frozen foods.
The main raw materials include surimi, meat, flour, etc.
, radiating to many upstream industries, with good driving benefits, and has been rated as a national key leading enterprise
in agricultural industrialization.

After more than ten years of development, the company has formed a marketing network centered on East China and radiating throughout the country, and has established 10 production bases
.
The company has an operating income of 6.
965 billion yuan and a net profit of 604 million yuan in 2020, and an operating income of 6.
096 billion yuan and a net profit of 496 million yuan from January to September 2021, and has grown into a more influential and well-known frozen food enterprise
in China.

The company mainly deals in "Anjing" brand quick-frozen food, including: popping juice small fish balls, Q fish plate, fish tofu and other quick-frozen surimi products; quick-frozen meat products such as Xia Mi dumplings, peeing meatballs, and kissing intestines; quick-frozen noodle rice products such as finger cakes, milk steamed buns, walnut buns, brown sugar steamed buns, brown sugar hair cakes, etc.
; Chiba tofu, egg dumplings and other quick-frozen dish products
.
At present, the company has more than 300 varieties of
quick-frozen food.

Second, the innovation and demonstration of processing and utilization models

Frozen surimi is one of the bulk raw materials purchased by the group, the group's annual freshwater surimi purchase volume accounts for about 50% of domestic surimi production, marine surimi purchase volume accounts for about 20% of domestic surimi production, in recent years, with the steady development of the company, the synchronization has also vigorously promoted the vigorous development of the upstream surimi industry, encouraged the development of freshwater aquaculture industry, indirectly driven more than 10,000 fisheries/farmers employment and increased income
。 At the same time, in order to ensure the quality and stable supply of raw materials, the company independently carried out technical research on key technical points in the upstream industry and made key breakthroughs, and the subsidiaries of the group also got involved in the upstream surimi industry to complete the full industrial chain coverage
from raw materials to finished products.

Development and promotion of high-yield surimi processing technology

Aiming at the outstanding problems of low yield of surimi products and large fluctuations in the fat content of products caused by rinsing, fine filtration and other processes in the domestic frozen surimi industry, and combined with domestic and foreign literature, we have successfully designed and developed oil and gas flotation rinsing equipment and spray water recovery equipment
.
The technical system is based on the traditional frozen surimi production process, combined with the self-developed oil and gas flotation rinse equipment and the traditional hydrostatic rinsing process, and cooperates with the spray water recovery process, effectively improving the connection of the original surimi production line, ensuring that the fat residue of frozen surimi products (in terms of dry mass) is less than 2%, and at the same time increasing the yield of frozen surimi by more than
10%.

In the process of technical research, a number of key technologies have been transformed into its own intellectual property rights, including "a processing method to improve the yield of small surimi, a new and efficient surimi degreasing processing equipment", etc
.
In order to promote the healthy development of China's frozen surimi processing industry, the company has licensed the above patented technologies to many upstream surimi enterprises for application free of charge to help them break through the production bottleneck and improve the yield and production efficiency
of frozen surimi.

Establishment of standards for frozen surimi products

The industrial production of low-value marine surimi in China has lasted for more than 20 years, but there has been a lack of relevant standards for a long time, resulting in chaotic quality of frozen surimi and frequent trade disputes.
At the same time, it also hinders the promotion and application
of frozen surimi HACCP and GMP.
In this regard, the company aims at the key quality indicators of frozen surimi, combined with the existing production and trade status of frozen surimi in China, unifies the detection methods of various indicators, and establishes an advanced and perfect quality evaluation system
for frozen surimi.

In 2014, the aquatic industry standard "Frozen Surimi" (SC/T 3702-2014) developed by our company and the Yellow Sea Fisheries Research Institute was officially released, which is the first industry standard in China to clearly define frozen surimi, determine the binding indicators and detection methods, since its implementation, frozen surimi enterprises have actively implemented the standards, carried out quality control of various indicators of surimi, and gradually formed a unified domestic frozen surimi trade evaluation system; Subsequently, in 2018, the industry standard was upgraded to the national standard "frozen surimi" (GB/T 36187-2018), and in 2021, it was upgraded to the international standard "frozen surimi" (ISO 23855:2021), which is also the first international standard
in the domestic fishery industry.

The establishment of the "Frozen Surimi" standard has promoted the standardized production and standardized trade of the surimi industry, promoted the healthy development of the industry, ensured the vitality of the development of the industry, and promoted the long-term sustainable and healthy development of
the industry.

Development and application of MTG adulteration detection technology

Frozen surimi is divided into different grades according to its gel strength, moisture content, whiteness and other factors, of which gel strength is the decisive factor, and the higher the grade of surimi in the sales process, the more expensive
it is.
With the increasingly fierce market competition, some adulteration behaviors
have gradually appeared by adding exogenous components such as microbial TG enzyme (MTG), soybean protein isolate, starch, etc.
to improve the apparent rupture value, depression and elasticity value of frozen surimi.
Although there is no food safety problem, the use of MTGase by unscrupulous manufacturers to improve the strength of surimi gel and make low-grade surimi pass off as high-grade surimi, but this behavior disrupts the order of the surimi market, harms the interests of surimi product manufacturers and regular frozen surimi manufacturers, and is very detrimental to the development of
surimi and its products industry.

In response to this industry chaos, the company and Jiangnan University jointly developed a detection method for microbial glutamine transaminase in frozen surimi, realized the detection of exogenous TG enzyme adulteration, the detection limit reached 20ng/mL, and formed its own intellectual property - microbial glutamine transaminase ELISA detection method
in frozen surimi.
The development and application of this detection technology effectively guarantees the quality and price of the raw materials purchased by the company, promotes the standardized development and progress of the industry, and ensures the rights and interests
of consumers.

Mixed processing technology of freshwater surimi and marine surimi

Due to the rapid development of the surimi products industry, the demand for surimi by surimi products enterprises has increased sharply; With the gradual reduction of marine fish resources, labor costs continue to increase, and the production of high-quality marine fish decreases
.
For various reasons, the price of surimi in China's seawater has risen year by year, but the quality has shown a downward trend
.
In contrast, in recent years, the freshwater fish aquaculture industry has developed rapidly, and the supply of freshwater surimi has been increasing year by year
.

In this regard, the introduction of freshwater surimi resources with abundant resources, stable sources and sustainable development, and independent development of freshwater surimi and seawater surimi mixed processing technology, with the development and maturity of technology, for the research and development of quick-frozen modulated surimi products to guide new ideas, but also successfully solve the shortage of marine fish raw materials and the utilization of freshwater surimi resources; The new technology makes full use of the complementary advantages between freshwater surimi and marine surimi to effectively improve the quality of surimi products, and successfully introduced a series of new quick-frozen prepared surimi products
with stable yield, high nutritional value and rich taste to the market.

Third, the value of demonstration and promotion

From the upstream high-yield surimi processing technology, and the establishment of standards for frozen surimi for upstream products and the development of MTG adulteration detection technology, to the development and transformation and application of core technologies for enterprise innovation and development such as freshwater surimi and seawater surimi mixed processing technology in the intensive processing link, it has well promoted the rapid growth of enterprises and simultaneously promoted the healthy and standardized development of
the upstream industry.

For the main freshwater surimi producing area in Hubei, the Group set up a factory in Hubei and added surimi production business, completed the procurement of raw materials nearby, saved transportation costs and vigorously promoted the development of local silver carp aquaculture industry, driving local fishermen/farmers to increase production and income
.

The development and maturity of freshwater surimi and seawater surimi mixed processing technology has introduced the long-term sustainable freshwater fish aquaculture industry into the company's industrial chain, ensured the stable supply of raw materials for the company, alleviated the company's urgent demand for marine fish resources, reduced excessive demand for marine resources, and played a positive guiding role in protecting marine resources; And while breaking the bottleneck of limited capacity development in the surimi products industry, it has vigorously promoted the development of
freshwater fish aquaculture industry.
At the same time, the completion of frozen surimi standards and MTG adulteration detection technology has well regulated the order of the industry and promoted the orderly development of
the industry.

Responsible Editor: Zhao Yu Review: Wang Jinchen