Cryogenic Processing, Packaging & Marketing of Crabmeat

1. Cryogenic Processing, Packaging & Marketing of Crabmeat Thomas E. Rippen University of Maryland Sea Grant Andrew Tolley Equipment Project Coordinator Bill Sieling Chesapeake Bay Seafood Industries Association

2. Domestic Crab Processing Industry • Strengths • Can produce fresh, unpasteurized crabmeat • Growing demand for local, fresh foods • Local crabmeat recognized for high quality • Weaknesses • Crabs are seasonal, best crabs when demand • Still need a way to extend shelf-life and inventory products • Pasteurized crabmeat perceived as more highly processed, less fresh • Traditional cans are expensive, available from only one manufacturer - must have a seamer for 401

3. Crab Industry Disaster Relief Funds • Appropriated by Congress • Administered in Maryland by MD DNR • Subcontracted to University of Maryland to implement • Current funds allocated in two awards for equipment, assistance (MCQAP and other projects), marketing • Find alternative to pasteurizing in cans • $392,000 for purchasing equipment

4. 1 lb plastic cup Fresh pack, used for freezing in this test. 401 diameter pasteurized can 307 diameter pasteurized can 307 diameter MD pasteurized can Crabmeat containers

5. Panama 307 closing machine Canco 60P 401 closing machine $27,400, between “as is and rebuilt” condition (Alard)

6. Is Freezing the Answer? • Dehydration • Water migration and recrystallization • Hydrophobic interactions • Concentration of reactants (What happened to Q10?) • Enzymatic softening in some fish • Formation of cross-links (e.g. formaldehyde from TMAO) • Oxidation of oils (rancidity) • Protein denaturation and structural damage – • Toughening • Excessive drip • Bland flavor • Oxidative changes • Yellowing • Off-flavors and odors

7. What’s required for best quality? • Pass through 27-15F quickly. • Target final equilibrium temp = storage temp • Use good barrier packaging • Hold storage temperatures steady • Fluctuating vapor pressure accelerates sublimation and accretion of ice crystals (a-axis and c-axis growth) • Hold storage temperature as cold as commercially feasible.

8. Will it Work for Crabmeat?

9. We Sure Hope So!

10. Cryogenic Freezing of Crabmeat • Rapid freezing • Currently used in Maryland and elsewhere with good experience • Product is thawed and sold as previously frozen • Studies show reduced tissue damage • SEM (Giddings and Hall, 1976) • And improved sensory quality for short-term holding (1½ months) • Webb, et. al. 1976 • Beyond 5-6 mos. pasteurization may be better option

11. Vent Relief Valve Liquid Nitrogen Dewar LN2 Hose Mini Freezer

16. Process ( 1 lb plastic cup) Initial temperature of crabmeat 31-34 º F Freezer cabinet control setting -100 º F Freezing time 60 minutes Center of can temperature at 60 minutes 25 º F to -10 º F

19. Interpretation of Data Pasteurization as Baseline 3 Year Payback Comparison of Equipment Combinations

21. Basic Data Generated from Phase 1, con’t

22. Mini and ewar Mini and Bulk

24. Comparison MiniCabinet Batch Cabinet

25. Bulk Tanks for Liquid Nitrogen

26. Freezer Cabinets Mini Freezer 75 lbs capacity Batch Freezer 200 lb capacity Double Door Freezer 400 lb capacity Too Large Too Small Just Right

27. Liquid Nitrogen Storage BulkTank Dewars 41 Gallon Capacity 1500 Gallon Capacity Cheap LN2 vs 5 yr lease Expensive NL2 vs low rent

28. Recommendation: Bulk and batch cabinet

30. Conclusion • Mini Cabinet is too small • Dewars are not practical for LN2 storage for crabmeat processors • A batch cabinet and bulk tank system are recommended • A production range for a LN2 freezer system is at least 7,500 lbs to 10,000 lbs per year (either in a single operation or a combination)

32. Responses of Eastern Shore consumers, skin-pack vs. metal can

33. Responses of Western Shore consumers, skin-pack vs. metal can

34. Consumer surveyImpression of tray vs. can Consumers indicating that the tray was better or much better than the metal can Eastern Shore: 68 percent Western Shore: 48 percent

35. Marketing OptionsCommunity Supported FisheryCharlie Petrocci and Noreen Eberly • CSF consumer survey • Survey Taken During Seafood Cooking Demonstrations at Harbor Day Event • 64 completed the survey • Community Supported Agriculture • Exploring potential for adding a seafood option • Survey instrument prepared and sent to 350 members of existing CSA on Eastern Shore

36. Consumer SurveyCommunity Supported Fishery • 1. Which locally caught species would make you more likely to participate in a CSF program in your area. Crabmeat 44; Striped bass 31; Live crab 26, Clams 25; Shucked oysters 20; Live oysters 20 • 2. I prefer: fillets/steaks 41; whole fish 16; headed/gutted 10; no preference 6 • 3. How often would your prefer to have these types of seafood available (mixed products each week/seasonally). Bi-weekly 32; weekly 20; monthly 5; quarterly 1.

37. Consumer Survey, cont.Community Supported Fishery • 4. Product available for pickup by you at set time and location. Average drive miles – 10; weekday afternoons - 33; weekend mornings - 30 • 5. On a scale of 1 to 10, would you sign up for a CSF arrangement/contract based on the species you chose above. One (very unlikely) - 4; Two- 4 ; Three-3; Four-4; Five-4; Six-0; Seven - 13; Eight - 3; Nine - 4; Ten (very likely) - 22

38. What’s next • Evaluate batch freezer performance under commercial conditions. • Conduct retail sales study comparing skin-pack trays to metal cans. • Conduct and monitor one or more alternative marketing strategies, e.g. CSF.