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HAVBRUK2-Stort program for havbruksforskning

Concept development of full-scale soluble gas stabilization (SGS) technology for seafood

Alternative title: Konseptutvikling av fullskala "soluble gas stabilization" (SGS) teknologi for sjømat

Awarded: NOK 10.0 mill.

In recent years, seafood products packaged in a modified atmosphere have taken over large market shares in Europe, with products ranging from minced products to a wide range of fresh fillets, shellfish and shells. Most consumers will relate the term modified atmosphere to food packaging where the product is packed in a tray with a volume of gas surrounding the product. The term can also have a broader meaning and also include vacuum-packaged products. In vacuum packaging, the atmosphere will be modified in the sense that it is physically removed from the presence of the product (e.g. oxygen is removed to prevent a product from going rancid). In gas packaging, the antimicrobial effect of the packaging concept will be determined by the amount of available carbon dioxide (CO2) that can be dissolved in the product. This is, in turn, given by the composition of the packaging gas and the degree of filling (i.e. the product volume vs. the total volume of the package). For seafood products, a degree of filling of between 25 and 33% of the total volume is recommended using an atmosphere containing 60-70% CO2. This will ensure good microbial stability, resulting in improved product shelf life, and avoid package collapse as a result of excessive changes in the headspace gas volume surrounding the product. Today, the degree of filling for products packed in gas presents challenges related to low packaging efficiency, which in turn affects logistics and distribution of the products. One way around this is to dissolve CO2 into the product before it is packaged. Lab-scale experiments have shown that 1 to 2 hours in pure CO2 at low temperatures (0-4°C) provides sufficient dissolution for several relevant product types. The filling level can, therefore, be increased in the packages without compromising the product quality and shelf life. Another option is to dissolve CO2 in the product followed by vacuum packaging. The method used to dissolve CO2 before the product is packed in either a tray surrounded by gas, or in a vacuum is called "soluble gas stabilization (SGS)". The technology can, if used correctly, have the potential to i) increase the degree of filling in the packages and thus provide better packaging efficiency and improved logistics, ii) and/or extend the shelf life of the products by maintaining the original degree of filling, and/or iii) provide improved shelf life in vacuum packaged products. In this project, we have developed a concept for making the SGS technology industrially available. A future industrial implementation will further contribute to a more sustainable value chain for packaged seafood products. This will be, as far as we know, the first concept where this type of technology solution has been developed. Although the project aimed to improve the packaging of seafood, a technology transfer to other food industries, such as the meat industry, is possible.

Teknologikonseptet som har blitt utviklet, er nå på et nivå (TRL 4/5) og vi ser nå et behov for at norsk leverandørindustri kommer på banen og ser på muligheten for å viderutvikle og komersialisere konseptet. Gjennom prosjektet har vi oppnådd kompetanse og formidlet potensielle løsninger for hvordan SGS teknologien kan tilpasses ulike produkttyper og prosesslinjer. Vi har også modellert, simultert og validert ulike startegier for å løse inn CO2 i produkter på en mest mulig effektiv og trygg måte. Som et resultat av korona-pandemien ble ikke foredlingsindustrien like mye involvert i prosjektet som opprinnelig planlagt. Sett i ettertid, er dette noe vi burde jobbet mere med for å fått et enda mer anvendt fokus på jobben som har blitt utført. Et par funn i prosjektet med betydning for industrien som vi ønsker å trekke frem er fordelene som oppnås ved å kombinere SGS med vakuumpakking av fersk filet, samt muligheten for å løse inn CO2 som en integrert del av kjøleprosessen etter varmebehandling av f.eks. fiskekaker/burgere. Å kombinere SGS med pakking av produkt i vakuum vil både gi tilsvarende bakteriostatiske effekt som oppnås med tradisjonell gas-pakking, samtidig som det totale volumet med emballasje som skal distribueres vil bli redusert. Produkter med lengre holdbarhet vil gjøre det mulig for industrien å nå nye, fremtidige markeder. Det vil også bidra til bedre utnyttelse av råstoffet, i tråd med bioøkonomiske prinsipper. Teknologisk sett vil en videre kommersialisering av et fullskala konsept for SGS-prosesseringsteknologi komme den norske næringsmiddelindustrien til gode, både som et konkurransefortrinn for leveradørbransjensom og for de som videreforedler det fantastiske råstoffet vi produserer i Norge.

The soluble gas stabilization (SGS) technology has been proven beneficial for prolonging the shelf-life of muscle food such as seafood and white meat. According to previous research, it has been shown in lab conditions that exposing the food samples to CO2 before packaging will increase the shelf-life and preserve the quality of muscle food for a longer period, without influencing taste and visual impression. Longer shelf-life is correlated with increased utilization of the raw material, food products and enables these products to reach new markets. Through previous work, lack of technology for on line industrial full-scale SGS treatment during production has been identified to be the main obstacle for implementing SGS treatment in the food industry. The project will focus on seafood but technology transfer to the meat industry will be possible. In order to develop an innovative concept for full-scale SGS processing technology that provides optimal bio-physical conditions for muscle food along the food supply chain all the way to the end consumer, both technology and bio-physical condition needs to be taken into consideration. In this research project, the main goal will be achieved through interdisciplinary research to secure the optimal solution to be found. The different WPs will be focusing on either technological research or life science challenges where we believe that the multidisciplinary focus of this project will be a driver for its success!

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Funding scheme:

HAVBRUK2-Stort program for havbruksforskning