Canada. Fisheries Service Industrial Development Branch

PROJECT REPORT

Ottawa/Hull 1972

SPECIALTY FISH PRODUCT DEVELOPMENT

IN NEWFOUNDLAND 1971

prepared by

Louis Lipton Haniff Madakia

for

Industrial Development Branch Fisheries Service

Environment Canada

acting in cooperation with

The Newfoundland Fisheries Development Authority

w. D. McDougall Project Supervisor

Opinions expressed and conclusions

reached by the author are not necessarily endorsed

by the sponsors of this project.

The Authors at a Product Development luncheon Show

( l. lipton (l), H. Madakia (R) )

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had been tapped.

ii

ABSTRACT

As part of a program to improve the fishing

industry in Newfoundland, 24 new recipes for the

manufacture of foodstuff suited to the retail market

have been developed. These items have been well

accepted at luncheon shows in Newfoundland, in Prince

Edward Island, and in Ottawa and trial orders were

placed by major buyers.

iii

ACKNOWLEDGEMENTS

The entire project could not have been carried out as ef­

fectively as it was, without the cooperation of many interested people.

Mr. Rupert Prince, of the Newfoundland Fisheries Development

Authority and Mr. Marvin Barnes, Newfoundland representative of the

Industrial Development Branch, Fisheries Service, Environment Canada

made all the facilities of their respective organizations available as

needed.

Miss Catherine O'Brien, Consumer Consultant in the St. John's

office of the Fisheries Service, Environment Canada was always ready

to assist us.

The Fisheries College in St. John's was most generous in al­

lowing us to use the plant set up there for preparing samples with the

newly created recipes.

Bonavista Cold Storage Co. Ltd., Bonavista was most helpful

in permitting the use of plant facilities.

Above all, we are indebted to Mr. Wally MacDougall of the

Industrial Development Branch, Fisheries Service, Environment Canada

(Ottawa) who offered valuable encouragement and assistance in every

form.

We wish to express our sincere thanks to all the above, to

the members of their staffs and to the many other people who provided

assistance.

iv

Introduction

Summary

Product Development

Re.UEeA

1. Fish Stock

2. Stuffed Crab Shell

3. Crab Meat Puffs

4. Au Gratin Sauce

5. Shrimp Au Gratin

6. Crab Au Gratin

7. Scallop Au Gratin

8. Cod Au Gratin

9. Salt Cod Au Gratin

10. Shrimp Scampi on Bed

11. Shrimp Fried Rice

12. Chowder Concentrate

13. Fish Chowder

14. Seafood Chowder

15. Salmon Chowder

16. Shrimp Chowder

TABLE OF CONTENTS

of Rice

v

1

2

3

7

8

9

10

11

12

13

14

15

16

17

18

19

19

19

19

Table of Contents Cont'd

Page

17. Lobster Chowder . . . . 19

18. Stuffed Squid · · 20

Lemon Butter Sauce 21

19. Stuffed Baby Flounder . . · · . 22

20. Egg Milk Batter · . . . . . . . · · 23

21. Breading . . · .. . . . . . · • 24

22. Deep Fried Cod Strips . . . . . 24

23. Marinated Squid 25

24. Chips . . . · · 26

vi

INTRODUCTION

At the present time a large part of the Newfoundland fish

catch is sold in the form of frozen fillets with minimum processing

requirements.

During 1971 Environment Canada and the Newfoundland Fisheries

Development Authority carried out a "fish product development" program

in an effort to increase the value of the catch and the number of jobs

available in the processing and related industries (e.g. packaging,

advertising, transportation), and to generally assist in diversifying

the fishing industry.

Several new products were developed using the fish available

in Newfoundland waters. Some of the ingredients utilized were by­

products normally discarded or utilized in fish meal.

- 1 -

SUMMARY

The program was directed mainly to the development of frozen

products for several reasons:

1. most plants in the area are equipped with freezing

facilities

2. the frozen product is better tasting than the canned and

is very similar to the fresh product

3. the market for prepared frozen products is steadily growing

and all kinds of consumers are receptive to such new items.

The recipes prepared resulted in specialty foods which could

be mass produced to be sold at popular prices. In addition to super­

market products which will find their way into the average home, the

program also developed products suitable for institutional and restaurant

trade, airline and railroad service and in-plant feeding.

A survey of several plants was made in order to determine the

catch distribution and the equipment available to each. The results

were used in selecting the products each plant was best able to produce.

Thus, recipes and procedures were tailor-made to each situation. Sample

batches of all new products were prepared for evaluation in Canada and

in the United States.

In Canada, eight luncheon shows were arranged to introduce

the products to potential customers.

- 2 -

Fish Steaks on a bed of Lumpfish Caviar trimmed with Smoked Char Slices

PRODUCT DEVELOPMENT

Most of the work was carried out at the Bonavista Cold Storage

Limited Plant in Bonavista. Some work utilizing vacuum packaging

techniques, was carried out at the Department of Fish Technology,

Fisheries College, St. John's.

The facilities of the test kitchen, Information and Consumer

Branch, Fisheries Service, Environment Canada, St. John's were also

utilized in the product development.

About 20 products were developed utilizing raw materials such

as scallop, shrimp, crab, lobster, cod, flounder, salmon, halibut, and

lumpfish roe. Some work was also carried out on suitable packaging

materials and convenient packaging for the products. Vacuum pack

'boil in bag' products were produced at the Fisheries College.

Fish frames were used as a principle ingredient. These are

the principle by-product from filleting lines and are presently used

for reduction to fish meal. A quantity of fish stock was prepared and

frozen for future use.

Lumpfish roe was processed into lumpfish caviar in 2 oz. and

3 oz. jars and also as bulk fresh lumpfish caviar. The caviar was dyed

black or red and the jar lumpfish caviar was later pasteurized in St.

John's and stored in a chill room. For details of the process, refer

to Technical Report No. 7 (1).

- 3 -

Processing Lumpfish Caviar - A Progress Report of Work in 1970 by

A.B. Dewar, Louis Lipton and G.E. Mack, of the Applied Research and

Development Laboratory, Inspection Branch, Canada Department of Fisheries

and Forestry, Maritimes Region, Fisheries Service, Halifax, N.S.,

March 1971.

The chowders were prepared next, in frozen concentrate form,

to be diluted by the consumer. They were:

(i) Fish chowder from any species of raw groundfish

(ii) Seafood chowder from a mixture of shrimp, salad crabmeat and fish

(iii) Salmon chowder from salmon

(iv) Shrimp chowder from pink shrimp

(v) Lobster chowder from lobster

The chowders were packed in 1/2 lb. and 1 lb. boil-in bags,

sealed and quick frozen.

The next products developed were the Au Gratins. They were:

(i) Shrimp Au Gratin

(ii) Crab Au Gratin

(iii) Scallop Au Gratin

(iv) Fresh Cod Au Gratin

(v) Salt Cod Au Gratin

- 4 -

The Au Gratin are packed in aluminum trays of two sizes, 1/2 lb.

and 1 lb., with a see-through plastic lid and are quick frozen. All the

customer has to do is to remove the plastic lid and place the frozen

Au Gratin tray in the oven to heat it before use.

Until the present time the plants processing snow crab in

Newfoundland were throwing away the shell (carapace) of the crabs. We

developed a product called stuffed crab shell. The shells are thoroughly

cleaned and sterilized before being filled with stuffing made from salad

crab meat and filler and are then quick frozen. They are packed 36

shells to a carton or 2 shells per tray for the supermarket trade. The

other product developed from salad crab meat was crab meat puffs; the

crab mixture is rolled into balls which may be frozen raw or deep fried

and then frozen. The balls are packed in 1 lb. poly bags or in aluminum

trays for the "heat and eat" trade if they have been pre-cooked.

Two seafood sauces were prepared utilizing shrimp, squid,

salad crabmeat and fish; they are seafood sauce with cream and seafood

sauce with tomato sauce.

A product called stuffed "Baby" flounder was prepared from

small flounder. It consists of stuffing between fillets. These are

dipped in batter and breaded and are quick frozen raw. The stuffed

"Baby" flounder is packed in aluminum trays and could be "baked or fried"

during processing or, by the consumer, during preparation for serving.

Pink shrimp caught in Newfoundland waters were prepared in

two forms:

(i) Shrimp scampi on a bed of rice

(ii) Shrimp fried rice.

- 5 -

The Shrimp scampi is packed in aluminum trays with transparent lid and

the shrimp fried rice in 1/2 pound and 1 pound size 'boil-in bags' which

are then sealed. Both products are quick frozen.

Two different squid recipes were prepared:

(i) Stuffed squid

(ii) Marinated squid

The stuffed squid is packed in aluminum trays and quick frozen, and the

marinated squid is packed in jars and kept refrigerated.

Packed 'portion control' halibut and salmon steaks in boil-in

bags from 4 to 12 ozs.were prepared, vacuum sealed and quick frozen.

Cod strips, cod cheeks, cod tongues, and capelin were prepared in heat

and serve form. These products were dipped in egg-milk batter and rolled

in breading prior to deep frying. They were then quick frozen.

With more research and development, the recipes presented here

and the technology used can be modified or improved to give better and

more attractive products. Some of the recipes, as presented here, are

small batches or test formulations. They may be used as the basis of a

commercial operation. Since the recipes are bland, they can be adjusted

to suit the particular flavor or characteristic the producer wishes to

emphasize.

No attempt was made to determine the exact cost of production

of the various recipes discussed in this report, as the objective of the

work was to determine whether or not high quality food products could be

achieved in a frozen package acceptable to the consumer.

- 6 -

Recipe No.1 - Fish Stock

The following ingredients are placed in a 50 gallon steam­

-jacketed kettle.

125 lb. fish frames

1/2 lb. salt

1/4 lb. pepper

*Fish frames, with gills and eyes removed, are thoroughly washed.

These and the other ingredients are then placed in the kettle. Water is

added to 6 inches below the top of the kettle. Bring to low boiling

point and cook for 2 hours. Shut off the steam and let the mixture

settle for 15 minutes. Skim the froth from the top and discard it.

Thoroughly strain the mixture. The liquid so obtained is the stock.

The fish stock can be packaged for sale or utilized for the

recipes in this report. The remains of the fish frames could be used in

a fish meal plant.

*Fish frames are the parts of the fish left after the fillets have been

removed.

- 7 -

Stuffed Crab Shell

Recipe No. 2 - Stuffed Crab Shell

8 lb. of (fine) bread crumbs or 2 tblsp. pepper cracker crumbs

2 tblsp. onion powder 5 lb. of margarine

2 tblsp. celery seed 1 1/4 lb. corn flake crumbs

2 tblsp. parsley flakes 10 lb. salad crab meat

2 tblsp. Italian seasoning 3 tblsp. monosodium glutamate

1 tblsp. garlic powder 6 u.s. qt. fish stock

1 tblsp. cayenne pepper 1 tblsp. oregano

1 tblsp. paprika 4 tblsp. salt

Melt the margarine in a pot and add the fish stock. Place

the bread crumbs and corn flake crumbs in a bowl or mixer, add the

spices and mix thoroughly. Blend the salad crab meat into the dry

mixture. Slowly add the liquid to the dry mixture.

Clean the carapaces and fill with stuffing (4 oz.). Sprinkle

the stuffing surface with parsley flakes and paprika. Freeze!

- 8 -

Crab Meat Puffs

Recipe No.3 - Crab Meat Puffs

5 lb. salad crab meat

4 lb. bread or cracker crumbs

10 oz. corn flake crumbs

1 lb. margarine

3 u.s. qt. fish stock

2 tblsp. salt

2 tblsp. parsley flakes

1 tblsp. pepper

1 tblsp. paprika

1 tblsp. monosodium glutamate

1 tblsp. Italian seasoning

1/2 tblsp. garlic powder

1 tblsp. onion powder

1/2 tblsp. cayenne pepper

1/2 tblsp. oregano

Melt the margarine in pot, add fish stock to it. Place the

bread crumbs and corn flake crumbs in a bowl or mixer, add all the

spices and mix thoroughly. Blend in all salad crab meat. Slowly add

the liquid mixing it with the other ingredients. Continue mixing

until an even consistency is attained.

Roll the mixture into balls, 16 to 20 balls to a pound.

Freeze them. 3 u.S. quarts = 2 1/2 Imp. quarts = 2 Litres.

- 9 -

Au Gratins

Recipe No.4 - Au Gratin Sauce

3 U.S. gal. fish stock

3 lb. cheddar spread

2 tblsp. onion flakes

2 tblsp. pepper

2 tblsp. salt

2 tblsp. parsley flakes

2 tblsp. monosodium glutamate

3 cups mushrooms

1 tblsp. garlic powder

1 tblsp. Italian seasoning

1 tblsp. oregano

1 tblsp. all-purpose mixed spices

1/2 tblsp. cayenne pepper

1 lb. margarine

1 lb. corn starch

1 tblsp. cream of tarter

1 1/2 lb. all-purpose flour

Place all the above ingredients except the corn starch, flour,

and cream of tartar in 2 gallons of fish stock in a pot. Bring the

mixture to a boil and let it simmer.

Prepare the thickening agent by mixing the all-purpose flour,

corn starch, and cream of tartar in a high speed beater.

Add the remaining gallon of cold fish stock to the thickener.

Mix slowly until a smooth batter is obtained. It should be thick enough

to flow smoothly.

Add the batter to the seasoned stock, stirring constantly,

until liquid thickens.

- 10 -

Recipe No.5 - Shrimp Au Gratin

3 u.s. gal. au gratin sauce (Recipe No.4)

5 lb. cooked, peeled, deveined pink shrimp

Parsley flakes

Paprika

The deveined pink shrimp is put into the pot of simmering

Au Gratin sauce and the mixture is stirred gently. When the mixture

is thoroughly blended, it is poured into a container of the desired size.

Add cheddar cheese to cover the surface of the product, sprinkle with

parsley flakes and paprika for decoration. Cover and freeze.

- 11 -

Recipe No.6 - Crab Au Gratin

3 U.S. gal. au gratin sauce (Recipe No.4)

5 lb. cooked crabmeat

Shredded cheddar cheese

Parsley flakes

Paprika

Add the cooked crabmeat to the pot of simmering Au Gratin

sauce. Stir gently. When the mixture is blended, pour it into a

container of desired size. Place 3 whole crab legs on top before

adding the shredded cheddar cheese to cover the surface of the product.

Sprinkle parsley flakes and paprika for decoration. Cover and freeze.

- 12 -

Recipe No.7 - Scallop Au Gratin

3 u.s. gallons au gratin (Recipe No.4)

5 lb. scallops

Cheddar cheese

Parsley flakes

Paprika

The scallops are parboiled for 5 minutes. They are then gently

stirred into simmering Au Gratin Sauce. When the mixture is thoroughly

blended, it is poured into a container of the desired size. To the

filled container, add shredded cheddar cheese to cover the surface of

the mixture. Sprinkle with parsley flakes and paprika for decoration.

Cover and freeze.

- 13 -

Recipe No.8 - Cod Au Gratin

3 u.s. gallons au gratin sauce (Recipe No.4)

5 lb. cod fillets

Shredded cheddar cheese

Parsley flakes

Paprika

The cod is parboiled for 5 minutes and then put into the pot

of simmering Au Gratin sauce. Stir gently. When these are thoroughly

blended pour the mixture into a container of suitable size. To the filled

container, add shredded cheddar cheese to cover the product. Sprinkle

with parsley flakes and paprika for decoration. Cover and freeze.

- 14 -

Recipe No.9 - Salt Cod Au Gratin

3 u.S. gallons au gratin sauce (Recipe No.4)

5 lb. salt cod

2 cans evaporated milk

Shredded cheddar cheese

Parsley flakes

Paprika

Soak 5 lb. of the salt cod overnight in fresh water. Dice or

shred the freshened salt cod and put it into the pot of simmering

Au Gratin sauce. Add 2 cans of evaporated milk and stir gently. When

blending is complete, pour the mixture into container of the desired size.

Cover the mixture with shredded cheddar cheese. Garnish with parsley

flakes and paprika. Cover and freeze.

- 15 -

Shrimp Scampi on a Bed of Rice

Recipe No. 10 - Shrimp Scampi on Bed of Rice

5 lb. converted rice 2 tblsp. garlic powder

7 lb. cooked, peeled pink shrimp 1 tblsp. onion flakes

3 cups mushrooms 1 tblsp. pepper

3 lb. margarine 2 tblsp. salt

1 tblsp. monosodium glutamate 2 tblsp. arrowroot

Parsley flakes 6 oz. sherry

Paprika

Boil 5 lb. of converted rice. Wash and drain it thoroughly.

Melt margarine, add all spices and 6 oz. of sherry. Blend. Add the

shrimp.

Half fill a container with cooled drained rice, and pour

the scampi sauce over the riee. Sprinkle with parsley flakes and

paprika.

- 16 -

Shrimp Fried Rice

Recipe No. 11 - Shrimp Fried Rice

2 1/2 lb. shrimp 2 tblsp. pepper

10 lb. converted rice 2 tblsp. onion flakes

3 cups mushrooms, 2 tblsp. monosodium glutamate sterns and pieces, drained, chopped

1 tblsp. oregano 4 oz. salt

1 tblsp. garlic powder 14 oz. soya sauce

1 tblsp. Italian seasoning 2 tblsp. gravy browning

Boil 10 lb. of rice. Wash and drain it thoroughly. Place

the rice in a mixing bowl. Add the spices and mushrooms to the cooked

rice. Mix thoroughly and gently. Add the gravy browning and soya

sauce and mix again. Add the shrimp and mix again. Place in vacuum

pack bags from 1/2 lb. up. Vacuum seal and freeze.

- 17 -

Recipe No. 12 - Chowder Concentrate

3 1/2 gals. fish stock (Recipe No. 1) 1 lb. corn starch

20 lb. peeled, diced raw potatoes 6 oz. salt

12 medium size onions, diced 4 oz. pepper

2 stalks of thinly sliced celery 4 cans of evaporated milk (6 oz.)

1 1/2 lb. all-purpose flour 1 1/2 lb. margarine

Add the vegetables, spices, flour and corn starch to the pot

of fish stock. Let the mixture boil for 15 minutes. Then add the

evaporated milk and margerine.

Prepare the thickening agent by lending 1/2 lb. of all-purpose

flour with 1 lb. corn starch. Use a high speed beater. Add 1 qt. cold

fish stock slowly until a smooth batter is obtained. It should be thick

enough enough to flow smoothly. Add batter to the pot of boiling liquid,

stirring until the liquid thickens.

Chill the cooked chowder thoroughly. Fill the vacuum pack

bags (from 16 oz. up) and freeze.

- 18 -

Recipe No. 13 - Fish Chowder

1 batch concentrated chowder (Recipe No. 12)

1 batch thickener

10 lb. of any species of ground fish

Prepare the chowder concentrate (Recipe No. 12) but before adding the

thickener, add the ground fish. Cook slowly for a further 10 minutes,

then add thickener slowly until a thick texture is obtained.

Recipe No. 14 - Seafood Chowder

Use Recipe No. 13, replacing the ground fish with 10 lb. mixed shrimp,

salad crab meat, and fish.

Recipe No. 15 - Salmon Chowder

Use Recipe No. 13, replacing the ground fish with 10 lb. of salmon.

Recipe No. 16 - Shrimp Chowder

Use Recipe No. 13, replacing the ground fish with 5 lb. of broken pieces

of shrimp.

Recipe No. 17 - Lobster Chowder

Use Recipe No. 13, replacing the ground fish with 3 lb. lobster meat.

- 19 -

Stuffed Squid

Recipe No. 18 - Stuffed Squid

Stuffing:

1 lb. hard bread crumbs

1 lb. any edible fish species

1 qt. (American) fish stock

1/2 lb. margarine

1/8 tsp. paprika

1 tblsp. salt

1/2 tblsp. pepper

1 tblsp. monosodium glutamate

1 tsp. parsley flakes

1 tsp. oregano

Meat tenderizer

Melt the margarine in the fish stock. Blend all the spices

and the fish with the hard bread crumbs. Then, slowly pour the liquid

into blended crumbs and mix thoroughly. The stuffing is now ready to

use.

Remove the tentacles and clean the squid thoroughly. Place

the cleaned squid into a meat tenderizer solution as directed by the

manufacturer (1/4 lb. of meat tenderizer powder to 6 qt. of water)

for 10 minutes. Remove the squid from the water, drain, and fill it

with the stuffing.

Place the stuffed squid in the container. Pour lemon butter

sauce* over the squid. Sprinkle with paprika and freeze.

- 20 -

*Lemon Butter Sauce

5 lb. margarine

1/4 lb. cream of tartar

2 oz. lemon juice

1/2 tsp. garlic powder

1/2 tsp. onion powder

1 tsp. salt

1 tsp. pepper

Melt the margarine and add the spices

- 21 -

Recipe No. 19 - Stuffed Baby Flounder

Stuffing:

1 lb. hard bread

1 lb. any edible

1 qt. (American)

1/8 tsp. paprika

1/2 lb. margarine

crumbs

fish species

fish stock

1 tblsp. salt

1/2 tblsp. pepper

1 tblsp. monosodium glutamate

I tsp. parsley flakes

1 tsp. oregano

Melt the margarine in fish stock. Blend all the spices and

the fish with the hard bread crumbs. Then, slowly pour the liquid into

the dry mixture and mix thoroughly.

Place the above stuffing between fillets. Then, dip the

stuffed baby flounder in egg-milk batter (see Recipe No. 20). Then,

bread, refer to breading recipe, Page 22, and freeze raw.

- 22 -

Recipe No. 20 - Egg Milk Batter

1 doz. eggs

1/2 lb. all purpose flour (sifted)

2 cans evaporated milk

2 tsp. corn starch

6 oz. oil.

Beat the eggs at a very high speed, blend with oil, milk,

then add flour and corn starch.

- 23 -

Recipe No. 21 - Breading

2 lb. fine milled hard bread 1 tsp. cayenne pepper

1 lb. extra fine corn flour 1 tblsp. allspice finely ground

1 lb. corn flake crumbs 2 tblsp. onion powder

1/2 lb. all purpose flour 1 tblsp. ground Italian seasoning

8 oz. corn starch 1 tblsp. paprika

1/4 lb. salt 2 tblsp. monosodium glutamate

2 tblsp. pepper 1 tsp. garlic powder

1 tsp. ground oregano

Mix all the above ingredients absolutely thoroughly.

Recipe No. 22 - Deep Fried Cod Strips

a) Cod Strips

b) Cod Cheeks

c) Cod Tongues

d) Capelin

Dip any of the above in egg-milk batter and roll in Breading,

(Recipe No. 21) and deep fry. Pack and freeze.

- 24 -

Recipe No. 23 - Marinated Squid

20. lb. of Squid

Pickling Solution

2 lb. sugar

1 qt. (American) white vinegar or cider vinegar

4 medium size onions, thinly sliced

1 tblsp. pickling spices

1 qt. water

Meat tenderizer

Place the squid into a meat tenderizer solution as directed

by the manufacturer (1/4 lb. of meat tenderizer powder to 6 qt. of

water) for 5 minutes. Remove and wash in hot water.

Cut the squid into pieces and place in pickling solution and

let stand for 3 days in the cooler. Pack in jars and keep refrigerated.

- 25 -

Recipe No. 24 - Chips

2 lb. tapioca flour

2 lb. fish

8 oz. cold water

1 egg

2 tblsp. salt

1 tsp. pepper

Beat the egg, water and spices thoroughly. Mince or grind

(extra fine) 2 lb. of any edible fish. Mix fish and flour thoroughly,

then slowly add the liquid and mix until the mixture is slightly moist.

Form into 1/2 lb. logs (1 1/2 inches diameter). Wrap in boil-in bags,

seal and place in retort at 2400 F. for 20 minutes. After cooking place

the logs in a refrigerator until the contents are sufficiently firm to

permit slicing. Slice into thin chips and dry thoroughly at 1000 - 2000 F.

maximum. Place the chips in plastic bag, and seal. Keep refrigerated.

The chips are deep-fat fried at 3500

- 3750

F. for about 10

seconds, or until they puff. The chips should swell about 3 times the

original size on frying.

- 26 -