Process for the filleting, treating, packaging, freezing, and thawing of varying types of tuna and other pelagic species

Abstract

A method of treating fish to maintain freshness after freezing and thawing. A whole fish is chilled and cut into four loins, each with two flat sides forming a corner. The loins are chilled and either sliced cross sectionally to form steaks or sliced parallel to one of the flat sides to form sashimi slabs. If sashimi slabs are formed, the slabs are then preferably dipped in a warm flavor enhancing solution. The steaks or slabs are then sealed in non-permeable bags, preferably in a “puzzle pack” configuration that maximizes density and minimizes interstices. The bag with the steaks or sashimi slabs is then submerged in a brine solution. A treatment gas is then injected into the bag. After a treatment time, the gas is removed and the bag is vacuum packed. The bags are then frozen for shipping and storage. When needed, the bags can be thawed in a brine solution.

What is claimed is:  
     
         1 . A method of treating fish to maintain freshness even after it has been frozen and thawed comprising: 
 chilling a substantially whole fish in a first ice brine solution containing water, ice and salt;    cutting the fish into four loins, each having a substantially V-shaped cross section;    chilling the loins in a second ice brine solution;    slicing the loins cross sectionally to form steaks;    sealing the steaks into non-permeable bags;    injecting a treatment gas into the bags;    evacuating the treatment gas from the bags after a sufficient treatment time;    vacuum packing the bags; and    freezing the steaks in the bags.    
     
     
         2 . A method according to  claim 1  further comprising: 
 placing the bags in salt water until the steaks are partially thawed; and  
 removing the steaks from the bags.  
 
     
     
         3 . A method of treating fish to maintain freshness even after it has been frozen and thawed comprising: 
 chilling a substantially whole fish having a backbone in a first ice brine solution containing water, ice and salt;    cutting the fish substantially horizontally and substantially vertically through an axis defined by the backbone to form four loins, each having a substantially shaped cross section;    chilling the loins in a second ice brine solution;    slicing the loins cross sectionally to form steaks;    sealing the steaks into non-permeable bags;    injecting a treatment gas into the bags;    evacuating the treatment gas from the bags;    vacuum packing the bags; and    freezing the steaks.    
     
     
         4 . A method according to  claim 3  further comprising: 
 placing the bags in salt water until the steaks are partially thawed; and  
 removing the steaks from the bags.  
 
     
     
         5 . A method of treating fish to maintain freshness even after it has been frozen and thawed comprising: 
 chilling a substantially whole fish in a first ice brine solution containing water, ice and salt;    cutting the fish into four V-shaped loins, each having two flat sides defining a corner and an arc shaped side;    chilling the loins in a second ice brine solution;    cutting the loins cross sectionally to form larger and other steaks;    placing four of the larger steaks in a substantially rectangular non-permeable bag having four corners so that the corners of each steak are in a corresponding corner of the bag;    placing other steaks between said four larger steaks in varying orientation to maximize density and minimize interstices within said rectangular bags;    sealing the bags;    injecting treatment gas into the bags;    evacuating the treatment gas from the bags;    vacuum packing the bags;    freezing the steaks.    
     
     
         6 . A method of treating fish to maintain freshness even after it has been frozen and thawed comprising: 
 chilling a substantially whole fish having a backbone in a first ice brine solution containing water, ice and salt;    cutting the fish vertically and horizontally through an axis defined by the backbone to form four V-shaped loins, each loin having two flat sides defining a corner and an arc shaped side;    chilling the loins in a second ice brine solution;    slicing each loin into sections parallel to one of said flat sides to form larger and other sashimi slabs;    placing a first larger sashimi slab in a rectangular non-permeable bag with four corners with said flat sides aligned with the corners of said bag;    placing a second larger sashimi slab in said rectangular bag in a reverse orientation and flipped over;    placing other sashimi slabs in said rectangular bag with said other slabs selected, rotated and flipped as necessary to maximize utilization of space and minimize contortion of the sashimi slabs;    sealing the sashimi slabs into the bag;    injecting treatment gas into the bags;    evacuating the treatment gas from the bags;    vacuum packing the bags;    freezing the sashimi slabs.    
     
     
         7 . A method according to  claim 6  further comprising: 
 placing the bags in salt water until the sashimi slabs are partially thawed; and  
 removing the sashimi slabs from the bags.  
 
     
     
         8 . A method of treating fish to maintain freshness even after it has been frozen and thawed comprising: 
 chilling a substantially whole fish in a first ice brine solution containing water, ice and salt;    cutting the fish into four V-shaped loins, each loin having two flat sides forming a corner and an arc shaped side;    cutting each loin substantially parallel to said flat sides to form sashimi slabs of predetermined thickness;    chilling the loins in a second ice brine solution;    placing the sashimi slabs into non-permeable bags    sealing the bags;    injecting treatment gas into the bags;    evacuating the treatment gas from the bags;    vacuum packing the bags;    freezing the sashimi slabs.    
     
     
         9 . A method according to  claim 8  further comprising: 
 placing the bags in salt water until the sashimi slabs are partially thawed; and  
 removing the sashimi slabs from the bags.  
 
     
     
         10 . A method of treating fish to maintain freshness even after it has been frozen and thawed comprising: 
 chilling a fish having a backbone in a first ice brine solution;    cutting the fish vertically and horizontally through an axis defined by the backbone of the fish to form four V-shaped loins, each loin having two flat sides defining a corner and an arc shaped side;    chilling the loins in a second ice brine solution colder than the first ice brine solution;    drying the loins;    cutting the loins substantially perpendicular to said flat sides to form steaks of larger and other sizes;    arranging four of the larger steaks on a rectangular substantially rigid supporting structure having four corners with a handle so that the flat sides of each steak are in a corner of the structure;    placing other steaks in the interior of the supporting structure between said four larger steaks in varying size and orientation to maximize density and minimize interstices within said rectangular bags;    sliding the structure with the steaks into a none-permeable plastic bag;    tilting the handle up and removing the structure but leaving the steaks in the plastic bag;    sealing and vacuum packing the bag;    submerging the bag in a third ice brine solution;    drying the bag;    injecting gas into the bag until all edges of the bag are covered;    clamping the opening in the bag where the gas was injected into the bag;    chilling the steaks and agitating them periodically;    evacuating the gas from the bag;    vacuum packing the bag;    submerging the steaks into a fourth ice brine solution;    removing the steaks from the fourth ice brine; and    freezing the steaks.    
     
     
         11 . A method according to  claim 10  wherein: 
 the first brine solution is at a temperature of between 28 and 36 degrees Fahrenheit;  
 the second brine solution is at a temperature of between 20 and 27 degrees Fahrenheit;  
 the third brine solution is at a temperature of between 23 and 30 degrees Fahrenheit; and the fourth brine solution is at a temperature of between and 30 degrees Fahrenheit.  
 
     
     
         12 . A method of treating fish to maintain freshness even after it has been frozen and thawed comprising: 
 chilling a substantially whole fresh fish in a first brine solution containing water, ice and enough salt to keep the solution temperature at between 28 to 36 degrees Fahrenheit;    cutting the fish on the vertical axis through the backbone of the fish;    cutting the fish on the horizontal axis through the backbone of the fish to form four V-shaped loins, each loin having two flat 90 degree sides and an arc shaped side;    skinning the loins;    chilling the loins in a second brine solution, colder than the first brine solution containing water, ice and salt at between 20 to 27 degrees Fahrenheit until each loin is between 27 to 35 degrees Fahrenheit;    drying the loins;    cutting the loins cross sectionally into slices of predetermined thickness to form larger steaks and other steaks;    arranging four of the larger steaks on a rectangular substantially rigid supporting structure having four corners with a handle so that the 90 degree sides of each larger steak are in a corner of the structure;    placing other steaks in the interior of the supporting structure between said four larger steaks in varying size and orientation to maximize density and minimize interstices in the interior of the supporting structure;    sealing and vacuum packing the bag;    placing the bag in a third ice brine solution at a temperature of between 23 to 30 degrees Fahrenheit;    inserting a gas nozzle into the bag;    injecting treatment gas into the bag;    clamping the opening in the bag where the gas nozzle was inserted    chilling the steaks at between 25 to 31 degrees Fahrenheit for 4 to 12 hours;    evacuating the treatment gas from the bags;    vacuum sealing the bags;    placing the steaks in the bags into a fourth ice brine solution at a temperature of between 23 to 30 degrees Fahrenheit;    removing the steaks in the bags from the fourth ice brine solution;    blast freezing the steaks in the bags with a high circulating rate of air at less than minus 10 degrees Fahrenheit;    stacking the bags in a container;    storing the steaks at less than 10 degrees Fahrenheit.    
     
     
         13 . A method according to  claim 12 , further comprising: 
 submerging each bag in a solution of cold water and approximately one tablespoon of salt per gallon of water until the fish is partially thawed;    removing the bag from the water and drying the bag; and opening the bag and drying the fish.    
     
     
         14 . A method of treating fish to maintain freshness even after it has been frozen and thawed comprising: 
 chilling a fish having a backbone in a first ice brine solution;    cutting the fish vertically and horizontally through an axis defined by the backbone of the fish to form four V-shaped loins, each loin having two flat sides defining a corner and an arc shaped side;    chilling the loins in a second ice brine solution colder than the first ice brine solution:    drying the loins with sterile absorbent paper towels;    cutting each loin into sections substantially parallel to said flat sides to form larger and other sashimi slabs;    dipping the sashimi slabs in a flavor enhancing solution;    arranging four of the larger sashimi slabs on a rectangular rigid supporting structure with a handle so that the flat sides of each sashimi slab are oriented in the corner of the structure;    placing other sashimi slabs in the interior of the supporting structure;    placing the supporting structure and sashimi slabs in a non-permeable bag;    removing the supporting structure from the bag;    sealing and vacuum packing the bag;    submerging the bag in a third ice brine solution;    drying the bag;    injecting treatment gas into the bag;    clamping the opening in the bag where the gas was injected into the bag;    chilling the sashimi slabs in the bag;    evacuating the gas from the bag;    vacuum packing the bag;    submerging the sashimi slab into a fourth ice brine solution;    removing the sashimi slab from the fourth ice brine; and    freezing the sashimi slabs.    
     
     
         15 . A method of treating fish to maintain freshness even after it has been frozen and thawed which comprises: 
 chilling a substantially whole fresh fish having a backbone in a first brine solution containing water, ice and enough salt to keep the first brine solution at a temperature of between approximately 28 and approximately 36 degrees Fahrenheit;    cutting the fish vertically and horizontally through an axis defined by the backbone to form four V-shaped loins, each loin having two flat sides defining a corner and an arc shaped side;    skinning the loins;    chilling the loins in a second brine solution containing water, ice and salt at temperature of between approximately 20 and approximately 27 degrees Fahrenheit until each loin is at a temperature of between approximately 27 and approximately 35 degrees Fahrenheit;    drying the loins;    cutting each loin into sections substantially parallel to said flat sides to form larger and other sashimi slabs;    dipping the sashimi slabs in a flavor enhancing solution;    arranging two of the larger sashimi slabs on a rectangular rigid supporting structure with a handle so that the flat sides of each sashimi slab are oriented in a corner of the structure;    placing at least one other sashimi slab in the interior of the supporting structure between said larger sashimi slabs to maximize density and minimize interstices in the interior of the supporting structure;    placing the supporting structure inside a gas impermeable bag;    removing the supporting structure from the bag leaving sashimi slabs in the bag;    sealing and vacuum packing the bag;    placing the bag in a third ice brine solution at a temperature of between approximately 23 to approximately 30 degrees Fahrenheit;    inserting a gas nozzle into the bag;    injecting treatment gas into the bag;    chilling the sashimi slabs at between approximately 25 to approximately 31 degrees Fahrenheit for 4 to 12 hours;    evacuating the treatment gas from the bags;    vacuum sealing the bags;    placing the bags into a fourth ice brine solution at a temperature of between approximately 23 to approximately 30 degrees Fahrenheit;    removing the bags from the fourth ice brine solution;    rinsing and drying the bags with absorbent paper towels;    blast freezing the bags with the sashimi slabs with a high circulating rate of air at less than minus 10 degrees Fahrenheit;    treating containers with a water resistant coating;    stacking the bags in the container; and    storing the sashimi slabs in the bags at less than 10 degrees Fahrenheit.    
     
     
         16 . A packing method for items of larger and smaller size where at least four of the larger items have sides forming a 90 degree angle, the method comprising: 
 placing four of the larger items in a bag so that the 90 degree sides of each item are in a corner of the bag; and    placing the smaller items in the interior of the bag in varying orientations to maximize density and minimize interstices within said rectangular bag.    
     
     
         17 . A package comprising: 
 a rectangular bag;    a plurality of larger and other items, at least four of said larger items having two flat sides defining a corner, said corners being positioned in corresponding corners of said bag and the other items being positioned in the interior of said bag between said larger items in varying orientations to maximize density and minimize interstices within said rectangular bag.    
     
     
         18 . A package according to  claim 17 , wherein said items are fish.