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Study on Soft Packaging Technology of Braised Leather Beard
At present, leather beard fish farming is very common, and the yield is high. However, due to market saturation, the price has dropped significantly. From September to October every year, a large number of leather beard fish are difficult to sell within a short period, leading to fierce price competition and low profits despite high production. To address this issue, the author conducted an experimental study on soft-braised leather beard fish silk packaging processing, transforming it into braised fish blocks, thornless braised fish, and small packaged portions. The relevant techniques are introduced below for reference by others in the industry.
First, the overall process includes: live fish acquisition → clear water holding → slaughtering → pickling → draining → cooking → vacuum packaging → high-temperature sterilization → inspection → packaging → final sales.
Second, the raw materials and equipment required include:
1. Main raw material: Live leather beard fish, with a weight of over 1000 grams, ensuring high meat yield. The fish should be fat, strong, disease-free, and have minimal injuries.
2. Vegetables and seasonings: Fresh ginger, evenly sized green onions, and food-grade soy sauce, rice vinegar, cooking wine, sesame oil, soybean oil, salt, MSG, and sugar.
3. Seasoning ingredients: In Henan Province, the main spices for braised meat include Amomum villosum, cloves, fennel, Sichuan pepper, pepper, Shanna, white peony, dried ginger, galangal, Longjing, and Caoguo. In Guangdong, the seasoning mix contains star anise, fennel, Amomum villosum, cloves, Chinese prickly ash, Hana, galangal, Longjiao, Caoguo, chicken extract, jade, shancha, white peony, red peony, and cinnamon.
4. Major equipment: Holding pools with water intake and drainage systems, braising stoves, double-chamber vacuum packaging machines, high-pressure steam sterilizers, and packaging bags and boxes made of two-layer materials with high-temperature resistance and good sealing properties.
Third, the operational steps are as follows:
1. Raw material handling: Live leather beard fish are kept in a holding pool for 24–48 hours with fresh water at 13–20°C. No feeding is done during this time, and water is changed regularly to remove the earthy smell.
2. Slaughtering: Fish are cleaned, heads and viscera removed, fins cut off, and then washed thoroughly in clean water.
3. Cutting: Three cutting methods are used—direct slicing, bone separation, and rib preparation for braised steak.
4. Pickling and draining: After boiling, salt is added to make up 10% of the water, and the fish are marinated for 30 minutes before being drained for 5–10 hours at 0–10°C.
5. Braising method: Heat oil, add ginger and green onions, then cook the fish for 3–5 minutes before adding spices, wine, sugar, vinegar, soy sauce, and salt. Cook for 20 minutes, then add MSG and sesame oil.
6. Packaging: Use vacuum-sealed, heat-resistant food bags with dimensions like 15cm×20cm or 16cm×21cm. Each bag contains about 150g of fillets, 200g of bone pieces, or 250g of ribs. The bags are sealed after air is removed using a vacuum pump.
7. Sterilization: High-temperature pressure sterilization at 110°C for 18 minutes ensures a shelf life of six months.
8. Cooling: After sterilization, the packages are cooled quickly in cold water (10–15°C) for about 20 minutes.
9. Inspection: Random sampling checks seal strength, damage, gas content, and weight. Meat appearance, color, and taste are also evaluated. Additional tests are conducted at 35°C for 10 days to monitor quality.
10. Final packaging: Outer packaging uses plastic layers, with 20 bags per box, suitable for easy transport and storage.
Fourth, cost calculations show that 1000g of live fish yields 650g after processing, resulting in a 60% yield. With a cost of 6 yuan per kg of live fish, plus 0.5 yuan for seasoning and 0.5 yuan for processing, the total cost for 600g finished product is 7 yuan, or 11.6 yuan/kg. For smaller packages, the cost is around 2.34 yuan per 200g. Braised fillets cost 9 yuan/kg, thornless meat 12.36 yuan/kg, and braised steak 2.25 yuan per bag.
Fifth, experience and suggestions: Leather beard fish is highly nutritious, less spiky, and easy to process, especially for small-packaged products, which can help children eat fish more easily. With abundant supply and low prices, there are many opportunities for processing. However, current methods are still experimental and not fully mechanized. For large-scale production, automation and assembly line operations are recommended, along with further research into detailed cooking and preservation techniques.
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