Products Control
1500 kg/batch
Gel strength .  Whiteness  .  Moisture   Impurities  .  Smell  
Folding  .  Microbial*  .  pH  

Aoki in-house laboratory is always ready to control the quality of final products by 1500 kg/batch. Our standard casing method was instructed by a Japanese veteran with over 40 years experience with surimi production in Japan and have satisfied many markets' standards.

* Microbial test samples will be sent to external certified laboratory everyday and additionally on schedule of our HACCP plan.

Sustainability is incomplete without traceability

Each block of Aoki surimi have a set of code numbers on PE bag to trace back to all its statistics stored in Aoki quality computer. The first 7 digits are unique to each Lot of production (1.5 MT), while the last three digits are unique to each block of 10kg. 

 

If customer can retain this information, Aoki can trace back to all production info: time and all parameters involve during processing, storage and further back to source of raw materials such as suppliers, transportation and fishing vessels.

7202106

796

block code

freight document

AOKI

product

storage data

processing control data

fishing boat

& area

Aoki staff

Panasonic food cutter, 2 blades, 2200 rpm

3.

Put meat paste in plastic bag, remove all air bubbles by vacuum machine : 2 times x 10 sec = 20 sec

4.

Put sample into the Stuffer, use the prepared bags to stuff a sausage sized 30mm x 195mm, weighed 150g, tie the other end of sausage after stuffing.

Make two sausages like that from one sample.

5.

Boiling the sausages in 94°C water, 30 minutes.

Aoki
Casing

Take two samples of 400g each from the Blender right after additive mixing.

Freeze samples the same way as final products. One sample stored away for later test, one will be cased immediately.

Prepare the Mixer, knife, chopping-board, Sausage Stuffer.

Weigh 12g salt (3% of sample’s weight).

Waterproof Betan DT bags 30mm x 200mm, tied one end.

    1.

Take one frozen sample (-5°C), use the knife to cut it into small pieces and put them into the Mixer.

Run the Mixer until sample’s temperature reach -1°C.

Put 12g salt into the Mixer and continue mixing until sample’s temperature reach 17°C, then stop and take sample out.

    2.

Vacuum machine and sausages stuffer

Water bath boiling 94°C in 30 minutes

Cooling in cold water for 45 minutes

Cut the 2 sausages into 10 sections 2.5 cm thick

RHEO TEX Type SD-700 II

Chroma meter CR-400

Cooling sausages in cold water for 45 minutes.

Take sample out and keep in room temperature for 5 minutes before testing.

Cut the sausage into 10 sections, 2.5cm thick each. Sectioned faces should be smooth and even. Remove the bag covers.

Start the Gel strength measurer. Place a section onto the machine so that the plunger is in the center and at a 90 degree angle with the sectioned surface.

Write down the result W, L from the machine’s monitor. Do the  same for all 10 sections.

The GS result will be average of 10 sections W and L

    6.

    7.

8.

Use the above sections for whiteness measuring as well.

Cut 5 thinner sections, 0.8 cm thick each.

Start the whiteness Chroma meter CR-400.  Test the machine with a standard sample using a lighting source C.  Checking the parameters if Y = 88.8, x = 0.3153, y = 0.3226. If the results are different we need to adjust the machine before resuming the test.

Check the real sample. Hold the Chroma meter 90 degree angle with the sectioned surface, the testing head face down. Press the section lightly with the testing head and press Start on the machine.

Write down results of the parameters  Z, L*, a*, b* from the machine's monitor.

The whiteness results will be average of 5 sections results

9.

Use the above sections for folding strength measuring as well.

Cut 5 thinner sections, 3 mm thick each.

Fold each sections in two, then in four using fingers to test the folding strength.

Folding test in two

Folding test in four

 
 
SURIMI  SPECIFICATIONS
PURE ITOYORI

Pure Itoyori is the highest quality surimi type in term of raw materials selection, whiteness and taste in Aoki.

With a 100% ratio of thread fin bream (Itoyori fishes), the materials are hand-picked by workers, separated, and chosen base on sub-species, size, freshness and preservation condition.

This product line usually has the best microbial score, the least impurity, while retaining a delicious taste and smell differentiate from the plain taste of cold-water-fish surimi.  

Raw materials

Additives formula

Gel strength Grade

Whiteness Z score

Whiteness L*a*b score

Moisture

Impurities

pH

:    Itoyori 100%

:    6.0   % Sugar

     0.2   % Egg white

     0.3   % STPP

:    200/300

     300/400

     400/600

     600/800

:    49 UP

:    78 UP

:    76% - 77%

:    < 6 pcs/ 10 gram

:    6.8 - 7.0

ITOYORI
MIX

Itoyori Mix is a very versatile product line with a wide range of specifications for customers to choose, whether your preference is whiteness, gel strength, or moisture, you can probably find a suitable product from Aoki.

Aoki customized recipes will always contain a portion of Itoyori to keep the characteristics of tropical Itoyori surimi taste and smell even in the lower grade 100/200/300. In high grade Itoyori Mix 400/600/800 we have large percentage of Itoyori and Kintokidai fishes to keep the gel strength and whiteness high.

The advantage you can get : from low to high grade, Aoki surimi is always subjected to strict processing and quality control to keep  consistent quality of the surimi and give customer real values and peace of mind.

Raw materials

Additives formula

Gel strength Grade

Whiteness Z score

Whiteness L*a*b score

Moisture

Impurities

pH

:    Itoyori          20 - 60%

     Kintokidai      0 - 40% 

     Others          20 - 60%

:    6.0   % Sugar

     0.2   % Egg white

     0.3   % STPP

:    100/200

     200/300

     300/400

     400/600

     600/800

:    40 - 47 UP

:    70 - 77 UP

:    76% - 77%

:    < 10 pcs/ 10 gram

:    6.8 - 7.0

PURE
ESO

Pure Eso is made of 100% lizard fishes. 

This surimi generally has low gel strength,  especially when processing without egg white for some customers' requirement, in which case the additive total will be 6.3% (without egg white percentage).

Therefore, the quality and price of Eso surimi will often be determined by whiteness level instead of gel strength.

Aoki has diverse suppliers for Eso raw materials, which allow us to process a wide range of whiteness level for Eso surimi and separate into different price range to suite different need of customers.  

Raw materials

Additives formula

Gel strength Grade

Whiteness Z score

Whiteness L*a*b score

 

Moisture

Impurities

pH

:    Eso 100%

:    6.0   % Sugar

     0.2   % Egg white

     0.3   % STPP

:    <100

     100/200

:    42 - 48 UP

:    74 - 76 UP

:    76% - 77%

:    < 10 pcs/ 10 gram

:    6.8 - 7.0

 
WHAT'S IN THAT SURIMI ?

Often buyers really concern about the additives composition of their surimi even more than the casing result. Especially the additives that are NOT on the declaration paper by the manufacturers, or ones that can cause allergic reaction for consumers.  In fact they should, because even the test conducted by themselves can be a misreading of the true nature of the surimi they bought, due to the highly effective food additives which can alter the quality reading while hiding itself from detection.

It is an entire science to learn about food additives. It is vast as much as deep, and our opinion is, there is nothing wrong in enhancing the product quality if doing so responsibly and having the buyers' consent.

Having said that, Aoki is aware of the potential of unfair values and advantages gained by surimi manufacturers by not declaring the use of supporting additives for surimi enhancement in some parameters. The most trouble for surimi buyers will come from the protein extracts from allergens such as soy, peanuts, seaweed, milk, wheat, buckwheat, shrimp and crab. Additive manufacturers usually use those in conjunction with transglutaminases for easily 40% upgrade in elasticity and firmness, or maltodextrin to create stronger binding and gelling property, fiber  with water retention property to increase stability and quantity; many of which are cheap, diverse in forms and features, tasteless and colorless, no easy way to detect.

The use of these enhancements on surimi has been a legitimate concern for brokers and users of surimi, which throughout the years had diminished the image of Vietnam surimi in the eyes of international customers. Undeclared substance can cause damage to surimi buyers in various degree, from lower quality, financial loss, to claim and legal action from their customers, loss of brand value and market share, and in case of allergic lawsuit in a market like Japan, that could mean the death of a brand. 

Aoki's esteemed customers, some have their own laboratory for testing "not-declared" substances in their materials, even so they are still worried because they cannot test all products they bought, and usually they need to know (or guess) what they are looking for in testing.

That is why, Aoki only work with people we can trust, and we are most happy when customer trust Aoki. Even when selling our surimi through brokers, Aoki want to know about the destination's manufacturers, how they use our surimi, in what product, what parameters they are looking for. Because better understanding, both in business and in person, will lead to a long-lasting relationship of trust, and it goes both way, Aoki always invite customers to visit factory even if you do not buy directly from Aoki. Building and cultivating relationships is the way Aoki want to build a sustainable business. 

 

_ _ _

 

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