Superchilling is an innovative process that allows the core of the fish to be cooled without freezing it. The superchilled product is firmer and more resilient to processing, resulting in a more attractive product with greatly increased primary product ratio and shelf-life.

The handling of raw material in whitefish processing has often left a lot to be desired, particularly when handling sensitive species like haddock or cod. By superchilling the product before processing, yield and quality are maximised, while the shelf life of fresh products can be extended by as much as three or even four days.

More valuable product
Superchilling allows the core of the fish to be cooled down to a sub-zero state without freezing the surface. Fillets become firmer and more elastic, and therefore much more resilient during subsequent processing stages.

In addition, the cooling energy inside the superchilled fish reduces drip loss during processing. The result is a much more attractive product, with a greatly increased primary product ratio compared to conventional methods. Higher product value and price is therefore a key benefit of the system.
 
Extended shelf life
Superchilling has the added advantage that the fresh fillets remain cold throughout processing and are still cold when packed, resulting in greatly improved conditions during transport. And as the cooling energy is contained inside the superchilled product itself, much less ice, if any, needs to be added for cooling, which can result in major savings on transport costs.

More importantly, shelf life can be extended by at least two and as much as four days, depending on conditions, a major benefit when fresh product needs to travel long distances to the customer. Since the product can be sold for a longer period of time, a longer shelf life also translates to increased sales, higher product quality and value, and greater customer satisfaction. In addition, it allows exporters to choose a more economical means of transport, such as sea freight instead of air freight.

How it works

Fillets pass through the Marel SuperChiller for 8-10 minutes, where they are cooled to a constant temperature of around -1.5°C through skin-side contact with the Teflon belt and cooling airflow. When they emerge, they are firm, elastic, robust and ready to withstand skinning and other handling during the rest of the production process.

As the cooling energy is contained inside the superchilled product itself, much less ice, if any, has to be added for cooling during transportation.

Following successful installations at a number of whitefish plants, this innovative process is currently being tested for use in processing several farmed species, such as salmon, catfish, tilapia and pangasius.

The super chilling concept is based on three main steps. 

1.  Preparing the fillets 
     Before super-chilling in special designed cooling tank for 10-12 minutes.

• Cooling down fillets before super chilling.
• Cleaning the fillets for a whiter and better appearance.

2.  Super-chill fresh products into sub-zero state (available in 3 standard sizes).
     Chilling capacity is based on the following.

• Fillets average size 500g (17.64 oz).
• Loading on freezing belt 8.80 kg/m2 (1.8 lbs/ft2).
• Fillets are super-chilled in 8 minutes.
• Capacity: 60-100 fillets/min.

3. Skinning machine is special designed for fillets in sub-zero state.

• Capacity of each machine: 40 fillets/min.
• Cod and Haddock fillets.
• Average length: 420 mm.