Sustainable Bio-Resources

SUSTAINABLE BIO-RESOURCES Management, product development and raw material quality Beate J.Thu and Agnes C.Gundersen (Eds.) Møreforsking Ålesund AS

Orkana Akademisk

Sustainable Bio-Resources Management, product development and raw material quality Edited by Beate J. Thu and Agnes C. Gundersen

This book is published by the financial support of The Institute of Marine Research Norway, Møreforsking Ålesund, the Norwegian Technical University, Innovation Norway, the Norwegian Research Council, the Norwegian Directorate if Fisheries, the Nordic Ministry Council, the Greenland Institute of Natural Resources and the Greenland Ministry of Fisheries.

Cover pictures: Møreforsking Design: DesignBaltic.com Printed and bound by Jelgavas tipogrāfija © Orkana Akademisk 2016 Orkana forlag as, 8340 Stamsund

ISBN 978-82-8104-290-2 www.orkana.no post@orkana.no

Innhold Preface 7 Introduction Sustainable bio-resources. Management, product development and raw material quality..... 11 Beate J. Thu and Agnes C. Gundersen, Møreforsking, Ålesund, Norway Chapter 1 Different staining techniques for ovarian tissue in fish gonads embedded in Technovit®.......17 Wenche E. Larssen and Agnes C. Gundersen, Møreforsking, Ålesund, Norway Chapter 2 Maturity of Greenland Halibut (Reinhardtius hippoglossoides W.) in East Greenland, Faroe Islands and Hatton Bank area.................................................................................35 Agnes C. Gundersen, Stig Tuene, Wenche E. Larssen, Jesper Boje, Lise H. Ofstad, Møreforsking, Ålesund, Norway, Greenland Institute of Natural Resources, Nuuk, Greenland, Faroese Fisheries Laboratory Chapter 3 Maturity of Greenland halibut (Reinhardtius hippoglossoides W.) in the waters off Iceland...... 51 Agnes C. Gundersen, Wenche E. Larssen, Stig Tuene, Einar Hjørleifsson, Møreforsking, Ålesund, Norway, Marine Research Institute, Reykjavik, Iceland Chapter 4 Spawning dynamics of Greenland halibut stock components in West Greenland..............63 Agnes C. Gundersen, Claus Stenberg, Jesper Boje, Inge Fossen, Ole Jørgensen, Møreforsking, Ålesund, Norway, DTU Aqua, Charlottenlund, Denmark, Greenland Institute of Natural Resources, Nuuk, Greenland Chapter 5 Fishery and management of Greenland halibut in East Greenland....................................81 J. Boje and A. Gundersen, DTU AQUA, National Institute of Aquatic Resources, Charlottenlund, Denmark, Greenland Institute of Natural Resources, Nuuk, Greenland, Møreforsking, Ålesund, Norge Chapter 6 The Norwegian Nephrops fishery – history, exploitation and management........................95 Guldborg Søvik, Dag Furevik, Terje Jørgensen, Snorre Bakke, Wenche E.Larssen, Trude Hauge Thangstad, Astrid K. Woll, Norwegian institute of Marine Research, Bergen, Norway, Møreforsking, Ålesund, Norway

Chapter 7 Seasonal variation in fertilized King Crab roe.................................................................121 Wenche Emblem Larssen and Kari Lisbeth Fjørtoft, Møreforsking, Ålesund, Norway Chapter 8 Norwegian spring-spawning herring by-products for human consumption: Product and market development...................................................................................133 Margareth Kjerstad, Erik Olav Gracey, Bjørn Tore Nystrand and Wenche Emblem Larssen Møreforsking, Ålesund, Norway Chapter 9 Fresh- and frozen-stored fillets of Atlantic mackerel (Scomber scombrus) – effect on oxidation and sensory quality of canned mackerel fillets...................................147 Grete Hansen Aas, Trygg Barnung, Margareth Kjerstad and Wenche E. Larssen Møreforsking, Ålesund, Norway, NTNU Ålesund, Faculty of Life Sciences

Chapter 8

Norwegian spring-spawning herring by-products for human consumption: Product and market development Margareth Kjerstad*, Erik Olav Gracey, Bjørn Tore Nystrand and Wenche Emblem Larssen Møreforsking Ålesund, Borgundveien 340, 6009 Ålesund

Keywords: By-products, rest raw materials, Norwegian spring-spawning herring, value creation, market potential, omega-3, circular economy, food production

Abstract

Pelagic processors are increasingly interested in higher value by-products for fillet-line rest raw materials, which include belly flaps, bits and pieces, backs, heads and tails. The authors assessed the feasibility of utilizing Norwegian spring-spawning herring by-products as food for human consumption. An initial analysis determined that Russia, China and Poland are particularly interesting markets. High quality by-products were produced from fillet-line rest raw materials, which were separated, collected, and packaged using modified production equipment; however, full automation of this process was not achieved. By-products contained high levels of nutrients and omega-3 fatty acids and were included in 15 new products tested by importers in China, Russia and Poland. Products created from belly flaps and bits and pieces were especially popular. The project demonstrates that herring by-products are an excellent raw material for consumer products and presents evidence of market readiness.

*

Corresponding author: margareth.kjerstad@moreforsk.no

133

Introduction

The Norwegian pelagic processing industry is generally a high-volume, low-margin operation characterized by large seasonal variation and relatively poor profitability compared to the pelagic fishing fleet. Norway is a global leader in Atlantic herring landings, but has seen its share of landed catch decrease from approximately 70% in 2010 to 55% in 2014 (FAO, 2014). There are two important herring stocks included in the catch statistics for Norway, the North Sea Herring stock (Clupea harengus) and the Norwegian Spring-Spawning Herring (Clupea harengus L.). Of the two, the Norwegian Spring-Spawning Herring stock (NSSH) has historically been the most important for Norwegian fishermen in terms of availability, catch quotas, and price (Myrland, Xie, Kinnucan, & Pettersen, 2012). The landed catch price of NSSH rose from 2 NOK/kg in 2010 to 5 NOK/kg in 2014, reflecting a growth in demand and a dip in supply due to reduced quotas (Norges Sildesalgslag, 2010–2014).

Head cut

Head cut

Tail cut

Belly cut

Tail cut

Belly cut

Belly flaps

Belly

Fillet

Bits and pieces Belly flap

Bits and pieces

Figure 1. Illustration and photos of belly flaps and B&P from Norwegian spring-spawning herring

These high prices, while a boon for fishermen, are decreasing the operating margins for Norwegian primary processors and foreign processors, particularly in Central and Southern Europe where herring processing is a long-standing tradition. As a result, pelagic processors across several countries are looking at alternative products to increase margins and diversify away from the unpredictability of round herring to fillet-based processing (Kjerstad, Emblem Larssen, & Nystrand, 2014). Sixty percent of all Norwegian landed herring were filleted in 2013 (Olafsen, Richardsen, Ragnar, Gunn, & Jan, 2014), yielding 178,000 t of rest raw materials (RRM), or «secondary» 134

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materials, some of which have market potential as by-products for human consumption; these include belly flaps, bits and pieces, heads and tails. Currently, most herring RRM in Norway is utilized for fishmeal and oil production, eventually ending up as ingredients in Norwegian aquaculture feed. The exception is herring roe, which a few processors have developed into a commercial product for niche markets (Nystrand, Helgesen, Kvalsund Otterlei, & Emblem Larssen, 2014). If herring by-products are handled correctly, both fresh and frozen material can have excellent quality and be perfectly suitable for human consumption. The Norwegian government made utilization of fisheries by-products a national priority (Norwegian Ministry of Fisheries and Coastal Affairs, 2012–2013) and pelagic by-products have the most potential, both in terms of raw material quantity and potential value creation.

Applying the same assumptions as Olafsen, Richardsen, Nystøyl, Strandheim, and Kosmo (2013) to a 2014 quota of 254,658 tonnes (60% of landed herring are filleted with a fillet yield of 46%), then 68,759 tonnes of NSSH rest raw materials were potentially available. However, not all RRM fractions are easily separated from the production line and/or are suitable as food products. Backs and heads are not ideal as food products due to the amount of blood remaining in these fractions.

Belly flaps are the thin, triangle-shaped area that remains when the fillet is cut from the abdomen of the fish. They have tiny bones and contain approximately double the amount of fat as the fillet. Bits and pieces (referred to at times as B&P) are trimmings from fillets cut into «cocktail» pieces or pieces that deviate from the desired size and shape. These two by-product fractions (see Figure 1) have the highest market potential and were the focus of consumer product testing.

Materials and methods Raw material NSSH were caught in the Norwegian Sea and near-shore areas of Nordland county during the traditional September to February fishery over three seasons (2012– 2014). After harvest, the fish were transported to industry partner Grøntvedt Pelagic in Uthaug, Norway for filleting and by-product separation. The fish varied in size, but most were between 300 to 400 grams. Samples for chemical analysis were taken from fish harvested in November.

Production line NSSH were processed using a Baader 221 LA fully automated production line, including the BAADER 488 automatic feeder, BAADER 221 heading and filleting machine and BAADER 56 skinner. Belly flaps were separated by mounting a collection trough under the flank knives of the fillet machine. After separation, belly flaps were rinsed with freshwater before manual removal of intestines/gonads and finished with a 5% salt rinse for 20 seconds before vacuum packing. Bits and pieces were collected with a customized sorting line attached to the main production line.

All samples were taken from the same fillet machine.

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135

Test products Over the course of three seasons (2012–2014), approximately 8.5 tonnes of minced herring, belly flaps, tails and B&P were produced and packaged using a WEBOMATIC APS ML 7100 deep-draw vacuum packer. The 1 to 10 kilo bags were frozen at -20°C and kept in cold storage. Length and width measurements were taken with slide calipers and rulers. Yield was estimated as a percentage of fish round weight.

Water, ash and salt content The herring was homogenized in a food processor (Braun Combimax 600), and the moisture content of a 5 g sample was determined by drying at 105°C until a constant weight was obtained (NMKL:23, 1991). Ash was determined using NMKL:173 (2005) and heating the samples in the furnace at 550°C for 8–12 h.

Results are expressed as grams of water or ash per 100 g muscle. The chloride content was determined by Mohr’s method (Mohr, 1856). A carbonized sample was added to potassium chromate and titrated with silver nitrate. Potassium chromate is used as an indicator. Results are expressed as g salt 100 g-1 muscle.

Fat and protein content Fat content was analysed at NIFES (National Institute of Nutrition and Seafood Research) using method 091. Lipids were extracted with ethyl acetate, after which the solvent was gasified by boiling and the remaining lipids were weighed. The method is accredited and has an uncertainty of less than 5 percent. Raw protein was analysed per method 171 at NIFES. The sample was burned in pure oxygen in a combustion chamber. The resulting nitrogen gas was tested for thermal conductivity in a thermal conductivity cell and total nitrogen content was measured. The amount of protein is obtained by multiplying the nitrogen content by 6.25. The method is accredited and has an uncertainty of less than 5 percent.

Producing minced and marinated herring In cooperation with Baader Norway, the mincing machine BAADER 600 was tested on belly flaps, B&P, backs, tails, heads, and fillets with minimal defects. This setup utilized a drum with 2mm holes and a modified cleaning belt to produce the different minced herring batches. Yield was measured and sensory analysis (superficial appearance) was performed on the different types of minced products. All samples were vacuum packed in 2 kg packages and frozen at -20°C. Three different marinades were made for testing out belly flaps: salt, spiced and vinegar. All marinating was performed in 120 L plastic barrels using Grøntvedt Pelagic’s own recipes.

Market and product testing Primary data was collected through in-depth interviews with producers of herring products in five countries. Innovation Norway (IN) performed an initial comprehensive mapping of market potential and utilization of herring by-products in Russia, Poland, South Korea, China and Turkey. Five interviews were conducted in China, ten in Korea, five in Turkey, five in Poland and three in Russia. After this 136

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initial assessment, producers in Poland (3), Russia (2) and China (7) were chosen for product testing. Product testing was performed in the months of April and July in 2013 and in the fall of 2014–2015.

The producers received and evaluated both marinated (vinegar and spiced) and natural belly flaps and B&P, as well as minced herring based on belly flaps, B&P, tails, backs and fillet rejects. Meetings were held with producers upon completion of product testing. In-depth interviews were conducted to assess interest in the products and to identify determining factors for including herring by-products in their respective product portfolios. Common factors were product quality, packaging, price, season, market potential and distribution. Innovation Norway assisted in the interview process in Poland and Russia. In China, the consulting firm Mayhope Development assisted in distributing the test products and performing the interviews. Grøntvedt Pelagic was represented in all meetings and interviews. In all, 13 interviews were conducted, six in Poland, two in Russia and five in China.

Results Products Belly flaps Belly flaps are the thin, triangular-shaped pieces of RRM formed from the abdomen, which is just below the fillet cutting line. By weight, they represent around 5–7% of the whole herring. Based on six production cycles (N = 260), the average dimensions of belly flaps are: Length 17.3 (± 26) cm and Width 3.6 (± 0.9) cm. The average weight was 19.9 (± 4.8) grams. In the fall period of September to November, the fat content of NSSH is optimally high and the belly flap is at its peak with respect to appearance and quality. As the season progresses towards spawning in February and March, belly flap thickness decreases and the product becomes less appealing. Interesting product applications evaluated for belly flaps include warm and cold smoking, canning (both smoked and boiled), mincing (as a spreadable condiment and for fish dishes) and fried or deep-fried, ready-to-eat dishes (see Figure 3 for examples). All companies commented on the high quality of the belly flap as a raw material. The high fat content and flavour were highlighted as positive attributes. The size, appearance and many bones were listed as negative attributes.

Three companies created canned test products from belly flaps. The high fat content necessitates customized processing steps to ensure that the final product does not contain too much oil. Some had success with pre-treatment, such as boiling or smoking before canning. The smoked varieties were most appreciated based on taste and were compared favourably with kippers. Belly flaps were hot and cold smoked. The consensus experience was that smoking temperatures (<70°C) were not high enough to soften the bones, except in the case of smoked, canned products.

Large belly flaps that are trimmed to fit the dimensions of the canning vessel are recommended, which also allows for fin removal during the trimming process. Smaller belly flaps are recommended canned whole and packed like sardines. The marinated Norwegian spring-spawning herring by-products for human consumption: Product and market development

137

belly flaps had such a strong taste that all producers preferred to discontinue those trials and proceed with natural belly flaps only. Frying or deep-frying the belly flaps softened the bones, allowing for more palatable marinated or ready-to-eat products.

This observation led to a great variety of ideas for fried herring, including as a pre-treatment before brining and canning. Others created ready-to-eat, wok style dishes packed in vacuum. Products served in Chinese fast food restaurants are often prepared in a semi-processed state where they can be quickly heated and served.

Multiple Chinese companies experimented with belly flaps with promising results.

Natural, pre-cooked canned in oil

Natural, pre-cooked in tomato sauce

Natural, deep fried belly flaps

Natural, tempura fried belly flaps

Figure 2. A sample of test products from belly flaps

Bits and pieces B&P were collected from two sorting steps in the production line. Pieces from the first sorting step had an average weight of 4.0 (±1.5) grams. Despite being larger in appearance, B&P from the second sorting weighed slightly less, at 3.7 (±1.5) grams.

It is hypothesized that the salting step, which occurs between the first and second sorting, is responsible for the weight loss. The normal «cocktail» pieces produced by Grøntvedt Pelagic have an average weight of 14 (±2.1) grams. B&P were tested as additions to pickled or canned products with different types of sauce (e.g. canned in tomato sauce), in salads, as minced herring or in fish nuggets (see Figure 3).

B&P product varieties were very well received by producers, who appreciated the flexibility of the raw material in its natural state. Some drawbacks mentioned by Chinese producers were the presence of bones and a tendency for the pieces to fall apart during cooking.

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B&P in aspic jelly with vegetables

Canned B&P in tomato sauce with vegetables

B&P in brine with vegetables

Canned B&P with vegetables

Herring balls from mince

Herring balls with onion in brine

Figure 3. A sample of test products from bits and pieces and herring mince

Minced herring Minced herring was produced from B&P, belly flaps, backs and fillet rejects (picked off the line). Minced herring yield was calculated at 56% (STD = 0.4) for belly flaps, 69% (STD = 0.6) for tails, 74% (STD = 0.4) for B&P and 77% (STD = 0.3) for fillet rejects. High content of red-brown muscle tissue in the tail-based mince resulted in a mass with darker colour than the rest. Minced herring was assessed as an ingredient in canned products (as a spreadable condiment) and in fish dishes, such as burgers and balls made from herring, and as fried products ready to eat (Figure 3). The fat content of belly flap mince was as high as 30% (see Table 1) and had to be mixed with other ingredients to achieve a satisfactory consistency (e.g. mixed with B&P mince). Minced herring was found to have desirable qualities as a spreadable condiment and as an ingredient in fish dishes. Moreover, product testing revealed that minced herring could benefit from the addition of antioxidants to Norwegian spring-spawning herring by-products for human consumption: Product and market development

139

increase product stability and shelf life. Mince from B&P had a lower fat content than mince from belly flaps.

Herring mince from tails, B&P, belly flaps, and fillet rejects was sent to potential clients for testing. In Poland, spreadable canned condiments are popular. One such condiment, called «paprykarz» in Polish, contains ground fish meat mixed with other ingredients. Spreadable herring mince products were well received by producers and there was a general sense of optimism for the product in Poland. «Paprykarz» made from belly flap mince was the most popular version based on taste and spreadability, both variables related to the high fat content. Herring mince has been reported to have a mild taste and is therefore highly adaptable. Among other interesting test products are herring balls and burgers, served either ready-to-eat or in a pickling jar with onions and brine, similar to salmon balls in Germany. Minced herring was not sent to China for product testing due to import difficulties; however, many Chinese producers expressed an interest. For all herring products, bones could be a problem for consumers. Producers thought that minced herring might be easier to introduce to the market due to the absence of detectable bones.

Table 1. Chemical nutritive analysis of test products (N=5) sent to overseas markets (g/100g)

Product

RRM

C. date

ADDT

Fat

Protein

Water

Ash

Salt

Mince

B&P

Nov.

N/A

14.1

17.0

67.8

2.3

0.4

”

Belly

Nov.

N/A

30.0

10.5

57.6

2.4

1.9

”

Fillet rej.

Nov.

N/A

11.0

18.0

69.7

2.1

0.3

”

Backs (B)

Nov.

N/A

8.7

14.2

74.6

1.1

0.2

”

Tails (T)

Nov.

N/A

7.6

17.9

74.8

1.6

0.3

”

T+B

Nov.

N/A

7.3

16.6

76.1

2.1

0.2

Natural

Belly

Nov.

Rinsed

34.5

12.0

50.1

3.3

2.0

”

Belly

Sep.

Unrinsed

41.4

11.8

46.5

1.8

0.6

Marinated

B&P

Jan.

Vinegar

13.6

13.8

62.9

8.1

7.0

”

B&P

Nov.

Salt

7.8

10.9

75.5

6.3

5.2

”

Belly

Nov.

Vinegar

40.5

10.1

38.8

7.3

6.4

”

Belly

Nov.

Spices

37.7

10.6

37.3

11.7

9.9

”

Belly

Nov.

Salt

39.1

9.9

39.4

12.6

10.9

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Chemical composition of rest raw materials and test products All test products sent overseas underwent chemical analysis to provide potential clients with information about product quality and chemical composition. Table 1 shows the variation in fat content between the different products. Whole belly flaps and belly flap mince have more than double the fat content of any other raw material. Protein content was highest for products produced from B&P, fillet rejects and tails. The marinated products have a higher salt and ash content due to salt addition in the marinade. Cleaned natural belly flaps and belly flap mince also have a relatively high salt content. This is likely due to the practice of rinsing the belly flaps in salt water and use of a 5% salt solution during cleaning. Uncleaned and unrinsed belly flaps had a salt content of 0.6%.

Discussion

The nutritional profile and palatability of NSSH by-products show clear potential as consumer products. However, the authors are not aware of any international processing industry creating consumer products from belly flaps or B&P from herring.

The Atlantic salmon processing industry started developing belly flaps as consumer products in the mid-1990s. Today, salmon belly flaps are a commercial product.

They are price sorted by width in 1–3 cm, 2–4 cm and 3–5 cm classes and sold in a variety of packaging. In 2011, 5,000 tonnes were exported from Norway at an average price of 15 NOK/kg. The widest belly flaps command the highest price and can reach up to 30 NOK/kg for the largest specimens (Olafsen, 2011). This product is primarily exported as «harasu» to the Japanese sushi market. Salmon belly flaps are smoked, eaten fresh, frozen, processed into rolls and fried in various products.

In response to high demand, Polish companies have developed new fillet techniques to maximize belly flap yield. Salmon belly flaps are also popular in the Chinese market where they are thinly sliced and crispy fried during barbeques (Kjerstad et al., 2014). The similarity between salmon and NSSH belly flaps could pave the way for commercialization in the same markets.

Production equipment During the fall of 2013, Grøntvedt Pelagic developed a sorting conveyer belt using equipment from Baader Norway that effectively collects and cleans bits and pieces from the production line. The sorting unit/trough was mounted under the flank knives and sorted out the belly flaps in an acceptable manner. However, the sorting line was not able to remove roe, milt and intestine attached to the inside of the belly flap. The manual cleaning was time consuming and the intestine was especially hard to remove due to its position at the back of the V-shaped cavity. Automated removal is possible, but necessitates removing the attachment point during filleting. The intestine was often empty, but the intestinal wall itself was about 0.2 cm to 0.4 cm and had a transparent-greyish colour. As it became clear that automation would be required for upscaling, many automated solutions to the belly flap cleaning process were unsuccessfully trialled. The consensus opinion after these trials is that the new technology should focus on the fillet step in the production line. Specifically, a sysNorwegian spring-spawning herring by-products for human consumption: Product and market development

141

tem that removes the intestine attachment point during filleting will likely provide the best solution to this technical challenge.

Conclusion

Over three harvesting seasons (2012–2014), approximately 8.5 tonnes of test products were produced from Norwegian spring-spawning herring belly flaps, tails, heads, backs, and bits and pieces. Based on market research performed in close collaboration with Grøntvedt Pelagic, Innovation Norway, and Møreforsking, 15 different test products were created and distributed to potential customers in Poland, China and Russia. These test producers found the products to be highly palatable and recommended them as consumer products. Qualities highlighted as especially positive are good quality, high content of omega-3 fatty acids, and expectations of a lower price than herring fillet. On the other hand, the presence of bones in the belly flaps and the small size of bits and pieces were considered negative characteristics.

There was some concern that the products are unknown in the marketplace and could therefore be challenging to introduce.

Based in part on enthusiasm for the test products and the sheer volume of fish products consumed in these countries, the Polish and Chinese markets were determined to have the highest potential for commercial success. The project has demonstrated that Norwegian companies can obtain a higher price and increased value creation by using Norwegian spring-spawning herring rest raw materials to create by-products for human consumption rather than feed applications. Forecasts suggest an increased level of processing in the Norwegian pelagic industry, which should provide more opportunities to realize the value potential in herring by-products.

Herring rest raw materials were successfully separated and collected for the purposes of the project; however, process automation was not achieved for belly flaps. Cleaning the belly flaps and removing the oft-attached intestines and gonads was the main barrier to automation. This process had to be performed manually and necessitated so much time that it potentially threatens profitability due to the high cost of Norwegian labour. The project resulted in process innovation as Grøntvedt Pelagic succeeded in developing a novel sorting line for bits and pieces.

Furthermore, the BAADER 600 grinder machine was found to be well-suited to producing herring mince from belly flaps, tails, bits and pieces and fillet rejects.

Overall, the project demonstrated that herring by-products are highly regarded in the marketplace and only minor technological innovation is required to allow for fully automated production.

Acknowledgements

Thank you to Ole Andre Nilsen and the employees at Grøntvedt Pelagic, RCN and FHF. Thank you to Kjell Arthur Linn-Olsen in Baader Norway, Aleksandra Buczkowska in Innovation Norway and Oliver Lee in Mayhope. Finally, a big thanks to the companies that tried out the test products.

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Norwegian spring-spawning herring by-products for human consumption: Product and market development

Sustainable bio-resources: Management, product development and raw material quality is the second anthology produced by Møreforsking and includes nine peer-reviewed articles covering a broad spectrum of the marine value chain, fishery management and performance, exploitation of new marine resources and processing and quality of raw materials. Through this anthology, Møreforsking Ă&#x2026;lesund provides industry and academia with examples of basic and applied research pushing the boundaries of scientific and technological progress with respect to improving the utilization and management of marine resources.

Collectively, these contributions demonstrate a great potential for sustainable utilization of marine resources. Their accessibility to the national and international scientific community, industry, decision-makers, and educational institutions will positively lift the status of knowledge for value creation from some of the important marine resources in the North Atlantic.

Orkana Akademisk ISBN 978-82-8104-290-2

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