보고서 정보
주관연구기관 |
해진물산(주) |
보고서유형 | 최종보고서 |
발행국가 | 대한민국 |
언어 |
한국어
|
발행년월 | 2011-10 |
과제시작연도 |
2010 |
주관부처 |
농림축산식품부 Ministry of Agriculture, Food and Rural Affairs(MAFRA) |
등록번호 |
TRKO201400026426 |
과제고유번호 |
1545002032 |
사업명 |
수산기술개발 |
DB 구축일자 |
2014-11-14
|
DOI |
https://doi.org/10.23000/TRKO201400026426 |
초록
▼
○ 연구결과
1)초고압처리기 장치
2)유해미생물 진단법 개발
3)노로바이러스 대체바이러스 진단법 개발
4)HPP처리 후 발생되는 관능적 변화분석
5)유해미생물 사멸조건
6)대체바이러스 사멸조건
7)관능적 변화를 최소화한 최적 가공.탈각조건 및 보존성 연장확인 연구
8)비열처리 생굴의 포장디자인 개발 및 시장성 조사
9)굴의 포장/가공 조건에 따른 최적 가공조건 및 유해미생물과 바이러스 사멸을 위한 생산공정 시스템 개발
10)초고압처리 시제품의 품질관리
11)생굴제품 생산 및
○ 연구결과
1)초고압처리기 장치
2)유해미생물 진단법 개발
3)노로바이러스 대체바이러스 진단법 개발
4)HPP처리 후 발생되는 관능적 변화분석
5)유해미생물 사멸조건
6)대체바이러스 사멸조건
7)관능적 변화를 최소화한 최적 가공.탈각조건 및 보존성 연장확인 연구
8)비열처리 생굴의 포장디자인 개발 및 시장성 조사
9)굴의 포장/가공 조건에 따른 최적 가공조건 및 유해미생물과 바이러스 사멸을 위한 생산공정 시스템 개발
10)초고압처리 시제품의 품질관리
11)생굴제품 생산 및 사업화
Abstract
▼
1. High Pressure Processing (HPP)
The High Pressure Processing (HPP) by Avure (QFP215L-600AT/U. S. A), which was installed by HAEJIN CO., LTD., was used, and its composition is as follows.
• HPP is composed of Main Pressure Device, Pressure Intensive Device, Water Supply Price and Air Supply
1. High Pressure Processing (HPP)
The High Pressure Processing (HPP) by Avure (QFP215L-600AT/U. S. A), which was installed by HAEJIN CO., LTD., was used, and its composition is as follows.
• HPP is composed of Main Pressure Device, Pressure Intensive Device, Water Supply Price and Air Supply Device, and High Pressure Part inside Main Pressure Device forms high pressure.
• High Pressure Water is supplied to Main Pressure Device through the water supply line.
• Air created at Air Supply Device is supplied to Main Pressure Device through theair supply line.
• Pressure Intensive Device supplies oil which makes Main Pressure Device to operate through an oil-supplying line.
• Main Pressure Device keeps airtightand resists to high pressure, and materials or processed products which need to be sterilized can be easily inserted into it and taken out of it.
• All operation processes are programmed through computers, and it can be automatically operated through a screen according to data put in advance.
2. Development of Detection Method for Harmful Bacteria
To review sterilization conditions of harmful bacteria in fresh oyster through HPP, changes in numbers of bacteria according to different HPP holding time, pressure and water temperature were observed and compared, and storage period and viral organisms were checked.
First of all, numbers of bacteria showed almost no change when HPP holding times was varied among 60, 180 and 360 sec under the same pressure. When the temperature of processing water was made to be 5, 15 and 30℃, numbers of bacteria got decreased as temperate went up, though the change was not significant.
And, sterilization performance of HPP according to different pressures such as HPP pressure 1000, 2000, 3000, 4000, 5000 and 6000bar was checked at the holding time of 90sec and at the temperature of 15℃. As a result of checking of number of bacteria at each pressure, number of bacteria was 39000 cfu/g in control group, 32000 cfu/g at 1000bar, 9600 cfu/g at 2000bar, 900 cfu/g at 3000bar and <100 cfu/g at 4000bar or higher.
With this result, it was confirmed that sterilization performance was affected and increased more by changes in pressure than holding time or temperature of water. Especially, at the pressure of 4000bar or higher, sterilization rate was 99.7% orhigher, and this is an outstanding performance.
In comparison of storage time of HPP according to different pressures, pressure of 1000, 2000, 3000, 4000, 5000 and 6000bar, were given under the same HPP condition of holding time 90sec and temperature 15℃, number of bacteria was checked once in two days over total ten days. When compared to the counter group, it didn't show any significant change at 1000bar.
However, it showed a decrease in number of bacteria and restrain in re-proliferation of injured cell after HPP at 2000bar or higher.
3. Development of Detection Method of Alternative Virus of Norovirus
Norovirus is a kind of virus, which makes the intestines of human body as its host, and it can't be cultivated under the usual cultivation method of other virus. For this reason, there are many difficulties in detecting and cultivating Norovirus.
Thus, this research was carried out by using Feline calicivirus (FCV) and Murine norovirus(MNV) since they belong to the family of Norovirus and Calicivirus and they has one strand of RNA and similar hereditary, biochemical, physical and chemical characteristics to Norovirus.
As a result of research into cultivation conditions of virus, one can know that feline calicivirus provokes infection on CrFK and murine norovirus on Raw 264. 7 murine macrophage, and, by giving cytopathic effect to each host cell, one can get them to be separated from their host cell.
To perform a quantitative analysis on virus, the plaque assay was used, in which virus was infected into cell monolayer, and virus was quantitatively detected according to number of plaques created. Also, another detection method of virus, TCID50, was reviewed, in which a statistical evaluation method on the infectivities is used to decide whether or not being infected.
4. Analysis on Changes in Sensory Characteristics after HPP
As a result of checking of appearance(color), scent, flavor, texture and taste of fresh oyster with its shell after HPP, we found that there were some changes according to different pressure and temperature. As pressure and temperature got down, sensory changes were small, and, especially, when temperature was high, sensory change (especially, its appearance) got deteriorated significantly compared to the counter group that didn't undergo processing.
Inevaluation on appearance with the evaluation scale of which highest point is 5, the scale was 3.6 when the temperature was 15℃ and 1.4 when the temperature was 30℃ at the same pressure of 3000bar, and it was a significant difference. Also, according to different pressures, with the standard water temperature of 15℃, the scale was 4.4 at 2000bar, 4.1 at 3000bar and 3.5 at 4000bar, and, that is, as pressure got higher, it was found that sensory change was more significant.
The evaluation scale regarding comprehensive appearance and sensory deterioration of oyster without its shell and oyster with its shell was 4.4 and 4.3 under 2000bar, 4.1: 3.8 under 3000bar, 3.5:3.3 under 4000bar, and, that is, oyster without its shells howed larger sensory change and deterioration.
In relation to color deterioration, in comparison between the unprocessed counter group and the processed group with HPP, Lightness of the unprocessed group was 51.07±0.53, and is was increased to be 54.24±0.74 at 2000bar and 59.88±0.66 at 4000bar, and, that is, it increased as pressure got higher. While the redness was -1.38±0.05 in the counter group and -1.17±0.031 at 4000bar, and it didn't show significant difference, but a little decrease.
In relation to physical characteristics, even after oyster underwent HPP, its fracturability, adhesiveness, springiness and cohesiveness showed little change, while its resilienceincreased according to an increase in pressure. Especially, hardness, gumminess, chewiness and share force was decreased at 2000 bar compared to the counter group, and, though, they were increased at higher pressure like 3000 bar or 4000bar. That is, there was an overall tendency of hardening.
5. Conditions for Extinction of Harmful Bacteria
As a result of observing changes in numbers of harmful bacteria according to different pressure conditions of HPP, it was confirmed one more time that, as pressure went up, and holing time was increased, the sterilization performance got stronger, and you can see this result by checking the result of a former experiment and table as follows.
Especially, even if HPP pressure condition was the same, rate of decrease in number of harmful bacteria showed difference among five different bacteria, say, Escherichia coli, Staphylococcus aureus, Listeria monocytogenes, Salmonella typhimurium and Vibrio parahaemolyticus. Under a low pressure condition, the decrease rate of Staphylococcus aureus and Salmonella typhimurium was the smallest. And, when processing was done at 3000bar for 120sec or longer, the decrease rate of bacteria in every experiment object was 95% or larger.
With this experiment result, it is concluded that the minimum HPP processing time for above five harmful bacteria is 120sec under 3000bar.
6. Conditions for Extinction of Alternative Virus
To take measurement on FCV extinction rate according to different pressure condition and holding time, a pretest was carried out, in which FCV sample in a concentration rate of 4.8 log TCID50/ml was checked under 6 different pressure conditions like 1000, 2000, 3000, 4000, 5000 and 6000bar. As a result, any significant difference or change was not seen at 1000bar, but, number of virus decreased significantly by 50.79% at 2000 bar, and it become extinct by 100% at 4000bar.
Based on the pretest result, pressure and holding time was segmented between the pressure of 2000 bar at which FCV started to decreaseand the pressure of 4000 bar at which it became totally extinct, and changes were observed through plaque assay and TCID50. The result was the same with that of the pretest, and one could see that, as processing pressure of HPP was increased, the decrease rate of FCV got larger. The decrease rate was 99% or larger at 3500bar, and it was 100% at 4000 bar or higher. Then, changes in the decrease rate according to different HPP holding times were observed, and it was found that, even though holding time was extended by 60 seconds under the same pressure, the decrease rate of FCV wasn't got larger significantly.
Thus, as a comprehensive conclusion, it can be said that number of FCV is more affected by increase of pressure than an extension of holding time, and that Norovirus is decreased by a larger rate when giving high pressure for a short period of holding time than giving low pressure for a long period of holding time.
7. Conditions for Optimal Processing & Shelling Method which Minimizes Sensory Deterioration & Research on Extension of Storage As a result of checking the shelling rate of oyster after High Pressure Processing, when 50 pieces of oyster was processed for 2 minutes under 2500bar, 46 pieces (92%) were shelled. When the same are processed for 3 minutes, 48 pieces (96%) were shelled, and, when processed under 3000bar, all of them were easily shelled with the hand.
To evaluate storage rate of oyster that was processed with HPP, changesin number of bacteria was checked once in two days for overall ten days. As a result, it was found that, as pressure increased, proliferation of bacteria got restrained, and you can check this result from following picture. Especially, there was a significant difference at the time of the 8th day between the one that was processed for 1 minute of time at 3000 bar and another that was processed for 2 minutes of time or longer.
From this result, wecan see that, if processing is done for 2 minutes of time at 3000 bar, storage time can be extended for two days when compared to the counter group.
8. Development of Packaging Design of Fresh Oyster & Research on Its Marketability
1) Development of Packaging Design
In order to market oyster as it is after HPP processing, a new packaging method was needed, which could solve the problem of frequent shelling of oyster after HPP.
Thus, a new packing method was developed, and, for this method, the contraction vinyl is used. As you can see from the picture below, the contraction vinyl is wrapped over oyster with its shell attached to be contracted, and then, the oyster is processed with HPP processing. With this method, when the contraction vinyl is taken off, flesh of oyster is easily separated from its shell. Though, if the vinyl isn't taken off, the oyster would maintain its form and appearance with its outer shell attached.
2) Set-up of HPP Conditions for Manufacturing of Prototype Products
Based on research results so far, HPP pressure conditions for manufacturing of prototype products are reviewed. Such conditions should make possible to reduce harmful bacteria and Norovirus, to shell oyster easily, to reduce sensory deterioration, to extend storage period and to consume oyster in a safe way, and, by considering these factors, the optimized HPP processing conditions are described in the following table.
3) Analysis on Taste of End Consumers
Fresh oyster with its shell was processed with HPP at the optimal processing condition (3,000bar, 2minutes, 15℃) and then packed into each 500g package. Then, aresearch was carried out to check evaluation by customers on its flavor, freshness, price and whether or not they have intention to re-purchase it. As a result, with the evaluation scale of which highest point is 5, flavor and freshness received 4. 3 and 4. 5 point respectively, relatively high points that represent high quality products. Though, customers evaluated that the price suggested was relatively high and gave 3.0 point, an average point, to evaluate it, and gave 3.4 point, a slightly high grade point, to evaluate their intention to re-purchase.
A research was also performed for each age group, and, in case of the evaluation on flavor, those in their 30s gave 4.1 point and those in their 40s and 50s gave 4.4 and 4.5 respectively, relatively higher points. In evaluation on the suggested retail price, those in their 30s gave 3.3 point and those in their 40s and 50s gave 3.1 and 2.6 respectively, and this shows that, as customers became older, their evaluation point on the price got lower. In evaluation on their intention to re-purchase, the most important matter to be evaluated, those in their 30s, 40s and 50s gave 3.4, 3.5 and 3.3 point respectively, and all of them gave similar point and showed relatively low intention. This tells us that customers were attracted to the flavor and the degree of freshness, but, they were not willing to re-purchase due to the high price. Thus, it is understood that ways to cut down cost of production, and thus, to decrease the retail price have to be suggested.
9. Conditions of Optimal Processing Method according to Characteristics of Packaging/Processing of Fresh Oyster & Development of Manufacturing System to Kill Harmful Bacteria & Virus
Oyster is vulnerable to marine pollution and deteriorates easily. It has the shortcoming of easy deterioration of quality in the process of farming, processing and circulation due to inappropriate handling, and it is very hard to market and circulate fresh oyster.
Through this research, the optimal processing conditions were established, by which it is possible to sterilize bacteria or virus of oyster effectively and to control its quality from its farming stage through its consumption stage by end consumers while maintaining its quality. Also, so far, there have been no othersolution in case of that oyster is contracted with salmonella or Norovirus in the process of farming due to marine pollution than to heat the contracted oyster to kill such virus. Though, when HPP technology is used, such problem can be solved effectively.
Principal Standards for Management were established, including management on farming ground, HPP processing conditions, hygiene of workers and work tools, foreign substance and temperature of work places and storage facilities. Also, separate management standards were established according to different processing methods of oyster such as shelled oyster or whole-shell.
Above table is to explain the management standards for raw materials and processing water and the standards for HPP processing, and those standards are established in the same way for all the processing stages.
10. Quality Control on HPP Prototype Product
To review safety of prototype products produced by the optimal HPP process system, a periodic sanitary examination was carried on prototype products to check five harmful bacteria including Escherichia coli, Listeria monocytogenes, Salmonella typhimurium, Staphylococcus aureus and Vibrio parahaemolyticus.
Samples of shelled oyster was processed with the optimal HPP process condition (3,000bar/2min), and then, number of germs and harmful bacteria in fresh oyster was examined and analyzed. The sample of all the counter groups weren't processed with HPP, and 8 times of experiments were carried out to compare result of each experiment.
First of all, as a result of checking of usual germs in oyster in case of undergoing HPP processing and in case of not undergoing it, the number of normal germs after Pressure Processing was smaller by approximately 1log than the number before Pressure Processing, and this shows that the number of germs can be decreased by 88.15% at an average with the help of HP Pprocessing.
In relation to changes in number of Escherichia coli, samples that were processed with the same pressure condition were tested 8 times. Among samples that weren't pressure-processed, Escherichia coliwas detected three times, but, among those which were pressure-processed, Escherichia coliwas detected from none of them, and this proves that Pressure Processing helps to kill Escherichia coli and harmful bacteria.
Other harmful bacteria such as Listeria monocytogenes, Salmonella typhimurium, Staphylococcus aureus, Vibrio parahaemolyticus weren't detected from samples before and after Pressure Processing, and it is confirmed that such bacteria don't live on oyster regardless of undergoing Pressure Processing.
11. Manufacturing of Fresh Oyster Products & Commercialization
Oyster is vulnerable to marine pollution and deteriorates easily. It has the shortcoming of easy deterioration of quality in the process of farming, processing and circulation due to inappropriate handling, and it is very hard to market and circulate fresh oyster.
When oyster is heated and sterilized, its storage time can be extended, but, the unique scent and taste of fresh oyster is ruined, and its texture is also changed, and thus, it can't be considered as a good way of processing.
As you can see from the above Clause 9. Conditions of Optimal Processing Method according to Characteristics of Packaging/Processing of Fresh Oyster & Development of Manufacturing System to Kill Harmful Bacteria & Virus, through this research, an optimal processing conditions were established, by which it is possible to sterilize bacteria or virus of oyster effectively and to control its quality from its farming stage through its consumption stage by end consumers while maintaining its unique quality.
Based on these research results, it was possible to create a safe manufacturing system for oyster products, and then, we took the first order for oyster products in the quantity of one 40ft container from one of our Japanese customers through overseas marketing activity and commenced to manufacture products to be sold to the overseas market.
We exported refrigerated I.Q.F Oyster that was sterilized with HPP to TW TRADING CO., LTD., a Japanese company, for the first time in 2011 May. The export quantity was 19tons, and the export amount was USD120,600.
Each year in Japan, there are frequent outbreaks of food poisoning accidents from Norovirus or other harmful bacteria that might exist in intestines of oyster, since Japanese people like eating oyster by heating its surface only when making Shabu-shabu dishes or fries with refrigerated oyster to avoid deterioration in taste or burning on bread crumb, and there were several cases in which those contracted with food poisoning from oyster died.
Then, we suggested I.Q.F Oyster with HPP sterilization processing to the local buyer in Japan, and the buyer accepted our suggestion, and then, we could export our products to that buyer.
In the future to come, we plan to selloyster products including I.Q.F Refrigerated Oyster, Whole-shell and Shelled Oyster to domestic CVS stores, medium and small-scale markets, Japanese Restaurants and Specialized Food Companies and various Specialized Companies of Refrigerated & Half-shell in Japan and Hong Kong by doing active promotion activities. And, our first sales goal is 450 million won starting from 2011 winter to 2012 spring, and we will keep doing our active marketing activities with the sales goal of 1.6 billion won per year starting from 2013 winter.
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