Introduction of Chikuwa Manufacturing Machine & Mixing Procedure Guidance
GADLE MARINE FOODS (India)
Industry: Processed surimi products manufacturing / Chikuwa & Kamaboko production
Challenge:
Lack of in-house know-how for formulations using the newly introduced chikuwa manufacturing machine
No established mixing procedure with the silent cutter, making temperature control of the paste after forming difficult
Insufficient temperature control during resting (holding) and baking processes, causing uneven wrapping and finish quality
Industry
Processed surimi products manufacturing / Chikuwa & Kamaboko production
Challenge
Lack of in-house know-how for formulations using the newly introduced chikuwa manufacturing machine
No established mixing procedure with the silent cutter, making temperature control of the paste after forming difficult
Insufficient temperature control during resting (holding) and baking processes, causing uneven wrapping and finish quality
Solutions
Basic Recipe Development Guidance Designed optimal mixing ratios of fish paste, binders, and seasonings for chikuwa and systematized the best recipe as internal knowledge
Mixing Procedure Design & Training Manualized mixing time, speed, and temperature control (15–20 °C) with the silent cutter and conducted hands-on training for staff
Resting (Holding) Process Temperature Control Guidance Established a method to maintain the core temperature of formed chikuwa at 70–75 °C, ensuring uniform baking and wrapping quality
On-site Operation Improvement Defined checkpoints for mixing, forming, and resting processes and introduced a daily checklist to enhance reproducibility
Results
Completely eliminated chikuwa wrapping defects
Standardized surface quality after baking, improving yield by ~10%
Achieved stable production from startup by implementing the standardized manual with on-site staff
Profile
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