CAVIAR: ROE PROCESSING MANUAL  

FOREWORD

1.0 CAVIAR PRODUCTS
1.1 INTRODUCTION
1.2 THE WORD 'CAVIAR'
1.3 LABELLING PRODUCTS
1.4 CANADIAN ROE RESOURCES
2.0 ROE
2.1 OVARIES
2.2 MATURITY
2.3 YIELD
2.4 FROZEN ROE
2.5 GRADING FRESHNESS
2.6 CHEMICAL COMPOSITION
2.7 EGG STRUCTURE
3.0 SCREENING
3.1 SCREENING OPERATION
3.2 SCREENING TECHNIQUE
3.3 SCREENING DEVICES
3.4 MECHANIZED SCREENING
4.0 SALTING
4.1 PRESERVATIVE ACTION
4.2 THE SALTING MECHANISM
4.3 SALINITY
4.5 CURING EFFECT
4.6 SALTING TIME
4.7 SALINITY MEASUREMENTS
4.8 DRAINING, EGG VISCOSITY AND VISCOSITY MEASUREMENTS
5.0 PACKING
5.1 FREEZING AND REFRIGERATION
5.2 BULK AND RETAIL PACKAGE
5.3 PACKAGE TYPE
5.4 CHEMICAL PRESERVATION
5.5 ADDITIVES AND DYES
5.6 PASTEURIZATION
5.7 PACKAGING OVERVIEW
6.0 QUALITY AND SHELF-LIFE
6.1 QUALITY GRADING
6.2 ORGANOLEPTIC TRIALS
6.3 DEFECTS
6.4 CHEMICAL AND BACTERIOLOGICAL EXAMINATIONS
6.5 SHELF-LIFE
6.6 QUALITY CONTROL AND ASSURANCE
7.0 THE CAVIAR SHOP
7.1 LAYOUT AND MECHANIZATION
7.2 PLANNING A SALMON CAVIAR OPERATION
7.3 WATER QUALITY
7.4 SALT QUALITY
7.5 BRINE PROPERTIES
7.6 BRINE MAKING REQUIREMENTS AND APPARATUS
7.7 SALTING TANKS
7.8 MISCELLANEOUS TOOLS, INSTRUMENTS AND MECHANISMS
7.9 SANITATION
8.0 PROCESSING DIFFERENT SPECIES
8.1 HARVESTING LUMPFISH ROE
8.2 PROCESSING LUMPFISH CAVIAR
8.3 WHITEFISH AND OTHER ORDINARY FISH
8.4 STURGEON FISHERIES
8.5 PROCESSING STURGEON CAVIAR
8.6 SALMON FISHERIES
8.7 PROCESSING SALMON CAVIAR
8.8 ARTIFICIAL CAVIARS

1.0 CAVIAR PRODUCTS

1.1 INTRODUCTION

The variety of products processed from fish roe is enormous. Fish roe constitutes by weight the largest fish byproduct. The nutritional value of fish roe is superior when compared to fish flesh of the same species. It always contains more proteins and fats. The attractiveness of roe is further enhanced by its pleasant yolky taste and the essential natural sterility of eggs, which are enveloped in the ovarian sack.

To harvest fish roe is always economically advantageous because spawners tend to congregate and/or to enter known areas of shallower water which makes it easier for fishing.

The use of fish roe for human consumption as a delicacy was popular in ancient Egypt and throughout the Mediterranean as far back as 2,000 B.C. under the name Batareh (Botarga). In modern times it is still processed from mullet, tuna, and any large freshwa-ter fish into salted, dry-cured, sun-dried, spiced or pressed whole ovaries to form 'Egyp-tian Caviar' or 'Italian Caviar'.

It is appropriate to stress the common misuse of the term 'caviar'. Figure 1-1 illustrates the groups, of 'caviar' type products. The subject of this manual is a roe product, which constitutes singled-out and salted fish eggs obtained by passing the ovaries through screens and then processed to remain singled out eggs or pressed into a cake like mass.

1.2 THE WORD 'CAVIAR'

Labelling of caviar type products has a confusing history, and continues to be a matter of discussion and argument. The central issue is how to use the word 'caviar'. The word it-self is of Italian/Turkish origin- 'caviare' (Italian) and 'khavjar' (Turkish). It was men-tioned in documents of the XVI century in Italy, France, Spain and England in a variety of spellings, pronunciations and native modifications. In modern English, two pronun-ciations are accepted: caviar and caviar.

The Russian synonym for 'caviar' is 'Ykra' ('ikra'), the generic term used in Russian for both fish eggs in the biological sense (ovaries or single egg), and for describing a wide range of products processed from roe, both singled-out eggs, (caviar) and whole ovary products. The Japanese term 'Ykura' used for salmon caviar is actually derived from the Russian term. However, this term is used only for singled-out, salted eggs. If whole ovaries are salted e.g. salmon ovaries, the product is called 'Sujiko'.

The respected Oxford Dictionary further contributes to the confusion: 'Caviar - the roe of the sturgeon and other large fish obtained from lakes and rivers of the East of Europe, pressed and salted and eaten as a relish'. This definition adds to the semantic mess - why 'large fish' or 'pressed'?

FIGURE 1-1

ROE UTILIZATION

Caviar - fish roe utilization

In modern times, caviar is made of all kinds of suitably sized fish roe. Many adjectives are used with the word 'caviar' to identify the product by fish species (Beluga, Keta, Lumpfish, etc.); by water body (Caspian, American, Winnipeg Lake, etc.); and, by processing pecu-liarities (granular, pressed, flavoured, pasteurized, etc.).

The word 'caviar' has also a figurative meaning. The play, I remember, pleased not the million, 'twas caviare to the general....' (Shakespeare's Hamlet). Thus the word was used in the past to stress that to enjoy the taste of caviar one has to acquire a taste for it. The 'general' public is not able to appreciate the taste.

Nowadays the word is synonymous for exceptionally high quality, stature, taste or value of edible or non-edible items.

1.3 LABELLING PRODUCTS

Any labelling practice has to comply with export-import regulations which may differ from country to country. In March 1917 the Food and Drug Administration (USA) dealt with the use of the term 'caviar' and issued the Service and Regulatory Announcement No. 3, which it is appropriate to present here.

The letter quoted below was written in reply to a request for information concerning the proper labelling of caviar made from whitefish, to which a harmless vegetable dye has been added.

"Dear Sir: Your question has been taken up at some length with the Commissioner of Fisheries. The bureau is informed that the term 'caviar" can properly be applied to any kind of fish eggs prepared after a special method. The eggs first prepared and most ex-tensively used were those of the sturgeon, and to many people the term 'caviar' is syn-onymous with 'sturgeon caviar'. In view of this fact and of other considerations, it is be-lieved that the name of the particular fish from whose eggs caviar is made should appear on the label. In the case in point an appropriate label would be 'whitefish caviar'. This bureau will made no objection to the use of the term 'caviar' on a product prepared ac-cording to the usual method and made from roe of whitefish, provided the name of the fish is given in conjunction with the word caviar."

The FDA policy remains the same today; the unqualified term "caviar" should be applied only to the product prepared by salting sturgeon roe. A product prepared from roe of other fish may be labelled "________ Caviar," the blank to be filled in with the common or usual name of the fish from which the roe was taken. All words in the name should be in type of substantially the same size and prominence.

A common name of the fish is the name which is easily understood by the public. The labelling regulations also require one to declare the net weight, country of origin of the product and the packer, if the later is different. To this extent the label 'Product of the Caspian Sea' may be deceiving, because more than one country is processing fish prod-ucts from the Caspian Sea.

Labels which contain words or expressions, figures or symbols that imply false informa-tion, or may reasonably be regarded as misleading or deceiving regarding the origin, technology or quality - are in violation of the regulations. For salmon caviar the Cana-dian Inspection and Special Services Branch of Fisheries and Oceans Canada has al-lowed the use of the generic name 'salmon' in the product common name providing the list of ingredients denotes the particular salmon species used by its usual name. This means the producer must have one label for each species used. Another permitted proce-dure is to list alternative species in the list of ingredients and incorporate the generic name 'Pacific Salmon Caviar'.

One can find in the marketplace 'Salmon Caviar' that does not list the species on the in-gredient list. It is common knowledge that chum or Keta salmon caviar is the most valu-able and in this case the customer is not able to differentiate it from other less valuable salmon caviar, e.g. Pink or Coho.

At the time of preparing the manual nutritional labelling is not mandatory. Caviar prod-ucts should be exempt from nutritional labelling because they are not making significant nutritional contribution per serving.

Most important, and mandatory in all countries, is to define on the label of caviar prod-ucts the storage conditions. As far as indicating the time of packing and the time up to which the food at the mentioned storage conditions is edible or 'best -different countries treat the issue differently. For example, the Austrian regulations would classify both fresh and frozen caviar as a semi-durable fish product, and the label should indicate the time limit in month and year up to which the food is edible. Soviet Union State standards imply similar requirements.

Canadian regulations do not require storage life time limits if the products shelf-life is more than 90 days. This implies, that if caviar is meant to keep for less than 90 days the 'best before' date should be declared. This may happen e.g. when retail packages are re-packed from low salt, old bulk packages and the packer wants to put on additional safe-guards to ensure the so called 'Durable life'. By definition, 'Durable life' means the pe-riod, commencing on the day on which a prepackaged product is packaged for retail sale, during which the product, when it is stored under conditions appropriate to that product, will retain, without any appreciable deterioration, its normal wholesomeness, palatabil-ity, nutritional value and any other qualities claimed for it by the manufacturer. But this is a purely legal aspect required by Canadian Regulations. Good manufacturing practice is always to indicate on the label some limits to the discretion of the processor, e.g. 'best before ...'.

1.4 CANADIAN ROE RESOURCES

In response to market demand and growing prices for caviar type products an increasing volume of roe resources is diverted to processing into caviar. Every time a new roe re-source is utilized some tuning of the technological process takes place. Table 1-1 lists landings of fish species from which roe are known to be utilized for caviar type products in other countries, mainly in the Soviet Union. According to USSR state standards 20352 and 5.2307-76 (GOST-61) caviar can be processed from any kind of sizeable fish eggs.

Table 1-1 includes ocean catches from both Pacific and Atlantic coasts as well as fresh-water and farmed fish harvests. Roe of farmed fish is available only when excessive numbers of fish are kept as brood stock. Farmed salmon are not grown to maturity for egg harvest, because the flesh becomes of lower grade. In European countries farmed trout caviar processing is very popular. Because of the high market prices of sturgeon caviar and the fact that the technology of sturgeon maturation in captivity within 5-7 years is feasible-it may happen in the future, that farming sturgeon for caviar processing will become an economically viable business.

Of those species shown in Table 1-1 only a few are utilized in Canada to process caviar: chum, lumpish, whitefish, sturgeon and to some extent carp and trout. Salmon roe (other than chum) and herring roe are considered good potential caviar resources in spite of the fact, that presently they are only processed as whole ovaries, exclusively for the Japa-nese market ('Sujiko' and 'Kazunoko').

TABLE 1-1

CANADIAN ROE RESOURCES

Caviar - fish roe suitable for caviar

      a Commercially utilized for caviar.
      b Potential to be commercially utilized.
      * Canadian Fisheries Annual Statistical Review, 1985-86 average and personal communications.
      ** 1980 Landings.
      *** All species

On the other hand, a similar popular product processed from whole gonads of sea-urchin ('Uni') cannot be considered as a potential caviar resource because of its tiny egg size.

As shown in Table 1-1 the potential resources for processing caviar are substantial. However, very often (apart from lack of market demand) fishing practices, discrepancies between fish maturation and fishing schedules, government regulations, sustained har-vest considerations, and technological obstacles are hindering roe utilization for caviar.

World caviar production, according to the FAO yearbook for fisheries statistics, is pre-sented in Table 1-2.

To introduce a new caviar type product to the market place one should:

  • Evaluate the roe resource: season for best roe maturity, roe weight as % of landings, opportunities for speedy delivery of fresh roe to the processing site;
  • Choose appropriate screening, salting, pasteurization or other appropriate technologi-cal steps.
  • Process and pack a pilot lot for shelf life examinations and marketing trials.

For the Canadian industry the average yearly caviar production level as a % of landings is: 0.8% (224 tons) for Chum in British Columbia, 18% (450 tons) for lumpfish in the Maritime Provinces and 0.9% (18 tons) for whitefish in Manitoba. A small amount of sturgeon caviar is produced in New Brunswick (0.5 tons).