PLATINIUM MARINE PRODUCTS SDN BHD

LOT 7, HOCK SENG INDUSTRIAL ESTATE, MILE 3 JALAN UTARA,

90000 SANDAKAN
SABAH
TEL: 089-237002 FAX: 089-237003

PRE-VALIDATION STUDY ON CCP 4 (FREEZING)

A Study on Freezing Methods of Blast Freezer used for Seafood Product Preservation

1. Introduction
Preservation techniques are required to prevent fish spoilage and to increase shelf life. Ancient
methods of fish preservation include drying, salting, and pickling. Now refrigeration, plate
freezer, air blast freezer and etc. play a role in the preservation of fish. Fisheries require an
efficient cooling system to ensure the fish remains fresh. Since fish is a highly perishable item of
food, it has to be immediately processed to preserve the quality and to increase the shelf life.
The objective of handling, processing, and preservation is to control or reduce the spoilage
process. To do so the general cooling method adopted is chilling and freezing. To produce a good
product, freezing must be accomplished quickly. Freezing time can be defined as the time taken
for the temperature of the warmest part of the fish to be reduced to -20 °C. The large variety of
biological properties from one species of fish to another is an important issue affecting freezing
time.

2. Objective
The purpose of this study is:
a) To investigate the total freezing time required for a different type of seafood achieved
core temperature ≤ -18 °C.
b) To justify the product core temperature ≤ -18 °C is acceptable for control of pathogenic
microorganisms’ growth.

3. Materials and methods

3.1. Experimental Design

Table 1: Experimental design for a validation study of CCP 4

No. Control Parameter Variable Parameter Expected Result Remarks

Product core All three-product
temperature recorded placed at 3 different
Three (3) different
The initial temperature of gradually decreases points in the freezer.
1. placements point of the
the product (≤ 4 °C). against freezing time. The initial core
product.
temperature shall be
AND (≤ 4 °C).
Size of each product All 3 products use the
2.
(sample validation) Product core same size (700/up)
temperature ≤ -18 °C The net weight for
Net Weight of the is acceptable for each product is 9.5 kg
3.
product control of pathogenic before the freezing
microorganisms’ process.
Full maximum loaded for growth. 1140 kg
4.
that blast freezer used.

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 PLATINIUM MARINE PRODUCTS SDN BHD
LOT 7, HOCK SENG INDUSTRIAL ESTATE, MILE 3 JALAN UTARA,
90000 SANDAKAN
SABAH
TEL: 089-237002 FAX: 089-237003

The initial thermologger Apply for the 1st

5. temperature of blast product is placed into
freezer (at least -18 °C). blast freezer.
All 3 products are
Time-in when the product
6. placed at the same
load into blast freezer
time (± 1 minute)
Time out when the All 3 products are
7. products are removed removed at the same
from the freezer. time (± 1 minute)

3.2. Materials, apparatus, and equipment.

a) Three (3) sets of ribbon fish products (sample) with the size 700/UP and net weight
per each is 9.5 kg.
b) Three (3) units of data logger with the probe.
c) 1 unit of blast freezer.
d) Ribbon fish products (117 sets) with variable mix size and weight 9.5 kg per each.
e) Tray – 120 sets
f) 1 unit of weighing scale
g) Blue baskets
h) Sufficient amount of ices
3.3. Methodology
a) Blast freezer and its fan is switched on and let the temperature drop until at least -
18° C.
b) Blast freezer fan is turned off first; before the products are loaded into the blast
freezer.
c) After the products are loaded into the blast freezer, the fan is turned on again.
d) Products are loaded into the freezer batch by batch until full maximum load
following the same procedure at steps no 2 and 3.
e) The sample validation study are loaded into a blast freezer at 3 different points
plate 1 (top), plate 6 (centre), and plate 11 (bottom).
f) After all of the products are loaded into a blast freezer for maximum full load (with
mix size but the same net weight of 9.5 kg each), the last 3 products (sample) with
the same size (700/UP; the largest size) with probe connected data logger are
loaded into blast freezer at 3 different point top, center, and bottom. Refer to Table
2. Position of 3 points for placement of ribbon fish in blast freezer; Figure 1. product
mapping in a blast freezer and Table 3. data logger with probe setting.
Note: The start button of each data logger is pushed first before the last 3
products are placed into blast freezer, 3 minutes is suitable time enough to place
the products inside the blast freezer, close the blast freezer door and turned on
back the fan.
g) Data logger with probe shall measure the core temperature of the products at
every 30 minutes of time interval until 12 readings that give total of 6 hours.

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 PLATINIUM MARINE PRODUCTS SDN BHD
LOT 7, HOCK SENG INDUSTRIAL ESTATE, MILE 3 JALAN UTARA,
90000 SANDAKAN
SABAH
TEL: 089-237002 FAX: 089-237003

h) The thermologger temperature display on blast freezer is monitored after putting

the products in (practice will count the blast freezer temperature at time in for the
1st product that loaded into blast freezer).
i) 3 products are remarked as 1 st, 2nd and 3rd and have been removed from the blast
freezer after reached 6 hours of freezing time.
j) Data Logger with probe are removed from the product and all data are retrieved
from the downloaded software in pc.
k) This products 1st, 2nd and 3rd are kept inside the ice box and stored in cold room
before sent to the external accredited laboratory for microbiology test to be
verified the acceptance level for pathogens.
l) The cold room’s temperature is monitored and be recorded for every 3 hours. The
temperature is maintained at temperature ≤ -18 °C.
m) These 3 products are being sent to external accredited laboratory using an ice box
which have been filled with sufficient ice gel packs to maintain the temperature
throughout the journey to the external accredited lab.

Table 2: Position of 3 points for placement of ribbon fish in a blast freezer

No. Size of ribbon fish Net weight Size of sample Net weight Position of Sample
product of the used for of the sample in a marking
products validation sample blast freezer
1. 100/200
2. 200/300
3. 300/500 9.5 kg 700/UP 9.5 kg Row 1st, 2nd, and 3rd
(1, 6 and 11)
4. 500/700
5. 700/UP

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 PLATINIUM MARINE PRODUCTS SDN BHD
LOT 7, HOCK SENG INDUSTRIAL ESTATE, MILE 3 JALAN UTARA,
90000 SANDAKAN
SABAH
TEL: 089-237002 FAX: 089-237003

Sample RF

1
Row 1st (Point 1)

2
3

Fan
4
5

Sample RF
6

Row 2nd (Point 2)

7

Product RF
8
9
10

Sample RF
11

Row 3rd (Point 3)

12

Figure 1: Product mapping in a blast freezer

**Each row will fit 10 trays (9.5 kg x 5 x 2 column = 95 kg); 1 Freezer maximum load (95 kg x 12
row = 1140 kg)

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 PLATINIUM MARINE PRODUCTS SDN BHD
LOT 7, HOCK SENG INDUSTRIAL ESTATE, MILE 3 JALAN UTARA,
90000 SANDAKAN
SABAH
TEL: 089-237002 FAX: 089-237003

Table 3: Data logger with probe setting

Parameter Data logger with a probe

Data logger 1 2 3
1st 2nd 3rd
Data logger position
Top (Row 1) Centre (Row 6) Bottom (Row 11)
Time interval 30 minutes
Delay after pushing the start button 3 minutes
Total reading taken 12
Total hour record 6 hours
Data logger record (start time) 08:43:14 am 08:42:46 am 08:42:51 am
Data logger record (end time) 02:43:14 pm 02:42:46 pm 02:42:51 pm
Different time (push start button) ± 1 minute

4. Result and Discussion

Table 4: Summary reading of product core temperature for ribbon fish (1 st, 2nd, 3rd) connected
with a probe of data logger.

Product core temperature (° C)

Index Date Elapsed time Data logger 3
Data logger 1 Data logger 2 (Bottom; Row
(Top; Row 1) (Centre; Row 6) 11)
1 3/6/2022 0:00:00 3.1 2.9 2.3
2 3/6/2022 0:30:00 -2.2 -2 -2.6
3 3/6/2022 1:00:00 -5.6 -6.1 -6.7
4 3/6/2022 1:30:00 -7.1 -8.3 -9.5
5 3/6/2022 2:00:00 -14.2 -16 -16.9
6 3/6/2022 2:30:00 -16.4 -19.8 -20.2
7 3/6/2022 3:00:00 -23.8 -25.5 -26.3
8 3/6/2022 3:30:00 -27.7 -29.3 -31.3
9 3/6/2022 4:00:00 -32.8 -33.4 -35.9
10 3/6/2022 4:30:00 -36.3 -37.9 -39.1
11 3/6/2022 5:00:00 -39.6 -39.8 -41
12 3/6/2022 5:30:00 -40.3 -41.7 -39.5
13 3/6/2022 6:00:00 -38.7 -39.3 -38.2

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 PLATINIUM MARINE PRODUCTS SDN BHD
LOT 7, HOCK SENG INDUSTRIAL ESTATE, MILE 3 JALAN UTARA,
90000 SANDAKAN
SABAH
TEL: 089-237002 FAX: 089-237003

Product Core Temperature vs Blast Freezing Time

10
Product Core Temperature (° C)

0
0:00:00 0:30:00 1:00:00 1:30:00 2:00:00 2:30:00 3:00:00 3:30:00 4:00:00 4:30:00 5:00:00 5:30:00 6:00:00

-10

-20

-30

-40

-50
Blast Freezing Time (Hour and Minutes)
Data Logger 1 Data Logger 2 Data Logger 3

Figure 2: Product core temperature vs blast freezing time for 3 different points of Data Logger
connected on the sample ( 1, 2, and 3).

The results in Figure 2. Indicate that product core temperature against blast freezing time for 3
different points of data logger connected on the sample can be very different. Table 4. Summarize
the reading of product core temperature for ribbon fish (1 st, 2nd, 3rd) connected with a probe of data
logger showed that the temperature is achieved ≤ -18 °C within 4 hours of total freezing each
sample. Ribbon fish 1 achieved a core temperature of -23.8 °C at the time of total freezing is 3 hours
compared to the ribbon fish 2 and 3 with a core temperature of -19.8 °C and -20.2 respectively
which only take total freezing is 2 hours and 30 minutes. Based on the results, we would define that
the hottest point is at 1 st point (top position (row 1)); since it can only reach the target product core
temperature (≤ -18 °C) at total freezing time about 3 hours. While coldest point is defined at 2 nd and
3rd point (centre (row 6) and bottom position (row 11)); since it has already reached target product
internal temperature around 2 hour and 30 minutely only. Next, other factors will determine the
freezing time is product temperature before freezing (initial temperature before loaded in blast
freezer). The warmer the product, the longer it will take to freeze. Fish should therefore be kept
chilled before freezing to maintain quality and reduce freezing time. For example, a ribbon fish 1 in a
blast freezer will take 3 hours when the initial temperature is 3.1 °C but, only 2 hours 30 minutes
when the temperature of ribbon fish 3 is 2.3 °C.

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 PLATINIUM MARINE PRODUCTS SDN BHD
LOT 7, HOCK SENG INDUSTRIAL ESTATE, MILE 3 JALAN UTARA,
90000 SANDAKAN
SABAH
TEL: 089-237002 FAX: 089-237003

Table 4. Result of Microbiological Analysis for frozen ribbon fish (1 st, 2nd, 3rd) product with different
test parameters.
Product Frozen Ribbon Fish Frozen Ribbon Fish Frozen Ribbon Fish
(1st) Row 1 (2nd) Row 6 (3rd) Row 11
Total Viable Count 1.2 x 10^3 CFU/g 7.5 x 10^2 CFU/g 3.0 x 10^2 CFU/g
Coliform Count 1.15 MPN/g 0.65 MPN/g 0.1 MPN/g
Staphylococcus Aureus < 25 (ND) CFU/g < 25 (ND) CFU/g < 25 (ND) CFU/g
Salmonella Absent in 50 g Absent in 50 g Absent in 50 g
Vibrio parahaemolyticus Absent in 25 g Absent in 25 g Absent in 25 g

Next, for the verification stage, the same sample were sent to external accredited laboratory for
microbiological analysis. From the result of microbiological analysis for frozen product ribbon fish 1 st
showed the highest total viable count which is 1.2 x 10^3 CFU/g compared to the ribbon fish 2 nd 7.5
x 10^2 CFU/g and 3.0 x 10^2 CFU/g for ribbon fish 3 rd respectively. Although the core temperature of
frozen products was above the critical limit, the total viable count was found below the
microbiological standard National Standard of the People’s Republic of China, National Food Safety
Standard for processed Aquatic Products of Animal (GB 10136 – 2015).

5. Conclusion
Based on the certificate of analysis (COA) for the microbiology test, frozen ribbon fish (remarks as 1 st,
2nd, and 3rd) are sent for lab analysis to verify that the microbiology limit is achieved as referred to
the critical limit that has been established at the step of blast freezing. The critical limit for CCP 4
freezing are established as below:
a) Blast freezing time: ≤ 4 hours
b) Product core/internal temperature: ≤ -18 °C
c) Blast freezer temperature: -41 °C ≤ temp ≤ -35 °C

We conclude that the critical limit as stated above (a, b, and c) for CCP freezing is validated by this
report and supported by Certificate of Analysis (COA) for microbiological test. However, precise
operating procedures may vary because our study can be affected by many factors such as cooling
temperature, air velocity, product shape, as well as mechanical and thermodynamic features of the
freezer.

Page 7 of 8
 PLATINIUM MARINE PRODUCTS SDN BHD
LOT 7, HOCK SENG INDUSTRIAL ESTATE, MILE 3 JALAN UTARA,
90000 SANDAKAN
SABAH
TEL: 089-237002 FAX: 089-237003

6. References

1. Sánchez-Alonso, I.; Martinez, I.; Sánchez-Valencia, J.; Careche, M. Estimation of freezing

storage time and quality changes in hake (Merluccius merluccius, L.) by low field NMR. Food
Chem. 2012, 135, 1626–1634.
2. Mozuraityte, R.; Standal, I.B.; Cropotova, J.; Bud ´zko, E.; Rustad, T. Superchilled, chilled and
frozen storage of Atlantic mackerel (Scomber scombrus)—Effect on lipids and low molecular
weight metabolites. Int. J. Food Sci. Technol. 2020, 56, 1918–1928.
3. Sun, Q.; Sun, F.; Xia, X.; Xu, H.; Kong, B. The comparison of ultrasound-assisted immersion
freezing, air freezing and immersion freezing on the muscle quality and physicochemical
properties of common carp (Cyprinus carpio) during freezing storage. Ultrason. Sonochem.
2019, 51, 281–291.
4. Boonsumrej, S.; Chaiwanichsiri, S.; Tantratian, S.; Suzuki, T.; Takai, R. Effects of freezing and
thawing on the quality changes of tiger shrimp (Penaeus monodon) frozen by air-blast and
cryogenic freezing. J. Food Eng. 2007, 80, 292–299.
5. Gonçalves, A.A.; Ribeiro, J.L.D. Optimization of the freezing process of red shrimp (Pleoticus
muelleri) previously treated with phosphates. Int. J. Refrig. 2008, 31, 1134–1144.

Prepared by: Verified by:

(………………………………………………) (………………………………………………)

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