Introdução
Crab stick, also known as imitation crab, is a surimi-based seafood product that has achieved global popularity. It is widely used in sushi, salads, and ready-to-eat meals due to its affordability and convenience. For food manufacturers, mastering the crab stick production process steps is essential to achieving consistent quality, high efficiency, and compliance with strict international food safety standards.
This guide explains each step in detail, from surimi preparation to packaging, and highlights best practices for industrial-scale production, you will understand the whole imitation crab stick line after reading the guide.
Step 1: Surimi Preparation
The process begins with surimi, a refined fish paste usually made from white-fleshed species such as pollock or hake. Frozen surimi blocks are thawed under controlled conditions and ground into a smooth paste. This process takes place in a bowl cutter under low-temperature conditions (based on our years of technical expertise, the temperature is typically maintained below 10 ° c). During high-speed chopping, crushed ice is added to control the temperature.
- Objective: Build a clean and elastic protein base.
- Process: Surimi is mixed with starch, sal, egg white powder, and flavor enhancers. Vacuum mixing and defoaming are applied to remove air bubbles.
- Importance: The quality of surimi determines the texture and mouthfeel of the final crab stick. For detailed standards on surimi quality, see the FAO technical guide.
Common Additives in Surimi Preparation:
| Ingredient | Função | Typical Percentage (%) |
| Starch | Binding, chewy texture | 15–25% |
| Egg white powder | Firmness and elasticity | 3–5% |
| Flavorings | Enhance seafood-like taste | 2–4% |
| Cryoprotectants | Stabilize protein during freezing | 1–2% |
| Salt | Protein solubility improvement | 1–3% |
Step 2: Forming & Alignment
The seasoned surimi paste is transformed into continuous sheets or layers that mimic natural muscle fibers. Based on the different requirements, the width and thickness of the sheet can be adjusted manually.
- Objective: Ensure a uniform sheet thickness and proper orientation.
- Process: The paste is spread and rolled before passing through alignment rollers to produce layered bands.
- Importance: Proper alignment allows the final product to “pull apart” like natural crab meat.
Step 3: Cooking (Steaming or Baking)
Cooking stabilizes the protein structure and prepares the surimi sheet for downstream processing.
- Objective: Achieve even gelation without drying the product.
- Process: Surimi sheets pass through a steam tunnel or drum steamer. In some regions, baking is used to obtain a firmer texture.
- Importance: The correct temperature ensures strong gel strength and prevents strand breakage later.
Step 4: Thin-Cutting & Bundling
Once cooked, the sheets are slit into fine ribbons and gathered into bundles.
- Objective: Develop the fibrous mouthfeel that resembles crab meat.
- Process:
- Slitting: Specialized blades slice sheets into thin strands (about 1–3 mm wide).
- Alignment: Guides orient strands for consistent fiber structure.
- Bundling: Strands are gently compressed into continuous bundles.
- Importance: This step creates the authentic “stringy” texture consumers expect.
Step 5: Coloração & Wrapping
The iconic red or orange coating is applied at this stage.
- Objective: Enhance the visual appeal of crab sticks.
- Process: Food-grade coloring is sprayed or rolled onto the surface. Some manufacturers wrap bundles with a thin colored film for stability.
- Importance: A uniform outer layer ensures brand consistency and stronger consumer recognition.
Step 6: Length Cutting
After coloring, the product is cooled and cut into retail-ready sticks.
- Objective: Stabilize texture and achieve exact lengths.
- Process: Cooling conveyors or chilled water systems reduce product temperature. High-precision cutting machines then slice sticks into standardized portions (7–10 cm).
- Importance: Consistency improves packaging efficiency and reduces waste.
Typical Cutting Specifications:
| Product Format | Standard Length | Application |
| Snack sticks | 5–7 cm | Ready-to-eat packs |
| Standard crab stick | 7–10 cm | Sushi, salads |
| Bulk format | 12–15 cm | Catering and foodservice |
Step 7: Packaging & Congelando
The final stage ensures product stability and long shelf life.
- Packaging: Vacuum or modified atmosphere packaging (MAP) is applied to prevent oxidation and microbial growth.
- Congelando: Individual Quick Freezing (IQF) locks in freshness and preserves texture.
- Objective: Provide safe, durable products for export markets.
- Importance: Proper handling ensures compliance with FDA seafood safety regulations.
Conclusão
The modern crab stick production process steps can be summarized as: Surimi Preparation → Forming & Alignment → Cooking → Thin-Cutting & Bundling → Coloring & Wrapping → Cooling & Length Cutting → Packaging & Congelando. By maintaining precise control at each stage, food manufacturers can consistently produce high-quality crab sticks that meet consumer expectations and global safety standards.