About Manufacturing

How do we manufacture the crab sticks of the “Vodny Mir” trademark

The manufacture of crab sticks is a high-technology food production process where high-priced equipment and strict adherence to main temperature conditions are necessary to ensure products of continuing high quality.

The manufacturing process begins with the careful selection and preparation of the raw components. The percentage of raw components is individual for each manufacturer and constitutes its trade secret. The eventual quality of the finished product (crab stick) depends specifically on composition, percentage and quality of components.

Manufacturing process pattern

The manufacture of crab sticks is a complex multiphase high-technology process that requires multifold automatic monitoring of temperature indices. The manufacturing of the crab sticks under the “Vodny Mir” brand is carried out by using new modern equipment - namely an automated production line made in Japan, packing equipment and spiral quick-freezing machines made in Germany.

Phase 1. The crab sticks manufacturing process starts in the factory’s laboratory with an upon-receipt inspection of raw materials for their compliance with necessary requirements. Surimi is slightly defrosted and chopped, other components are weighted in accordance with the unique formula of the “Vodny Mir” brand.

Phase 2. Prepared components are combined in strictly specified succession and minced in a vacuum cutter into a homogeneous paste. A separate cutter is used for preparing colored paste.

Phase 3. A coextrusion-like method is used for molding the main paste and colored paste into a continuous sheet which then is prepared in a steam tunnel at temperature not higher than 90 °С. Temperature, humidity and sheet thickness are all monitored automatically.

Phase 4. A prepared sheet is cooled and slitted in order to imitate natural fibers, and then it is rolled, wrapped up in inner film and cut into crab sticks of the required length.

Phase 5. Crab sticks are then vacuum-packed into a flexible film with an imprinted design including all the necessary information for the customers. Vacuum packing ensures the sterility of the product and prolongs its shelf life, thus maintaining the high quality of the product.

Phase 6. The packed crab sticks are then pasteurized in a steam tunnel at a temperature not higher than 95 °С, and then cooled down to +10-15 °С.

Phase 7. In the case of frozen product manufacturing, crab sticks are frozen in a spiral freezer at a temperature of -18-20 °С. The freezing process should not exceed 30-40 minutes; otherwise ice crystals will grow inside the product and after defrosting its structure will be loose and limp.