Nienstedt has introduced a new processing technology designed to eliminate material losses associated with conventional frozen block sawing, offering seafood and protein processors a way to achieve full utilization of frozen raw materials while expanding product development opportunities.
Yield optimization has become an increasingly important priority for processors as raw material costs rise and manufacturers seek to improve sustainability and operational efficiency. Traditional sawing methods used to produce products such as fish fingers, fillets and other convenience foods typically generate sawdust and trimming waste, resulting in material losses of between 2% and 5%, depending on the application.
Nienstedt’s Flake Shaping technology is designed to overcome these limitations by converting frozen protein blocks into shaped products without removing any material during processing.
The process begins by transforming frozen whole-muscle protein blocks into flakes while preserving the structure of the muscle fibers. These flakes are then weighed into uniform portions before being formed into three-dimensional products with the desired size and shape.
Unlike conventional sawing, which cuts away material to achieve specific dimensions, the Flake Shaping process redistributes the original raw material into controlled portions, allowing processors to utilize 100% of the frozen block.
The technology can process a variety of raw material formats, including standard frozen blocks, lower-grade frozen blocks and individually quick frozen (IQF) products. It is suitable for multiple protein sources, including fish, poultry and plant-based ingredients.
Beyond improving yields, the system offers manufacturers greater flexibility in sourcing raw materials and developing new products. Processors can combine different fish species within a single formulation to achieve targeted texture, flavor or nutritional profiles, while vegetable ingredients and other plant-based components can also be incorporated into hybrid products.
The ability to utilize a broader range of raw materials may also help manufacturers optimize production costs while maintaining product specifications.
Nienstedt says the technology aligns with the food industry’s growing emphasis on sustainability by reducing avoidable processing waste and improving overall resource efficiency. As environmental reporting and waste reduction become increasingly important across the sector, higher raw material utilization can contribute to both sustainability objectives and production economics.
While frozen block sawing remains a widely used and effective technology for many industrial applications, evolving market demands are driving interest in alternative processing methods that offer higher yields, greater manufacturing flexibility and broader product innovation opportunities. Flake Shaping represents one such approach, enabling processors to maximize raw material utilization while supporting the development of next-generation convenience food products.
Find out more at: https://www.nienstedt.com/