Recipient Organization
BIOCHORIC, INC
103 N WESTERN DR
BOZEMAN,MT 59718
Performing Department
(N/A)
Non Technical Summary
This project will investigate how a novel, patent-pending technology (isochoric freezing) can be used to cleanly separate the meat from the shells of common shellfish in the US aquaculture industry and be financially competitive with traditional shell removal techniques. The experiments this project will conduct will determine which of and how the major domestically-aquacultured shellfish can be deshelled at competitive prices and produce high quality, appealing meat for consumers, using BioChoric Inc's proprietary isochoric chambers, which are designed and built in the United States.Reducing the cost of deshelling will lower prices for consumers, increasing their access to, and choices of, high-quality protein. This will also improve profit margins for domestic aquaculture, driving the expansion of aquaculture and its supporting industries, in support of the May 7th, 2020 Executive Order 13921, "Promoting American Seafood Competitiveness and Economic Growth".Further, the success of this project provides a meaningful opportunity to strengthen the competitiveness of American aquaculture exports, in support of the April 17th, 2025 Executive Order 14276, "Restoring American Seafood Competitiveness". This project recognizes that food security is national security, and food supply chain independence with healthy, low-cost meat choices for consumers is vital.
Animal Health Component
20%
Research Effort Categories
Basic
0%
Applied
20%
Developmental
80%
Goals / Objectives
Goal: To investigate the extent to which our isochoric freezing technology can efficiently separate the meat from the shells of shellfish significant to the American aquaculture industry, as a means to drive down costs for consumers, increase profits for producers, expand the domestic aquaculture industry, and support the competitiveness of US seafood exports in the global market (in support of the April 17th, 2025 Executive Order 14276, "Restoring American Seafood Competitveness"). Using key shellfish of the American aquaculture sector, such as clams, mussels, crawfish, etc., we will determine the values of various cost-driving operating parameters in isochoric freezing (e.g. pressure, process duration) required for effective deshelling with high meat quality and consumer appeal, and the extent to which this innovative patent-pending process is financially competitive with (or superior to) established deshelling techniques. Our proposed path to unlocking the isochoric deshelling process includes:Objective 1: Determine which shellfish, of major shellfish significant to the American aquaculture industry (shrimp, scallops, mussels, clams, crawfish, and crabs), can be deshelled with isochoric freezing chambers at non-cost-prohibitive low pressures. The metric to evaluate the results of Objective 1 is a pass or fail result for at least 90% of the contained meat being released as a single, contiguous piece for each shellfish species at the highest pressure that is financially viable for that species. This highest pressure is calculated for each shellfish using a financial viability model developed by BioChoric based on first principles stress analysis, mechanics of materials, and input from the American high pressure manufacturing supply chain, incorporating both one-time fabrication (capital expenditures) costs and ongoing process costs (operational expenditures).Objective 2: Determine optimal processing parameters for the three species of shellfish that showed the most promise from Objective 1 (measured by meat release at the most profitable pressures, as estimated by the financial viability model). The processing parameters Objective 2 will study are: minimum deshelling pressure; maximum cooling speed; and ideal processing fluid salinity. The metric used to evaluate Objective 2 will be expected cost to deshell one ton of a given shellfish, as pressure, cooling speed, and salinity are the cost-driving parameters in isochoric freezing, and can be parameterized to estimate their amortized contribution to the capital and operational expenditures of isochoric equipment and processing.Objective 3: Determine consumer acceptance of the meat of the three shellfish species released using the optimized deshelling parameters from Objective 2. The metric to evaluate consumer acceptance will be sensory panels conducted with commonly-accepted industry-standard methods such as the Quality Index Method (QIM). Standard methods like the QIM are routinely used for both finfish and shellfish with qualitative 0 - 3 scoring for appearance, odor, and texture. Additionally, quantitative metrics of the industry, like the mechanical properties of the deshelled meat (e.g. a stress-strain curve), pH, and the ratio of lipids to antioxidants will be used to evaluate the deshelled meat. Conventional deshelling methods of the shellfish will be used as a control reference, scored to compare the effects of isochoric deshelling, if any, on the meat, and thus the appeal of the meat to the consumer and market success of this novel process.
Project Methods
This project will be conducted through a structured, three-phase experimental framework designed to evaluate the technical feasibility, optimize operational parameters, and assess consumer acceptance of isochoric freezing for shellfish deshelling. Isochoric freezing, unlike conventional high-pressure processing (HPP), uses constant-volume freezing under mildly sub-zero conditions (yet without ice formation in the food product) to generate elevated pressures. No complex pressurization systems like the mechanical pumps characteristic of HPP equipment are needed, representing a significant simplification in capital equipment to deshell shellfish. Further, while HPP deshelling has been trialed around 300 to 400 MPa, the initial results of isochoric freezing have shown meat release in blue mussels and oysters around 30 MPa, a 10x reduction in pressure.Phase 1: Feasibility Testing of Shellfish (Objective 1)The project will begin by evaluating whether isochoric freezing can effectively remove shells from a range of key aquacultured shellfish species in the U.S.: shrimp, scallops, clams, mussels, crawfish, and crabs. While only initial experiments on blue mussels and oysters have been explored, the working hypothesis that the combination of mildly sub-zero but ice-free temperature and elevated pressure disrupt the connective tissue between the shell and the meat is reasonable to assume to be extensible to other shellfish of similar anatomy. However, this hypothesis must be tested. Each species will be tested at the maximum pressure level that remains economically viable, as determined by a pre-established cost model (based on material stress analysis and pressure vessel fabrication costs). For each test, shellfish samples will be placed in BioChoric-designed and made-in-America isochoric chambers for either 24 or 48 hours. The outcome (pass/fail) will be determined based on whether at least 90% of the meat is released from the shell. No control is needed at this stage, as the pass/fail effectiveness is evaluated by the proportion of meat release.Phase 2: Process Optimization (Objective 2)The top three shellfish species showing the highest viability from Phase 1 will undergo a multi-parameter optimization study. This phase is critical in identifying the most cost-efficient deshelling protocols to set up translation from the lab to commercial adoption in pilot deployments. Data collected will include success/failure outcomes, pressure/time correlations, cooling rate curves (via thermocouples), and observed mechanical behavior of the shellfish meat. This will include:- Pressure sensitivity: Identifying the minimum pressure required for successful deshelling across two time points (24 and 48 hours).- Cooling speed: Determining how the rate of temperature drop influences effectiveness using different cooling methods (such as liquid nitrogen, chamber immersion in chilled fluids, chilled fluids in a heat exchanger jacket attached to the chamber, and natural and forced convective air cooling of the chamber).- Working fluid salinity: Varying salt concentrations (0.2%, 1%, 2%, 3%) to observe effects on deshelling efficacy and pressure requirements.Phase 3: Sensory and Quality Evaluation (Objective 3)To ensure consumer acceptability, shellfish meat deshelled using optimized parameters resulting from Phase 2 will be analyzed using both subjective sensory analysis and objective quality metrics. The Quality Index Method (QIM) will be used to evaluate appearance, odor, and texture by trained panelists. Objective data will include:- pH levels (indicative of freshness)- Modulus of deformability (via stress-strain testing)- Lipid oxidation levels and volatile nitrogen compounds (e.g., trimethylamine)These metrics will be compared to those from conventionally deshelled shellfish, serving as the control. This comparative approach ensures that the new method not only works from an industrial processing perspective but also meets consumer expectations for quality and freshness.Efforts to Cause Change in Knowledge, Action, and ConditionTo drive the adoption and impact of this technology, the project includes educational and outreach initiatives targeting seafood processors, aquaculture stakeholders, and technical partners. These efforts include:- Technical reports and protocols disseminated through publications in peer-reviewed journals- Promotions and reports with highlighted data sent to industry trade groups targeting academic researchers and industry R&D departments.Evaluation and Measurement of ImpactEvaluation will occur at multiple levels, aligned with the project's technical and commercial goals. Quantitative and qualitative metrics will be used to assess success at each phase and across the broader set of project outcomes.Scientific and Technical Measures:Deshelling success per species at cost-effective pressures (from Objective 1).Identification of optimized effective parameters (from Objective 2).Sensory and chemical equivalence to control products (from Objective 3).Educational and Outreach Measures:Number of publications that come out of the projectMaterials disseminated (e.g., protocols, videos, reports) by download and/or view statistics from webpage analytical tools.Surveys measuring change in knowledge or intention to adopt.Adoption and Market Measures:Number of seafood processors expressing formal interest or piloting trials.Engagement from automation/technology providers (tracked via MOUs or inquiries).Detailed projections of cost savings and processing volume increases based on experimental data.Tracking of any downstream commercialization or licensing agreements stemming from project outputs.Key Milestones:Completion of testing across all six shellfish species (Phase 1).Finalization of optimized parameters for top three species (Phase 2).Completion of sensory testing with validated consumer-grade quality (Phase 3).