Development and Quality Characteristics of Grilled Pacific Cod (Gadus macrocephalus) Fillet Home Meal Replacement (HMR)

Changes in lifestyle and food consumption patterns have contributed to a growing demand for home meal replacements (HMRs), emphasizing the need for high-quality seafood-based products. This study aimed to develop a grilled Pacific cod (Gadus macrocephalus) fillet HMR prototype and to evaluate optimal processing conditions, quality characteristics, and shelf-life stability. High-frequency thawing was selected to improve raw material handling by minimizing drip loss to 11.91% and reducing thawing time to 15 min. A thyme-based marinade at a concentration of 3% for 20 min was applied to reduce odor and enhance sensory quality, and superheated steam grilling was compared with conventional heating methods. Processing parameters were optimized using response surface methodology, and smoking conditions were evaluated using different wood types. Superheated steam grilling produced superior sensory attributes under optimal conditions of 340 °C for 4 min, followed by cherry wood smoking at 60 °C for 5 min. The combined processing approach reduced total bacterial counts while maintaining acceptable physicochemical quality characteristics. Thermal processing increased texture firmness and nutritional density due to moisture loss, reduced lipid oxidation, and modified amino acid and fatty acid profiles. Shelf-life modeling indicated safe storage for up to 18 months under frozen conditions. These findings demonstrate that integrated marination, superheated steam grilling, and controlled smoking can be effectively applied to produce a safe, stable, and high-quality grilled Pacific cod HMR product.