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Good manufacturing practice GMP
Canned seafood fish manufacturing app
CANNED FISH & SEAFOOD MANUFACTURING APP FROM PRODUCEPAK
1) Receipt of fish:
• The plant has the productivity of enterprises in conformity with the specifications required as prerequisites to the requirements of good manufacturing practice-compliant with the Hazard Analysis and Critical Control Points (HACCP) since all production processes in line with European standards of health and safety.
• Fresh fish are arrived on ice covered with adequate insulation in the transfer of appropriate for this purpose.
• Unload fish from insulators vans to the especially baskets the process of testing and screening and weight.
• Prepare the fish with viscera and wash well for the introduction to the production line immediately after the transfer of surplus to the stage of preliminary preparation for the cold freeze.
• Frozen fish arrived to the factory in insulation and refrigerated temperature of not more than (-18co).
• Quality procedures are applied at all stages of the process of receipt to ensure the safety and quality of fish received for production or freeze.
2) Freezing and storage:
• Include the possibilities of the process of freezing and storage on a number of cold storage for conservation (8 stores), and one frozen operating with high-tech equipment and machines and control devices for inventory control have been introduced this technique recently to increase the inventory capacity.
• Maximum capacity is about 700-800 tons of storage in addition to the possibility of storage and cooling of the amount of 10-20 tons.
• The temperature of the conservation of fish stocks reach around (-20co) including up to freezing temperatures (-35co to -38co).
• Control health requirements and hygiene for the conduct of the preparations, and freezing and storage, where they are monitoring and recording of temperature in the stores continued to maintain the high quality of the stock.
3) The Initial Processing (cutting, cooking and cooling):
• Cut off the head and tail of the fish by means of leaflets and interrupt the body to cut off across.
• Clean and chop fish by water.
• Packing pieces of fish in the baskets which are made of stainless steel designed for the process of cooking, and transferred to the cooking unit.
• Fish cooked at temperatures between (100co-95co) periods of time determined by the size of fish and temperature of primary
• The process of initial cooking by free of impurities of sea water is the best of primary treatment for fish, where fish to get rid of excess fat and gained characteristics required to achieve quality standards.
• After completion of the initial cooking and cooling the fish in cooling room under low temperatures to make it taste and flavor, color and firmness and processing of the subsequent stage of production.4) The Clearing of the fish:
• Quantities of cooled fish entered the initial peel tables to removal of the skin.
• The cleared fish moved automatically to the tables in the second stage of peeling.
• Peeling halls are according with the specifications and equipped for this purpose, where it prepared with adequate lighting and air conditioning required to maintain the low temperatures in the working environment and handling of fish. These halls are wide rooms to accommodate large numbers of workers up to (80) distributed on (5) lines of peeling.
• In the peeling process, the separation of black meat and bone and any unwanted parts for human consumption, and separating the fish in accordance with the specifications of others, such as cutting the fish changing color (green), sponge, decaying, and retaining only the white meat tuna.
• Examine the pieces of fish by workers carefully examining every line of peeling and under the supervision of a production controller.
• Monitoring and control is the quality of performance in the peeling of the fish during the first and the second phase by the quality control supervisors.
• Pieces of fish collected after the completion of clearing and peeling in full, and checked that it conform to the specifications of quality in the clean basins suitable for use to the food to manufacturing lines.
• Lines of manufacturing composed of several machinery and equipment is determined by well-known with high quality international companies (FMC-SOMMTREAD-FISHBAM-HERFRAGA - BARRIQUAND, etc.).
• Machinery are designed well and sound in order to facilitate cleaning and disinfection.
• All the equipment and machinery are made of materials not rust (stainless steel) of high quality.
• Cleared pieces of fish packed into machine in an appropriate manner to maintain the quality of packaging and parts.
• Pressing pieces of fish and cut in by a machine in empty cans and weighed to measure at least (70%) of the net weight of the contents.
• Check boxes filled with fish from the points of examination are designed to match the weight of the cans of others (defective)
• Add the oil and the net temperature of not more than adequate (65Co) by no more than a percentage (25-20%).
• Cans tightly closed lock dual manner after the inclusion of data of productivity and competence on cans covers.
• Clean cans with hot water after the closure to remove the sediment suspended by the mental, if any.
\ • Collect cans in baskets transfer directly to the sterilization unit.
• The completion of the sterilization of canned goods in accordance with the equation of temperature and time in the documents of the factory and with the least possible period of time between the closure and sterilization.
• Quality procedures are implemented to control the manufacturing of continuous monitoring (to adjust the weights and the closure of cans) to ensure that critical limits for the process of industrialization.
Processing the final product:
• After sterilization time baskets are unloaded in plastic non-solid containers and set at temperatures (35 co -37co) for a period of not less than (7-10) days for help to detect the production of defective for marketing, and this is called the incubation period.
• Non-viable cans for marketing are separated after the incubation period.
• After checking the validity of the product, a label to be placed in the machine-paste cans.
• Cardboards are binding for transport to the stores.
• This product is ready for marketing.
Canned or tinned fish are fish which have been processed, sealed in an airtight container such as a sealed tin can, and subjected to heat. Canning is a method of preserving food, and provides a typical shelf life ranging from one to five years.
Fish have low acidity, levels at which microbes can flourish. From a public safety point of view, foods with low acidity (pH greater than 4.6) need sterilization under high temperature (116–130°C). Achieving temperatures above the boiling point requires pressurized cooking. After sterilization, the containing can prevents microorganisms from entering and proliferating inside. Other than sterilization, no other method is dependable as a preservative. For example, the microorganism Clostridium botulinum (which causes botulism) can only be eliminated at temperatures above the boiling point.
Preservation techniques are needed to prevent fish spoilage and lengthen shelf life. They are designed to inhibit the activity of spoilage bacteria and the metabolic changes leading to a loss of fish quality. Spoilage bacteria are the specific bacteria that produce the unpleasant odours and flavours associated with spoiled fish.
Canned fish manufacturing appedit]
The "father of canning" is the Frenchman Nicolas Appert. In 1795, he began experimenting with ways to preserve fish in jars. He placed jars of fish in boiling water. During the first years of the Napoleonic Wars, the French government offered a 12,000 franc prize to anyone who could devise a cheap and effective method of preserving large amounts of food. The larger armies of the period required increased and regular supplies of quality food. Appert submitted his invention and won the prize in January 1810. The reason for lack of spoilage was unknown at the time, since it would be another 50 years before Louis Pasteur demonstrated the role of microbes in food spoilage. However, glass containers presented challenges for transportation. Shortly after, the British inventor and merchant Peter Durand patented his own method, this time in a tin can, creating the modern-day process of canning foods.
Canning was used in the 1830s in Scotland to keep fish fresh until it could be marketed. By the 1840s, salmon was being canned in Maine and New Brunswick. The commercial salmon canneries had their origins in California, and in the northwest of the US, particularly on the Columbia River. They were never significant on the U.S. Atlantic coast. By the 1940s, the principal canneries had shifted to Alaska.
See also: Salmon cannery
A salmon cannery is a factory that commercially cans salmon. It is a fish processing industry that pioneered the practice of canning fish in general. It became established on the Pacific coast of North America during the nineteenth century, and subsequently expanded to other parts of the world that had easy access to salmon.
Prior to canning, fish were salted to preserve them. Cobb says that at the start of the 19th century, the Russians marketed salted salmon caught in Alaska in St. Petersburg. Shortly after, the Northwest Fur Company started marketing salted salmon from the Columbia River. It then merged with the Hudson's Bay Company, and the salmon was marketed in Australia, China, Hawaii, Japan and the eastern United States. Later, some salmon salteries were converted to salmon canneries.
The first industrial scale salmon cannery in North America was established in 1864 on a barge in the Sacramento River by the four Hume brothers together with their partner Andrew S. Hapgood. In 1866 the Hume brothers relocated the business to a site 50 miles inland on the Columbia River. The history of North American salmon canneries is exemplified by their history on the Columbia River. Within a few years each of the Hume brothers had his own cannery. By 1872, Robert Hume was operating a number of canneries, bringing in Chinese willing to work for low wages to do the cannery work, and having local Native Americans do the fishing. By 1883, salmon canneries had become the major industry on the Columbia River, with 1,700 gillnet boats supplying 39 canneries with 15,000 tonnes of salmon annually, mainly Chinook.
Typical can of sardines, in salt water
Sardines (or pilchards) are canned in many different ways. At the cannery, the fish are washed, their heads are removed, and the fish are cooked, either by deep-frying or by steam-cooking, after which they are dried. They are then packed in either olive, sunflower or soybean oil, water, or in a tomato, chilli or mustard sauce.
Canned sardines in supermarkets may actually be sprat (such as the “brisling sardine”) or round herrings. Fish sizes vary by species. Good quality sardines should have the head and gills removed before packing. They may also be eviscerated before packing (typically the larger varieties). If not, they should be purged of undigested or partially digested food or feces by holding the live fish in a tank long enough for them to empty their digestive systems.
Sardines are typically tightly packed in a small can which is scored for easy opening, either with a pull tab (similar to how a beverage can is opened), or a key, attached to the underside of the can. Thus, it has the virtues of being an easily portable, nonperishable, self-contained food.
The close packing of sardines in the can has led to their metaphorical use of the name ("packed like sardines") in describing any situation where people or objects are crowded together, for instance, in a bus or subway car. "Sardines" has also been used as the name of a children's game, where one person hides and each successive person who finds the hidden one packs into the same space until there is only one left out, who becomes the next one to hide.
See also: Tuna § Canned
Canned tuna for sale at a supermarket
Tuna is canned in edible vegetable oils, in brine, in water, or in various sauces. In the United States, canned tuna is sometimes called tuna fish and only albacore can legally be sold in canned form as "white meat tuna"; in other countries, yellowfin is also acceptable. While in the early 1980s, canned tuna in Australia was most likely southern bluefin; as of 2003 it was usually yellowfin, skipjack, or tongol (labelled "northern bluefin").
Tunas are often caught far from where they are processed for canning, so poor interim conservation can lead to spoilage. Tuna is typically gutted by hand and later precooked for prescribed times of 45 minutes to three hours. The fish are then cleaned and filleted, canned (and sealed), with the dark lateral blood meat often separately canned for pet food (cat or dog). The sealed can itself is then heated (called "retort cooking") for 2–4 hours.
The retort cooking process kills any bacteria but retains the histamine that can produce rancid flavors. The international standard sets the maximum histamine level at 200 milligrams per kilogram. An Australian study of 53 varieties of unflavored canned tuna found none to exceed the safe histamine level, although some had "off" flavors. The level of omega-3 oils found in canned tuna can be highly variable, since some common manufacturing methods destroy omega-3 oils.
Australian standards once required cans of tuna to contain at least 51% tuna meat, but these regulations were dropped in 2003. The remaining weight is usually oil or water. In the United States, the Food and Drug Administration (FDA) regulates the amount of tuna in a can. In 2008, some tuna cans dropped from 6 ounces (170 g) to 5 ounces (140 g) due to "higher tuna costs". In the United States, 52% of canned tuna is used for sandwiches, 22% for salads, and 15% for casseroles and dried, packaged meal mixes.
Other fish species
- Canned anchovies, Italy
- Canned cod liver, Russia
- Canned cat food in jelly
- Children cleaning Atlantic herring at a cannery
CANNED FISH / TIN FISH MANUFACTURING
Receiving and storage
We receive the pieces of Bonito del Norte White Tuna and Yellowfin Tuna at our facilities in Bermeo. We also have the additional raw materials necessary for the production of canned fish (oil, brine, vinegar, etc…) and, of course, the containers, labels, and packaging we need for distribution.
Cutting the pieces
Upon receiving the fish, the belly is removed. Then, depending on the size we are working with, we will leave the fish whole or cut it into sections.
When cooking, we add the perfect mix of water and brine and calculate the time it takes each fish to cook since it varies depending on whether it is whole fish, sliced, or belly.
Cooled and stored refrigerated temperatures
When finished cooking, the racks are stacked in an area near the cooking area for further cooling.
PHASE TWO OF THE PRODUCTION PROCESS
First we clean the whole pieces and slices and remove the skin, bones, fins, and any remaining entrails or dark meat. The fillets are then cut for subsequent packaging.
Packaging, adding liquid to cover them, and closing the containers
Once parts have been cleaned, they are then manually packaged, the sauces are prepared and the liquids to cover them are added: oil, brine, or Catalan sauce.
PHASE THREE OF THE PRODUCTION PROCESS
Sterilization and final cooling of the containers
The temperatures and sterilization times are standardized by the company and vary depending on the sizes, products, and packing liquids that are to be sterilized. they are rapidly cooled via overpressure to avoid any deformations in the containers.
Labeling, packaging, storage, and distribution