s4n017 Planing a engineering data 2 Fish caning 4 Processing GQ *ocrrPoraepocunerrserosonr Produced by: Fisheries and Aquaculture ‘Department Title: Planning and engineering dat. 2. Fish Canning. More detail 4. PROCESSING 4.1 Technological Processes 442 Processing Operations: 4.1 Technological Processes ‘The main objective of canning is to obtain a shell-stable product that can be stored in sultable containers for a considerable lenath of time (atleast two years) without undergoing food spolage, while retaining desirable nutrional ‘and sensory quales. ‘To achieve satisfactory sheltife the folowing conditions must be observed: |. The contents ofthe cans must be commercially sterlized {i The inside ofthe can must be resistant to and damaging effects from the contents and the outside must be resistant to corrosion under reasonable storage conditions. li, The can ends must be Sealed to prevent ingress of water andior air or any form of contamination. 4.2 Processing Operations 4.2.1 General Fish should be chil stored at a temperature between 0° and 2 *C, or sorted frozen in freezers at temperatures below 28°C. When frozen fish is used, it must be thawed before grading andlor dressing. In the following descriptions ofthe pracessing stages for various products, operations which are simfar are described in Chapter 4.2.2 “Description of canning tuna in brine’, and subsequently only mentioned. 4.2.2 Description of canning tuna in brine ‘The description is related to canning plant with a capacity of 20 tons whole raw fish (bluefin or yellowfin tuna) per 8 hours, The overall yield is approximately 50-55% which gives approximately 10 000 450 g (1 pound) cans or 20 000 225 g (1/2 pound) cans per 8 hours. See Figure 4 "Layout for tuna cannery" Simplified flow sheets for canning tuna in brine, tuna flakes with vegetables and tuna. pet food are shown in Figures 8, ‘and 7 respectively. ‘Sequential processing operations for canning tuna are described as folows: a. Frozen tuna is thawed, preferably, by means of running water at a temperature of 10-15 °C. Loss during thawing is 0.5-1.0%, Holding of rozen tuna for long periods before thawing may lead to oxidation of fatresuting in a yellow to orange: lscolouration on the surface of the cooked loins, Usually this surface discolouration can be removed when the fish i cleaned. ». Longitudinal cuts are common with large sized tuna and the viscera are removed from the fish on board fishing vessels prior to freezing. Bonito and skip jack are frozen with viscera. Once thawed, the tuna is washed and inspected for spoilage. Iftuna isnot eviscerated on board vessels tis must be done inthe plant, The spliting {and evisceration procedure isthe aaly butchering operation performed on the tuna while i fs nthe raw Condition. All other cleaning Is performed after the tuna has been cooked. Loss of weight is approximately 24- 2%, Iiip ww fo or gdoerop00QREB1BEIRESTEEOS Hm sees4n017 Planing ad engineering data 2 Fish caning 4 Processing crtnarons, wennert 5 ‘BND COUPON + "Hawn CONTANERS. Seung PREPARATION Convever Sahn Conveyor TUNA code paskers Wash PACHNE FoR Sass 5, TONn PRE-cooreR ‘2. FECDNG CONVEYOR FoR “Una BASKETS sn. ean TABLE 12. ROLLER COnVEYOR 1 Patki TABLE 1S. YDRAULE PRESS. . BeTY CAIs Th AUTORAmC FLUNG HACHNE Fon Tk ‘specTON owas Arora samme nao me asin cowevor eroats WASHING £ ORYIG MACINE conveyor Chee caareane PaLLenanG oth ———— ed a os a brim 5 § Figure 4 Layout fortuna cannery Iiip ww fo or gdoerop00QREB1BEIRESTEEOS Hms4n017 FROZEN TUNA FROM STORAGE {THAWING sing FILLING IN” TRAYS ANO RACKS: PRECOOKING IW STEAM, [ERPATON OF BONES SKIN AIT OneR|_/BONES STE] TONTROL OF QUALITY & WEIGHT SEAR WATER [STEAMWATER, JWASTE WATER, | armed ome EE TABELLING, PACKING CARTONS CLOSINGS COONG_CARTONS: PALLET STORAGE, Figure 5 Flow sheet for canning tuna in brine nip hww fo. gfdoeropO09RR6818EIRESTBEDS Nm Planing a engineering data 2 Fish caning 4 Processings4n017 Planing a engineering data 2 Fish caning 4 Processing ‘SEPARATIONS, ‘SEAMING v FURTHER OPERATIONS SAME AS. FLOW SHEET FOR CANNING TUNA Figure 6 Flow sheet for tuna flakes with vegetables wana} Eee] y me] : 3 Deane Ed FURTHER OPERATIONS SAME AS FLOW SHEET FOR CANNING TNA, Figure 7 Flow sheet for tuna pet food «, The tuna is given a pre-cook by heating at a temperature in range of 102 to 104 °C, This operation is necessary to make it possible to hand pick the light meat from the carcass and also to remove some of the ol rom oly fish The fish is placed in baskets which are placed on racks. The racks of butchered fish are rolled into the cookers which are usually of rectangular eross section and made of reinforced steel plate wih a doar, of doors, at ane or both ends. The pre-cooking isa batch type operation, ‘Steam is admitted through a steam spreader on the floor ofthe cooker. Steam vent and drain valves are provided to permit removal of air and condensate, Pre-cooking may also De carried out in boing brine. nip hww fo. gfdoeropO09RR6818EIRESTBEDS Nms4n017 Planing a engineering data 2 Fish caning 4 Processing ‘The pre-cooking time fr individual batches varies widely according tothe sizeof tuna. For example, the cooking time may vary from 1 1/2 hours for small tuna to & to 10 hoUrs, or more, for larger tuna, Loss of we}BRINING / WASHING }_ paste a] paxoag} {none Td SAR FEC] ER] z {FOROENSED | ot abe oF TE Senn oS Sune L RO SEATON FURTHER OPERATIONS SAME AS FLOW SHEET FOR CANNING TUNA Figure 11 Flow sheet for canning sardines in ol 3. After nobbing the sardines pass through a washing process to remove blood and surface slime. Washing ‘machines of many types may be used, Washing should be with potable waler or sea water of similar quality. (For certain species with hard and inedible scales, such as pllchard, special washing machines sutable for removing scales are used) The sardines are then transported, usually by a conveyor, to a brining machine. The brining can elther be a batch or a continuous operation. The speed of the process and the concentration of the brine can be controled. ‘The fish are loaded ito the brining unit in one end where they are immersed in concentrated salt soluton, and then serewed through the unit and simultaneously brined, The fish are then discharged atthe opposite end of the unt, ‘Salts absorbed by the flesh; a salt content of about 1-2% of fish weight, when in boxes is acceptable. The brining machine is equipped with fitr to sereen particles from the Brine In addition to giving the product the desired salt content, brining has other beneficial effects. The process brightens the appearance of the fish by remaving remaining slime and also toughens the skin; when unorined fish are canned much of the skin adheres to the can. Alter brining, the fish are allowed to dean before being transported tothe packing table. The brine must be prepared from salt which does not contain large quantites of magnesium chloride, a common contaminant in unrefined salt. The brine should be replaced regularly as otherwise it becomes a source of contamination 5. After the brining process the sardines are packed (manually or automaticaly) into pre-ashed cans, ‘A manually operated packing line is equipped with conveyor belts, the speed of which can be altered in order to ensure a smooth supply of sardines and cans tothe packers. The filed cans and waste are removed by the conveyor after packing In commen sardine lines the filed cans pass over a weight control unt to a can algner and then to a can pusher, which automatically feeds the conveyor transferring them to the pre-cooker. CChange of yiels during the packing process depends on the quality of raw material, but on average 5% loss of ‘weights expected. 6. A typical flash cooker for sardines consists of 2 sections, one for cooking (in steam at about 96 °C) and one for {tying (in hot air at about 120 °C). The cans wth the open end upwards are automatically transferred to crates, hier are hanging on crossbars mounted on a continuous chain conveyor ring in slings up awards ino the ‘ooking section, and into sings downwards in the drying section. nip hww fo. gfdoeropO09RR6818EIRESTBEDS Nm s1n2s4n017 8. Planing a engineering data 2 Fish caning 4 Processing Between the two sections water is drained from cans as the erates are tured through 360° around a tumbler. ‘The heat inthe cooking section is obtained from supply of direct steam while the heat in the drying section is indirectly supplied from a heat exchanger. A fan located onthe top of the section circulates the heated ai Weightloss during this operation is approximately 25 %. From the cooker the cans are automaticaly transferred onto a conveyor which takes then to the ol dispenser and onto the seaming machine where they are sealed. Before the retoring process the cans are washed to remove fish residues and oll from the outside of the containers, Further operations as for canning tuna in brine, See chapter 4.2.2. . ‘Table 9 Examples of retorting temperatures and time for canning sardines Gan type | Temp. (6) | Retortng time (min) eu | et % Wa angley |_ 115-116 & 4.2.5 Description of canning pre-smoked sardines in tomato sauce or oil Most ofthe operations in this process are similar to those described for canning sardines in ol “Tho description is related toa plant capacity of § tons of raw fish per 8 hours. The yield from canning of sardines and other pre-smoked smal fishes approximate the yields obtained when canning sardines in ol See Figure 12 "Flow sheot for canning pro-smoked small sh in tomato sauce and ol, and Figure 13 “Layout for oro» ‘smoked small fish cannery" which shows a plant ofthe capacty mentoned above. ‘The various operations are described below, 1 2 3 7 - Grading is similar to the operation described for canine sardines in ol, Brining is similar to the operation described for canning sardines in oll The fish are rodded, I, hung an rods thraugh the eyes. This operation can be done automaticaly or manually. The automatic rodding being a complicated pracess is only practised in large plants. The rodded fish are placed Into frames which are fited to tre smoking racks. ‘The frames have usually accommodate for 30 rods, each with 30 ish The fish are smoked for approximately 1 hour at temperatures up to [30 °C. The main purposes of the smoking Isto enhance flavour and to lower the water content ofthe fish, Usualy tunnel type smoking kins are used in which there is @ controlled temperature gradient between 30° and 125-130°C, ‘The air passes through a heat exchanger while smoke added, The smoke is produced by a smoke generator Using sawdust from hard woods (oak or similar) Loss during smoking is approximately 25%. ‘After smoking the bodies ofthe fish are separated from the heads with an automatic cuting machine. The heads are then removed from the rods with an automatic rod striping machine. Loss of weight during the deneading ‘operation is approximately 10-12%, ‘The packing, the fling of sauce or il and the double seaming operations are similar to those described for canning sardines in ol \When preparing tomato sauce, puree of good qualiy must be used and to ths is addad ove ol or fish oll, ote ‘Typical mixtures comprise one part ol and two parts tomato puree (20% concentration). {Al subsequent operations are similar to those described for canning sardines inal 4.2.6 Description of canning fish paste products ‘The description is related toa fish paste canning plant with a capacty of 10 tons whole raw fish per 8 hours. The production is based on ether deheaded, gutted fsh with an average weight of 1.5 kg of smaller industial fish, Seo Figure 14 "Layout for fish paste products cannery" which shows a plant of the capacity mentioned above, ‘Overall yield when manufacturing canned fish paste products depends on species involved, however, approximately 45-65% of raw fish weight could be used for planning purposes. itp dew fo. gfdoerep09RR6818EIRETBEDS Nm sors4n017 Planing a engineering data 2 Fish caning 4 Processing ‘The output from a plant producing meatballs is approximately 25 000/850 mi cans per 8 hours; alternatively 8 000/850 mi cans of fsh cakes or 15 000/850 ml cans of meat balls could be produced. FRESH FISH FROZEN FISH Trans} fase ie] car Tan {as om ami OPAED Re] ODOING ESE OAL — FSH Ou, COM ans} SHORING ese ware Pega On ) x TERCED cas PACING Teen | EO : SEAMING bos, coins STERIUZATION T FURTHER OPERATIONS SAME AS FLOW SHEET FOR CANNING TUNA, Figure 12 Flow sheet for canning pre-smoked small sh in tomato sauce and ol “The flow sheet fr canning fish paste produc is shown in Figure 16 “The various processing operations are summarised as flows. ‘Tho raw material has to go through @ grincingchopping and mincing process. 4. Tho fsh are washed, doscalod when necossary,evscorated and deheadod 2. According to skin thickness and size, the fish will have to be split into halves from head to tall along the backbone, 3. The splt and opened fish are washed and cleaned. 4. The washed splt fish is separated in a meat-bone separator. According tothe type of ish one will get an acceptable minced product, and offal, Bones and skin. 5. Ifthe minge is unacceptable, (|. ciscaloured because of blaod ete. jit may be necessary to have t washed ang then dewatered by means of a screwpress 6. The minced fish's mixed ina bowl chopper or mincer with the other ingredients. itis important to add the salt first and to allow the minoor to work for afew minutes Oetore adding the remaining ingredients to the mixture. ‘This will improve the binding properties of the fish, See Figure 16 "Processing line for fish meat’ itp dew fo. gfdoerep09RR6818EIRETBEDS Nm a2s4no17 Planing a engineering data 2 Fish caning 4 Processing OPERATIONS, MACHINERY AND EQUIPHENT | 1 RNG 2. BRNING TANK 3 ROOONG TABLE 1. breesmoneR }---—-------+ 5. CONTANER FOR HEADS 1 roo STRIPPER CUTTING MACHINE FOR heads (AN CONTAINER. PACKING UNE TOMATO FLING MACHINE Te GAN SEAMING MACHNE vata CuNCHER a. fevoar easker 1B RETORT 1. CAN WASHING & DRYING ache 15, CARTON 8 PALLETS fon cn mae ® ® x 1 I Figure 13 Layout for pre-smoked small fish cannery itp ww fo orgdoerop00QREBIBEIRESTEEOS Hms4n017 Planing ad engineering data 2 Fish caning 4 Processing ‘TORNGT Fama CPL Root eau ir catons ra 7 HANK) < ‘OSES [WaaPPING i — figous}o[ vases | er = pg By a a zg] lel 18 bees iid . J Er : 3 —, jTROLe| page E a | ie MINCER | Ma 7 a Fafa] coon ron visu suis (Aetne cal oom ee eee ht SCALE IN METRES Figure 14 Layout for fish paste products cannery nip hww fo. gfdoeropO09RR6818EIRESTBEDS Nm 18122s4n017 Planing a engineering data 2 Fish caning 4 Processing waren WATER var} {hems | — es] —E iNCED FISH L. Say |} ——————faurmaciarincnc AER HN Ea cae UIA TSAO CoOME Fare fH | —_a A a (ger seen] T FURTHER OPERATIONS SAME AS FLOW SHEET FOR CANNING TUNA, Figure 15 Flow sheet for canning fish paste product 7. Starch, spices and, f necessary, onions, fat, etc, are added. 8. Liquid mik is added and according tothe type of mincer, it will take 10-12 min forthe materials to reach a soft and fermable conditions. 9. The fish balls can be formed in machines, by hand with spaon, or by hands only, and dropped into a1 112% solutions of salt water at approximately 90 °C. 10. After cooking in the salt solution for approximately §-8 min the fish balls are filed into cans. 11, Hot brine or fish boullon is added, 12, After seaming the product goes immediately to retoting. (hae =. a Fish CONVEY SCREW PRESS. Boo f i Ye Figure 16 Processing ine for fish meat itp dew fo. gfdoerep09RR6818EIRETBEDS Nm 622s4n017 Planing a engineering data 2 Fish caning 4 Processing aay, Kanne -- —frrorns : Seaver 3 Sorat faces core s 5 5 fe cenne TaeLuns cao contre firape | sana T Na SCALE IN METRES Figure 17 Layout for salmon cannery Several ateratives fr retorting temperatures and times are shown in Table 10. ‘Table 10 Examples of rtorting temperatures and times for canned fish paste products ‘Alternative Initial product temp. (C) Heating Temp. (C)] time (in) Fish meat ballin bnelboailon| AGO m/ G9 112mm cane nip shew fo ogfdoerepO09R6818EIRESTEEDS Nm srees4no17 Planing a engineering data 2 Fish caning 4 Processing 1! 20 tos | 20 | 0 | 15 w 2 7 || as | 425 ml (99x 63m) ears T 2 wm [a] m@ 13 7 20 we [| as | % Fish cakes in bonefboulion aS0 m1 9x 119mm) cans T 3 wm [0] mo |S 450,19 69 mm)_cans T 2 wo [| im | @ Further descriptions are as fer canning tuna in brine 4.27 Description of canning salmon “The description is related toa processing plant with a capacity of 8 tons of raw fish per 8 hours; this capacity has been based on using whole ish weighing 4 kg each. See Figure 17 “layout for salmon cannery’ “The overall yield when canning salmon is between 55 to 60 %, depending on the size of the fish, With a yield of 55%, 1 ton of raw salmon wil give 3 400, (8437) 228 g (1/2 pound) cans. ‘The processing operations are described below. See Figure 18 "Flow sheet for canning salmon™ 1. The fsh are transported to sorting table and sorted by species. 2. The salmon are eviscerated with an iron chink machine which remaves the head, fins and viscera from the salman (s00 Figure 1) The loss of woight is approximately 35-40 % 3. The eviscerated, deheaded fish is next conveyed tothe siming table. Sliming consists of removing fins, viscera {and blood, ec. not removed by the buchering machine. During the sling operation the fish's throughly ‘washed. The loss of weight is approximately 3-5 %. a i = joeneclcoern x Cai 7AND KIDNEY, (eae en FASS OF) 1 a nd ue L CANS FILLING ‘sar WEIGHING z ios “CLINCHING war SEAMING WASHING STE WATER] L STERILIZATION T FURTHER OPERATIONS SAME AS FLOW SHEET FOR CANNING TUNA Figure 18. Flow sheet for canning salmon. nip hww fo. gfdoeropO09RR6818EIRESTBEDS Nms4n017 Plareing and enginexing data 2. Fish caning 4 Processing 4. From the siming table the leaned fish i conveyed toa sh cuter ites with revolving skies which cut the fish Ifo ies. The see are hen fede an automate ing mactino, Te ss cf wig eperxiataly 05-10 5. The filing machine fils the cans with the salmon after which salts added 6. The filed cans pass through an automate scale which sors for under Welght cans. 7. Fram the scale the cans pass ino a vacuum seaming machine 8. The filed and sealed cans are then discharged from the seaming machine through a can washer. 8. After seaming the product goos immediately to retorting. Retorting conditons of approximately 115 °C for 100, min are used for 450 ml cans 10. Further descriptions are as for canning tuna in brine 4.2.8 Description of canning shrimps Headless, peeled sirimps are graded according to number of shrimps per 100 g of drained product. See Table 11 (Codex Stan 37-1981), 2. FISHIN POSITION FOR HEADING 5. BULL RING WHICH CARRIES FISH THROUGH THE MACHINE: 4 BACK PINCERS 5. TAIL PINCERS ADVANCED AND GRASPING FISH 8. TAIL CUA OFF SAW 7. BELLY FINNING KNIFE 15, BACK PINCERS ADVANCED AND GRASPING FISH 9. BACK FINNING KNIFE 40. BELLY SLITTING SAW 11, GUIDE TO OPEN BELLY FLAPS FOR GUTTING REEL 12, GUTTING REEL TO REMOVE VICERA. 19. KNIFE AND REEL TO SLIT KIDNEY MEMBRANE AND TO REMOVE KIDNEY ‘4, BRUSH TO REMOVE BLOOD AND MEMBRANES 45, ROLLER TO SUPPORT ULL RING 418. FISH RELEASED AS BACK AND TAIL PINCERS RETRACT $7, CONVEYOR TO REMOVE BUTCHERED FISH Figure 19 ron chink for dressing salmon Table 14 Number of shrimp per 100 g of drained product Size Designation ‘Conventional Cleaned Ex lage or jumbo | Tess than 12.3 Tess than 13.4 Lage Ste TFT weave Bato TO.t nehane Medium | more than 18.1 bral more than 91.8 [more than 191 ul nt more than 36.6 Smal ‘more than S18 bu not more than 60 | more than 246 but not more than 65.3 “Tiey or inuscular more than 60.0 more than 652 itp dew fo. gfdoerep09RR6818EIRETBEDS Nm a2s4n017 Planing a engineering data 2 Fish caning 4 Processing omrne |] [cooana 2 fase z 8 z 5 a 3 fe g $2] = Eo z . 3 iC eeunc z ra PALLETIZING 5 g i rm @ # | | 8g a é 2 = 5 frasHinGeORr ING row ort St SLE wera Figure 20 Layout for shrimp cannery It is usual to can only those shrimp which fallin the medium to very smal size range. ‘The description is based on a processing plant capacty of 3.6 tons raw shrimp per 8 hours. This corresponds to production of 12 000-14 000 cans, each containing 75 9 shrimp, in & hours, “The overall yield ‘rom canning shrimp is between 25 ta 30% of raw weight. See Figure 20 "Layout for shrimp cannery” \which shows a plant ofthe capacity mentioned above. The description is based on using iced raw shrimp asthe raw material, The shrimps are usually graded before delivery tothe cannery. See Figure 21 "Flow sheet for canning shrimps! The operations in the canning process are summarized below: 2. On artval atthe cannery, ce is removed before washing the stimps. ». The shrimps are throughly washed while being conveyed into the plant itp shew fo. gfdoerep 0968 18EIRESTEEDS Nms4n017 Planing a engineering data 2 Fish caning 4 Processing «After washing the shrimps are inspected and foreign debris removed, 4. The shrimps are then conveyed to a peeling machine, which separates the shells and heads from the body. This ‘operation can also be done manually, Aproximately 46% ofthe total weigh is lost during this process. «2. Alter peeling, the shrimps pass through to a waste separator, which removes fragments left after peeling. {The cleaned shrimps are loaded into baskets and placed into a bong sal solution for cooking, Average salt concentration inthe solution is 11-13%. The cooking time varies from 6-10 minutes depending on the size ofthe shrimps. {9. After cooking the shrimps are inspected and any broken ones andlor pieces are removed. The shrimps are then cried by fans. 1. The shrimps are weighed and hand-filed into cans. The weight ofthe shrimps . should be 64% ofthe content of, the can, Aluminium cans are preferably used ‘or shrimp canning, however if tin plate cans are used, layers of parchment paper should be placed between the shrimps and the can to prevent corrasion. Hat or cold brine is. filed into the cans. Table 12 Example of mixture for brine Sat (ae Suara Giine acid [091 water | 7001 1. The cans are automaticaly closed and transferred to retorts for processing, FRESH SHRIMP Ie ware} wasn as maine} [ase] £ c we Tsine (ast aR INSPECTION Toa aot |} _—fasttaren wa Et A ine oe a 5 ane} cag il Wiha of STERILIZATION STE WATER] [SOLUTION FURTHER OPERATIONS SAME AS FLOW SHEET FOR CANNING TUNA. Figure 21 Flow sheet for canning shrimp ‘Table 13 Examples of retorting temperatures and times for canning shrimp [Alternatives [Preheating Conditions | Processing Conditions| ‘emp. [time | temp. | dime ce) | tiny | cc) | min) T 104 a +6 2 0 108 0 j. Further operations are as for canning tuna in brine nip hww fo. gfdoeropO09RR6818EIRESTBEDS Nm ames4no17 Planing ad engineering data 2 Fish caning 4 Processing Iiip ww fo or gdoerop00QREB1BEIRESTEEOS Hm