PRODUCTION OF SARDINES

1. Receiving raw sardine fish

The sardines enter the cannery on ice, in a refrigerator or pre-frozen at sea.

Inspectors examine and evaluate the fish while they are unloaded. The
inspectors monitor the condition of each sardine, check the temperature and
collect samples for chemical analysis. Unacceptable fish do not make it to the
next step. Also, frozen sardines are thawed under controlled conditions

2. Grading

Involved the process where the degree of freshness of the raw material (sardine)
and it is preservation go a long way to determine the quality and the shelf life of
the processed canned product. Fish intended for canning must be in first class
condition and must be in first class condition and must be handled in an hygienic
manner to reduce microbial load on the fish (Oyelese and Opatokum, 2006).

3. Knobbing (Beheading and evisceration)

Conventionally sardine is canned after evisceration and beheading (Madhavan et

al., 1974). The head is rarely used for human consumption and can be removed
in most cases. Evisceration is usually done by a clean cur between the posterior
end of the gut and close to the head. This method of evisceration avoids cutting
the fish but makes it difficult to control the quality of the gutting operation. The
flesh in the belly part of the fish is vulnerable to bacterial contamination after
evisceration and it is therefore very important that the membranes in this part,
which protect the muscle, are kept intact (Rora et al., 2001).
4. Trimming and cleaning

Different standards of trimming are used, ranging from just removing the
backbone to full removal of all visible fat, pinbones and the skin. Then fish then is
cleaned with water to remove any foreign material that enter during processing of
sardine.

5. Brining

The sardines are soaked in 25% brine solution for 15 minutes. The main purpose
of brining is to separate water from the fish and replace it with salt. Thus, the
water concentration in fish decreases. Chlorine and sodium ions are carried from
brine to fish, and water dipoles are carried from fish to the environment (Kolsarici
& Candoğan, 1997).

6. Hand packing in cans

The empty and clean can is washed to remove any dirt contain in the can. The
cans and its lid will undergo exhausting process. The objective of exhausting is to
remove air so that the pressure inside the container following heat treatment and
cooling will be less than atmospheric (less oxygen content). The reduced internal
pressure (vacuum) helps to keep the can ends drawn in, reduces strain on the
containers during processing.

7. Pre-cooking

The sardines, after having been brined, are packed by hand in open cans. The
cans are placed in baskets or racks and then moved to a steam chamber where
the sardines are cooked by the steam while in the cans. The sardine is given a
pre-cook by heating at a temperature in range of 80 to 85ºC for 20 minutes. This
operation is necessary to make it possible to hand pick the light meat from the
carcass and also to remove some of the oil from oily fish. After having been
cooked in the steam chamber, the baskets of cans are then removed from the
chamber, and the baskets are tilted to drain the condensed steam, brine, and fish
oil from the can.

8. Filling solution

The above treated fishes are filled in the can by mechanically usually a small top
space is left which is also called head space and generally filled with inert gas.
The fishes are arranged inside the can as compact as possible. Necessary
additives (salt, tomato sauce, starch, sugar etc) may use to develop
characteristics flavour and improve keeping quality. Exhausting is done by the
application of heat space and between two fish pieces will be removed and a
partial vacuum will be formed. Exhausting is done to prevent bulging of can,
oxidation of the food or inside erosion of the tin plate.
9. Canning (double seam)

All fish cans prepared in this country are closed by the double-seaming method
and the operation is usually called seaming. A seal must be achieved that will
prevent passage of contamination material, carried either in air or water, into the
can after it has been sterilized. Proper care and maintenance of seaming is vital
and its performance should be checked at frequent intervals throughout the
working day. The seaming operation must be monitored throughout the
processing and visual inspections should be carried out at least every 30 minutes
(Warne, 1993).Good manufacturing practice indicates that the. Overlap should be
at least 45 % of the internal seam length to ensure that the seam will function
correctly and resist to minor abuse. Washing of can is done by the hot water
spray to removed adhering materials.

10. Sterilization at 121̊ C for 2.5 minutes

Heat processing is the most important step during the whole canning procedure.
It is done for predetermined time at the respectively temperature. To fulfil the
canning objectives 30 minutes are required at 110̊ C or 2.5 minutes is required at
121 ̊ C. The temperature of the can is determined a recorded which is called
thermo couple. Heat processing is done in a special instrument called retort and
so the process is called retorting.
11. Cooling

Cooling is done as quickly as possible after retorting. Otherwise off flavour may
produce because considerable changes may take place during heat processing

12. Drying/ Labelling

After cooling, cans of large fish such as herring and pilchards are stored for a
period of weeks before labelling. Cans of small fish are usually labelled directly,
since they are not so susceptible to damage. Ingenious machines are available
for labelling cans and capable of fixing the lid label, placing a key on this, and
wrapping the whole in a greaseproof wrapper. Larger cans may have the top
label pasted on by hand, and the side label by machine. Many canners label by
hand, making use of female labour during off-season period. In recent years, the
production of decorated lids has a cut down the use of paper labels

13. Storage

Unopened canned sardines should be stored in a cool, dark place, at about 18℃
or less, where they will keep for about 1 year. Once opened, they will keep for up
to two days if you wrap them well and refrigerate them. Rinse fresh sardines and
gut, if necessary. Store them in the coldest part of the refrigerator around 0.5 ℃ in
a single layer, in a dish, and covered with dampened paper towels. Ideally, fresh
sardines should be cooked the day of purchase, but they will last about 2 days if
stored properly. Some recommend storing sardines in the fridge in a mix of ice
and salted water. Frozen sardines should be wrapped air-tight and will keep for 6
months at -26℃.
References:

1) Oyelese, O.A. and Opatokum, M.O. (2006). Exposure time on bacteria

flora/count and shelf life of canned sardine (Sardinella pilchardus) under
ambient and cold storage condition. Journal of Fisheries and International 1.
Page 111-117
2) Rora, A.M.B., Morkore, T., Einen, O. (2001). Primary processing (evisceration
and filleting). In: Kestin, S.C. and Warris, P.D. (Eds) Farmed Fish Qualityl,
Blackwell, UK, page 249-260