DYNAMICS OF DEVELOPMENT IN FISH PROCESSING SECTOR

UPAMA DASMEENU JENNY

REMEESA RAFIDELEENA NV

M.SC 2ND SEMSCHOOL OF INDUSTRIAL FISHERIES

COCHIN UNIVERSITY OF SCIENCE AND TECHNOLOGY

Fish processing• The term fish processing refers to the processes associated with

fish and fish products between the time fish are caught or harvested, and the time the final product is delivered to the customer.

• Fish processing is the transformation of raw ingredients, by physical or chemical means into food, or of food into other forms. Fish processing combines raw ingredients to produce marketable food products that can be easily prepared and served by the consumer. Fish processing typically involves activities such as mincing and macerating, liquefaction, emulsification, and cooking (such as boiling, broiling, frying, or grilling); pickling, pasteurization, and many other kinds of preservation; and canning or other packaging. (Primary-processing such as dicing or slicing, freezing or drying when leading to secondary products are also included.

• Although the term refers specifically to fish, in practice it is extended to cover any aquatic organisms harvested for commercial purposes, whether caught in wild fisheries or harvested from aquaculture or fish farming.

INTRODUCTION

Present market trends reflect a rapidly growing demand for ready to cook and ready to serve convenience products. Value addition can increase considerably the unit value of fish products and, hence, it is necessary to adopt modern technologies in processing of value added fish products and ensure food safety by adopting HACCP and ISO 9000 series.The increased demand for fish has prompted the development of many new preservation techniques which can be adopted by the fish processing industry without sacrificing safety, quality, shelf life and consumer satisfaction. The recent developments in technological equipments, products, packaging, preservation and quality control of fish and fish based products are briefly reviewed in the following sections.

TECHNOLOGICAL DEVELOPMENT IN FISH PROCESSING SECTOR

Upama dasM.Sc IF, 2nd sem

Ro-18SIF,CUSAT

Product development Meenu Jenny

Modernization in packaging Deleena NV

Advancement in quality control Remeesa Rafi

• Since prehistory, fish has been caught and eaten first by hominids (Australopithicus and Homo erectus) and then by men (Homo sapiens) (Stewart, 1994).

• Fish drying, smoking and salting were used to cure fish from very ancient times in different cultures.

• Fish salting and fish fermentation were already a flourishing integrated industry almost in contemporary terms (capture, farming, processing, packaging, transport and distribution) in the Roman Empire about 100 B.C. (McCann, 1988).

• Curing techniques have been revised and refined several times during the history of mankind and are still widely used.

• It is reported that salting herring onboard was introduced by the Dutch in the fourteenth century. This allowed longer fishing trips and reduced post-harvest losses, improving the production and economics of salted herring.

• Likewise, in the twentieth century, freezing trawlers and factory vessels were introduced to freeze and process fish onboard.

•Total world fish production- 167.3 MT

•Direct consumption- 146 MT, others used for non-consumption purpose.

•Per capita food fish supply- 20.1 MT

•Frozen- 30%•Dried-12%•Prepared and preserved form- 13%

GROWTH OF PROCESSING SECTOR IN INDIA

•Processing plants in India- 465

•Capacity- 20255 MT

•Cold storage- 479

•Kerala has the highest number of processing plants- 113

•9.45 MT seafood exported from India to USA (28.46%), South-east Asian countries (25%), Japan (8.6%)

DISPOSITION OF FISH CATCH - INDIA, 1991-2012

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

TOTALOTHERSUNSPECIFIEDMISCELLANEOUSOFFAL FOR REDUCTIONREDUCTIONCANNINGCURINGFROZENMARKETING FRESH

DISPOSITION OF FISH CATCH - INDIA, 1991-2012

Centre No Capacity (MT)Regional Office Kochi 99 3,005.71Sub Regional Office Quilon 14 417.30

Sub Regional Office Mangalore

36 2,155.13

Regional Office Mumbai 48 3,449.80Sub Regional Office Goa 14 900.46Regional Office Veraval 103 5,508.93Regional Office Kolkata 32 914.86Sub Regional Office BBSR 21 663.70

Regional Office Vizag 56 2,272.50Regional Office Chennai 9 163.15Sub Regional Office Tuticorin

33 803.60

Total 465 20,255.1

FrozenRegion-wise Processing Plants with Capacity as on 15/07/2014

COLD STORAGE

REGION WISE STORAGES WITH CAPACITY – AS ON 15/7/2014

CENTRE COLD STORAGE CHILLED STORAGE

DRY FISH STORAGE

OTHER STORAGE

TOTAL

NO CAPACITY NO CAPACITY NO CAPACITY NO CAPACITY NO CAPACITY

KOCHI 120 50210.00 1 861.00 2 19.00 2 41.00 125 51131.00

QUILON 24 6317.50 0 0.00 0 0.00 0 0.00 24 6317.50

MANGALORE 19 6298.50 0 0.00 9 2115.00 17 6329.00 45 14742.50

MUMBAI 47 31343.30 1 30.00 8 796.00 0 0.00 56 32169.30

GOA 13 4626.50 0 0.00 1 920.00 1 200.00 15 5746.50

VERAVAL 98 44728.80 3 1322.80 15 1370.00 4 259.00 120 47680.00

NEW DELHI 0 0.00 0 0.00 0 0.00 0 0.00 0 0.00

GUWAHATI 0 0.00 0 0.00 0 0.00 0 0.00 0 0.00

KOLKATA 35 5279.00 0 0.00 9 1040.00 1 60.00 45 6379.00

BHUBANESWAR 22 8458.00 17 7038.00 0 0.00 0 0.00 39 15496.00

VISHAKHAPATTANAM 60 21185.00 1 50.00 8 3346.00 0 0.00 69 24581.00

CHENNAI 10 6541.20 1 804.00 1 125.00 0 0.00 12 4470.20

TUTIKORIN 31 11476.20 5 1270.00 4 1775.00 7 812.00 47 15333.20

TOTAL 479 193464.00 29 11375.80 57 11506.00 32 7701.00 597 224046.80

• 1953 -First shipment of frozen shrimp was sent from the port of Cochin.

•Late 1960′s -The export of other varieties of Fish, Squid, Cuttlefish, Octopus, Crabs, Clams and Mussels started.

●A major stand in the Global Seafood Market and our seafood is one of the biggest foreign exchange earners.

●Today we have world class seafood factories following quality control procedures meeting the most stringent of international standards.

• We export mainly basic raw material for reprocessing to Japan whereas our exports to the United States consists of value added products for direct use in the American Food Service Industry and for retail sale in the supermarkets.

• Our seafood exports now include crabs, lobsters and other kinds of fish.

• We reached a peak export level of US$1.3 billion per annum in 2001 and subsequently the industry has stagnated due to recession and the after effects of Tsunami.

• The Indian Seafood Industry is compromised mainly of small and medium size family concerns and large corporate companies have almost no presence here.

• Investments •Existing 465 processing facilities in India.•Over 150 processing facilities have received

European Union approval.•What needs to be noted is that of the 30,000

crores exports, more than 50% is for shrimp aquaculture.

Technological change• Used in several different senses to describe

a variety of phenomena• Firstly, it refers to the effect of changes in

technology• It will improve human welfare quantitatively

through increase in real income• Technological progress include new process

of production, new goods, & new method of industrial organization

Methods used to preserve fish and fish products include• The control of temperature using ice,

refrigeration or freezing• The control of water activity by drying,

salting, smoking or freeze-drying• The physical control of microbial loads

through microwave heating or ionizing irradiation

• The heat treatment – canning, boiling, smoking.

…Methods used to preserve fish and fish products include•Drying •Salting •Smoking •Chilling•Freezing•Quick Freezing•Freeze Drying•Canning•Irradiation •High pressure processing

Quick Freezing• It is the process of rapidly freezing products.  In

fast freezing, small ice crystals form and good quality is maintained. 

• When meat is frozen slowly, large ice crystals form that break the fibers and cells. 

• Upon defrosting, these meats lose more juice and the texture is not good.  Although the meat loses quality, it is safe to eat. 

• Temperature just below 0◦C is the critical zone for spoilage by protein denaturation. 

• Quick freezing recommended that all the fish should be reduced from a temperature of 0◦C to -50◦ C in 2hours or less. 

IQF (Individually Quick Frozen) Food•The history of IQF technology has

started in the 1960s when the tray freezer appeared on the market.

•Since the 1970s, IQF freezers used a stainless steel type of mesh-belt to avoid the high air speed problem.

•In 1980s IQF freezers were provided with plastic belts which increased the quality of the frozen results.

The OctoFrost™ bedplates represent a remarkable technological progress in the IQF industry. (Sweden)

• OctoFrost™ has contributed to the evolution of IQF freezers by introducing the innovative perforated bedplates.

• The perforated bedplates ensure an active fluidization of almost 100% of their surface.

• Moreover, the diameter and shape of the perforated holes can be configured to provide excellent frozen results.

• Another advantage of the perforated bedplates designed by OctoFrost™ is that they are removable and can be efficiently cleaned outside the IQF freezer. http://www.octofrost.com

IQF (Individually Quick Frozen) Food• IQF (Individually Quick Frozen) equipment is used to

rapidly freeze individual pieces of fish before packaging.

• This process helps to preserve taste, texture and nutritional value in food.

• The reasons for availability of effective demand

i) hygienically processed and packaged

ii) properly retention of quality parameters in the packaged product

iii) recent advancement of technology in this field.

DIFFERENT TYPES OF FREEZERS

AIR BLAST FREEZER(IQF)• Tunnel freezer • Belt freezer or spiral freezer• Fluidized bed freezerContact freezer• Plate freezer

Horizontal plate freezer Vertical plate freezer

• Band freezer• Drum freezerSpray or Immersion freezerCryogenic freezer

GEA AY-series IQF tunnels can handle up to 25 tons per hour capacity

Higher YieldGentle product handling for sensitive productsSuperior IQF treatment with Long Wave Fluidization™Cost effective IQF treatmentOptimum energy consumption with -37°C/-35°F evaporating temperatureLower product dehydration with shorter freezing timeHygiene and reliabilitySuperior, industrial tough in-house built floor and enclosure designStainless steel constructionEasy cleaning and inspectionLarge access for ease of cleaning and maintenanceAll drive motors and fan motors externally mountedEasy, short installationModules pre-assembled in factory for short installation time

Tunnel freezer

• IQF as well as Block frozen product can be made

•Any size, any thickness•Temperature: -35◦C to -40◦C•Force of chilled air: 4-7 m/sec•Versatile application•Freezing time is longer•Poor heat transfer•Slow freezing process

Larger size of Tuna fish can be freezed.Freezing time: 5-8 hoursBelts move slowly

Spiral freezer

Produce IQF product70% of frozen products are shrimpFaster process

Fluidized bed freezer

Widely used in seafood industryProduct thickness should not be more than 60 mmFreezing time depends on product thickness and the type of refrigerants usedPlates can be moved by hydraulic systemCapacity depend upon the number of platesTemperature: -40◦C

Horizontal plate freezer

Used in onboard freezingTemperature: -30◦C to -40◦CLarger size of Tuna can be placedSashimi grade Tuna is produced

Vertical plate freezer

Features and Benefits

- Widths To Match Production Equipment - Both Top Loading and Front Loading - Easy to Clean - Hydraulic Top Lifting - In-line Operation - Production Flexibility - Quick Installation - Uses Very Little Space 

Cryogenic Immersion

Immersion freezer or spray freezer• It is mostly used for IQF products of small

size frozen within minutes.  The fish product to be frozen is in direct contact with the refrigerated liquid (freezant).  One type is brine freezing by immersing fish such as tuna in a tank of re-circulating cold sodium chloride brine at -150 C in a brine immersion freezer that may take about 3 days to freeze a large tuna completely. 

“The state-of-the-art factory is well equipped with facilities for processing Fresh Chilled, Blast /Tunnel Frozen, Plate Frozen and IQF Products {Raw, Balanced & Cooked } with a total freezing capacity of 43 metric tonnes per day and total storage capacity of 350 metric tonnes, with in house laboratory. The factory's locational advantages include nearness to the major fishing harbours for fresh raw material procurement, easy access to the sea port for shipment, close to the international airport to facilitate air shipments, good transportation and communication network, etc.’’

‘’Our modern computerized inventory and state of the art refrigerated warehouse provides you with safe wholesome seafood.”

‘’A modern processing plantIntegrated preprocessing centerSelf sufficient, in house ice productionCutting edge laboratory facilities &A large fleet of insulated trucks’’

Fish processing vessel• A factory ship, also known as a fish

processing vessel, is a large ocean-going vessel with extensive on-board facilities for processing and freezing caught fish. Modern factory ships are automated and enlarged versions of the earlier vessels and their use for fishing has grown dramatically. Some factory ships are equipped to serve as a mother ship.

• In the twentieth century, freezing trawlers and factory vessels were introduced to freeze and process fish onboard.

•Use of Refrigerated Sea water (RSW)•Use of Chilled Sea Water (CSW)

TECHNOLOGIES DEVELOPED BY CIFT

Solar Fish Dryers• CIFT has developed different models and capacities of

Solar Dryers for hygienic dying of fish.  Designs of solar dryer vary from very simple direct dryers to more complex hybrid designs.

• The hybrid model Solar Dryers are having LPG, Biogas, Biomass or Electricity as alternate back up heating source for continuous hygienic drying of fish even under unfavorable weather conditions.

• The capacity of these hybrid solar dryers varies from 6 sq.m to 110 sq.m tray spreading area for drying fish (capacity 10kg to 500kg).

 

Comparison of performances of different CIFT dryers, Fasludeen N.S. et al.

•Costly•Drawbacks•Uneconomical

Fish De-scaling Machine• The Central Institute of Fisheries Technology

(ICAR) has designed and developed a fish de scaling machine for removing the scales of fishes in batches. The operation of the machine can be extended for removal of scales from all types of marine as well as fresh water fishes.

• Trials conducted have shown that 98% of the scales can be removed using descaling machine.

Designed and fabricated different models of fish de-scaling machines. They are---

• Variable speed De-scaling machine, 10 Kg capacity, fitted with 1.5HP induction motor and a Variable Frequency Drive (VFD) to vary the speed of the drum depending on size/ variety of fishes

• Table- top De-scaling Machine, 5 kg capacity, with constant drum speed and

• Hand operated Low cost fish de-scaling machine.

Fish Meat bone Separator• An improved version of the Fish Meat Bone Separator was

designed and developed, especially suited for fin fishes with pin bones.

• The all stainless steel machine is powered with 3Hp constant torque DC motor with meat collecting drum of 204mm in diameter.

• A machine based on the new design has already been fabricated and supplied to College of Fisheries, Guru Angad Dev Veterinary and Agriculture Science University, Ludhiyana.

Countries with developed technology(from http://www.worldatlas.com, March 9,2016)

•China•Norway•Vietnam•USA• India•Canada•Chile•Sweden•The Netherlands• Indonesia

MODERN TECHNOLOGICAL EQUIPMENT IN PROCESSING INDUSTRIES

DRYER

DEFORSTING

The BAADER 1750 Spiral Tank is designed to suit various capacities. The system is made entirely of high-grade stainless steel, ready assembled without joints, crevices etc., allowing easy cleaning and a high level of hygiene.

Bleeding / chilling tank

Buffer / chilling tank

Customer Benefits:Large capacity possible

Efficient and gentleFully adjustable

Prepared for temperature control for inlet/outlet water

Advanced electrical control anduser friendly software system

Applications:

Buffer tank between two processing areas (e.g. killing, gutting and filleting) to ensure an even flow of fish throughout the processing plant.

Cooling tank to cool down the product or to keep it cool. For this application the water inlet and outlet temperature can be monitored.

Bleeding tank in case that the tank is used in combination with a stunning and bleeding system.

International DeliveryAir Freight ensures the product reaches its destination within a week of being dispatched from our cold storage facility. The maximum quantity per load via air freight is 1250kg.Refrigerated Shipping Containers deliver up to 24000kg of frozen prawn economically to its destination port in approximately 2 to 4 weeks.Domestic TransportRefrigerated road freight carriers, designed to keep frozen products at below -18°C can transport to most major cities in Australia quickly and economically.

As a guide –

“We can provide a quote for our products by the pallet landed to virtually any destination in the world.’’

Brisbane Overnight Sydney 2 Days Melbourne 3 Days Adelaide 4 Days Perth 7 Days

Australian Ocean King Prawns 

“Our fleet of six, modern EU accredited, steel vessels are all equipped with state of the art refrigeration systems and land a combined total of 300-400 tonnes of prawns per year.From the boat, the catch is transferred to our own commercial cold storage facility in Hervey Bay to ensure that product is handled and kept in ideal storage conditions (-25 degrees Celsius) at all times.’’

NO MACHINE NAME INTRODUCTION

01 Forming machine Raw material (Minced meat,Minced fish,Vegetables,Mixing food)

02 Battering machine(thin) After forming,thin battering,prepared for coating dry starch03 Preduster Coat starch for good taste,and more crisp.04 Battering

machine(thickness) Coat thickness batter05 Breading machine Coat bread on the cover of food,more crisp and good taste06 Frying production line Medium fried,then get into quick freezer07 Aircooling line Reduce the cover oil and lower the temperature08 Quick-freezer Get frozen prepared food then distribute09 Packing machine Pack frozen fried food then sell

FORMING MACHINE

Advantages1. Taking advantage of belt conveying and ingenious dropping system, our breading machine bypasses the potential damages to structures and shapes of Japanese style fresh bread crumbs. 2. Upper, lower belt and upper wire belt are controlled by variable frequency drive for easy and fast adjustment. 3. Our breading machine is fitted with strong air knife to blow off excess bread crumbs. 4. Electrical components are supplied by Siemens for maximized safety and reliability.5. Stainless steel non-metallic materials, which are used for fabrication of our breading machine, are complying with HACCP standards.

Breading Machine with Japanese Style Fresh Bread Crumbs

http://hiwellmachinery.com

MINCER

PIN BONE REMOVER

SEAC's brand new FPM-400 machine for nobbing and filleting small fish.

Fish Gutting and Filleting Machines

http://www.foodprocessing-technology.com

Exhauster

Seaming machine

Irradiation chamber

Sterilizer

Steaming chambers

Smoking oven

Conveyer belt

The features of microwave drying machine1.Fast heating speed: directly heat on the internal and external of material at the same time, do not need to preheat. While there must be a preheating process in the traditional production. 2. Heating evenly: microwave drying is completed through electromagnetic waves produced by magnetron.The internal and external of material will be heated at the same time . 3. Less nutrition loss: material just stay in the microwave heating box for a short time, and do not need air and steam to conduct heat, therefore can maximize keep nutrients in the material. 

GRT Fish Processing Machine/Industrial Fish Microwave Drying Equipment

4. Sterilization and alcoholization:The microwave drying equipment also have sterilizing and alcoholizing function. 5. Reduce the labor intensity, improve work efficiency 6. Friendly environment equipment 7.PLC automatic control can realize the data storage, output, printing. 8.Using non-contact infrared temperature measurement technology, high precision, simple control. 9.Compliance with national GMP certification requirements.

480 channels fish sorting machine Color sorter

High pressure processing• Although the Non-Thermal Pasteurisation

effect of high pressure on foods has been known since the 19th Century, it was not until the 1990´s that the first HPP products were developed.

• Since 2000, High Pressure Processing has been successfully implemented in all type of food industries worldwide.

YEAR 2000

..High pressure processing•One of the most successful developments made to date is High Pressure Processing (HPP).

•High Pressure Processing is a cold pasteurization technique which consists of subjecting food, previously sealed in flexible and water-resistant packaging, to a high level of hydrostatic pressure (pressure transmitted by water) up to 6000 bar / 87,000 psi for a few seconds to a few minutes. It is the same effect as subjecting the food to an ocean depth of 60 Km deep -if an ocean this deep existed.•Even the Mariana Trench should be covered 6 times to get the pressure used in HPP.

YEAR 2000

Advantages

•Natural, environmentally friendly process•Yeast and mold cannot survive in high pressure environment.•Minimal processing with no additives.•Helps maintain the fresh food characteristics like flavour and nutrients. •Real alternative to traditional thermal and chemical treatments.

Andreas Hernando had a plan to implement the high pressure processing method in food industry. Once he met with Mr. Jose, head of Nicholas Korea group, who liked Andreas Hernando’s idea of HPP. So the process came in commercial use in the year of 2000. thus Hiperbaric came in existence.

HIPERBARIC 55

HIPERBARIC 120

HIPERBARIC 135

HIPERBARIC 300

HIPERBARIC 420

HIPERBARIC 525

HIPERBARIC 525 new

PACKAGING EQUIPMENTS

Singapore Fish Processing Company's 1st Choice Of

Thermoforming Packaging Machine

Features: Sealing temperature, conveying speed, vacuum extraction time and gas flushing time are adjustable.Adopt security warning systems (e.g., overload protection).Order-made is available.ApplicationDZQ-210H series semi automatic tray vacuum gas flushing packaging machine is suitable for all kinds of plastic trays, used to pack various products (fresh food in supermarket, fast food and student’s snack), of which the height is the same or lower than their trays. 

VACUUM GAS-FLUSHING PACKAGING MACHINE

http://www.acefinepack.com

Features: The machine is suitable for shrink packing both single object and combined object.Application:1. Shrink packing for many industries, such as printing, pharmacy, floor, chinaware, beverage, beer etc.2. It’s suitable for all kinds of shrink films such as PVC, POF, PP , PE etc TF6540S

A+5540M

http://www.acefinepack.com

A conveyor system is often the lifeline to a company’s ability to effectively move its product in a timely fashion. Increasing the service life of your conveyor system involves: choosing the right conveyor type the right system design and paying attention to regular maintenance practices. A conveyor system that is designed properly will last a long time with proper maintenance. With years of experience and know-how in the industry , we are developing and building systems that convey your product the latest technology. Some applicable industries: Cosmetic Beverage Pharmaceutical Printing and many more………

CONVEYOR SYSTEMS

http://www.acefinepack.com

 One or multiple-ways conveyors Rotating Platform Accumulation Tables Delaying Devices Gravitational, Motorized and Friction rollers PU Belt Conveyors Slat Belt Conveyors Modular Chain Conveyors

OPTIONS..

Expansion Financial Assistance Schemes

• Purpose of acquisition of all types of fish processing machinery for production of value added marine products.

•Modernization of infrastructure and processing facilities & quality upgradation

…ExpansionTechnology Upgradation Schemes for Marine

Products (TUSMP):

• Encouraging the production and export of Value Added products from the country.

• Eligible for a maximum of ` 1.5 Crore as subsidy

…ExpansionFinancial assistance for setting up of new

ice plants/renovation of existing ice plants.

• Setting up of independent ice plant is encouraged

• The quantum of subsidy for stainless steel components is @ 25% subject to a maximum of ` 31.00 lakh in the case of new units,

• 14.00 lakh for Flake/ Chip/ Tube ice units and • 26.00 lakh for renovated unit.

…ExpansionFinancial Assistance for Creating Basic Facilities for Dried

Fish Export.• This is a new scheme approved by the Ministry on

27.8.2009. • Objective - to promote effective utilization of low value fish

by dried processing for export hygienically and• To upgrade the quality of dried fish exported for higher

value realization and • to encourage the dry fish exporters to pack and store the

dried fish hygienically. Financial assistance is extended for both the schemes @ 33⅓ % of the actual cost incurred.

• There are two components under this scheme. Scheme – A: Assistance for the setting

up of dried fish handling/curing/solar drying facility (with LPG back up). The maximum eligible subsidy for fish curing, drying facility will be ` 23.50 lakh per beneficiary.

Scheme – B: The scheme is exclusively for providing assistance to the dried fish exporters registered with MPEDA for the setting up of dried fish packing and storage facility. The maximum amount of assistance is limited to ` 8.25 lakh per unit or 33⅓% which ever is less.

…ExpansionSetting up of Common Pre-processing Centres.

• A grant of `526 lakh for establishing two Common Preprocessing Centres which are being set up at Ambalapuzha in Alleppey District and Sakthikulangara in Kollam District of Kerala.

• Both the projects has been completed in 2010-11.

Pollution control

India’s Green Common Effluent Treatment Plant upgrades its aeration system

Economic development- a comparison between developed and developing countries• Fish as food is, like any product, dependent on

supply and demand, but people, particularly in developing countries, often tend to be more production- (supply) oriented than demand- (marketing) oriented and this can lead to bad investment and consequent losses.

• Food price and quality• Increase in the number of working person• Developed machineries• The large volume of discards and by-catch losses

Economic development•Less labour•Capital intensive•Less idle time•Less wastage•More production•Technological supervision and result•Low cost of production•Faster production•High profit•Quality product•Fulfilling consumers’ demand in some

extent

References • FAO journals• CIFT technological divisions• CIFT annual reports• MPEDA annual reports • http://www.worldfishing.net• http://www.foodprocessing-technology.com• www.chinafoodmachinery.com• http://hiwellmachinery.com• www.superocean.net • http://www.hiperbaric.com• www.oceanking.com• www.aireo2.com• http://www.trade-seafood.com• www.alibaba.com• ADVANCES IN HARVEST AND POST-HARVEST TECHNOLOGY OF

FISH, PROF. D. D, NAMBUDIRI• FISHING CHIMES• K. BALACHANDRAN, POST HARVEST TECHNOLOGY OF FISH

FISHERY PRODUCTS AND

THEIR DEVELOPMENT

It is evident that fish processing starts fromancient periods (11,700 years ago)

Objective of processingTo prevent fish from

deteriorating

Different processing methods

•Temperature reduction(chilling & freezing)•Heat treatment( canning, boiling& smoking)•Reduction of available water (drying, salting &smoking)•Changing the storage environment(packaging, refrigeration)

FISH UTILIZATION AND PROCESSING (WORLD DATA)•The share of world fish production utilized for direct

human consumption has increased.•67%- 1960s•87%- 2014(146 million tonnes)•Remaining 12% (21 mt)-Non food products

76%(15.8 mt)-fish meal & fish oil 24% -utilized for

▫Ornamental purposes▫Culture activities▫Bait▫Pharamaceutical uses

FAO

...FISH UTILIZATION AND PROCESSING (WORLD DATA)Direct human consumption•46% (67 mt)-live,fresh or chilled fish•30% (44 mt) frozen form•13%(19 mt) prepared or preserved form•12%(17 mt) dried ,salted ,smoked & other cured

forms

...FISH UTILIZATION AND PROCESSING (WORLD DATA)•Latin American countries produce the highest percentage

of fishmeal. • In Europe and North America, more than two-thirds of

fish used for human consumption is in frozen and prepared and preserved forms.

•Africa’s proportion of cured fish is higher than the world average.

• In Asia, much fish is still commercialized in live or fresh forms. Live fish is particularly appreciated in Southeast Asia and the Far East (especially by the Chinese population) and among immigrant Asian communities.

FAOTHE STATE OF WORLD FISHERIES AND AQUACULTURE 2015-2016

...FISH UTILIZATION AND PROCESSING (WORLD DATA)• In recent decades, major innovations in refrigeration, ice-

making and transportation have allowed a growing distribution of fish in fresh and other forms. ▫25% in 1960s increased to 57% in 2014 in usage

of frozen products•Proportion of prepared or preserved form

remained stable-27% in 2014 alsoThe innovations in value addition, together with

changing food habits are converging on convenience foods and a wider range of high value added products

Indian scenario• India's seafood industry has become one of the leading suppliers of quality seafood to all the major markets of the world.

• India has world class seafood processing plants that follow quality control regimes complaint to stringent international regulatory requirements.

• In 2015-2016 the export industry shows a declining trend from US$ 5511.12 millionin 2014-2015 to US$ 4687.94 million in 2015-16

• Frozen shrimp contributes the major proportion 66%(US$ 3096.68 miillion)

• But it also shows a reduction from previous year (US$ 3709.76 millions)

Item wise export statistics from MPEDA(2010-

2016)

Item 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16

Fr. Shrimp Quantity in ton 151465 189125 228620 301435 357505 373866 Value in Crore 5718.13 8175.26 9706.36 19368.3 22468.12 20045.5 US$ Million 1261.81 1741.2 1803.26 3210.94 3709.76 3096.68Fr.Fin Fish Quantity in ton 312358 347118 343876 324359 309434 228749 Value in Crore 2623.89 3284.15 3296.86 4294.81 3778.5 3462.25 US$ Million 583.48 683.5 617.59 708.63 619.66 529.85Fr.Cuttlefish Quantity in ton 59159 54671 63296 68577 82353 65596 Value in Crore 1104.57 1346.72 1354.28 1386.98 1833.21 1636.11 US$ Million 244.62 282.72 251.54 228.13 300.69 250.31Fr. Squid Quantity in ton 87579 77373 75387 87437 69569 81769 Value in Crore 1010.57 1228.19 1378.08 1731.97 1275.25 1615.21 US$ Million 223.67 262.72 256.9 284.6 209.84 247.53Dried items Quantity in ton 79059 53721 72953 67901 70544 43320 Value in Crore 954.94 562.65 819.9 998 1010.16 725.58 US$ Million 212.22 117.66 152.81 167.89 165.52 111.57Live items Quantity in ton 5208 4199 4373 5080 5488 5493 Value in Crore 142.15 154.61 197.89 281.85 301.51 308.81 US$ Million 31.46 32.46 36.82 46.7 49.62 47.77Chilled items Quantity in ton 21118 21278 26868 19755 31404 33150 Value in Crore 257.54 357.42 537.11 527.84 635.93 809.5 US$ Million 56.93 74.03 99.87 88.48 104.71 124.51Others Quantity in ton 97145 114538 112841 109212 124947 113949 Value in Crore 1089.67 1488.24 1565.78 1623.5 2138.94 1817.87 US$ Million 242.72 314.16 292.86 272.34 351.31 279.71Total Quantity in ton 813091 862021 928215 983756 1051243 945892 Value in Crore 12901.47 16597.23 18856.26 30213.26 33441.61 30420.83 US$ Million 2856.92 3508.45 3511.67 5007.7 5511.12 4687.94

Export price in India(in rupees)Species 1997-98 2007-08 2014- 15 2015-16

Ribbon fish 27 52 87 110

Pomfret 172 228 358 372

Tuna 38 58 84 102

Mackerel 40 64 107 135

Sardine 34 21 40 72

Seerfish 67 133 396 385

Squids 75 118 198 210

Cuttle fish 84 160 202 218

Shrimps 292 297 542 544

Source:Cmfri annual report 2015-16

Traditional processing techniques

CuringDryingSmokingSaltingPicklingFermentation

Cured products

Dried products Dried fish Dried and salted fish Dry-salted and smoked fish Brined and smoked fish

Dried fish

Beche-de-mer

Smoked products

Lox

Arbroath smokie

Bokkoms

Kipper

Cakalangfu

Caviar

Finnan haddock

katsubushi

Fermented products

Bagoong

Bottarga

Chepa shukti

Ngari

Trassi

Balao balo

Burong isda

Freezing •Freezing, or solidification, is a phase

transition in which a liquid turns into a solid when its temperature is lowered below its freezing point.

•It made a revolutionary change in fish processing field

•In 1861 USA made first assignment for frozen fish

Frozen fishery Products Frozen Fishes Frozen reef cod gutted

whole round

Frozen IWP /IQF(Individually Wrapped Portions/Individually Quick Frozen)

Sole fish , Seer fish, Indian mackeral ,Croakers,pomfrets

Frozen pan ready croaker

Ribbon fish Whole, Headless, Tailless, gutted Whole, Tray packed Steaks

Shrimp products•Whole shrimp

Butterfly cut

Cooked & peeled shrimp

Cooked tail on shrimp

Easy peel shrimp

Headless shrimp

Peel & eat shrimp

Peeled & deveined cooked shrimp

Peeled & deveined shrimp

Peeled & undeveined shrimp

Peeled & undeveined tail on shrimp

Peeled & deveined tail on shrimp

Squid productsAFD(accelerated freeze drying) squid

IQF squid tentacles

Frozen squid fillet

Frozen squid whole

IQF squid ring

Frozen squid whole cleaned

Cuttle fish products

•Frozen cuttle fish deskinned•Frozen cuttle fish blanched•Frozen cuttle fish wings•Frozen cuttle fish meat•IQF cuttle fish tentacles•Frozen cuttle fish beak•AFD(Accelerated freeze drying) cuttle fish

Frozen cuttle fish whole round

IQF cuttle fish whole cleaned

IQF cuttlefish strips tray pack

Cuttle fish fillet pine cut/diamond cut

Frozen baby cuttle fish tray pack

Frozen cuttle fish roe

Lobster •Rock lobster whole •Lobster meat•Frozen sand lobster•Deep sea lobster whole cooked•IQF lobster products

Cooked rock lobster

Lobster tail

Crab •Chilled crab•Frozen whole crab•Frozen cut crab without claw•Frozen cut crab with claw

Live crab

Pasteurized crab meat

Frozen stuffed crab

Octopus •Frozen cleaned octopus•IQF baby octopus•Frozen octopus tray pack•IQF whole cleaned octopus

Frozen octopus

Frozen baby octopus

IQF octopus cut & cooked (v cut)

IQF octopus tentacles

Scampi •Farmed head on•Farmed headless•Farmed cooked easy peel•Farmed deep cut

Surimi It is a wet frozen concentrate of

myofibrillar proteins of fish muscle. It is deboned,washed and stabilized fish mince

•For making surimi we use Lizard Fish, Big Eye Tuna, Reef Cod, Japanese Thread Fin Bream, Croaker ,Ribbon Fish.

•The products prepared using surimi are:

Crab bite imitation crab flake

Imitation crab stick (solid)

Imitation shrimp

Imitation lobster

Surimi crab claw breaded & battered

Value-added products•H/L SQWC skewer•CFWC ,PD shrimps•IQF squid tentacles & shrimp•Fish soup powder

• CFWC skewer(cuttle fish whole clean)

•Frozen mussel•Clam meat pickle•Fish curries•Prawn curries•Prawn spring rolls

Fish flakes

Prawn Dim Sum

Coated seafood

Frozen whelk

Breaded shrimps

Fish wafers

Battered Fish fingers

CFWC shrimps SQWC skewer

Cuttle fish fillet roll

Prawn gyoza

Fish filletGhol fish, sole fish, snapper,reef cod

Shrimps burger patty

Fish steaksSeer fish, snapper,barracuda

SQWC skewer(squid whole clean)

Squid fillet skewer

Stuffed squid with shrimp

Frozen clam

By-products •Pearl essence

•Surgical sutures

•Fish liver oil

Shark fin rays

fish maws/isinglass

Ambergris

Squalene

Chitin

Chitosan

Products in other countries

Contd….Vietnam products

Crab fraci Curry fish spring roll Lobster dumpling

Pangassius fish ball

Constraints In global view

• The developing countries, still lack▫ adequate infrastructure ▫ hygienic landing centres, ▫ reliable electricity supply, ▫ potable water, roads, ▫ ice, ice plants,▫ cold rooms, ▫ refrigerated transport ▫ appropriate processing and storage facilities.

• High post –harvest losses and quality deterioration in tropical temperatures▫ In Africa, some estimates put post-harvest losses at 20–25%, and even up to

50%. ▫ The estimates shows that 27% of landed fish being lost or wasted between

landing and consumption. • Globally, if discards prior to landing are included, fish losses and waste

amount to 35% of landings, with at least 8% of fish being thrown back into the sea, and hence not utilized.

Constraints in India•Lack of diversified raw material•Lack of skilled labours for production of

value-added products•Lack of machineries and infrastructure•Stringent quality control for products

Recent develpoments in fishery products• Fibre-rich seaweed (Caulerpa racemosa and Ulva

lactuca) incorporated semi-sweet biscuits and extruded snack product was developed.

• A prototype mould for the preparation of shrimp analogue product from fish mince was frabricated and analogue prepared.

• Microencapsulated fish oil with fish protein hydrolysate

• Tuna protein hydrolysate-incorporated health drink was formulated.

• Thermal processing of dolphin fish in brine medium• Preparation of low sodium dried fish products

reference•Mpeda www.mpeda.gov.in/•CMFRI annual report 2015-16•The State of Food and Agriculture 2016 |

FAO•CIFT annual report 2015-16

Developments in quality

control

Remeesa rafim.sC if

Roll no 11

INTRODUCTION•Quality is generally considered as the

degree of excellence.•In relation to seafood, quality is the sum

total of its composition, nutritive value; degree of freshness; physical damage; deterioration while handling, processing storage, distribution and marketing; hazards to health; satisfaction on eating and yield and profitability to the producer and the middleman

▫Quality control, in case of seafoods, means all the steps taken between harvesting and retail trade to protect the quality of the final product.

▫ISO 9000 defines quality control as "A part of quality management focused on fulfilling quality requirements“

▫Controls include product inspection, where every product is examined visually, and often using a stereo microscope for fine detail before the product is sold into the external market. Inspectors will be provided with lists and descriptions of unacceptable product defects such as cracks or surface blemishes for example.

HISTORY OF QUALITY CONTROL AND INSPECTION SYSTEMS IN INDIA.

• When India started exporting frozen seafood in 1953, there was no scientific quality control system prevailing.

• Later, Govt. of India decided that the consignments exported from India have to meet certain pre-determined and specified standards of quality.

• Compulsory pre-shipment inspection of frozen shrimps was introduced on 15' September 1964 (Iyer, 1990) as per the provision of section 6 of the export (Quality control and Inspection) Act 1963.

• According to this system of inspection, the exporters willingly subjected their products to prescribed standards.

• Then, the export of marine products was brought under compulsory inspection system with effect from 15"‘ March 1965.

• In 1969, the scheme was taken over by Export Inspection Agency (EIA). Bacteriological requirements were added in 1975 (Nair, 1995b).

HISTORY OF QUALITY CONTROL AN INSPECTION SYSTEMS IN

INDIA. • There were mainly four objectives for this inspection system. They were, • (i) to ensure that the product had been prepared from quality raw material and it had

never been grossly contaminated,• (ii) to ensure that product was absolutely free from pathogens or toxins of public

health significance, • (iii) to ensure that the product was processed under ideal conditions., and• (iv) to ensure that the product would have a reasonably extended shelf life (Iyer,

1990).• In the consignment inspection, for a commodity to be inspected under this system, the

exporter applies to the EIA for inspection and issue of export certificate.

• The inspection agency carried out inspection adopting laid—down techniques to ascertain whether they met the prescribed standards. Based on the inspection results, certificate of export worthiness was issued by the EIA Mathen (1979) reported that at least 10 percentage of the products were found to be substandard.

• The end product might have been produced to the notified requirements and it cannot enquire into the conditions under which these products had been manufactured

IN PROCESS QUALITY CONTROL•With a view to make the quality control

and inspection scheme more meaningful and effective, it was felt imperative that, in addition to the end product inspection, the processing plants should be encouraged to adopt Good Manufacturing Practices.

•Accordingly, Govt of India introduced the In-process Quality Control (IPQC) scheme for processed seafood with effect from 31/12/1977

• In 1977, a revised notification was introduced stipulating various requirements to be implemented by the processing units for ensuring hygiene and wholesomeness of the product.

• Under the provisions of the notification of the In-process Quality Control (IPQC) scheme of fish and fishery products, a panel of experts had been constituted to assess the facilities prescribed therein.

• Based on the recommendations of the panel (1 member each from EIA, CIFT, MPEDA, BIS and the Industry), the units were declared as approved or non-approved; Iyer (1990) to qualify for such an approval, the processing units must have the minimum sanitary and hygienic facilities and the Inprocess Quality Control checks in different stages of processing.

• Under the scheme, the following procedures of inspection were being followed. A day’s

production constituted a control unit having more subunits depending up on the type of the product.

• Those of the lots which met the laid down standard were treated as approved lots (Majumdar, 1935).

QUALITY CONTROL INSPECTION IN APPROVED UNITS (QCIA) AND MODIFIED INPROCESS QUALITY CONTROL (MIPQC)

• This modified system of IPQC scheme was introduced as per the notification of Government of India dated 9.4.1988.

• The IPQC system was re-titled as Quality Control Inspection in Approved Units (QCIA). Another change was the introduction of a new system- Modified In-process Quality Control (MIPQC) scheme.

• For the approval under this system of inspection, it is the sole responsibility of processors themselves to exercise total surveillance of their units under the guidance of Export Inspection Agency to ensure organoleptic and bacteriological quality of the product.

• However, in the case of all the above systems of inspection, the Export Inspection Agency issues certificate of export worthiness.

• The Pre-Shipment Inspection and Quality Control manual published by EIA from time to time gives the instructions and procedures to be followed under this scheme (Anon, 1985).

• Subsequent to the rejection of a few tonnes of Indian shrimps by Japanese Quarantine Authority due to the contamination of cholera genns, Vibrio cholerae detected in frozen shrimp consignments exported to Japan more stringent measures were taken by the EIA (Majumdar, 1985).

• Modified In-process Quality Control scheme is re-titled as In Process Quality Control, under this scheme. Only those processing units already approved under QCIA system and have some additional infrastructure facilities are allowed to export (Iyer, 1990 ).

ISO 9000 SERIES•ISO 9000 :Explains fundamental quality concepts and provides guidelines for the selection and application of each standard

•ISO 9001 :Model for quality assurance in design, development, production, installation and servicing.

•ISO 9002 :Model for quality assurance in the production and installation of manufacturing systems

• ISO 9003 :Quality assurance in final inspection and testing.

• ISO 9004 :Guidelines for the applications of standards in quality management and quality systems

HACCPH-HazardA-AnalysisC-CriticalC-ControlP-Point

HAZARD ANALYSIS CRITICAL CONTROL POINT (HACCP)

Is a prevention based safety program that identifies and monitors the hazards associated with food production.

Is designed to anticipate and control problems before they happened.

It provides the most effective and sufficient way to ensure that food products are safe.

HACCP implementation12 codex steps 1. Assemble HACCP team2. Describe product3. Identify intended use4. Construct flow diagram5. Onsite confirmation of flow diagram6. Conduct hazard analysis7. Establish CCP8. Establish critical limit9. Establish monitoring procedures10. Establish corrective actions in case of deviations11. Establish verification procedures12. Establish documentation & record keeping procedures

BENEFITS OFFERED1. To the company

Production of safer food-lower business risk Improved maintained reputation Staff have clearer areas of food safety requirements and

practices Demonstrates company’s commitment to food safety

2.To the customer Less risk of illness Improved quality of food Greater confidence in food

3.To the government▫facilitate easy food safety inspection▫More efficient food control

7 PRINCIPLES OF HACCP•Principle 1- Hazard Analysis

▫this involves identifying hazard that might be introduced to food by certain food production practices

▫ hazards- (biological, chemical, and physical) are conditions which may pose an unacceptable health risk to the consumer

…7 PRINCIPLES OF HACCP•Principle 2- Identify Critical Control Points (CCPs)•CITICAL CONTROL POINT(CCP)

-is an operation (practices, preparation step, or procedures) in the flow of food which will prevent, eliminate, or reduce hazard to acceptable level

-it provides “kill step”(destroys bacteria) or a control step”(prevents or slows down the rate of the bacteria

…7 PRINCIPLES OF HACCP•Principle 3- Establish the Critical limits (thresholds)

Which must be met at each Critical Control Point• Critical Limits-it must be specified and validated if

possible for each Critical Control Point. In some cases more than one critical limit will be elaborated at a particular step

…7 PRINCIPLES OF HACCP•Principle 4-Establish Procedures to Monitor CCPs•Monitoring

Is a critical part of the HACCP system and provides written documentation that can be used to verify that the HACCP system is working properly

is a planned sequence of measurements or observations to ensure the product or process is in control (critical limits are being met).

Is necessary to ensure that the process is under control at each critical control point

…7 PRINCIPLES OF HACCP•Principle 5- Establish the Corrective Action to Be

Taken When Monitoring Shows That a Critical Limit Has Been Exceeded

•1st. Determine what went wrong•2nd. Choose and apply the appropriate corrective

action

…7 PRINCIPLES OF HACCP•Principle -6 Record keeping•The HACCP system requires the preparation and

maintenance of a written HACCP plan together with other documentation.

•This must include all records generated during the monitoring of each CCP and notations of corrective actions taken.

• Usually, the simplest record keeping system possible to ensure effectiveness is the most desirable.

…7 PRINCIPLES OF HACCPPrinciple -7 Verification •Verification has several steps. The scientific or

technical validity of the hazard analysis and the adequacy of the CCP's should be documented. Verification of the effectiveness of the HACCP

TOTAL QUALITY MANAGEMENT (TQM)•WHAT IS TQM?•Meeting quality expectations as defined by the

customer• Integrated organizational effort designed to improve

quality of processes at every business level• During the development and manufacture of the

product, various departments and sections of the company make their contribution in building quality

• According to Sadgrove (1996), Total Quality Management is a blue print for tomorrow’s business.

• It improves quality, boosts productivity and cuts costs.

• TQM companies are twice as profitable as ordinary firms.

•TQM increases customer satisfaction by boosting quality

SANITATION STANDARD OPERATING PROCEDURES (SSOP)• Sanitation standard operating procedure (SSOP) develops the basics

for maintaining a good facility that has a clean, sanitary environment that is free from hazard.

• Before developing a HACCP plan, it is essential to have a sound base of good hygienic and manufacturing practice. This means that all basic hygienic practices, encompassing facilities and operation, need to be in place and operating effectively.

• Sanitation standard operating procedures (SSOPs) are written procedures that an establishment develops and implement to prevent direct contamination or adulteration of product.           

…SANITATION STANDARD OPERATING PROCEDURES (SSOP)

• The establishment must also maintain daily record sufficient to document the implementation and monitoring of the SSOPs and any corrective action taken.

• The establishment is required to maintain these written procedures on file, and they must be available for inspection.

• If the establishment or inspection agency feels that the SSOPs fail to prevent direct contamination or adulteration of products, the establishment must implement corrective actions that include the appropriate disposition of product, restoration of sanitary conditions, and measures to prevent recurrence.

• Some hazard that cannot be effectively controlled by CCP’s, can be effectively controlled by procedure which control sanitation. These controls are called sanitation control procedure or SOP’s.

SSOP Scope

• SSOP sections are based on eighth FDA key sanitation conditions. Those sections as follows:

• 1. Ice and water safety, used on fish processing. Water, used on fish processing, get from safe sources and it manage with good system.

• 2. Condition and cleanlines of equipments surface that are directly contact to product have to clean and sanitize, including gloves, work dress etc

• 3. Cross contamination control.

• 4. Hand washing (hand sink), sanitizer and toilet. Toilets have to complete with door and clean at the end of processing. Hand sink should complete with wáter, soap and towel.

• 5. Product protection from packaging materials.

• 6. Labeling, storing and material using based on instruction. Sanitizer, oil, and pesticide and toxic chemical have to complete with label and store on special room.

• 7. Worker health control. When the workers work on factory, they have to clean and healthy.

• 8. Pest controlling on factory environment using chemical substances, environment should be clean from pest.

MOST SIGNIFICANT ACHIEVEMENTS BY CIFT• Exclusive presence of enterohaemorrhagic Escherichia coli O157:H7 and Yersinia enterocolitica in seafood sourced from local fish markets revealed cross contamination from animal meat.

• Among pathogens, highest prevalence was recorded for E. coli (25%), followed by Salmonella (18%), Vibrio parahaemolyticus (15%), Listeria monocytogenes (2%), Aeromonas hydrophila (1.2%) and V. vulnificus (0.87%).

• In salted and dried fishery products, Staphylococcus aureus was detected as the major contaminating pathogen. A moderate level (23.8%) of the isolates were capable of producing enterotoxin.

• Application of lytic bacteriophages for control of Salmonella and Listeria in seafood processing was evaluated. A minimum exposure time of 2.5 hours was optimized to bring down surface contaminated Salmonella in tuna products by 6 logs and 5 logs for cooked clam meat.

• Recontamination potential of Salmonella in cooked and raw shrimp products was assessed. Higher recovery (67.04%) and higher survival (95-100%) of Salmonella typhimurium was recorded in cooked and frozen shrimp (L.vannamei) compared to raw product.

• LC-MS/MS method for determination of 160 pesticides in fish and fishery products and simultaneous analysis of tetracycline and sulphonamide antibiotic residues in shrimp were developed.

• Surveillance sampling and root-cause analysis of export rejections was carried out for hazards like Salmonella, Crystal violet, Coliform and L. monocytogenes for various seafood establishments and mitigation measures were suggested.

• Biogenic amine build up in high pressure treated tuna was modelled for predictive analysis during subsequent chilled storage conditions.

Expansion• QUALITY CONTROL.• Quality control is a very vital element in the seafood industry. MPEDA has a mandate to

take such steps to improve the quality of seafood exported from the country. The MPEDA is oriented towards strengthening the seafood industry to produce internationally acceptable quality fishery products for export market. An outline of the work done by the MPEDA during 2009-10 is given below: -

1: Subsidy for setting up of mini laboratory.• For the effective implementation of in-process quality control, MPEDA assists the

processing plants to set up their own quality control laboratories by subsidizing 25% of the cost subject to a maximum of ` 1,50,000 per unit. During 2009-10, an amount of ` 10.01 lakh was sanctioned as subsidy assistance to 13 processing plants.

2: Assistance to seafood processors to establish captive / independent preprocessing plants with upgraded facilities.

• The scheme aims to bring the pre-processing activities under the control of processors and to upgrade the facilities as per HACCP and EC Regulations. The subsidy assistance is 50% of the actual expenditure with a ceiling of ` 15 lakh for new construction and 45% of the actual expenditure with a ceiling of ` 13.5 lakh for renovation, which is also linked with the area of the pre-processing hall. The maximum limit for independent pre-processing centers is ` 22 lakh. During the year 2009-10 an amount of ` 177.15 lakh was sanctioned to 19 units (12 Captive and 7 Independent, including additional subsidy to 4 units).

…Expansion3: Assistance for upgradation of seafood plants to EU

standards.4: Setting up of labs with ELISA in Andhra Pradesh.• As a measure to contain the presence of banned antibiotics

in the farmed shrimp, it has been made mandatory that all the processors are required to source aquaculture shrimp only after the same is subjected to screening tests. In order to facilitate the pre-harvest screening, MPEDA has set up 16 labs with Elisa reader with 6 such labs in the state of Andhra Pradesh, which is the major centre producing aquacultured shrimp. The remaining testing facilities (ie.10 nos.) have been set up in other states, where farming activities are prevailing. All the labs are in operation

•Shassi.s Development of total quality management system in seafood (freezing) industry in kerala. https://dyuthi.cusat.ac.in•MPEDA- QUALITY CONTROL http://mpeda.gov.in/MPEDA/quality_standards.php•CIFT ANNUAL REPORT 2015

REFERENCE

PACKAGING OF FISHERY PRODUCTS

PACKAGING•Fish is an extremely perishable food and should be handled with great care•Fish quality deteriorates rapidly and potential life is reduced if they are not handled and stored properly•Fish must be refrigerated or frozen

immediately after landing to prevent microbial deterioration

•The quality/type of packaging materials and the method of packaging are, therefore, of great importance for preserving the quality of fish.

• Fish and fish products can be grouped into fresh fish, frozen fish, canned fish, dried fish and other value added fish products.

•Each category requires special packaging materials and different handling procedures

AIMS OF PACKAGING•Packaging should protect the product

from contamination and prevent it from spoilage, and at the same time it should:

• - extend shelf life of a product•- facilitate distribution and display•- give the product greater consumer

appeal• - facilitate the display of information on

the product

Traditional packaging materials•bamboo baskets• wooden boxes •second hand plywood cases• gunnies •palmyrah leaves• screw pine mats

•packaging of fresh and processed fish for local markets and to a limited extent for the export trade

•The next big change in the packaging industry was brought about by the development of plastic.

•This resulted in the development of many new types of packaging products including plastic bottles, jars, tubes, drums, crates, injection moulded tubs, thermoformed trays and a wide range of packaging films.

•Tin plate which is a very commonly used material is now indigenously manufactured, although tin is still imported.

•Traditional glass containers have a very wide application in the field of packaging. These are presently available to the packers in a variety of shapes, designs and colours (Vaziralli, 1974).

•Aluminium is yet another material which is used in large quantity in packaging industry.

Packaging materials•PAPER A very considerable proportion of

packaged foods is stored and distributed in packages made out of paper or paper based material.

•PAPER BOARD Thicker paper is called as paper board.

There is not a clear cut dividing line between the heaviest grade of paper and the lightest board.

Packaging materials

•CELLOPHANES Cellophane was the first commercial

film. By incorporating various coatings and modifications, over 100 different grades of cellophane are available now.

POLYPROPYLENE - (PP) Polypropylene is produced by the polymerization of propylene

Packaging materials•POLYETHYLENE (PE) Polyethylene is the

largest volume single film used in the flexible packaging industry. It is available in 4 forms: (1) Low density

(2) Medium density (3) High density (4) Shrink film

INDUSTRY IN INDIA•In the year 1990-91 India exported

1,34,598 tonnes of frozen prawns, fish and cuttle fish together employing 6.73 crores of waxed duplex cartons, as many as 6.78 millions of corrugated fibre board, and 419 tonnes of plastic materials in the form of film. The approximate expenditure on packaging is estimated to be around 11 crores of Rupees.

Modern packaging methods

Modified atmospheric packagingActive packagingAseptic packagingShrink packagingVacuum packagingThermal processingRetort pouch packaging

Modified atmosphere packaging

•MAP, a technologically viable method has been developed as a supplement to ice or mechanical refrigeration to reduce the losses and extend the storage life of fresh fish/food products.

•Air is replaced with different gas mixtures (Carbon dioxide= >20%, Nitrogen, Oxygen = <0.5%) to regulate microbial activity and to retard discoloration of the products. Temperature is kept below 5◦C.

Modified atmosphere packaging

CO2

• the most important gas used in MAP of fish, bacteriostatic • inhibits growth of many spoilage bacteria• the inhibition is increased with increased CO2 concentration in the

atmosphere

O2• set as low as possible to inhibit the growth of aerobic spoilage bacteria.

Its presence is reported to increase oxidative rancidity• High levels of oxygen are used in red meat and red fish meat (tunas,

yellowtails, etc.) to maintain the red colour of the meat.• inhibit reduction of TMAO to TMA

N2• an inert and tasteless gas, and is mostly used as a filler gas in MAP,

because of its low solubility in water and fat. • replace O2 in packages to delay oxidative rancidity• inhibit growth of aerobic micro-organisms, as an alternative to vacuum

packaging

Active packagingIt is a technique used for extending the shelf-life of seafood or fresh foods by addition of active agents that absorb or release a compound in the gas phase.Active agents can be useful in a package, such as oxygen or carbon dioxide scavengers, moisture absorber and oxygen or carbon dioxide emitter.It can also be used to reduce O2 in high fat products to prevent chemical deterioration e.g., oxidative rancidity and aerobic microbial spoilage.

Aseptic packagingAseptic packaging is the final step in

aseptic food processing, in which food products are continuously sterilized, ensuring that no microorganisms—which cause either food decay and/or food poisoning—are present.

Aseptic packaging ensures that the containers for the food are also sterilized continuously and that the food is inserted into the container in a completely sterile environment.

Shrink packagingIt is the method of shrinking film around an article or

a group of articles to give a skin tight wrap.

• It use a shrink packaging machine followed by quick freezing at -40◦C and further frozen storage at -20◦C from the different steps involved in this method of fish preservation..

Vacuum packaging•Vacuum packaging involves the removal of air from the package, then the application of a hermetic seal.

Mainly used for cooked food products. •Vacuum packaged food will taste fresher and last

longer than food stored in conventional containers.•But the food is not devoid of moisture and potentially

lurking pathogens, so it is not an alternative of refrigeration.

Thermal processing•Thermal processing is the heat treatment applied to

food products packed in hermetically sealed containers including flexible pouches, to make them safe for human consumption.

• It kills the spores of Clostridium botulinum pathogen thus making the product safe.

Retort pouch packaging•A retort pouch is a type of food packaging created by aseptic processing, made from multiple layers of flexible laminate, allowing for the sterile packaging of a wide variety of food and drink

•The packaging process is very similar to canning, except that the package itself is flexible The lamination structure doesn't allow permeation of gases from outside into the pouch. The particular retort pouches used for several products consists of four layers bonded in a lamination machine.

BLOCK FROZEN SHRIMPS IN LDPE POUCHES

IQF Lobster in LDPE Pouches

Plastic Laminated Cartons forFrozen Shrimp

Plastic Trays for IQF Crabs

CONCLUSION• Each packaging type has its own advantages and

disadvantages and one cannot be easily replaced by another just for the sake of environmental issues

• Duplex board cartons and corrugated fibre board boxes either waxed or polymer coated are extensively used for frozen fish both as unit and bulk packaging.

• Paper and paper board, though eco-friendly in view of renewable nature of forest resources, requires proper afforestation management and replenishment. Paper industry uses a lot of water during production and presence of chlorinated organics and dioxins in effluent water cause environmental problems at the production centres.

• The disposal of poly laminated or waxed cartons create problems at the disposal end, as there are technical difficulties to recycle or repulp. Exporters are to be prepared to meet additional charges for disposal of these coated / laminated boxes at the destination markets

• Of all packaging materials, plastics have a major share, as they are versatile and can be

converted into any form, lend to excellent decoration, have excellent barrier properties

REFERENCES• T. K. SRINIVASA GOPAL ,PACKAGING MATERIALS FIIR

SHRIMP, FISH AND FISH PRODUCTS, THEIR PROPERTIES, SELECTIIIN AND EFFECT [IF DIFFERENT PACKAGING MATERIALS IN THEIR SHELF LIFE

•Indian Food Industry, Vol-20, No. 3, May-Jun ’01, Packaging of Value-added Fish Products by T.K. Srinivasa Gopal, C.N. Ravi Shankar, Central Institute of Fisheries Technology, Cochin