Dynamics of development in fish processing sector

DYNAMICS OF DEVELOPMENT IN
FISH PROCESSING SECTOR
UPAMA DAS
MEENU JENNY
REMEESA RAFI
DELEENA NV
M.SC 2ND SEM
SCHOOL 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 das
M.Sc IF, 2nd sem
Ro-18
SIF,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

0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
TOTAL
OTHERS
UNSPECIFIED
MISCELLANEOUS
OFFAL FOR REDUCTION
REDUCTION
CANNING
CURING
FROZEN
MARKETING FRESH
DISPOSITION OF FISH CATCH - INDIA, 1991-2012

Centre No Capacity (MT)
Regional Office Kochi 99 3,005.71
Sub Regional Office Quilon 14 417.30
Sub Regional Office
Mangalore
36 2,155.13
Regional Office Mumbai 48 3,449.80
Sub Regional Office Goa 14 900.46
Regional Office Veraval 103 5,508.93
Regional Office Kolkata 32 914.86
Sub Regional Office BBSR 21 663.70
Regional Office Vizag 56 2,272.50
Regional Office Chennai 9 163.15
Sub Regional Office Tuticorin 33 803.60
Total 465 20,255.1
Frozen
Region-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 freezer
Contact freezer
• Plate freezer
 Horizontal plate freezer
 Vertical plate freezer
• Band freezer
• Drum freezer
Spray or Immersion freezer
Cryogenic freezer

GEA AY-series IQF tunnels can
handle up to 25 tons per hour
capacity
Higher Yield
Gentle product handling for sensitive
products
Superior IQF treatment with Long Wave
Fluidization™
Cost effective IQF treatment
Optimum energy consumption with -37°C/-
35°F evaporating temperature
Lower product dehydration with shorter
freezing time
Hygiene and reliability
Superior, industrial tough in-house built
floor and enclosure design
Stainless steel construction
Easy cleaning and inspection
Large access for ease of cleaning and
maintenance
All drive motors and fan motors externally
mounted
Easy, short installation
Modules 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 hours
Belts move slowly
Spiral freezer

Produce IQF product
70% of frozen products are shrimp
Faster process
Fluidized bed freezer

Widely used in seafood industry
Product thickness should not be more than
60 mm
Freezing time depends on product
thickness and the type of refrigerants used
Plates can be moved by hydraulic system
Capacity depend upon the number of
plates
Temperature: -40◦C
Horizontal plate freezer

Used in onboard freezing
Temperature: -30◦C to -40◦C
Larger size of Tuna can be
placed
Sashimi 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 plant
Integrated preprocessing center
Self sufficient, in house ice production
Cutting 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

MODERNTECHNOLOGICAL EQUIPMENT
IN PROCESSING INDUSTRIES

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

Customer Benefits:
Large capacity possible
Efficient and gentle
Fully adjustable
Prepared for temperature control
for inlet/outlet water
Advanced electrical control and
user 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 Delivery
Air 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 Transport
Refrigerated 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 starch
03 Preduster Coat starch for good taste,and more crisp.
04
Battering
machine(thickness)
Coat thickness batter
05 Breading machine Coat bread on the cover of food,more crisp and good taste
06 Frying production line Medium fried,then get into quick freezer
07 Aircooling line Reduce the cover oil and lower the temperature
08 Quick-freezer Get frozen prepared food then distribute
09 Packing machine Pack frozen fried food then sell

Advantages
1. 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

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

Fish Gutting and Filleting Machines
http://www.foodprocessing-
technology.com

The features of microwave drying
machine
1.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.

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.
Application
DZQ-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
TF6540SA
+5540M

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

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

…Expansion
Technology 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

…Expansion
Financial 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.

…Expansion
Financial 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.

…Expansion
Setting 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 from
ancient periods (11,700 years ago)

To prevent fish from
deteriorating

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

FISHUTILIZATIONANDPROCESSING (WORLDDATA)
• 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

...FISHUTILIZATION ANDPROCESSING (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

...FISHUTILIZATION ANDPROCESSING (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 also
The 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 3096.68
Fr.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 583.48 683.5 617.59 708.63 619.66 529.85
Fr.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 244.62 282.72 251.54 228.13 300.69 250.31
Fr. 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 223.67 262.72 256.9 284.6 209.84 247.53
Dried 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 212.22 117.66 152.81 167.89 165.52 111.57
Live 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 47.77
Chilled 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 88.48 104.71 124.51
Others 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 242.72 314.16 292.86 272.34 351.31 279.71
Total 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

Curing
Drying
Smoking
Salting
Pickling
Fermentation

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

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

Frozenpan 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 products
AFD(accelerated freeze drying) squid
IQF squid tentacles

Frozen squid whole
IQF squid ring

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

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

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

Battered Fishfingers
CFWC shrimps SQWC skewer

Cuttle fish fillet roll
Prawn gyoza

Fish fillet
Ghol fish, sole fish, snapper,reef
cod
Shrimps burger patty

Fish steaks
Seer fish, snapper,barracuda
SQWC skewer(squid whole clean)

Squid fillet skewer
Stuffed squid with shrimp

By-products
• Pearl essence
• Surgical sutures
• Fish liver oil

Shark fin rays
fish maws/isinglass

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
Remeesarafi
m.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

HACCP
H-Hazard
A-Analysis
C-Critical
C-Control
P-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 implementation
12 codex steps
1. Assemble HACCP team
2. Describe product
3. Identify intended use
4. Construct flow diagram
5. Onsite confirmation of flow diagram
6. Conduct hazard analysis
7. Establish CCP
8. Establish critical limit
9. Establish monitoring procedures
10. Establish corrective actions in case of deviations
11. Establish verification procedures
12. Establish documentation & record keeping procedures

BENEFITS OFFERED
1. 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

• 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

• 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

• 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

• 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.

Principle -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).

…Expansion
3: 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
• 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 packaging
Active packaging
Aseptic packaging
Shrink packaging
Vacuum packaging
Thermal processing
Retort 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
• 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
CO2
• 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
O2
• 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
N2

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 packaging
Aseptic 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 packaging
It 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

Plastic
Laminated
Cartons for
Frozen Shrimp

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

Dynamics of development in fish processing sector

Dynamics of development in fish processing sector

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