Fish Processing
Fish Processing
Humans have been processing fish since neolithic times. This 16th century fish stall shows many traditional fish products. 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. 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. Larger fish processing companies often operate their own fishing fleets or farming operations. The products of the fish industry are usually sold to grocery chains or to intermediaries. Fish are highly perishable. A central concern of fish processing is to prevent fish from deteriorating, and this remains an underlying concern during other processing operations. Fish processing can be subdivided into fish handling, which is the preliminary processing of raw fish, and the manufacture of fish products. Another natural subdivision is into primary processing involved in the filleting and freezing of fresh fish for onward distribution to fresh fish retail and catering outlets, and the secondary processing that produces chilled, frozen and canned products for the retail and catering trades.[1] There is evidence humans have been processing fish since the early Holocene.[2] These days, fish processing is undertaken by artisan fishermen, on board fishing or fish processing vessels, and at fish processing plants.
Contents
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1 Overview 2 Handling the catch o 2.1 Handling live fish 3 Preservation o 3.1 Control of temperature o 3.2 Control of water activity o 3.3 Physical control of microbial loads o 3.4 Chemical control of microbial loads o 3.5 Control of the oxygen reduction potential o 3.6 Combined techniques 4 Automated processes 5 Waste management 6 Transport 7 Quality and safety 8 Final products o 8.1 Value addition 9 History 10 See also 11 Notes 12 References 13 External links
[edit] Overview
Tuna under the knife Fish is a highly perishable food which needs proper handling and preservation if it is to have a long shelf life and retain a desirable quality and nutritional value.[3] The central concern of fish processing is to prevent fish from deteriorating. The most obvious method for preserving the quality of fish is to keep them alive until they are ready for cooking
and eating. For thousands of years, China achieved this through the aquaculture of carp. Other methods used to preserve fish and fish products include[4]
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 chemical control of microbial loads by adding acids oxygen deprivation, such as vacuum packing.
Usually more than one of these methods is used. When chilled or frozen fish or fish products are transported by road, rail, sea or air, the cold chain must be maintained. This requires insulated containers or transport vehicles and adequate refrigeration. Modern shipping containers can combine refrigeration with a controlled atmosphere.[4] Fish processing is also concerned with proper waste management and with adding value to fish products. There is an increasing demand for ready to eat fish products, or products that don't need much preparation.[4]
Cleaning fish, 1887. By John George Brown. When fish are captured or harvested for commercial purposes, they need some preprocessing so they can be delivered to the next part of the marketing chain in a fresh and undamaged condition. This means, for example, that fish caught by a fishing vessel need handling so they can be stored safely until the boat lands the fish on shore. Typical handling processes are[3]
transferring the catch from the fishing gear (such as a trawl, net or fishing line) to the fishing vessel holding the catch before further handling sorting and grading bleeding, gutting and washing chilling storing the chilled fish unloading, or landing the fish when the fishing vessel returns to port
The number and order in which these operations are undertaken varies with the fish species and the type of fishing gear used to catch it, as well as how large the fishing vessel is and how long it is at sea, and the nature of the market it is supplying.[3] Catch processing operations can be manual or automated. The equipment and procedures in modern industrial fisheries are designed to reduce the rough handling of fish, heavy manual lifting and unsuitable working positions which might result in injuries.[3]
[edit] Preservation
Preservation techniques are needed to prevent fish spoilage and lengthen shelf life. They are designed to inhibit the activity of spoilage bacteria and the metabolic changes that result in the loss of fish quality. Spoilage bacteria are the specific bacteria that produce the unpleasant odours and flavours associated with spoiled fish. Fish normally host many bacteria that are not spoilage bacteria, and most of the bacteria present on spoiled fish played no role in the spoilage.[5] To flourish, bacteria need the right temperature, sufficient water and oxygen, and surroundings that are not too acidic. Preservation
techniques work by interrupting one or more of these needs. Preservation techniques can be classified as follows.[6]
Ice preserves fish and extends shelf life by lowering the temperature See also: Refrigerating and Freezing (food) If the temperature is decreased, the metabolic activity in the fish from microbial or autolytic processes can be reduced or stopped. This is achieved by refrigeration where the temperature is dropped to about 0 C, or freezing where the temperature is dropped below -18C. On fishing vessels, the fish are refrigerated mechanically by circulating cold air or by packing the fish in boxes with ice. Forage fish, which are often caught in large numbers, are usually chilled with refrigerated or chilled seawater. Once chilled or frozen, the fish need further cooling to maintain the low temperature. There are key issues with fish cold store design and management, such as how large and energy efficient they are, and the way they are insulated and palletized.[6] An effective method of preserving the freshness of fish is to chill with ice by distributing ice uniformly around the fish. It is a safe cooling method that keeps the fish moist and in an easily stored form suitable for transport. It has become widely used since the development of mechanical refrigeration, which makes ice easy and cheap to produce. Ice is produced in various shapes; crushed ice and ice flakes, plates, tubes and blocks are commonly used to cool fish.[3] Particularly effective is slurry ice, made from micro crystals of ice formed and suspended within a solution of water and a freezing point depressant, such as common salt.[7] A more recent development is pumpable ice technology. Pumpable ice flows like water, and because it is homogeneous, it cools fish faster than fresh water solid ice methods and eliminates freeze burns. It complies with HACCP and ISO food safety and public health standards. Finally, it uses less energy than conventional fresh water solid ice technologies.[8][9]
Ice manufactured in this ice house is delivered down the Archimedes screw into the ice hold on the boat, Pittenweem
enzymatic reactions involved in spoilage. There are a number of techniques that have been or are used to tie up the available water or remove it by reducing the aw. Traditionally, techniques such as drying, salting and smoking have been used, and have been used for thousands of years. These techniques can be very simple, for example, by using solar drying. In more recent times, freeze-drying, water binding humectants, and fully automated equipment with temperature and humidity control have been added. Often a combination of these techniques is used.[6]
Fish barn with fish drying in the sun Van Gogh 1882.
Cod flakes, platforms where cod dry in the sun before being packed in salt
Ruins of the Port Eynon Salt House seawater was boiled to extract salt for preserving fish
Microbial loads can be physically controlled by canning and then sterilizing with heat Heat or ionizing irradiation can be used to kill the bacteria that cause decomposition. Heat is applied by cooking, blanching or microwave heating in a manner that pasteurizes or sterilizes fish products. Cooking or pasteurizing does not completely inactivate microorganisms and may need to be followed with refrigeration to preserve fish products and increase their shelf life. Sterilised products are stable at ambient temperatures up to 40C, but to ensure they remain sterilized they need packaging in metal cans or retortable pouches before the heat treatment.[6]
Patent issued to Clarence Birdseye for the production of quick-frozen fish, 1930
Non edible fish scrap processing, 1884 Waste produced during fish processing operations can be solid or liquid.
Solid wastes: include skin, viscera, fish heads and carcasses (fish bones). Solid waste can be recycled in fish meal plants or it can be treated as municipal waste.
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Liquid wastes: include bloodwater and brine from drained storage tanks, and water discharges from washing and cleaning. This waste may need holding temporarily, and should be disposed of without damage to the environment. How liquid waste should be disposed from fish processing operations depends on the content levels in the waste of solid and organic matter, as well as nitrogen and phosphorus content, and oil and grease content. It also depends on an assessment of parameters such acidity levels, temperature, odour, and biochemical oxygen demand and chemical oxygen demand. The magnitude of waste management issues depends on how much waste volume there is, the nature of the pollutants it carries, the rate at which it is discharged and the capacity of the receiving environment to assimilate the pollutants. Many countries dispose of such liquid wastes through their municipal sewage systems or directly into a waterway. The receiving waterbody should be able to degrade the organic and inorganic waste components in a way that does not damage the aquatic ecosystem.[14]
Primary treatments: use physical methods such as flotation, screening, and sedimentation to remove oil and grease and other suspended solids.[14] Secondary treatments: use biological and physicochemical means. Biological treatments use microorganisms to metabolise the organic polluting matter into energy and biomass. "These microorganisms can be aerobic or anaerobic. The most used aerobic processes are activated sludge system, aerated lagoons, trickling filters or bacterial beds and the rotating biological contractors. In anaerobic processes, the anaerobic microorganisms digest the organic matter in
tanks to produce gases (mainly methane and CO2) and biomass. Anaerobic digesters are sometimes heated, using part of the methane produced, to maintain a temperature of 30 to 35C. In the physicochemical treatments, also called coagulation-flocculation, a chemical substance is added to the effluent to reduce the surface charges responsible for particle repulsions in a colloidal suspension, thus reducing the forces that keep its particles apart. This reduction in charge causes flocculation (agglomeration) and particles of larger sizes are settled and clarified effluent is obtained. The sludge produced by primary and secondary treatments is further processed in digesting tanks through anaerobic processes or sprayed over land as a fertilizer. In the latter case, care must be exercised to ensure that the sludge is freed of its pathogens."[14]
[edit] Transport
Fish is transported widely in ships, and by land and air, and much fish is traded internationally. It is traded live, fresh, frozen, cured and canned. Live, fresh and frozen fish need special care.[15]
Live fish: When live fish are transported they need oxygen, and the carbon dioxide and ammonia that result from respiration must not be allowed to build up. Most fish transported live are placed in water supersaturated with oxygen (though catfish can breathe air directly through their gills and body skin, and the climbing perch has special air-breathing organs). The fish are often "conditioned" (starved) before they are transported to reduce their metabolism and increase packing density, and the water can be cooled to further reduce metabolism. Live crustaceans can be packed in wet sawdust to keep the air humid.[15] By air: Over five percent of the global fish production is transported by air. Air transport needs special care in preparation and handling and careful scheduling. Airline transport hubs often require cargo transfers under their own tight schedules. This can influence when the product is delivered, and consequently the condition it is in when it is delivered. The air shipment of leaking seafood packages causes corrosion damage to aircraft, and each year, in the US, requires millions of dollars to repair the damage. Most airlines prefer fish that is packed in dry ice or gel, and not packed in ice.[15] By land or sea: "The most challenging aspect of fish transportation by sea or by road is the maintenance of the cold chain, for fresh, chilled and frozen products and the optimisation of the packing and stowage density. Maintaining the cold chain requires the use of insulated containers or transport vehicles and adequate quantities of coolants or mechanical refrigeration. Continuous temperature monitors are used to provide evidence that the cold chain has not been broken during transportation. Excellent development in food packaging and handling allow rapid and efficient loading, transport and unloading of fish and fishery products by road or by sea. Also, transport of fish by sea allows for the use of
special containers that carry fish under vacuum, modified or controlled atmosphere, combined with refrigeration."[15]
whole fish: the fish as it originally came from the water, with no physical processing drawn fish: a whole fish which has been eviscerated, that is, had its internal organs removed dressed fish: fish that has been scaled and eviscerated, and is ready to cook.
pan dressed fish: a dressed fish which has had its head, tail, and fins removed, so it will fit in a pan. filleted fish: the "fleshy sides of the fish, cut lengthwise from the fish along the backbone. They are usually boneless, although in some fish small bones called pins may be present; skin may be present on one side, too. Butterfly fillets may be available. This refers to two fillets held together by the uncut flesh and skin of the belly"[17] fish steaks: large dressed fish can be cut into cross section slices, usually half to one inch thick, and usually with a cross section of the backbone fish sticks: "are pieces of fish cut from blocks of frozen fillets into portions at least 3/8-inch thick. Sticks are available in fried form ready to heat or frozen raw, coated with batter and breaded, ready to be cooked"[17] fish cakes: are "prepared from flaked fish, potatoes, and seasonings, and shaped into cakes, coated with batter, breaded, and then packaged and frozen, ready-tobe-cooked"[17] fish fingers
Filleting hake
fish roe
Fish oil capsules In general value addition means any additional activity that in one way or the other change the nature of a product thus adding to its value at the time of sale. Value addition is an expanding sector in the food processing industry, especially in export markets. Value is added to fish and fishery products depending on the requirement of different markets. Globally a transition period is taking place where cooked products are replacing traditional raw products in consumer preference. "In addition to preservation, fish can be industrially processed into a wide array of products to increase their economic value and allow the fishing industry and exporting countries to reap the full benefits of their aquatic resources. In addition, value processes generate further employment and hard currency earnings. This is more important nowadays because of societal changes that have led to the development of outdoor
catering, convenience products and food services requiring fish products ready to eat or requiring little preparation before serving."[13] "However, despite the availability of technology, careful consideration should be given to the economic feasibility aspects, including distribution, marketing, quality assurance and trade barriers, before embarking on a value addition fish process."[13]
Surimi: Surimi and surimi-based products are an example of value added products. Surimi is prepared from the mechanically deboned, washed (bleached) and stabilised flesh of fish. "It is an intermediate product used in the preparation of a variety of ready to eat seafood such as kamaboko, fish sausage, crab legs and imitation shrimp products. Surimi-based products are gaining more prominence worldwide, because of the emergence of Japanese restaurants and culinary traditions in North America, Europe and elsewhere. Ideally, surimi should be made from low-value, white fish with excellent gelling ability and which are abundant and available year-round. At present, Alaskan pollack accounts for a large proportion of the surimi supply. Other species, such as sardine, mackerel, barracuda, striped mullet have been successfully used for surimi production."[13] Fishmeal and fish oil: "A significant proportion of the world catch (20 percent) is processed into fishmeal and fish oil. Fishmeal is a ground solid product that is obtained by removing most of the water and some or all of the oil from fish or fish waste. This industry was launched in the 19th century, based mainly on surplus catches of herring from seasonal coastal fisheries to produce oil for industrial uses in leather tanning and in the production of soap, glycerol and other non-food products. Presently, it uses small oily fish to produce fishmeal and oil. It is worthy to mention that, only where it is uneconomic or impracticable for human consumption, should the catch be reduced to fishmeal and oil. Indeed, cycling fish through poultry or pigs is a loss because there is a need for 3 kg of edible fish to produce approximately 1 kg of edible chicken or pork."
Fish and fish products are consumed as food all over the world. With other seafoods, it provides the world's prime source of high-quality protein: 1416 percent of the animal protein consumed worldwide. Over one billion people rely on fish as their primary source of animal protein.[1][2] Fish and other aquatic organisms are also processed into various food and non-food products.
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[edit] History
In Ancient Roman society, garum, a type of fish sauce condiment, was popular. Sharkskin and rayskin which are covered with, in effect, tiny teeth (dermal denticles) were used for the purposes that sandpaper currently is. These skins are also used to make leather. Rayskin leather (same'gawa) is used in the manufacture of hilts of traditional Japanese swords.[3] Some other species of fish are also used to make 'fish leather', though this is relatively uncommon. The flesh of many fish are primarily valued as a source of food; there are many edible species of fish, and many fish produce edible roe. Other marine life taken as food includes shellfish, crustaceans, and sea cucumber. Sea plants such as kombu are used in some regional cuisine.
Surimi refers to a Japanese food product intended to mimic the meat of lobster, crab, and other shellfish. It is typically made from white-fleshed fish (such as pollock or hake) that has been pulverized to a paste and attains a rubbery texture when cooked. Fish glue is made by boiling the skin, bones and swim bladders of fish. Fish glue has long been valued for its use in all manner of products from illuminated manuscripts to the Mongolian war bow. Fish oil is recommended for a healthy diet because it contains the omega-3 fatty acids, eicosapentaenoic acid (EPA), and docosahexaenoic acid (DHA), precursors to eicosanoids that reduce inflammation throughout the body.[4] Fish emulsion is a fertilizer emulsion that is produced from the fluid remains of fish processed for fish oil and fish meal industrially. Fish hydrolysate is ground up fish carcasses. After the usable portions are removed for human consumption, the remaining fish body guts, bones, cartilage, scales, meat, etc are put into water and ground up. Fish meal is made from both whole fish and the bones and offal from processed fish. It is a brown powder or cake obtained by rendering pressing the whole fish
or fish trimmings to remove the fish oil. It used as a high-protein supplement in aquaculture feed.
Fish sauce is a condiment that is derived from fish that have been allowed to ferment. It is an essential ingredient in many curries and sauces. Isinglass is a substance obtained from the swim bladders of fish (especially sturgeon), it is used for the clarification of wine and beer. Tatami iwashi is a Japanese processed food product made from baby sardines laid out and dried while entwined in a single layer to form a large mat-like sheet.
Pearls, mother-of-pearl, and abalone are valued for their lustre. Traditional methods of pearl hunting are now virtually extinct. Sea horse, star fish, sea urchin and sea cucumber are used in traditional Chinese medicine. The Sea snails Murex brandaris and Murex trunculus are used to make the pigment Tyrian purple. Some sepia pigment is made from the inky secretions of cuttlefish. Kelp is a major source of iodine, can be used as fertilizer, and kelp ash can be used in soap and glass production.
[edit] Byproducts
A shimmery substance found on fish scales, most usually obtained from herring and one of many by-products of commercial fish processing, can also be used for pearlescent effects, primarily in nail polish, but is now rarely used due to its high cost, bismuth oxychloride flakes being used as a substitute instead.[5]
VII.2.1. Ngapi (Burma) The raw material used in this product is small anchovy (Anchoviella comersonii) or shrimp (preferably the small planktonic types which give a better natural pink colour to the product). There are a number of methods for making ngapi, depending on the type of product required. In one process, which uses one part of salt to three parts of partially dried fish, the fish or shrimps are first washed in sea water and then dried for two days in the sun. About half of the required salt is then added to the fish and mixed in a bamboo basket. This mixture is pounded for several hours until a paste is formed. The paste is then packed into wooden tubs or boxes, care being taken that all air bubbles are removed. Fermentation takes place over 7 days and the paste is then removed, further pounded for three hours during which time the remaining salt is mixed in. The mixture is then spread out to dry in the sun for 3-5 hours. The product is repacked into tubs and the fermentation continues for about a month. After a third pounding, it can be packed for sale in cellophane or brown paper. Artificial dyes are often added to improve the colour. However, their use is not recommended as some may be toxic. When stored anaerobically in the tubs or earthenware pots, the product is said to keep for about 2 years. The average composition of a shrimp or fish ngapi is 43% moisture, 20% protein, 1% ammonia, 2% fat and 22% salt. VII.2.2. Bagoong (Philippines) Bagoong is one of the major preserved fish products of the Philippines where, in many communities, it constitutes a staple food. The product is also exported as far as the USA to the large ethnic Filipino community. A by-product of bagoong is patis, which is the exuded liquor from the fermentation process and is similar to the Vietnamese nuoc-mam. Bagoong has a pasty consistency, and is reddish in colour with a slightly fishy cheeselike odour. It can be prepared from fish of the genera Stolephorus, Sardinella and Decapterus, and small shrimp. In the process described by Subba Rao (1961), the fish are washed in clean water, placed in a concrete or wooden vat and mixed thoroughly with salt. The ratio of salt to fish is about one third. The mixture of fish and salt is then transferred to earthenware jars, oil drums or cement tanks and either sealed immediately or, preferably, covered with cheese cloth for five days and then sealed. The sealed containers are held in the sun for one week and the product is then transferred to five gallon cans. These cans are, in turn, sealed by soldering of the lids, and the product is allowed to ferment further for between three months and one year. The storage life of the product is many years, and the typical composition is not less than 40% total solids, 12.5% protein and 20-25% sodium chloride. Bibliografie : Wikipedia.org/wikifish-procesing Wikipedia.org/fishery-products