Fish Canning Handbook

315 Pages·2010·8.353 MB·English

P1:SFK/UKS P2:SFK
fm BLBK266-Bratt March15,2010 13:39 Trim:244mm×172mm
Fish Canning Handbook
Fish Canning Handbook Edited by Les Bratt
© 2010 Blackwell Publishing Ltd. ISBN: 978-1-405-18099-3
P1:SFK/UKS P2:SFK
fm BLBK266-Bratt March15,2010 13:39 Trim:244mm×172mm
Fish Canning Handbook
Edited by
Les Bratt
Consultant in Food Technology
Cleeve Prior, Worcester, UK
A John Wiley & Sons, Ltd., Publication
P1:SFK/UKS P2:SFK
fm BLBK266-Bratt March15,2010 13:39 Trim:244mm×172mm
Thiseditionfirstpublished2010
(cid:1)C 2010BlackwellPublishingLtd
BlackwellPublishingwasacquiredbyJohnWiley&SonsinFebruary2007.Blackwell’spublishingprogrammehasbeen
mergedwithWiley’sglobalScientific,Technical,andMedicalbusinesstoformWiley-Blackwell.
Registeredoffice
JohnWiley&SonsLtd,TheAtrium,SouthernGate,Chichester,WestSussex,PO198SQ,UnitedKingdom
Editorialoffices
9600GarsingtonRoad,Oxford,OX42DQ,UnitedKingdom
2121StateAvenue,Ames,Iowa50014-8300,USA
Fordetailsofourglobaleditorialoffices,forcustomerservicesandforinformationabouthowtoapplyforpermissionto
reusethecopyrightmaterialinthisbook,pleaseseeourwebsiteatwww.wiley.com/wiley-blackwell.
TherightoftheauthortobeidentifiedastheauthorofthisworkhasbeenassertedinaccordancewiththeUKCopyright,
DesignsandPatentsAct1988.
Allrightsreserved.Nopartofthispublicationmaybereproduced,storedinaretrievalsystem,ortransmitted,inanyform
orbyanymeans,electronic,mechanical,photocopying,recordingorotherwise,exceptaspermittedbytheUKCopyright,
DesignsandPatentsAct1988,withoutthepriorpermissionofthepublisher.
Wileyalsopublishesitsbooksinavarietyofelectronicformats.Somecontentthatappearsinprintmaynotbeavailable
inelectronicbooks.
Designationsusedbycompaniestodistinguishtheirproductsareoftenclaimedastrademarks.Allbrandnamesand
productnamesusedinthisbookaretradenames,servicemarks,trademarksorregisteredtrademarksoftheirrespective
owners.Thepublisherisnotassociatedwithanyproductorvendormentionedinthisbook.Thispublicationisdesignedto
provideaccurateandauthoritativeinformationinregardtothesubjectmattercovered.Itissoldontheunderstandingthat
thepublisherisnotengagedinrenderingprofessionalservices.Ifprofessionaladviceorotherexpertassistanceis
required,theservicesofacompetentprofessionalshouldbesought.
LibraryofCongressCataloging-in-PublicationData
Fishcanninghandbook/editedbyLesBratt.
p.cm.
Includesbibliographicalreferencesandindex.
ISBN978-1-4051-8099-3(hardback:alk.paper) 1.Cannedfoods–Sterilization. 2.Fishes–Preservation.
3.Canningandpreserving. 4.Fisheryproducts–Microbiology. 5.Cannedfishproducts–Safetyregulations–Europe.
6.Cannedfishproducts–Safetyregulations–NorthAmerica. I.Bratt,L.(Les)
TP371.35.F572010
664(cid:2).942–dc22
2010003296
AcataloguerecordforthisbookisavailablefromtheBritishLibrary.
Setin10/12ptTimesbyAptara(cid:1)R Inc.,NewDelhi,India
PrintedinSingapore
1 2010
P1:SFK/UKS P2:SFK
fm BLBK266-Bratt March15,2010 13:39 Trim:244mm×172mm
Contents
Listofcontributors xi
Preface:reviewofthemarketfor,andsourcesof,cannedfish xiii
1 LegalrequirementsforproducerssellingcannedfishintoEurope 1
JohnHammond
1.1 Introduction 1
1.2 ImportsintotheEU 2
1.3 Generalfoodlaw 2
1.4 Product-specificcontrols 4
1.5 Hygienerules 6
1.6 FisheryproductsfromoutsidetheEU 8
1.7 Identificationmarking 10
1.8 Microbiologicalcriteria 10
1.9 Labelling 11
1.10 Lotmarking 20
1.11 Foodcontactmaterials 22
1.12 Additives 24
1.13 Flavourings 25
1.14 Contaminants 26
1.15 Pesticides 26
1.16 Veterinarymedicinalproducts 27
1.17 Weightsandmeasures 28
1.18 Warning 29
References 29
2 LegalrequirementsforproducerssellingcannedfishintoNorthAmerica 32
KennethLum
2.1 Introduction 32
2.2 Cannedfishdescription 32
2.3 Whyareregulationsnecessary? 33
2.4 Legalrequirementsandfoodsafety 33
2.5 RegulatorysystemsinCanadaandtheUnitedStates 34
2.6 Canadianrequirements 34
2.7 UnitedStatesrequirements 43
3 HACCPsystemsforensuringthefoodsafetyofcannedfishproducts 51
AlanWilliams
3.1 Introduction 51
3.2 TheHACCPPrinciples 52
P1:SFK/UKS P2:SFK
fm BLBK266-Bratt March15,2010 13:39 Trim:244mm×172mm
vi Contents
3.3 Prerequisiteprogrammes 52
3.4 HowtosetupandconductanHACCPstudyforcannedfishproducts 54
3.5 Implementation 74
3.6 ISO22000 74
3.7 Conclusions 74
References 75
Appendix1:Usefulwebsites(forHACCPGuidanceandincluding
genericHACCPplansinsomecases) 77
Appendix2:ModularHACCPapproachforthecanningoftunaproducts,
showingtypicalactivitieswithineachmodule 78
Appendix3:Exampleofatabulardocumentationformatforprerequisite
programmes 79
Appendix4:Extractfromanon-tabularformatHACCPplanapproachfor
canseaming(CCP2) 80
Appendix5:ExtractofatabularHACCPChartforCCP3sterilisationand
CCP4inthegenericfishcanningflowdiagram 82
4 Nationalandinternationalfoodsafetycertificationschemes 85
HarrietSimmons
4.1 Introduction 85
4.2 Foodsafetylegislation 85
4.3 Foodsafetymanagementsystems 85
4.4 Certification:Abriefoverview 86
4.5 Hazardanalysiscriticalcontrolpoints 88
4.6 TheGlobalFoodSafetyInitiative 90
4.7 Acomparisonofmajorglobalcertificationprogrammesforfoodsafety 100
4.8 Summaryofcomparisonofglobalcertificationprogrammes 100
5 Fishquality 102
TonyGarthwaite
5.1 Introduction 102
5.2 Importantfishspecies 102
5.3 Pollutionaspects 104
5.4 Handlingandtransport 106
5.5 Spoilagefactors 106
5.6 Receptionandtesting 111
5.7 Storage 114
5.8 Defrostingfrozenfish 116
5.9 Fishpreparation 121
5.10 Chemicalindicatorsofquality 130
References 130
6 Designandoperationoffrozencoldstores 132
StephenJ.JamesandChristianJames
6.1 Introduction 132
6.2 Factorsaffectingfrozenstoragelife 133
P1:SFK/UKS P2:SFK
fm BLBK266-Bratt March15,2010 13:39 Trim:244mm×172mm
Contents vii
6.3 Coldstoredesign 140
6.4 Specificationandoptimisationofcoldstores 143
6.5 Thawing 145
6.6 Conclusions 149
References 150
7 Packagingformatsforheat-sterilisedcannedfishproducts 151
BevPage
7.1 Overviewofthebasicmaterialsusedforheat-sterilisedfishpackaging 151
7.2 Metalcansforheatsterilised-fishproducts 151
7.3 Plasticcontainersforheat-sterilisedfishproducts 177
7.4 Glasscontainersforheat-sterilisedfishproducts 177
Furtherreading 178
8 Retortingmachineryforthemanufactureofheat-sterilisedfishproducts 179
ClaudeVincent
8.1 Introduction 179
8.2 Retortingequipmentavailable 180
8.3 Technicalfeaturesofhorizontalbatchretorts 195
8.4 Generalarrangementofasterilisingplant 200
8.5 Utilitiesrequiredforbatchretorts 203
8.6 Thedifferentusagesofaretort 207
8.7 Legalstepstobetakenwheninstallinganewretort 208
9 Managementofthermalprocess 210
NickMay
9.1 Roleofthethermalprocessmanager 210
9.2 Documentationofthermalprocessrequirements 211
9.3 Maintainingandcalibrationofkeyinstrumentation 213
9.4 Trainingofkeystaff 214
9.5 Reviewofproductionrecords 215
9.6 Managingnon-conformance(processdeviations) 215
9.7 Conclusion 217
References 217
10 Principalcausesofspoilageincannedfishproducts 218
JoyGaze
10.1 Thequalityofrawmaterials 218
10.2 Hygieneandgoodmanufacturingpractice 219
10.3 Potentialspoilageissuesassociatedwithcannedfishproducts 219
10.4 Typicalcausesofspoilageincannedfishproducts 220
10.5 Typesofspoilage 221
10.6 Microbiologicalexaminationofsuspectspoiltcans 223
10.7 Microbiologicalinvestigations–decisioncriteria 223
10.8 Conclusion 223
References 224
P1:SFK/UKS P2:SFK
fm BLBK266-Bratt March15,2010 13:39 Trim:244mm×172mm
viii Contents
11 Commercialsterilityandthevalidationofthermalprocesses 225
GeoffShaw
11.1 Introduction 225
11.2 Temperaturemeasurementsystems 226
11.3 Processingvessels 228
11.4 Temperaturedistribution 228
11.5 Retortsurvey 229
11.6 Testloading 229
11.7 Dataanalysis 230
11.8 Heatpenetrationmeasurement 231
11.9 Commercialsterilityandlethality 231
11.10 Generalmethod 233
11.11 Heatpenetrationexperimentalmethods 234
11.12 Flexiblepackaging 235
11.13 Futuredevelopmentsandinformation 236
References 236
Othersourcesofinformation 237
12 Thequalitydepartmentinafishcannery 238
LeilaRadi
12.1 Avant-propos 238
12.2 Theorganisationandthescopeofoperationsofthequalitydepartment 238
12.3 Qualityassuranceforthemanagementofpre-requisitemeasures 239
12.4 Qualitycontrol 244
12.5 Establishmentofaqualityplan 246
12.6 Standardqualityprocedures 246
12.7 Trainingofqualitystaffagainstprocedures 247
12.8 Handlingofnon-conformingmaterials 247
12.9 Establishmentandmonitoringofcorrectiveactions 248
12.10 Legislativecompliance 248
12.11 Researchanddevelopment 249
12.12 Security 249
12.13 Conclusion 250
Acknowledgement 250
References 250
13 Thelaboratoryinafishcanningfactory 251
LindaNicolaidesandLesBratt
13.1 Laboratoryfacilities 251
13.2 Chemicalanalyses 254
13.3 Microbiologicaltesting 255
13.4 Analysisrequiredforcannerywaterandretortcoolingwater 256
13.5 Swabtesting 256
13.6 Incubationtests 257
13.7 Sterilitytests 257
13.8 Laboratoryaccreditation 260
Furtherreading 260
P1:SFK/UKS P2:SFK
fm BLBK266-Bratt March15,2010 13:39 Trim:244mm×172mm
Contents ix
14 Cleaninganddisinfectioninthefishcanningindustry 262
PeterLittleton
14.1 Introduction 262
14.2 Thecleaningprocess 262
14.3 Principlesofcleaning 264
14.4 Openplantcleaning 265
14.5 Floorcleaning 270
14.6 Trayandrackwashingmachines 271
14.7 Principlesofdisinfection 272
14.8 Factorsaffectingdisinfectanteffectiveness 273
14.9 Choosingtherightdisinfectant 274
14.10 Wheretodisinfect 274
14.11 Typesofdisinfectants 275
14.12 Oxidisingdisinfectants 275
14.13 Non-oxidisingdisinfectants 277
14.14 Effectsoftimeandconcentration 278
14.15 Specificissuesrelatingtofishcanningoperations 279
14.16 Cleaningmanagement 279
14.17 Cleaningprogramme 280
References 282
15 Thecanningfactory 283
LesBratt
15.1 Thefishcanningfactory:Introduction 283
15.2 Siteselection 283
15.3 Factorydesignandconstruction 284
15.4 Theprincipalareasofthefactory 289
15.5 Services 296
Referencesandsuggestionsforfurtherreading 298
Index 299
P1:SFK/UKS P2:SFK
fm BLBK266-Bratt March15,2010 13:39 Trim:244mm×172mm
List of contributors
LesBratt NickMay
LesBratt(FoodTechnology)Ltd,CleevePrior, CampdenBRI,ChippingCampden,
Worcestershire,UK Gloucestershire,UK
TonyGarthwaite LindaNicolaides
ConsultantFoodTechnologist,TGAssociates, FoodSafetySpecialist,NaturalResources
Grimsby,UK Institute,Greenwich,UK
JoyGaze BevPage
MicrobiologyDepartment,CampdenBRI, PackagingConsultant,Ravenshead,
ChippingCampden,Gloucestershire,UK Nottingham,UK
JohnHammond LeilaRadi
CampdenBRI,ChippingCampden, InternationalQualityControlCorporation,
Gloucestershire,UK Rabat,Morocco
ChristianJames GeoffShaw
FoodRefrigerationandProcessEngineering EllabUKLimited,Bawburgh,Norfolk,UK
ResearchCentre(FRPERC),TheGrimsby
HarrietSimmons
Institute(GIFHE),Grimsby,Lincolnshire,UK
TechnicalDirectorfortheFoodInspection
StephenJ.James Services,NationalBritanniaLtd,Caerphilly
FoodRefrigerationandProcessEngineering BusinessPark,Caerphilly,UK
ResearchCentre(FRPERC),TheGrimsby
ClaudeVincent
Institute(GIFHE),Grimsby,Lincolnshire,UK
STERIFLOWS.A.S.,Paris,France
PeterLittleton
AlanWilliams
TechnicalServicesManager,Holchem
DepartmentofFoodManufacturing
LaboratoriesLtd,Haslingden,Rossendale,
Technologies,CampdenBRI,Chipping
Lancashire,UK
Campden,Gloucestershire,UK
KennethLum
GMA/FoodProductsAssociation,Centerfor
NorthwestSeafood,Seattle,WA,USA
P1:SFK/UKS P2:SFK
fm BLBK266-Bratt March15,2010 13:39 Trim:244mm×172mm
Preface: review of the market for, and
sources of, canned fish
Canning is a well-established and traditional means of providing food which is stable at ambient
temperatures, has long shelf life and in consequence is eminently suitable for world-wide dis-
tribution. Canned fish is therefore exported from countries all over the world into the consumer
marketsofEuropeandNorthAmerica.Themanufacturingofcannedfishhasprovided,andcontin-
uestoprovidemuch-neededemployment,individualincomesandthemeansforforeigncurrency
exchange for developing countries, particularly in Southeast Asia, South America and the Indian
Ocean.
Withinthepast20yearsorsotherehavebeennoticeablechangeswithinthecannedfishindustry.
The increased emphasis on food safety has given rise to better understanding of the process of
heatsterilisation,togetherwithever-sophisticatedequipmentprovidingthemeanstomeasurethat
sterilisation;theintroductionoftheISO9000StandardhasledtothebetterorganisationofQuality
Management Systems in which responsibilities are better defined and understood; modern pro-
cessingequipmentwithmicroprocessorcontrolhasprovidedthebetterregulationoftemperatures
and pressures during thermal processing; and the widespread adoption of HACCP systems has
allowedcompaniestoidentifyandconcentratetheireffortsonthosematterscontributingtoproduct
safety.
Thechangesthathaveoccurredwithintheindustryhavealsobeenduetolong-termpressurefrom
theretailandtradingcompanieswhoprovideauditof,andtechnicalhelpto,theirsuppliersinorder
toensurethatfoodprovidedtotheircustomersissafe.Inrecentyearswehaveseentheintroduction
of numerous industry-led standards such as the International Food Standard or the British Retail
ConsortiumStandardtherequirementsofwhichmanufacturingcompaniesarerequiredtomeetif
theywishtosupplytothemajorpurchasingorganisationsinEuropeorNorthAmerica.
The introduction of new legislation has also taken place particularly within Europe. The three
basicfoodhygieneregulationsare:
(cid:1)
852/2004onthehygieneoffoodstuffs;
(cid:1)
853/2004layingdownspecificrulesforfoodofanimalorigin;and
(cid:1)
854/2004layingdownthespecificrulesfortheorganisationofofficialcontrolsonanimalproducts
intendedforhumanconsumption.
Foodbusinessoperatorsareeffectivelyrequiredtoputinplace,implementandmaintainapermanent
procedure,orprocedures,basedonHACCPprinciples.
Cannedfishisseenasintrinsicallyhealthy,convenientandtasty.TheUKmarketforcannedfish
iscurrentlyworthsome£474millionatretail,equivalentto108624tonnes.Standardtunaproducts
at55%comprisethelargestsectorofthismarket,cannedsalmonissecondwith20%,andtheoily
fish,sardines,mackerelsandpilchardstogethercomprise13.8%.Addedvaluetunaproductsnow
accountfor5%ofthecannedfishcategoryandhavebeenakeydriverforgrowthinrecentyears.
Productinnovationhasbeeninstrumentalinprovidingnewproductslaunchedtomeetincremental
consumerneedsidentifiedthroughconsumerresearch.