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2.1 Design and Maintenance of Fish Processing Plants

Refrigeration is essential in seafood processing and storage to maintain quality from harvesting to consumption. Proper plant layout and refrigeration are also important for efficient operations, as processing areas require temperatures below ambient. Key areas of a plant include pre-processing, processing, and packing. Air conditioning helps control temperature and humidity in these areas. Other important aspects of plant design include adequate space for current and future capacity needs, as well as ventilation. Strict hygiene practices and quality control programs are also necessary throughout the supply chain from collection to transportation to storage and handling. Compliance with legislation and standards helps address challenges in areas like food safety, market competition, and resource management.

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JAVIER ROMO RIOS
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551 views

2.1 Design and Maintenance of Fish Processing Plants

Refrigeration is essential in seafood processing and storage to maintain quality from harvesting to consumption. Proper plant layout and refrigeration are also important for efficient operations, as processing areas require temperatures below ambient. Key areas of a plant include pre-processing, processing, and packing. Air conditioning helps control temperature and humidity in these areas. Other important aspects of plant design include adequate space for current and future capacity needs, as well as ventilation. Strict hygiene practices and quality control programs are also necessary throughout the supply chain from collection to transportation to storage and handling. Compliance with legislation and standards helps address challenges in areas like food safety, market competition, and resource management.

Uploaded by

JAVIER ROMO RIOS
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Basic Design Practices in

Seafood Processing Plant and


Cold Storage

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 Refrigeration is the heart of fish or shrimp processing plant. It all starts with
the use of ice from the time of harvesting until it reaches to final consumer
kitchen. It is highly necessary to keep the temperature chain intact to keep the
quality of the product, whether it is fresh or frozen.

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 For a refrigeration plant to work efficiently it is really necessary to
have a good processing plant layout. The simple reason is that every
part inside the processing plant maintains a lesser temperature than
the ambient temperature in most parts of the year. It means the
building is energized, even more; appropriate to say that it is
refrigerated. This is true for even those plants which do not have an
air conditioning system inside the pre-processing and processing area.
These areas are getting cooled by the energy given out by the melting
of Ice.

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Fish collection

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Legislations:
EU Legislations:
 178/2002 - General principles and requirements
of Food Law
 852/2004 - Hygiene Rules of food stuffs
 853/2004 - Specific hygiene rules for food stuff
of animal origin
 854/2004 - Official controls on animal products
 882/2004 - Official control to ensure verification
of compliance with feed and food law

National Legislations:
 Uganda Standards (US 201, US 28)
 The Fish (Quality Assurance) Rules
 SOPs for Fish Inspection & Quality Assurance
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Post Ban Interventions:
 UFPEA formation 1992
 Infrastructure Improvement
 Donor Funding:
• CDE
• UNIDO
• USAID

 Capacity Building
• External Support Programs;
• Training of Fish Inspectors;
• Implementing HACCP, GMP’s, traceability;
• Quality Assurance Managers’ Association QAMA;
• Traceability and Product recall procedure;
• Common approach in addressing quality
problems.
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Plant design
 Normally the plant design starts with a simple layout drawing. So the
sizing of each process location is very important from the energy
conservation point of view.
 The area should be well enough to process the required quantity. The
additional area should be provided only if there is a requirement for
future expansion.
 Not only the length and width but also the height of the processing
area should be well enough to have more air space and good air
ventilation. However, too high a process area will require more
energy per unit area.

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 The entire product handling area can be divided majorly
into three portions, pre-processing, processing and
packing area. It is required to maintain a minimum
temperature of 22 to 24°C in all these portions. Another
challenge in the industry is that the relative humidity in
these areas goes above 95% due to heavy use of water and
ice in the process.

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 Over and above certain area near process refrigeration
equipment, the air temperature goes below dew point
temperature which condenses the moisture in the air. So it
is necessary to maintain the above said temperature and
bring down the RH level between 60 to 70%. A well
designed air-conditioning system can directly give three
benefits.

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Process area Air-conditioning with
textile socks arrangement

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Fish storage

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Harmonization
 Infrastructure up-grading - (1997)

 Quality, Hygiene and Food Safety Standards:


• External Support Programs (UNIDO);
• Training of Fish Inspectors;
• Implementing HACCP, GMP’s, traceability;
• Establishment of QAMA.

 Compliant EU Inspections

 Periodic CA Compliant Inspections


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Fish transportation

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Temperature maintenance

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Good hygiene practices

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Quality Control

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Addressing Challenges
 Effective upstream control
 Hygiene;
 Fishing;
 Handling & storage;
 Transport;
 Food safety training
 Implementing / maintaining quality systems
 Prerequisite programs (GMPs) – CDE + UNIDO
 HACCP
 ISO 9001:2000 (QMS) – USAID (SPEED PROJECT)
 ISO 22000:2005 (FSMS) – UNIDO
 Market competition – CDE
 Value addition – UNIDO (COMPETE PROJECT) 18
Addressing other Challenges
 Resource management
 Self-monitoring & control program
 Fish for Future campaign (FFF)
 Formation of Regional Association

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