MFRD Text Final.indd - SEAFDEC Institutional Repository (SIR)

The selected PPEs were involved in various pre-processing activities such as shrimp pre-processing (cutting/peeling and/or deveining), fish meat/filleting, crab meat picking and shrimp salting. Sea catches used to be the main source of raw materials to supply the fishing industry.

Table 2. Classifi cation of picked crab meat

Shrimp Salting PPE in Philippines Shrimp salting is an important process

The number of workers who manage operations in crab processing plants ranges from the management of individual households to medium-sized production, with a capacity of several hundred workers. Semi-processed post-harvest crabmeat - chilled crabmeat is usually further processed (e.g. canning) into value-added products.

Process Flow Diagram

Outline of Processing Steps

Good Manufacturing Practice (GMP)

At the customers' request, the headless prawns can also be peeled and/or deveined. deheaded/peeled and/or weighed) are sent to other processors for further processing into value-added products such as block frozen or IQF (individual quick frozen) shrimp, cooked shrimp, battered and breaded shrimp, etc.

Shrimp Pre-Processing

De-heading/Peeling and or Deveining)

Countries: Malaysia, Myanmar, Thailand and Vietnam

Product Name: Shrimps (de-headed/peeled and or deveined) Product Description

Final wash and/or chemical bath/dip The shrimp are washed in ice water at a temperature of maximum 5°C. The semi-processed shrimps are well frozen and/or stored in a cold room before they are distributed.

Figure 2. Shrimps are de-iced and washed using potable iced water.

GMP For Shrimp Pre-Processing

De-icing and Washing
De-icing and Washing
Grading
De-heading/ Peeling and or Deveining
Inspection
Inspection
Washing
Chemical Bath/Dip
Packing
Packing
Storage and Distribution
Storage and distribution

Raw shrimp should be de-iced and washed with chilled or ice water from an approved potable water supply. De-heading/peeling and/or peeling shrimp must be done hygienically and as quickly as possible in a sanitary area. Inspection of shrimp prior to packaging should be done as quickly as possible, keeping product temperatures low at all times.

Inspection should be performed as quickly as possible at low temperatures to minimize contamination and microbial growth of the product. The inspected shrimp must be washed with ice or chilled water from an approved drinking water supply. The semi-processed shrimp must be washed again to reduce the microbial load in the product.

The shrimp should be packed as soon as possible in a hygienic manner, in clean and suitable packaging materials or containers with the temperature of the shrimp no more than 5°C at all times. Packaging is done as quickly as possible to minimize product contamination and microbial growth. Packaged shrimp should be stored labeled and distributed in such a way as to minimize temperature abuse.

Fish Meat/Filleting

Countries: Indonesia and Malaysia

Product Name: Fish Meat/ Fillets (for surimi otoshimi processing) Product Description

Ice functions as a cooling agent during the washing steps of the raw whole fish by lowering the temperature to an optimum level that does not exceed 5°C. Packaging materials such as food grade plastic (polyethylene) bags are used to pack the fish meat/fillets before transporting them to the surimi processing plants. The fish are washed in clean and drinkable ice water before they are further processed.

This step removes the head and all of the contents of the fish's intestinal or abdominal cavity. This step involves cutting, either manually or mechanically, roughly parallel to the spine, a strip or slice of largely boneless flesh from along the length of a fish to produce from one side of the fish a fillet. The fish meat/fillets are visually inspected for remaining bones, which are then trimmed off.

The fish meat/fillets are finally washed or rinsed before being weighed, packed and labelled. The fish meat/fillets are weighed and packed in food grade plastic bags, which are then marked for identification and traceability. The fish meat/fillets in plastic bags are stored in properly labeled containers with ice and distributed to surimi processing plants with minimal temperature abuse.

GMP For Fish Meat/Filleting

De-heading and Gutting Fish are de-headed and gutted to remove the
Filleting, Skinning and Trimming Filleting, skinning and trimming processes
Washing
Weighing
Packing
Labelling

Each incoming shipment of unprocessed whole fish must be assessed for condition and quality. Inspection of the fish meat/fillets should be carried out as soon as possible after filleting, skinning and trimming and the fish meat/fillets should be sufficiently frozen to maintain a low temperature at all times. Inspection of the fish meat/fillets should be carried out as quickly as possible at low temperatures to minimize microbial growth and spoilage and contamination of the product.

The fish meat/fillets must be washed with ice or chilled water from an approved drinking water supply before packaging. The fish meat/fillets must be washed again to minimize the possibility of contamination and also to reduce the microbial load in the product. Weighing must be carried out in a hygienic and sanitary manner and as quickly as possible.

Weighing must be done in a sanitary and hygienic manner to prevent cross-contamination of the products. The fish meat/fish filters must be packed as soon as possible in a hygienic manner in clean and suitable packaging materials or containers with a temperature of the fish meat/fish filters at all times not exceeding 5ºC. The packages of fish meat/fillets must be stored in properly labeled containers or cartons and distributed as quickly as possible in such a way as to minimize temperature abuse.

Crab Meat Picking

Countries: Cambodia and Philippines Product Name: Chilled Crab meat

Receiving Packaging Materials Packaging materials such as polyethylene bags are used to package the chilled crab meat. The crabs are sorted and graded according to species, sex, size/weight and/or quality characteristics such as freshness. The sorted crabs are prepared by steaming or boiling in water for sufficient time, depending on their size.

The cooked crabs are then quickly cooled with potable running water, or the cooked crabs are placed on slotted trays and covered with nets and cooled with cold circulated air. If not used immediately, cooled crabs are kept in clean PE bags and stored on ice in styrofoam boxes which are then stored in a cold room until needed. The crab meat from the different parts of the crab (body, claws and legs) is then picked and stored separately in coded containers which are then placed in an ice bed to keep the crab meat at chilled temperatures.

The crab meat is packed in clean, food-grade PE bags before being stored in Styrofoam boxes filled with ice. Weighing can be included in this step to ensure that there is a consistent amount of crabmeat in each package. Packed crabmeat in styrofoam boxes is transferred to a clean sanitary area away from any raw raw materials before being delivered to processing plants for further processing, with minimal temperature abuse.

Figure 3. Crabs iced in containers prior to further processing.

GMP For Crab Meat Picking

Washing
Washing
Sorting and Grading
Sorting and Grading
Cooking
Cooking
Cooling
Cooling
Picking
Chilling

GMP 1B.1 Receipt of Packaging Materials Packaging materials (eg polyethylene bags) that are damaged and dirty must be rejected/refused. The incoming shipment must be inspected upon receipt to ensure that only live crabs are selected for processing. Each incoming shipment must be contained in clean and appropriate containers upon receipt and adequate hygiene controls are in place.

The incoming shipment of raw materials must be evaluated to ensure that no infected, diseased or dead crabs are used for further processing. Picking the crabs should be done as quickly as possible in a clean and sanitary area. The boiled crabs before picking and the picked crabmeat must be kept at low temperatures not exceeding 5ºC at all times.

Picked crab meat should be packed as quickly as possible in suitable packaging material such as PE bags. Crab meat packed in polythene bags should be kept chilled by placing them in containers filled with crushed ice. The properly labeled packaged crabmeat should be transferred to a clean sanitary area away from unprocessed raw materials and distributed as quickly as possible in such a way as to minimize temperature abuse.

Good Manufacturing Practice (GMP)FlDi

Shrimp Salting

Country: Philippines

Product Name: Salted shrimp (for shrimp paste processing) Product Description

Packaging materials such as food grade polyethylene bags are used to package the salted shrimp before transporting them to the fish paste processing plants. Each shipment of shrimp must be registered and assessed to ensure they are safe and suitable for processing. The goal is to increase the concentration of solutes in the meat, remove water and decrease the water activity of the shrimp.

Salting can be dry salting in which the shrimp are packed or covered with hard salt and the resulting brine is allowed to drain, or wet salting by soaking in hard brine. Immersion in an airtight fermentation vessel limits the presence of oxygen, slows oxidation reactions and the development of sourness, although some spoilage is essential for the development of the characteristic flavor of the product. Salted shrimp are sorted by discarding those unacceptable shrimp based on several quality aspects such as weight, spoilage rate, color and damage.

Salted shrimps are packed in polyethylene grocery bags before being stored in tin containers. This will allow the salted shrimp to ferment for 2 days before being sent to shrimp paste processing. Labeled containers are sent for delivery to shrimp paste processing plants at room temperature.

Figure 1. Live, chilled shrimps upon receipt.

GMP For Shrimp Salting

Salting conditions
Ensuring uniform salting Shrimps that are salted in piles should be re-
Sorting
Sorting
Packing
Packing
List of Contributors

Bags of salt must be regularly and neatly stored above the ground in a clean and dry area specially designated for this purpose. A clean and dry place must be provided for the storage of salt, 1. free of insects, which must be planned and constructed in such a way that a) it allows for proper maintenance and cleaning, b) it prevents the access and retention of pests; and c) allow for a minimal likelihood of contamination. 2. Suitable non-wooden racks must be installed to store salt away from the floor.

Shrimp salting should be carried out in a cool and clean room with a temperature lower than 10°C. Salted shrimp must be graded by type, size and other merchantable quality categories for the relevant market. Utensils and tools used for sorting must be made of materials that do not transmit toxic substances, odors or tastes, are non-absorbent, resistant to corrosion and can withstand repeated cleaning and disinfection.

Salted shrimp should be packed as soon as possible in clean, food grade polythene bags and suitable containers. Containers used for the distribution of brine shrimp must be clean and made of non-corrosive materials, except for wood and water-absorbent materials, and must have smooth surfaces without cracks and crevices. Salted shrimp must be stored at room temperature away from direct sunlight before shipping to shrimp paste processing plants.

Appendix

Head of Fish Processing and Fish Handling Division of Fisheries Extension and Fish Quality Control.

Notes