Pangasius and Tilapia Fish fillets Processing of Bangladesh
Virgo Fish and Agro Processing Plant is continuing its construction and other improvement as well. This processing plant is going to process Fish fillets, Fish oil and Fish feeds. It needs to develop for the commissioning and starting of processing and to get license to ship out of product.
2. Fish Fillet Process Plant
2.1. Construction of Fish fillets processing:
Fish fillets processing plant is divided into different section depend on processing flow. This can be named as Receiving section, Filleting section, Skinning section, Trimming section, Freezing section, Packing section and Final product cold storage. Every section is highly secure and sensitive from receiving to Final product cold storage.
2.1.1. Landing and receiving section:
Landing station need to cover with shade. Shade will be outside of the receiving shade where small truck will be unloaded fish to the receiving belt. Conveyor belt system is needed to water shading and quality check to receiving area. Receiving section will have to facilitate with room temperature, Air exhausted and outside lighting. Glass can’t be used to protect from outside area into the processing plant. There should have a facility of fish blood shedding tank. Manual and automatic line also starting to divided very carefully from here. The room temperature will be 18 ± 2 º C and lighting facility will be 300 lux. Weight machine is needed for weighing of receiving raw material. Worker entry should be divided by male and female. There should have a separate section for female worker dress change. Dress locker facility with lock system for every person in this section is highly required. Insect killer light is needed to the entry foot dip area.
2.1.2. Filleting section and skinning section:
Manual section and automatic section well decorated depend on receiving area. The room temperature will be 18 ± 2 º C and lighting facility will be 550 lux. Worker entry should be divided by male and female. There should have a separate section for female worker dress change. . Dress locker facility with lock system for every person in this section is highly required. Insect killer light is needed to the entry foot dip area. Every Filleting line end should have a skinning machine facility. There are two pocket windows between filleting and trimming section. A pocket windows is needed between third filleting lines to third trimming line
2.1.3. Trimming section:
Very important and sensitive section of the plant and for ensuring quality of the plant is trimming section. There should have facility to transport of ice to every trimming line. Manual section and automatic section well decorated depend on filleting area. The room temperature will be 18 ± 2 º C and lighting facility will be 550 lux. Worker entry should be divided by male and female. There should have a separate section for female worker dress change. . Dress locker facility with lock system for every person in this section is highly required. Insect killer light is needed to the entry foot dip area. After final wash of fillet will go to the tumbling section place to the freezing area to add additive or other solution.
2.1.4.Tumbling section and Freezing section:
Tumbler will be used as mixer of fillet and other additive and chemicals. Tumbler room suggested to separate from other freezing section as separate room. There are three kinds of freezing system in freezing section. Plate freezer ( efficiency of freezers, cleanliness, temperature control efficiency for maintaining product core temperature and freezer temperature below -18ºC and -40ºC for 20 minute respectively), Blast freezer ( efficiency of freezer, insulated door-durable, clean and well closed, wall and floor- water resistant and washable, S/S racks, trays rust free, walls and ceiling- free from peeling paints, cleanliness), Tunnel freezer ( efficiency of freezer for attaining product core temperature below -18ºC, wall and floor water resistant and washable). Calibrated and having thermocouple for calibration of freezers are to ensure. The room temperature will be 18 ± 2 º C and lighting facility will be 550 lux. Worker entry should be divided by male and female. There should have a separate section for female worker dress change. . Dress locker facility with lock system for every person in this section is highly required. Insect killer light is needed to the entry foot dip area. After every section of final freezing product will go for final packing as per buyer requirement.
2.1.5. Packing and ante room:
Ante room temperature maintained ?10ºC. Necessary materials (de-panning and packing table made of SS,). There should have weighing machine, dehumidifier, safe packing management (materials, wrapping, racks and sealing. There must be metal detector with calibration Kits. The room temperature will be 18 ± 2 º C and lighting facility will be 550 lux. Worker entry should be divided by male and female. There should have a separate section for female worker dress change. Dress locker facility with lock system for every person in this section is highly required. Insect killer light is needed to the entry foot dip area. Packing area and ante area should separate with well protective nonabsorbent washable wall. Export door (made of appropriate durable material, easy cleaning and well closing).
2.1.6. Chilling room:
Thermometer at entrance showing temperature of chill room (cooler exist and appropriate temperature should maintain at up to 4ºC) is suggested. There have to adequate lighting for operation and protective and covered.
2.2. Water supply system:
Overhead tank (adequate, made with proper material, clean and secure), water treatment (Filtration, RO, UV/Ozone), clean separation between potable and non-potable water supply system with designated color coding.
2.3. Ice Production Facilities:
There should have facility about Ice made of potable water and sufficient quantity in respect of requirement in a day, Ice machine (well protected door/ windows, clean, rust free), Ice storage (clean door, floor, ceiling and walls), and Ice carrying facilities (trolley made of SS).
2.4. Machine room:
All machine should have control panel and temperature recording appropriate. Safety and emergency devices (fire extinguisher, gas-musk, glass for eye and cold protected jacket) are highly suggested.
2.5. Packaging material store:
It is required for dry packaging store to keep door and windows (well protected) and adequate air exhaust facilities, Dunage (minimum space from wall 8 inch) rack, shelf, fire extinguisher and for sometimes dehumidifier available, storage condition (arrangement, dryness, light, dirt free, coverage , vermin and rodent control system).
2.6. Laboratory facilities:
Every food processing plant should have well decorated lab with suitable location with available space and arrangement with temperature controlling devices, having valid equipment instruments, utensils and other facilities required for physical, Organoleptic and Microbiological tests, required chemicals and test kits for physical organoleptic and microbiological tests are labeled with required information and kept in order.
2.7. Facilities for staff:
According to Labor law, EU and USA regulation factory should have below facilities.
(a.i.1) Toilet ( adequate number for male and female, sensible location, floor/wall mosaic/tiles, flush system, toilet paper, soap and washing water)
(a.i.2) Hand washing basins (with foot operated tap, liquid soap, chlorinated water (20-50 ppm), disposable tissue, hand dryer and waste bin available)
(a.i.3) Required dress (different color apron and cap based on division of labor, musk, head gear, gloves, nail brush etc)
(a.i.4) Dress changing facilities (cupboard, individual cabinet, stand for gum boot/ shoe/ slippers)
(a.i.5) Rest room (separate for male and female)
(a.i.6) Cafeteria (located and food facilities)
(a.i.7) Child care center (well arrange)
(a.i.8) Health care facilities (doctor’s room)
(a.i.9) Laundry facilities (well equipped)
2.8 Layout and surroundings:
The plant should have highly secured layout (adequate area, clean-dirty area and food material- nonfood material area separated ), surroundings ( having walls separated from other establishments outside area, cleaned and hygienic, vegetation free, drains covered etc.)
2.9 Pest control:
Plant should have well decorated and protected rodent, vermin, insect and other pest control.
2.10. Sanitation Standard Operation Procedure (SSOP):
There should have proper SSOP system with safety of water and ice, cleaning and disinfection of food contact surfaces, Prevention cross contamination, maintenance hand washing sanitizing and toilet facilities, Protection of food from adulterants, Labeling and safe storage of hazardous chemicals, personal hygiene and health and pest control.
2.11. Operation management of the processing Establishment:
This chapter include
a) Laboratory (qualified microbiologist, approved Standard Operation Procedure (SOP) for lab, proper documentation of lab)
b) HACCP and own check system (approve HACCP and HACCP plan, HACCP team Raw material specification, Flow diagram, Identification CCP, Verification processing procedure and proper documentation.)
c) Recall and traceability ( written procedure, product labelling, Nutritional fact and corrective measure)
d) Staff policy and Labor law compliance ( Labor law 2006 and 2008, worker id card, health card, maintain staff register, payment register, leave register and shift register, appointment and termination procedure and employment and child labor issue etc)
e) Waste management (sewage handle, waste water treatment mark waste bin with color coding, and documented monitoring procedure)
f) Training( staff training in house and outside DoF and others)
g) Product diversification and value addition
h) Raw material and product transportation (temperature control refer van for product transportation)
2.12 Required Accessory
|Name of Fitting||Ground Floor||First Floor|
|Liquid Hand Wash Stand||29||08|
|Foot operating Waste Bin||50||08|
2.13. Chemical :
Chemicals recognized by USFDA & EU are used for sanitization, sterilization and pest control of the factory. Chemicals are stored in a well-ventilated cleaned storeroom with correctly labeled.
|Trade name of the chemical||Active ingredients||Manufacturer||Use|
|Liquid lifebuoy||Puralin, Palmitee acid, Stearic acid, Fat||Unilever Bangladesh Ltd||Hand washing|
|Wheel Powder||Linear benzene, sulphonic acid, Na2CO3, Na2SO4||Unilever Bangladesh Ltd||Detergent used for utensils, equipment and other food contact surfaces|
|Chlorotech ( approved by EU organic regulation)||Sodium hypochloride (5.25% Cl2)||Global heavy chemical ltd.||Sanitizer cleaning and disinfection in all areas and section of the factory|
|Bleching powder||Ca(OCl)Cl||Unilever Bangladesh Ltd||Disinfection activities outside of the plant|
|Harpic||Germicide||ACI Limited, Bangladesh||Cleaning, disinfectant and deodorizing agents used in bathroom, toilet, commode, basin, pans, outer drains etc. in non-food contact areas|
|ACI Aerosol insect spray||0.2% w/w S-bio alitherine 0.12% w/w Permethrine||ACI Limited, Bangladesh||Insecticide|
2.14 Required employee for Production floor for first commissioning :
|Production Manager (1)||Minimum 7 years’ experience in fish plant academic background relax|
|Microbiologist (1)||Minimum 3 years’ experience in fish plant and having microbiology or biological science post graduate|
|Super visor ( freezing unit) (1)||Minimum 5 years’ experience in fish or shrimp with same post and academic background relax.|
|Packing and cold store supervisor (1)||Minimum 5 years’ experience in fish or shrimp with same post and academic background relax.|
|Super visor receiving , filleting and trimming (3)||Minimum 3 years’ experience in fish or shrimp with same post and academic background relax.|
|Worker ( 6)||Having science background HSC passed|
3. Fish oil and feed process:
All processing unit and machineries are in the ground of processing area and need to clear designed and established.