NATIONAL UNIVERSITY OF CAJAMARCA

INDUSTRIAL PROCESSES
INDUSTRIAL TUNA PRODUCTION PROCESS

STUDENT:
GIL SANCHEZ, Dsure

TEACHER:
Eng. LEZAMA BUENO, Jorge

CYCLE:
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Index pag.

INDUSTRIAL PRODUCTION PROCESS OF TUNA................................................................... 3

I. INTRODUCTION............................................................................................................... 3
II. OBJECTIVES.................................................................................................................... 4
III. LITERARY REVIEW............................................................................................... 4
3.1. Definition canned................................................................................................ 4
3.2. attributes from canned foodss .......................................................................... 4
3.3. BACKGROUND HISTORICAL OF TECHNOLOGY OF
PROCESSING OF FISH CANNING.................................................... 6
3.4. PROCESS CANNED FISH MANUFACTURING..................... 7
3.5. PROCESS Tuna ProductionN ........................................................... 7
3.3.1. Reception of raw materials............................................................................ 8
3.3.2. Washing and eviscerationo ............................................................................................ 9

3.3.3. Decapitated....................................................................................................... 10
3.3.4. Cooking............................................................................................................... 11
3.3.5. Filetedo ............................................................................................................. 12
3.3.6. Packaging............................................................................................................ 13
3.3.7. The vacuum in the canned goodss ..................................................................... 14
3.3.8. Addition of the coating liquid15
3.3.9. Container cleanings ............................................................................................. 15

3.3.10. Sterilization from the preserves......................................................................... 15

3.3.11. Cooling from the preserves.......................................................................... 16
3.3.12. Labelledo .......................................................................................................... 17
3.3.13. Storageo 17
3.6. Issues environmental in the fish canning sector.......................... 19
3.6.1. Emissions to the atmosphere.................................................................................. 19

3.6.2. Waste productions ..................................................................................... 20

3.6.3. Discharge production...................................................................................... 20
IV. CONCLUSIONS......................................................................................................... 21
V. BIBLIOGRAPHY22
 INDUSTRIAL PROCESSES

INDUSTRIAL PRODUCTION PROCESS OF TUNA

I. INTRODUCTION

The tuna is a very abundant fish in the Pacific Ocean, there it is caught.
by fishing boats equipped with freezing equipment to freeze the fish
and keep them in perfect condition until reaching the processing plant.
The most important marine species for the production of canned goods
tuna are: Katsuwonus pelamis (Skipjack tuna), Thunnus alalunga (albacore tuna)

albacore), Thunnus albacares (yellowfin tuna) and Thunnus obesus (tuna

big eye).

One of the main ways to process this type of fish is as

canned. The companies that are engaged in canned tuna processing
they have a series of machinery and equipment for the production of
tin containers and lids that are used later in the filling
and subsequently sealing the products in cans.

The can is an opaque and durable container that is suitable for packaging.
liquids and food preservation, these can be made of steel and/or aluminum, and they
hermetically sealed to protect the food against the
ultraviolet light, oxygen, and microorganisms. The foods
canned foods are not always sterile from a bacteriological point of view, but
they are considered commercially sterile if they do not include microorganisms, in
especially Clostridium botulinum, which can multiply under conditions
currents.
The main areas of a canned tuna processing plant are: area
of refrigerators (freezing chambers), cleaning of the tuna, filling or
tinned tuna, sterilization, packaging and dispatch of the product
finished. Each of them has a control monitoring of
quality that ensures that the final product meets the parameters
established, so that it remains in optimal conditions for the
human consumption.

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II. OBJECTIVES

General Objective
Know and analyze the process of tuna production

Specific Objectives
Determine all the inputs used in the elaboration
of tuna products
Analyze the different processes through which the raw material passes.
and the conditions under which it must be maintained.

III. LITERARY REVIEW

3.1. Definition of conserve

"Food preservation" is the result of the process of handling the

foods in such a way that it is possible to preserve them in the best
possible conditions over a long period of time; the final goal
Canning is to keep food preserved from the action of
microorganisms capable of modifying sanitary conditions and flavor
of the foods. The period of time that the foods are kept in
canned food is far superior to what it would be if canned food did not exist.

3.2. attributes of canned foods

The essential elements, carbohydrates, lipids, and proteins contained

In food, there is almost no modification during the preservation process.
Lipid oxidation is infrequent compared to cooking.
homemade, during which many times lipid peroxidation tends to occur that, in
In some cases, it can become a health risk. Regarding the
proteins and carbohydrates, the only minor modification that occurs facilitates
the digestion of these elements.

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Regarding the macronutrients of canned foods, the

essential components and their caloric and equivalent energy values
are maintained to the same extent as fresh foods. Vitamins
Fat-soluble substances found in fats are systematically preserved.
while water-soluble vitamins are usually eliminated during the
washing and processing operations just like in home cooking.

The washing process during the conservation process is subject to

rigorous controls to ensure that losses are minimal. Analysis
independents have shown that 70% of the vitamins are maintained
after sterilization, which is exceptional considering
that after the storage and homemade preparation of fresh products
only 10% of the vitamins are retained

This was the birth of industrial conservation technology, which to

from the mid-19th century onwards meant access for all social classes
affordable and quality food.
Focusing on canned fish, Varela's work in the late
from the 90s, about the behavior of fatty acids in canned foods
sardines have shown that when they are kept in olive oil,
there is an exchange between these and the oil used in conservation.
Thus, it has been found that there is a significant decrease in acids.
saturated fats in canned sardines in that oil, which does not happen
when fried in normal home cooking.

On the other hand, one might wonder what happens to fatty acids.
unsaturated, with a known tendency to isomerizations and to
polymerizations, reactions that completely invalidate the nutritional power of
the same. To bypass this problem, the best method of preservation is
in a steel can with an inert atmosphere, so that radiation cannot act
luminescent, which would give rise to the formation of free radicals, catalysts of
the entire process. Additionally, when the sterilization temperature does not
exceeding 135 ºC, they also do not suffer alterations. As a consequence, the acids

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w-3, of high nutritional interest, remain practically unchanged.

during the validity period of the preserve.

Finally, during the processing of preservation, the

liposoluble vitamins, A, D, E, and K, which under the mentioned conditions more
They remain stable above, despite their sensitivity to light.

3.3. HISTORICAL BACKGROUND OF TECHNOLOGY

PROCESSING OF FISH CONSERVES

Man has always wanted to preserve the hunted food or

collected, once their immediate needs are met, as these
they degraded quickly. By the Neolithic, man knew that the cold
it was used to preserve food and it used ice for that purpose. It also
realized that salt and oil were not only used for seasoning
foods, also for preserving them. The Egyptians, for example, were
considered important exporters of smoked fish, another famous
conservation system. The crossings of the ocean to the Americas are
they were made with nuts, seeds, and salted foods, although with the risk of
a mysterious disease, scurvy, due to a lack of vitamins.

It was also known that fruits and some vegetables could be preserved.
in sugar, and certain legumes and fruits tolerated vinegar. But all these
procedures preserved food for a short time and with few
guarantees, that is, some methods were not entirely reliable.
Fish is a perishable product and, without a doubt, one of the most exposed.
to the action of bacteria. Fortunately, times have changed today.
and we are much safer when consuming it. However, not
it is advisable to forget that canned fish is a healthy, safe and
comfortable to enjoy this food, since we can savor it always
whenever we want, at any time and in any place.

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Before canning, other methods were known to preserve

properties of food, how to store them in dry and dark places,
cover them in protective substances like sugar to preserve fruits and
vegetables, vinegar for legumes and fruits, fat, oil, clay, honey
ice, etc., and the processes for making smoked and salted products were known.

3.4. FISH CANNING MANUFACTURING PROCESS

The canning industry is the most important method of preservation.

foods and is the one that has developed the most in recent times. This
industry allows us to enjoy all the foods of the entire world in
any place and time. But this is nothing more than a superficial advantage that
we obtain from the industry: The real importance lies in the fact that it has
eliminated the frequent possibilities of hunger. They assure bit parts.
the sufficient supply of food throughout the year. It has arrived
to be the greatest security of nations against blockades in case of
war. Furthermore, the food canning industry has created a
demand that did not exist previously; that is why it is very likely that in the
In the coming years, future generations will talk about the 20th century as 'the century

from the preserves." (Banlieu, 1947).

3.5. TUNA PRODUCTION PROCESS

Operations in the process of fish canning

The main objective of fish canning is the
obtaining high-quality and profitable products. For
To achieve it, one must rely on the data provided by an adequate
quality control that covers everything from raw materials to the product
final, ready for consumption.
For products to be absolutely safe, manufacturers of
canned fish must ensure that such heat treatment is
that are subjected is enough to eliminate all microorganisms
pathogens responsible for decomposition, among these, Clostridium
botulinum is undoubtedly the most known because it achieves

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reproduce inside the sealed container and can lead to the formation of
a potentially deadly toxin. The safety of the products
packaging is only guaranteed if it is fully understood and controlled
adequately all aspects of heat treatment. The description
what follows is only general in terms of its essence, that both the process,
as the necessary equipment for this varies somewhat according to the type of
canned goods that you produce. (Banlieu, 1947).

3.3.1. Reception of raw materials

The fish is received at the plant in a rectangular cement pool.

majolica cover, where an inspection is carried out to ensure that it
they meet the health standards at the time of receiving the fish and
remove the inappropriate specimens.

This is the stage of the process in which we must control the following
factors:

Raw material temperature, in fresh products the fish

it must have a temperature between 0ºC and 4ºC, in the products
Frozen foods must be at a temperature of less than -18ºC. These controls are
they have to carry out on all received batches regardless
of its origin or species.

Skin appearance and crushing in the meat, in this case we have

to make a visual observation of the color of the skin and the mucous membrane
of the fish, as well as observing possible cracks and bruises in the
fish meat. The fish must have the skin and the whole flesh.
a uniform color without discoloration.
Rancidity, observation of the color and odor of the subcutaneous areas
and external in fresh and frozen fish, the absence is essential
of yellowish areas in the fish meat, as well as smell of
rancid

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The coding of raw materials to which it is very important

they are assigned a batch number, through which we will be able to know in
any moment the history of that fish.

The task of weighing is also very important; with this weight, we will know.
the performance obtained with each unit, an important piece of information since we

it will allow us to know which raw materials are more interesting to buy,
based on the results obtained. For example, with the Mackerel
(Scomber Scombrus) from each kilo of raw fish we will obtain 300
grams of fish useful for the preserve then we obtain a yield
of 30%. Depending on the size and the fishing season, you can
achieve different results.

The manufacturing process of canned fish begins with the

receipt of the different raw materials from the different
slices. This raw material is subjected to a series of treatments before
its packaging.

3.3.2. Washing and evisceration

All the fish that are going to be processed will require a wash, so
as a visual observation of the presence of diverse species or materials
strange.

This operation consists of the removal of the entrails (intestines),

blood, dirt, and mucus found in the raw material to be
processed, the first two factors being putrefaction or
decomposition.

Evisceration is performed manually or mechanically depending on the work.

Allow. Large tables and stainless steel knives are used.
previously washed. The cut for evisceration is made in the abdomen.

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Once the fish is beheaded, it passes through a disc with holes where
through a vacuum pump it sucks up the organs which are collected in a
special deposit. Its management and maintenance are simple.
Currently, science has made many advancements in mechanization of
the handling of fish, most of these operations can be
perform with automatic or semi-automatic equipment.

In developed countries where labor is expensive, there tends to be

use machines instead of manual operations, while in the
developing countries where cheap labor is much more employed
manual operations.

Eviscerating machine

3.3.3. Decapitated

We will observe the jugular area of the decapitated fish.

decapitation will be carried out through clean and straight cuts, without crushing or

Tenderize the meat, the surface of the cut should be smooth. If the
cuts produce tears in the meat, these facilitate the entry into the
muscle of microorganisms present on the surface.

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3.3.4. Cooking

In this phase, measuring the cooking time is very important.

measurement of the temperature of steam or cooking water, measurement of the
temperature of the central spine, visual observation and the texture of the meat.

Once cleaned and deheaded, the fish is manually placed in

the grills to be cooked at 100 ºC in brine or steamed. The cooking
The fish is one of the most important parts in the process of
manufacturing, there is no estimated time, it always depends on the size
and the fat of the fish will depend on the origin and season of
fishing.

Indicating cooking times is a very delicate task, an excess of

cooking leaves the fish dry and not very juicy, as well as a loss of
performance. If we undercook the fish, we will also reduce the
performance due to the fish crumbling in the hands of the
workers, and it will have a high percentage of water.

Two methods are used to check the cooking; in both, we take out a
piece of the cooking balsa. Once the piece is obtained, we can either
observe the firmness and structure of the meat, or divide the fish into
two parts and take the central spine of the fish, break the spine and
observe if the tendon on the inside of the central spine breaks or stretches
like a rubber band, breaking would mean that the fish is not yet here
perfectly cooked and requires more time.

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The cooking process

3.3.5. Filleting

In this phase, we must remove all remnants of bones, entrails, skin and
of blood, as well as of darkened areas. The cuts must be made
longitudinally to the body of the fish, clean cuts, without tears and
without spines from the abdominal cavity in small species.

As has already been mentioned, once the fish has been cooked, it is given
delivery to the team of people in charge of scraping and filleting that
they will obtain four clean fillets from a piece of cooked fish. In this
process the fillets are carefully cleaned, removing all the
thorns and skin.

All the fillets are weighed and when comparing with the gross kilos we can
obtain the yield per batch produced. The fillets of each worker are
heavy to encourage those who gain more weight. The
productivity tables are changed based on size and quality of
fish, the smaller the fish, the fewer kilos of fillets it has
that the operator obtains. The operators are informed individually.
every hour of their productivity.

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The traditional filleting operation is carried out on a steel table.

stainless steel in which the center carries a 12-inch sanitary belt driven
for a gear motor that is the part that transports the waste to a
end of the table where they are collected and taken to the flour mill.
The fillet boards are placed on top of the belt.
carrier to be taken to the guillotine where they will be cut off from
according to the type of containers to be used, for example for cans
for 1/2 pounds, the pieces must be 1 ¼ inches and for the cans of 1
libra, the pieces should be 2 inches.

3.3.6. Packaging

The small fish must be packaged as a whole piece, the size of

the parts of a container should be as homogeneous as possible, the number of
pieces per container within the same batch must be similar. For tunas
packaged in log or block, there must be enough space for
receive the covering liquid.

Once we have obtained the fillets, we move on to trimming them manually.

They will then be selected and placed in the cans or glass containers.
after ensuring that the fish is properly packaged.

In a different way, the preserves are filled into the cans according to the type and
the shape of the packaging. Packaging is a process that needs to be controlled
above all the weight and can be done mechanically or by hand. For
In this operation, there are various types of automatic machines.

The packaging tables vary considerably being the object in all

the cases guarantee a constant supply of fish and cans to the
packaging machines. They are generally stainless steel tables with space for
the top where the cans are received and below a chain
conveyor that carries the filled cans to the vacuum tunnel. The cans must
wash them before filling them. Figure 8 shows the filling of cans at the
packaging table.

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Tuna packaging

3.3.7. The vacuum in canned goods

The vacuum is an essential operation, which consists of expelling air,

before sealing it, which creates a vacuum when it cools down. A good vacuum
it maintains the bottom lid of the collapsed container, prevents pressure
unnecessary about the stapling and sealing during sterilization and
reduce the biochemical changes that may arise.

In commercial practice, the appropriate procedures to expel the

The area of the cans is:

a) Evacuation due to heat.

b) Mechanical evacuation.
c) Steam injection.

The evacuation by heat involves heating the contents of the cans.

immediately before closing them, when they are coming through
a steam tunnel at a temperature of 65° to 75 °C, this way it
remove the air contained with the product.

In mechanical evacuation, the air contained in the filled cans is extracted

using vacuum separation machines and steam injection is carried out

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injecting a steam current into the headspace, when placed in the

appropriate position for the closure.

3.3.8. Addition of the cover fluid

In this phase, we are preparing to fill the container with the liquid of
covering, which depending on the cases will be olive oil, vegetable oil,
tomato, or pickled. The covering liquid should range between 35% and
10% of the container's capacity, according to product, presentation form,
dimensions of the packaging and what is indicated on the label. The tomato is obtained

making a mixture with tomato, water, oil, and salt. The marinade
we managed by mixing vinegar, water, and salt.

3.3.9. Washing of containers

The containers are washed with hot detergent solutions with the
purpose of removing the dirt caused during the filling and overflow of the liquid
government. If this is not done, the dirt is harder to
detach. Washing machines are machines equipped with chains
carriers and stainless steel tubes with rows of holes and a
pump for the continuous flow of the product that washes the product cans
packaging.

The washed cans are falling into some carts that transport them.
the cans into the autoclaves. These carts are made of iron strips or
perforated metal sheets, structured in this way to allow
that the steam is distributed evenly within the filled carts
canned goods

3.3.10. Sterilization of preserves

This operation, generally known as processing, is the crucial point.

of the entire canning process, since the preservation properties in

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to a certain extent, the quality of the product depends on the correct use of the

processing technique.

In some countries, it is required that those who supervise the operations in

The autoclave operators in the canning factories must have completed a course.
of specialized training in the principles of control of the
thermal treatments. One of the goals of those courses is to teach the
supervisors some standard operating procedures that reduce the
danger of mistakes due to ignorance or negligence.

The true packaging industry began with the use of the

autoclaves that replaced the old method of water bath.
Currently, autoclaves are chambers in which processing can take place.
canned foods under the action of steam superimposed at pressure.

3.3.11. Cooling of the preserves

After the heat treatment, the cans are quickly cooled in order
to stop the action of heat that would harm the nutritional value of
product. There are three cooling methods:

a. Outdoor cooling.
b. Cooling with water.
c. Cooling under pressure.

In outdoor cooling, the carts with the preserves are extracted.

autoclave and they are left to cool in the open air; it is the most practical and most
cheap, but takes up more space and time.

Cooling with water is faster than cooling in open air:

It can be labeled and stored faster. The cans should not cool down.
below 37 °C, which allows the retention of a certain amount of
sufficient heat to ensure quick drying and thus avoid corruption.

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Pressure cooling is the process that should be used for the containers.
large oval type, since this system maintains the pressure
inside the can, thus avoiding deformations in the seal.

3.3.12. Labeling

The minimum content of the labeling will be: Product name,

presentation format, net and drained weight, normalized capacity of
packaging, ingredient list, manufacturer identification and date of
preferred consumption

3.3.13. Storage

The storage area must be clean and dry, the packaging must be
of a size that prevents the movement of the containers. The packaging
They must be stacked in cages or at a reduced height to avoid crushing.
All handling of packaging must be careful in order to avoid
bumps, which could dent the containers, affecting their seams and
compromising its hermeticity, in addition to diminishing its appearance.

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Flowchart of fish production

It is recommended to use, as a scheme for the distribution of

installations, theflowof operations aimed at expressing
graphically the entire production process, from reception
from raw materials to product distribution
finished, obviously going through the manufacturing process.

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3.6. Environmental issues in the fish conservation sector

For the preparation of fish preserves, regardless of the

the raw material being addressed, the following can be defined globally
stages:

Previous treatments: They consist of the manipulation of matter

first in order to give it the appropriate shape and dimensions for
its packaging. This stage includes operations such as washing,
skinned and gutted, removal of the spine,
chipped and fragmented. Currently, many of these
operations are carried out automatically, although still
There are factories where they are done manually.

Large amounts of water are used in these processes and are

they generate high amounts of wastewater with high load
organic.

3.6.1. Emissions to the atmosphere

The atmospheric emissions resulting from activity come from the

steam production boilers. Currently, there are facilities
that use steam boilers with natural gas as fuel and
cogeneration systems with gas turbines that are from the point of
more suitable environmental view.

Main emissions generated in canning industries:

Emitting focus Origin Characteristics of the emission

Generation boilers Cooking process and Combustion gases

vapor sterilization

Water generation boilers Can washing Combustion gases

hot

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3.6.2. Waste production

The waste generated in companies could be classified as

Industrial waste, a definition that would encompass both the waste
dangerous and non-dangerous that can be generated in a company.

Main waste generated in canning plants:

waste origin characteristics

Paper, plastic, Several activities Waste no

metal, etc. dangerous
Fish leftovers Cleaning and Cutting No waste
dangerous
Fats of Debugging of Waste no
treatment plant waters dangerous
Muds of Debugging of Waste no
sewage treatment plantwaters dangerous
Oil residues Preparation of the Waste
edible preserve dangerous
Used oils and Maintenance of Waste
fat teams Dangerous
Used containers RP packaging Waste
dangerous
Soot Boilers Waste
dangerous
Solvents Maintenance Waste
Religious

3.6.3. Production of discharges

The activity of canneries consumes large volumes of water and

generates large volumes of waste. The characteristics of the waste are
conditioned by the type of process and the water used in the process
(sweet, salty, or both).

There are fundamentally two types of effluents: those corresponding to

the stages of bleeding and cooking that account for 25% of the discharged flow
and 90% of the organic load discharged. And the effluents coming from the

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thawing, fish washing, sterilization and operations of

maintenance which accounts for 75% of the flow and 10% of the load
organic waste.

Main discharges generated in canneries:

Spill Origin Features

DBO5DQO (solids in
Water of Cleaning of equipment and
suspension), detergents,
maintenance facilities
oils and fats
Waters of Water with low load
Canning sterilization
sterilization Organic
Water of
Maintenance of
refrigeration Hot water with SS
boilers
and boilers
Wastewater Dressing rooms and offices
DBO5, DQO, SS
sanitary ammonia and detergents
Waters of High content in
Thawed
process I Chlorides

Waters from
Washing the fish DBO5, and SS
process II
Waters of
Bleeding DBO5, SS and chlorides
process III

Waters of Large amounts of

Cooking fish DBO5, SS, chlorides and
process IV Fats

IV. CONCLUSIONS

To determine the inputs used in the preparation of

the tuna products among which are tuna, oil, water
among other products

The different processes through which matter was analyzed were achieved.
first is subjected, from the beginning of obtaining the material
first until obtaining the final product which is the processed tuna.

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V. BIBLIOGRAPHY

Suburb, J. (1967). Technique of food canning.

Spain: Editorial Sintes.

Burges, G. (1979). The fish and the industries derived from fishing.
Zaragoza, Spain: Acribia Editorial

Navarrete, O. (2001). Processing of canned tuna, bonito,

horse mackerel, jack mackerel, and sardine.

Navarrete Chávez, D. (n.d.). Description of the canning process

tuna in water.

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