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Complete and standard flow lines commonly used for seafood processing
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Tuesday, 22 October, 2019, 08 : 00 AM [IST]
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Dr P A Raajeswari and R Pragatheeswari
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The standard flow line is designed to be part of an integrated processing solution from the receiving of the whole fish to the dispatch of the end-product, enabling processors to greatly reduce processing time and enhance worker performance while also allowing for a much higher throughput, as well as improved yield and product quality.
Flow lines have separate conveyors for all incoming and outgoing products. The top conveyor delivers the incoming product, a second conveyor transports all outgoing product, while a third transports off-cuts. Each flow line has a number of operator workstations, equipped with a worktable with bins for products and trimming. This involves far less handling when compared to a manual table or tray system. Handling all raw material in a continuous flow considerably reduces the processing time and increases productivity. Standard flow lines include Ergonomic design, Continuously collect valuable data, Additional extras include information displays per station and lights on Quality Control stations.
1) Primary Processing
Organise daily production according to purchase orders or customer expectations with weighing and grading equipment.
Process-Weighing, Grading and Batching Weighing
Weighing units are specifically designed to withstand the harsh environment of food processing plants – without any trade-off in weighing accuracy. The bench and floor scales can be combined with a comprehensive range of weighing indicators and HMIS, printers, software and accessories to suit individual processing needs.
Authorised scales are suitable as stand-alone installations or part of a complete production management system.
Total Weight Measurement
The Certified Flowscale is a compact, durable, high-capacity belt weigher used to weigh a continuous flow of material moving on a conveyor. Similar to the way water or electricity meters function, the scale registers the total weight of the product flow that is moving across it. It displays this measurement on a sealed M2200 display.
Versatility
The Certified Flowscale can be used to measure the total catch of fish coming from a fishing vessel into a processing factory, or to measure the total amount of food material in and out of specific process.
The Certified Flowscale is self-contained and has a built-in conveyor belt. It is designed for the weighing of fish as well as other food industry applications and has W&M approvals for use in commercial business. It has a hygienic and easy-cleaning design.
Grading and Batching
In the wide range of high quality fish batching and grading equipment, one will find the product that fulfils one’s needs in the production line and the most stringent requirements in the fish industry and in the marine industry, thanks to their versatility and easy-to clean design. With fixed-weight batching and grading equipment one keeps giveaway as low as possible when packing products from one’s food processing lines. Multihead weighers batch raw material frozen or fresh and create packs based on target weight with very high capacity and accuracy.
2. Secondary Processing
Fast, intelligent, precise portioning to increase the primary product ratio, optimise yield, and improve raw material utilisation.
Process: Weighing, Grading and Batching (as seen above) Fillet Processing, Inspection, Portioning
Fillet Processing-Pinboning-for Fish
Best results in yield, quality and production time for whitefish processors, depending on throughput requirements and the capacity of other processing equipment.
Inspection
Minimise bone complaints and increase product quality and value with cutting-edge X-ray bone detection. SensorX Fish delivers much more reliable and consistent results than manual inspection, and enables processors to offer superior quality boneless fish products.
Portioning
Intelligent, high-speed, high-precision portioning systems that are designed to consistently increase the primary product ratio, optimise yield and improve raw material utilisation.
With solid units like the I-Cut 11 Portion Cutter and the Strip Cutter or sophisticated, high-tech systems like the FleXicut, an endless variety of value-added products can be created; from fixed-sized strips, dices and splits to high-value portions of fixed weight and length.
The latest in innovative cutting patterns for loin and fillet cuts is available in advanced portioning lines that deliver custom made portions directly to orders.
Portion Cutting
Good portion cutting is all about automated, high speed, high precision performance.
Modernisation offers the best portion cutting solutions for the high speed production of fixed weight or fixed length products. With a wide range of machines to choose from, one can produce an endless variety of products. Their high precision performance results in minimal giveaway, thereby providing excellent profit opportunities.
Combining the portion cutting equipment with intelligent production software, will offer easy-to-use remote programming, control, real-time monitoring and reports on actual performance.
Portion Sawing
High-speed, precision bandsaws for optimum cutting yields, accuracy, hygiene and operator safety.
3. Value-Added
A range of efficient, forming, marinating, coating, frying and cooking systems that enhance taste and texture, while also delivering high yield and added value.
Process: Portioning (as seen above), Breading and Coating, Forming, Weighing, Grading and Batching, Frying, Heat Treatment
Breading and Coating
A coating influences yield and will largely determine the bite, taste and presentation of end-products. Presentation plays a key factor in the consumer’s choice for a product. It is of vital importance to get coating right.
Coating enhances taste and texture and increases yield. It also protects products from damage during freezing. The number of possible coatings is abundant. Will one’s choice be for wet or dry, or rather a combination of both? The process sequence will depend on the end-product one chooses.
Forming
Both high-pressure and low-pressure formers - formers increase utilisation of raw material, offer great yield and a highly customisable product range. The high pressure portioning and forming enables the development of a wide range of products such as nuggets, croquettes and burgers for the home and catering industries.
Frying
Frying is an important heat treatment step in production process. The coating is fixed and fish products acquire their attractive, golden crispy finish and taste. Frying contributes to food safety, product quality, taste, presentation and prolonged shelf life.
High-end machines designed specifically allow one to deep or flash fry fish product at consistent, high standards. These fryers are equipped with a highly sophisticated oil management system for extended oil life. Therefore it achieves a better yield.
By frying, one optimally fixates coating and gives product that perfect crunchy layer.
Heat Treatment
Steaming, Cooking or Grilling
Cooking is another form of heat treatment that can add value to fish products. The complete cooking of product in oil results in high oil absorption and in moisture loss. Because of the increasing demand for healthy products, more and more processors choose the combination of deep-frying and oven cooking.
4. Packing and Labelling
Accurate, efficient and easily customisable, end-of-line systems offer an array of pack, tray and labelling options.
Process: Checkweighing, Packing and Dispatch, Labelling Checkweighing
Check weighing solutions monitor and optimise the accuracy of one’s equipment, ensure compliance with weight legislation, and centralise program management.
Packing and Dispatch
Accurate, efficient and easily customisable, end-of-line systems offer an array of pack, tray and labelling options.
Labelling
Designed for maximum efficiency and quality, labellers are accurate, reliable, inexpensive and easy to operate.
Above all, plant location, physical environment and infrastructure, processing procedures and personal hygiene of the workers also determine the safety and quality of the final product.
(Dr Raajeswari is assistant professor in Department of Food Science and Nutrition and R Pragatheeswari is Ph.D. scholar at Avinashilingam Institute for Home Science and Higher Education for Women, Coimbatore. They can be contacted at raajraajeswari@gmail.com)
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