15 MFSP

Vocational Higher Secondary
Education (VHSE)
SECOND YEAR
MARINE FISHERIES
AND SEA FOOD PROCESSING
Reference Book
Government of Kerala
Department of Education
State Council of Educational Research and Training (SCERT),

KERALA
2016
Reference Book
Participants
1. Anil Kumar S.
Voc. Teacher in Fisheries, Dr. VVVKAM GRFTVHSS
Karunagapally
2. Ajith V.R.
Voc. Teacher in Fisheries, Govt. VHSS Cheriazheekal
3. Johny T.J.
Voc. Teacher in Fisheries, Govt. VHSS Poovar
4. Smitha K.S.
Voc. Teacher in Fisheries, Govt. VHSS Valiyathura
5. Pushparajan S.
Voc. Insrtuctor in Fisheries, Dr. VVVKAM GRFTVHSS
Karunagapally
Experts
Dr. Pramod Kiran R.B.
Asst. Prof. Dept. of Aquatic Biology
Kerala University
Academic Co-ordinator
Dr. Sobha Jacob
Assistant Professor, SCERT
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MARINE FISHERIES AND SEA FOOD PROCESSING
Dear Learners,
This book is intended to serve as a ready reference for learners of vocational
higher secondary schools. It offers suggested guidelines for the transaction of
the concepts highlighted in the course content. It is expected that the learners
achieve significant learning outcomes at the end of the course as envisaged
in the curriculum if it is followed properly.
In the context of the Right- based approach, quality education has to be
ensured for all learners. The learner community of Vocational Higher
Secondary Education in Kerala should be empowered by providing them
with the best education that strengthens their competences to become
innovative entrepreneurs who contribute to the knowledge society. The
change of course names, modular approach adopted for the organisation of
course content, work-based pedagogy and the outcome focused assessment
approach paved the way for achieving the vision of Vocational Higher
Secondary Education in Kerala. The revised curriculum helps to equip the
learners with multiple skills matching technological advancements and to
produce skilled workforce for meeting the demands of the emerging industries
and service sectors with national and global orientation. The revised
curriculum attempts to enhance knowledge, skills and attitudes by giving
higher priority and space for the learners to make discussions in small groups,
and activities requiring hands-on experience.
The SCERT appreciates the hard work and sincere co-operation of the
contributors of this book that includes subject experts, industrialists and the
teachers of Vocational Higher Secondary Schools. The development of this
reference book has been a joint venture of the State Council of Educational
Research and Training (SCERT) and the Directorate of Vocational Higher
Secondary Education.
The SCERT welcomes constructive criticism and creative suggestions for
the improvement of the book.
With regards,
Dr. P. A. Fathima
Director, SCERT, Kerala
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Reference Book
Unit No. Name of units Page No.
3.1 Basic Microbiology 10

• Bacterial structure
• Growth of bacteria
• Classification of bacteria
• Pathogenic and non pathogenic bacteria
3.2 Fishery Microbiology 18
• Sampling methods
• Methods of sterilisation
• Total Plate count
• Laboratory equipments
3.3 Microbes in Public health 25
• Escherichia coli
• Faecal Streptococcus
• Staphylococcus aureus
• Salmonella typhi
• Vibrio cholerae
• Vibrio parahaemolyticus
• Clostridium botulinum
• Shigella
• Microbial limits in seafood
3.4 Hygiene and Sanitation in Fish Processing Plants 32
• Good Manufacturing Practices (GMP)
• Standard Sanitary Operating Procedures (SSOP)
• Chlorination
• Cleaning schedule
3.5 Quality Standards for Fish and Fishery Products 40
• National and International standards
• Various inspection systems
• Hazard Analysis and Critical Control Point (HACCP)
• Registers maintained in processing plants
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Module 4 : FISHERY VALUE ADDED AND BYPRODUCTS

4.1 Value Added Fishery Products 62
• Fish marinades
• Fish cutlet
• Fish wafers
• Fish sausage
• Fish ball
• Fish finger
• Fish momos
• FPC
• Fish soup powder
• Dried prawn pulp
• Masmin flakes
4.2 Fishery Byproducts 72
• Chitin and chitosan
• Shrimp extract
• Fish meal
• Fish body oil
• Pearl essence
• Isinglass
• Fish silage
4.3 Miscellaneous Aquatic Products 78
• Algin
• Agar agar
• Carrageenan
• Beche-de-mer
• Ambergris
4.4 Packaging of fishery products 83
• Packing materials
• Packaging of frozen products
• Packaging of dried products
• Packaging of value added fishery products and byproducts
• Packaging of canned fish and fish pickle
• Modern packaging techniques
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Reference Book
PART - A
MARINE FISHERIES AND SEAFOOD PROCESSING
ABOUT THE COURSE
Vocational education, a dream of Mahatma Gandhi, was realized by the central
government in the year 1983 to address the problem of massive unemployment
among the youth in our country. Among the different vocational courses introduced,
Fisheries courses have great relevance. Being a country with a vast coastline of
about 8000 km, fishing and allied industries play an important role in providing
employment to a vast majority of the population, as well as sustaining the economy
with the foreign exchange earned from the export of various fisheries products.
Among the maritime states of India, Kerala holds a remarkable position in fisheries
sector. That is why the importance of fisheries in the economic development of
Kerala was emphasized by Dr. APJ Abdul Kalam.
The course ‘Marine Fisheries & Sea food Processing’ (MFSP) is a two year
vocational course introduced in Kerala VHSE curriculum as an updated, modified,
multi skilled course. Since Kerala has a large coast line and an active fishing community
relying on the marine fisheries, the course will enable the students to acquire various
skills needed for the industry. It offers scope in studying new technologies, and help
to improve the fishing industry, which directly or indirectly helps to improve the
standard of living of fisher folk and also generate employment opportunities.
Since the sea food processing industry is deeply connected with marine fish resources,
the introduction of multi skilled modular based ‘Marine Fisheries & Sea food
Processing’ course with four modules namely Fishing Technology, Fish
Processing Technology, Fish Quality Control and Inspection Systems and
Fishery Value Added and Byproducts has great importance in vocational
education.
MAJOR SKILLS
After completing the course, the learner achieves the following skills in:
1. Quality Control and Inspection system
• Bacterial cell structure, growth phases, and classification.
• Different growth phase of a bacteria and plotting the growth curve.
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• Sampling methods for microbial examination, methods of sterilization,

identification of different media for bacterial culture and TPC of Fishery
products.
• Seafood quality control standards.
• Use of different lab equipments used in microbiological laboratory.
• Use of dfferent glassware used in Fishery microbiology lab.
• Personal hygiene, factory hygiene, temperature maintenance during
processing.
• Freezing and packing related to production and process control.
• Cleaning schedule, estimation of available chlorine, evaluation of chlorination
levels of different areas of processing plant.
• National and International standards in sea food industry, explanation of
various Inspection systems.
• Hazard Analysis Critical Control Point in Sea food industry.
• Keeping records maintained in processing plants.
2. Fishery Value added and Byproduct and packaging of sea foods
• Preparation of fish marinades, fish /clam/prawn pickle, fish /clam/ prawn
cutlet, Fish wafers, Fish sausage, Fish Ball, Fish Finger, Fish momos, Fish
Protein Concentrate, Fish soup powder, Dried Prawn pulp, Masmin flakes.
• Preparation of various fishery byproducts like chitin & chitosan, shrimp
extract, Fish meal, Fish body oil, Pearl essence, Isinglass, Fish silage
• Various aquatic products like Algin, Agar agar, Carrageenan, Beche-de-
mer, Ambergris.
• Packing materials like Glass containers, Metal cans, Types of paper
packages, Cellophane, LDPE, HDPE, Aluminium foil and Retort pouch
• Packing of IQF products and Block Frozen Products
• Packing of various value added fishery products and byproducts.
• Packing of canned fish and fish pickle.
• Modern packing methods like MAP, CAP, Vacuum packing.
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SYLLABUS
Module 3: FISH QUALITY CONTROL AND INSPECTION SYSTEMS
Unit No. Name of units Periods
3.1 Basic Microbiology
• Bacterial structure
• Growth of bacteria 60
• Classification of bacteria
• Pathogenic and non pathogenic bacteria
3.2 Fishery Microbiology
• Sampling methods
• Media used for bacterial culture 90
• Methods of sterilisation
• Total Plate count
• Laboratory equipments
3.3 Microbes in Public health
• Clostridium botulinum
• Salmonella typhi
• Vibrio cholerae
• Vibrio parahaemolyticus 50
• Escherichia coli
• Staphylococcus aureus
• Streptococcus
• Shigella
• Microbial limits
3.4 Hygiene and Sanitation in Fish Processing Plants
• Good Manufacturing Practices (GMP)
• Standard Sanitary Operating Procedures (SSOP) 70
• Chlorination
• Cleaning schedule
3.5 Quality Standards for Fish and Fishery Products
• National and International standards
• Various inspection systems 70
• Hazard Analysis and Critical Control Point (HACCP)
• Records maintained in processing plants
TOTAL 340
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Module 4 : FISHERY VALUE ADDED AND BYPRODUCTS

Unit No. Name of units Periods
4.1 Value Added Fishery Products
• Fish marinades
• Fish cutlet
• Fish wafers
• Fish sausage 150
• Fish ball
• Fish finger
• Fish momos
• FPC
• Fish soup powder
• Dried prawn pulp
• Masmin flakes
4.2 Fishery Byproducts
• Chitin and chitosan
• Shrimp extract
• Fish meal 130
• Fish body oil
• Pearl essence
• Isinglass
• Fish silage
4.3 Miscellaneous Fishery Products
• Algin
• Agar agar 10
• Carrageenan
• Beche-de-mer
• Ambergris
4.4 Packing of fishery products
• Packing materials
• Packaging of frozen products
• Packaging of dried products
• Packaging of value added fishery products and
byproducts
• Modern packaging techniques 50
TOTAL PERIODS 340
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PART – B
MODULE . 3. FISH QUALITY CONTROL AND INSPECTION
SYSTEMS
Bacteria are widely distributed in nature. They are present in animals, plants, soil, air
and water. There are both useful and pathogenic bacteria, the former one brings
changes including decomposition of dead tissues of both plants and animals and the
latter causes various types of diseases.
Indian marine products are preferred in the markets of developed countries due to
our constant efforts in quality maintenance. Various quality inspection systems are
enforced in our country to ensure seafood quality. These regulations are intended to
ensure that the marine products are wholesome, safe and produced under hygienic
conditions.
This module highlights both the basic and applied aspects of fishery microbiology
and quality assurance in sea food processing and equips the learners with understanding
on microbial hazards and appropriate control measures.
UNIT NO. 3.1 BASIC MICROBIOLOGY
Introduction
This unit provides an overall idea of bacteria. Learners get acquainted with the
structure of a bacterial cell, growth phase and classification based on preference to
various environmental parameters and Gram’s staining. On completion of the unit
the learners get the concept of preventing bacterial spoilage by altering different
environmental conditions.
Microbiology is the study of microscopic organisms and how they interact with
humans and environment. This unit describes the structure of a bacterial cell, different
growth phases of bacteria, classification of the bacteria based on shape, temperature
tolerance, oxygen requirement, nutrient requirement, salinity tolerance, and gram
staining. This unit also deals with pathogenic and non pathogenic bacteria.
Learning Outcomes
The learner :
• Describes the structure of a bacterial cell
• Describes the different growth phase of a bacteria and plots the growth curve
• Classifies bacteria based on shape, temperature tolerance, oxygen requirement,
salt requirement, nutrient requirement, Gram staining
• Differentiates pathogenic and non pathogenic bacteria
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STRUCTURE OF A BACTERIAL CELL

Bacteria are prokaryotic, unicellular and
microscopic organisms. They are found
everywhere from the ocean to guts of
animals. They are the most abundant
micro-organisms. Though the bacterial
structure is very simple, they are very
complex in behaviour. The bacterial cell
is enclosed in a rigid cell wall.
Cytoplasmic membrane is the compound membrane enclosing the protoplasm. There
is no well differentiated nucleus. Their genetic material is very long molecule of
DNA. Some bacteria have an extra circle of genetic material called a plasmid.
Summary of characteristics of typical bacterial cell structures
Structure Function
Flagella Locomotion
Pili/fimbriae Attachment to surfaces
Capsule Attachment to surfaces; protection against phagocytic
engulfment; reserve of nutrients or protection against
desiccation
Cell wall Prevents osmotic lysis of cell protoplast and provides rigidity
and shape to cells
Plasma membrane Permeability barrier; transport of solutes; energy generation;
location of numerous enzyme systems
Ribosomes Sites of translation (protein synthesis)
Chromosome Genetic material of cell
GROWTH OF BACTERIA
Bacteria multiply by simple division called binary fission. When the bacteria are
grown in a suitable medium under favourable condition, the bacterial cell grow in
size. Usually the cell elongates to twice its original length and it divides into two.
Thus two daughter cells are formed. Under favourable condition the growth and
division are repeated very rapidly. To study the bacterial growth population, the
viable cells of the bacterium should be inoculated on to the sterile broth. The dynamics
of the bacterial growth can be studied by plotting the cell growth versus the incubation
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time or log of cell number versus time. The curve thus obtained is a sigmoid curve
and known as a standard growth curve of bacteria. This growth curve has four
distinct phases.
• Lag phase: When a micro organism is introduced into the fresh media it takes
some time to adjust with the new environment. There is no multiplication at this
stage. This phase is termed as lag phase.
• Logarithmic phase (Log phase): During this phase the micro organisms are
in a rapidly growing and dividing state. The culture reaches the maximum growth
rate and the number of bacteria increases exponentially. This will result in a
balanced growth. The time taken by the bacterium to double in number during
a specified time period is known as the generation time.
• Stationary phase: As the bacterial population continues to grow, all the nutrients
in the growth medium are used up by the micro organisms for their rapid
multiplication. This results in the accumulation of waste materials, toxic
metabolites and inhibitory compounds such as antibiotics in the medium. This
shifts the conditions of the medium such as pH and temperature, thereby creating
an unfavourable environment for the bacterial growth.
• Decline or death phase: The depletion of nutrients and the subsequent
accumulation of metabolic waste products and other toxic materials in the media
will facilitate the bacterium to move on to the Death phase. During this phase,
the bacterium completely loses its ability to reproduce. Individual bacteria begin
to die due to the unfavourable conditions and the death is rapid and at uniform
rate. The number of dead cells exceeds the number of live cells. Some organisms
resist this condition and survive in the environment by producing endo spores.
Graph showing growth phase of bacteria
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CLASSIFICATION OF BACTERIA BASED ON SHAPE

Bacteria are classified into 4 categories based on their shape
1. Spherical / coccus: They are spherical or oval shaped
Eg. Staphylococcus
2. Baccilus: They are filament or rod shaped
Eg. Salmonella
3. Comma: They are shaped like slightly curved rods or comma shaped
Eg. Vibrio
4. Spiral: These bacterial cells are twisted and resemble like corkscrews
Eg. Spirillum
CLASSIFICATION OF BACTERIA BASED ON TEMPERATURE

REQUIREMENT
Each bacterium has a range of temperature in which it has optimum growth. There is
a minimum temperature below which the bacterial growth does not take place and a
maximum temperature above which bacteria cannot grow. The optimum temperature
is the most favourable temperature for growth.
Depending on their temperature preferences, bacteria are broadly classified as
Psychrophiles,Mesophiles and Thermophiles.
Psychrophiles (Psychro=Cold, Philes=Love): Psychrophiles are cold loving bacteria
They grow best between temperature range of 0-200C, the optimum being 150C.
Many fish spoilage bacteria belong to this group.
Eg: Pseudomonas sp
Mesophiles: Mesophiles grow best at moderate temperature. Most mesophiles
prefer temperature range of 200c -450c with an optimum of 300c – 370c. Most of
the pathogenic bacteria belongs to this group.
Eg. Salmonella,Staphylococcus
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Thermophiles (Thermo =Temperature, Philes = Love)

Thermophiles are those bacteria which grow best in higher temperature. They prefer
temperature range of 400C– 900C with an optimum temperature of 550C
Eg. Clostridium
CLASSIFICATION OF BACTERIA BASED ON OXYGEN
REQUIREMENT
Bacteria can be broadly classified into four major categories based on their oxygen/
air requirement.
1. Aerobic -Bacteria which require the presence of oxygen for their growth are
called aerobic bacteria or aerobes.
Eg. Staphylicoccus, E.coli
2. Anaerobic - Bacteria which can grow only in the absence of free oxygen are
called anaerobic bacteria or anaerobes.
Eg. Clostridium
3. Facultatively anaerobic – Bacteria capable of growing both in the presence
and absence of oxygen are called facultatively anaerobic bacteria.
Eg. Listeria, Salmonella
4. Micro aerophilic – These bacteria require extremely low concentration of
oxygen for their growth.
Eg. Lactobacillus, Streptococcus
CLASSIFICATION OF BACTERIA BASED ON THE
NUTRITION REQUIREMENT
Based on their nutritional requirement bacteria are broadly classified into three.They
are autotrophs, chemo autotrophs and heterotrophs.
• Autotrophs : These are bacteria which prepare their own food. Due to the
presence of chlorophyll like pigment they perform photosynthesis.
Eg:Cyanobacteria
• Chemo autotrophs – As the name indicates they survive on chemicals. These
are bacteria which synthesize their own food by use of energy obtained from
chemical sources.
• Heterotrophs – These are bacteria which do not synthesize their own food
but obtain it from others.
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CLASSIFICATION OF BACTERIA BASED ON SALINITY

TOLERANCE
Based on the salinity tolerance bacteria are classified into
• Halophilic bacteria –They are highly salt tolerant. So they flourish in
environments with high level of salts. They need less water than other non
halophilic organisms.
Eg. Serratia salinaria
• Halophobic bacteria- These bacteria die at salt concentrations above 1%.
They are salt hating bacteria
Eg. E.coli
• Halotolerant bacteria- Halotolerant bacteria would be able to survive in salty
environment, but can also live outside of this environment. Halophilic and
Halotolerant bacteria cause spoilage in salted fish products.
CLASSIFICATION OF BACTERIA BASED ON GRAM STAINING
Bacteria can be classified into two groups on the basis of Gram staining.
1. Gram positive bacteria (G+ve)
Eg. Staphylococcus
2. Gram negative bacteria (G-ve)
Eg. E.coli
Gram staining :Gram staining is a differential staining process developed by Christian
Gram. Crystal violet and safranine are two stains used in this process.A dilute solution
of crystal violet and ammonium oxalate is used as the primary stain to act on the
bacterial film for a minute. After washing away the stain with water, a dilute solution
of iodine is added on the film and allowed to act for one minute. This is destained by
washing with alcohol. Finally safranine is added as counterstain and allowed to act
for one minute. It is washed with water, dried and observed under microscope.Some
bacteria retain the violet stain even after treatment with destaining agent like alcohol.
They are called Gram positive and others which fail to retain crystal violet, but take
the counter stain safranine and appear red are called Gram negative.
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PATHOGENIC AND NON PATHOGENIC BACTERIA

The terms pathogenic and non-pathogenic are often applied to various microbes. A
pathogen causes disease, while non-pathogen is considered harmless. Our bodies
are host to many microbes, most of which do not cause disease and many of them
are beneficial.
Pathogenic bacteria
The bacteria which cause a disease is called a pathogenic bacteria. Virulence is the
term used to describe the ability of a pathogen to cause disease. The degree of
pathogenicity of a bacteria depends on its invasiveness and ability to produce toxins.
Pathogenic bacteria can be spread to human population in a range of ways. Air,
water, and soil are all common vectors, and people may also pass bacteria directly
among one another through physical contact.
Examples: Streptococcus, Salmonella, Staphylococcus, Vibrio cholerae
Non pathogenic bacteria
These are bacteria incapable of causing disease. For example, non pathogenic E.coli
live naturally in the large intestine of human being. It aids digestion by breaking down
undigested sugars, also produces biotin and vitamin K. Non pathogenic
Staphylococcus epidermis found in human skin, saliva, sweat glands. Lactobacillus
sp. helps in food fermentation process such as yogurt production. Nitrogen fixing
bacteria such as Nitrosomonas, Nitrosococcus present in the soil or in plant roots
change nitrogen gas in atmosphere into solid nitrogen compounds.
Practicals
Preparation of a bacterial cell model
Draw and label the parts of a bacterial cell
Assessment Activities
Class test
Quiz based on the classification of bacteria
Group discussion on pathogenic and non pathogenic bacteria
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TE QUESTIONS
1. Given below are the important parts of a bacterial cell.
• Cell Wall
• Flagella
• Plasma Membrane
Draw a neat diagram of bacterial cell and label the above parts.
2. Different phases of bacterial growth are given below:
• Lag phase
• Log phase
• Stationary phase
• Death phase
Draw a graph showing different growth phases of bacteria.
3. Listed below are different bacteria
(Staphylococci, Vibrio cholerae, Salmonella).
• Classify these bacteria according to their shape.
4. Select the correct statement related to mesophilic bacteria from below.
• Optimum temperature for its growth is 37oC
• They are cold loving bacteria.
• They grow best in higher temperature above 40oC
• Most of them are spore forming bacteria.

5. Pick the odd man from the list below.
Aerobes, Anaerobes, Micro aerophiles, Halophilic
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UNIT 3.2- FISHERY MICROBIOLOGY

Introduction
In this unit the learners get an idea about the different bacterial species present in
fish and fishery products. The sampling methods for microbial examination practised
in a fish processing plant, estimation of the total plate count, colony characters of
various pathogenic bacteria, different media used for bacterial culture and the safe
limits of different bacteria in sea food are dealt with.
Learning Outcomes
The learner :
• Employs sampling methods for microbial, physical, organoleptic and chemical
examination
• Identifies different culture media such as Stock buffer, Nutrient Agar, B P
Agar, T 7 agar, Alkaline Peptone Water, TCBS Agar, Peptone water, Lactose
Broth, BS Agar / X L D Agar, Mac Conkey broth
• Employs the methods of sterilization such as heat sterilization, chemical
sterilization, filtration and radiation sterilization
• Employs TPC of Fishery products
• Identifies and operates different lab equipments used in microbiological
laboratory such as: Autoclave, Hot air oven, Incubator, Colony counter, Water
bath, Water still, BOD incubator
• Identifies and handles different glasswares used in Fishery microbiology lab
SAMPLING METHODS
Samples of seafood are collected for the estimation of different quality parameters.
Inspections are carried out for four types of parameters. They are
• Physical parameters of the products like type of pack, size, grade, quality of
the packing material etc.
• Organoleptic parameters like appearance, colour, odour, texture, etc. which
are assessed by sensory evaluation.
• Chemical parameters like heavy metals, antibiotics and pesticides in cephalopods
and crustaceans (Shrimps), which are assessed by the chemical analysis
conducted by the EIC approved external laboratory.
• Microbiological parameters which indicates the sanitary / hygienic conditions
of the processing unit, bacterial load in the processed product and presence of
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pathogenic bacteria by contaminations. These are assessed by the

microbiological testing in the in house Laboratory.
Inspection of the final product is done code wise and grade wise of the production.
Sampling is done as per the sampling scale given below.
Sampling Scale
Number of cartons Number of cartons to be selected
(Lot Size) (samples)
Up to 12 2
13 – 24 3
25 – 40 4
41 – 80 5
81 – 120 6
121 – 180 7
181 – 250 8
251 – 350 10
351 – 500 12
501 – 750 14
751 – 1000 18
1001 – 1300 22
1301 – 1600 26
1601 – 2000 30
2001 & above 40
The number of cases /master cartons produced under each type of production is
called a “lot”. From each master carton, one slab is drawn as a sample. In case of
block frozen products 20 % of the number of pieces subject to a minimum of 25
pieces are drawn as samples. If the number of pieces is less than 25 the entire
contents of the carton is considered as a sample.When more than 10 packets are
there in a carton, 10% of the packets are drawn as samples.
Drawing of bacteriological samples: Approximately 100 grams of the samples
are drawn for the testing at the in-house lab for the following parameters:
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• Total plate Count

• E. coli
• Staphylococcus
• Salmonella
• Vibrio cholerae
• Vibrio parahaemoliticus
Drawing of samples for chemical residues.
For chemical residual parameters, a composite sample of 150 grams are drawn
from each variety of consignment of the products covering all the codes of production
and it is then sent to the EIC approved labs (CIFT Kochi) for the analysis. Analysis
for the physical parameters and the organoleptic parameters are conducted after
melting the products and spreading on a table. The quality factors are recorded in
the registers for organoleptic analysis.
Media used for bacteriological analysis
SlNo. Bacteriologycal analysis Media
1 Total plate count Buffer, Nutrient Agar
2 Stapyhlococcus Baird Parker Agar
3 E.coli Tergitol 7 agar
4 Vibrio cholerae Alkaline Peptone Water, TCBS agar
(Thiosulphate-Citrate-Bile slats-Sucrose agar)
5 Vibrio parahaemolyticus Peptone water ,TCBS Agar
6 Salmonella Lactose Broth, BSA (Bismuth Sulphite Agar)
/ XLDA (Xylose Lysine Dextrose Agar)
7 Coliform Bacteria Mac Conkey broth
METHODS OF STERILIZATION
There are mainly three kinds of sterilization methods followed in seafood quality
control lab. They are
1. Heat sterilization
2. Chemical sterilization
3. Filtration
Heat sterilization: There are two methods of heat sterilisation. They are Moist
heat sterilisation and Dry heat sterilisation.
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• Moist heat sterilization: This is done by autoclaving the items to be sterilized.

Culture media are usually sterilized by this method
• Dry heat sterilization: This is done by using hot air oven. Hot air oven is a
thermostatically controlled metal chamber, heated electrically. Thermostat
maintains the temperature at the required level. The recommended time temp.
pattern is 145oC for 2 hrs. Glass wares are sterilized by this method.
Chemical sterilization:Disinfectants, antiseptics, germicides and sanitizers, alcohols,
aldehyde etc. are used for local sterilization
Filtration: Heat labile liquids can be sterilized by filtration. Eg membrane filter,
asbestos disc filter.
TOTAL PLATE COUNT
Total plate count gives information about the total number of aerobic bacteria present
in a sample. A high bacterial count indicates the level of contamination of the product,
conditions of storage, the extent of spoilage, etc.
Procedure:
Aseptically collect 10 g of sample in a sterile sample dish.Transfer the sample into a
sterile mortar. Homogenise with 90 ml sterile phosphate buffer.Take this as 10-1
dilution. Pipette 1 ml of this to 9 ml diluent and mix well. Take this as 10-2 dilution.
Pipette I ml of this to 9 ml buffer and take this as 10-3 dilution. Pipette 1 ml of this to
9 ml buffer and take this as 10-4 dilution.
10 g sample+90 ml buffer———(1ml)——>9 ml buffer——(1 ml)——>9 ml
buffer——1 ml——>9ml buffer
1 ml each from the required dilutions is transfered to separate sterile petri dishes.
Add to each petridish 10-15 ml of sterile Tryptone glucose Beef Extract Agar, mix
well and allow to solidify. The plates are then incubated at 37oC for 48 hours and
the colonies are counted.
TPC per gram = Number of colonies X dilutions
Weight of the sample
Preparation of stock buffer and working buffer in lab
Stock buffer: Take 34 gm of Potassium dihydrogen phosphate ( KH2PO4) in
500ml distilled water. Adjust the PH to 7.2 with 1N NaOH. Bring the volume to
1000ml with distilled water. Autoclave 15 minutes at 15 lbs ( 121 C)
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Working buffer: Take 1.25ml of stock solution and bring volume to 1000ml with
distilled water. Dispense in to conical flasks ( 90ml ), and test tubes ( 9ml ). Sterilize
15 minutes at 15 lbs.
LABORATORY EQUIPMENTS
AUTOCLAVE: An autoclave is a pressurised device designed to heat aqueous
solutions above their boiling point at normal atmospheric pressure to achieve
sterilization. It was invented by Charles Chamberland in 1879. The term autoclave
is also used to describe an industrial machine in which elevated temperature and
pressure are used in processing materials.
A simple autoclave is a cylindrical vessel with a heavy lid fastened with screws. It is
provided with an outer safety jacket and an electrical heating coil. A pressure gauge
is provided on the lid. The cylinder should contain water to a level above the heating
coils. On heating steam arises and mixes with air inside and carries it out through the
discharge tap. When the air is completely expelled the valve is closed. The steam
pressure rises to the desired level of 15 lbs per sq inch, the temperature reaches
121oC.
The equipments to be sterilized shall be autoclaved at 121oC for not less than 15
minutes. The following precautions shall be observed here.
Distribute the items with in the
autoclave so that steam will be able to
circulate freely. Make sure that there
is enough water in the autoclave so that
the coil is fully immersed in water.
Ensure that all the air in the autoclave
is expelled before it is closed.
Uses
Autoclaves are widely used in microbiology, sterilizing instruments for body piercing,
veterinary science and dentistry. As damp heat is used, heat-labile products (such
as some plastics) cannot be sterilized by autoclaving as they will melt; paper or other
products get charred.
Hot Air Oven: Hot air oven is a double walled thermostatically controlled equipment
with inner chamber made of Aluminium/stainless steel and outer body with mild
steel. Beaded heating elements are placed under the ribs at the bottom and sides.
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Temperature is controlled by hydraulic

thermostat from 10º C above ambient
to 240º C. Temperature is measured
using a thermometer fitted on the front
panel at the top. It is suitable to work
on 220 volt A.C supply.
The equipments to be sterilized shall be
placed in the oven in such a way that
hot air will be able to circulate freely
around each item. Switch on the oven
and note the time when temperature
reaches 165o C . Maintain the oven
temperature at 160 to 165o C for 60 to
90 minutes, then cool before opening the
door.
Incubator: Incubator is a warm cabinet
in which you can set the temperature
ideal for the growth of bacteria. About
35º C is ideal temperature for most
bacteria. This is close to the human body
temperature. The incubator temperature
shall be correctly recorded using a
standard thermometer, well inserted in
the equipment and check the
temperature of the water bath used for
incubation regularly by immersing a
standard thermometer in water
Practicals
Practise sampling procedure during OJT.
Practise TPC in school laboratory.
Identify and operate different laboratory equipments.
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TE QUESTIONS
1.Match the bacterial organisms given in column A with the culture medium given in
B column.
A B
TPC TCBS Agar
E. coli BSA, HEA, XLDA
Vibrio cholerae TGBE Agar
Salmonella BP Agar
Streptococci T 7 Agar
Staphylococcus KF Agar
2. Moist heat sterilisation
Dry heat sterilisation
Chemical sterilisation
• Listed are important sterilisation methods followed in quality control lab.
Identify its importance and explain the methods in brief.
4. Select the exact use of the medium given in A column from column B.
A B
TCBS • Culture medium of Vibrio cholerae
• Culture medium of E.coli
• Culture medium of Staphylococcus
5. Choose the correct statement related to TPC from those given below.
• It is the total number of anaerobic organisms found in a gram of seafood
• It is the total number of Aerobic bacteria found per gram of seafood sample
• It is the measure of total faecal indicator organisms.
24
UNIT NO. 3. 3
MICROBES IN PUBLIC HEALTH
Introduction
Certain micro organisms are pathogenic and cause diseases in man, animals and
plants. This unit gives an idea about some of the pathogens of public health
importance. The learner gets an idea of the symptoms of diseases caused by sea
food borne pathogens and their control measures.
Learning Outcomes
The learner :
• Observes the characteristics and identifies the sources of contamination and
control measures of E. coli.
• Observes the characteristics and identifies the sources of contamination and
control measures of Faecal Streptococcus
• Observes the characteristics and identifies the sources of contamination, disease
and symptoms and control measures of Staphylococcus aureus.
and symptoms and control measures of Salmonella typhi
and symptoms and control measures of V. cholerae
and symptoms and control measures of V. parahaemoliticus
• Observes the characteristics and identifies sources of contamination, disease
and symptoms and control measures of Clostridium botulinum
and symptoms and control measures of Shigella
Escherichia coli
Characteristics: It is a Gram negative, rod shaped and non-spore forming bacterium.
Primary habitat : The primary habitat of E.coli is the intestinal tracts of man, animals
and birds. Therefore, its presence in seafood is genererally considered as an indication
of faecal contamination. These organisms are not present in off-shore waters and in
fish collected from such waters.
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Sources of contamination :- Near-shore waters, contaminated boat deck, fish

boxes and other contact surfaces, polluted process water, unclean workers, poor
sanitary conditions in processing units. Natural water get contaminated with E.coli
either by direct contact or mixing up with terrestrial sewage.When this water is used
for fish processing, these organisms get entry into the product. Similar possibilities
arise when ice used for preservation or the utensils used for processing are
contaminated with E.coli. When the temperature is also favourable, the contaminated
organisms multiply rapidly and further aggravate the condition.
Control measures: Since the presence of E.coli in seafood indicates the faecal
contamination. It is adviced to adopt hygienic fish handling practises and avoid fishing
from polluted coastal waters. Use only chlorinated water for processing and ice
manufacturing. Proper time temperature maintenance is also essential to avoid
contamination and multiplication of this bacterium.
Faecal Streptococci
Characteristics: They are Gram positive, non-spore forming non motile cocci.
Primary habitat: The primary habitat of Faecal Streptococci is the intestinal tracts
of man, animals and birds.Their presence in fish food is considered as an indication
of faecal contamination just like E.coli.These organisms are not present in off-shore
waters and in fish collected from such waters.
Sources of contamination: Near-shore waters, contaminated boat deck, fish boxes
and other contact surfaces, polluted process water, unclean workers, poor sanitary
conditions in processing units.
Control measures: Practise hygienic fish handling and avoid fishing from polluted
coastal waters. Use only chlorinated water for processing and ice manufacturing.
Staphylococcus aureus
Characteristics:They are Gram positive, non-motile cocci occurring singly, in pairs
or in the form of irregular cluster resembling bunches of grapes.
Primary habitat: - The main reservoirs of S.aureus is man. Hands, face, sweat,
boils, ulcers, nasal cavities, ear gum and nasal drips of man contain this organism in
considerable numbers. About 30% of human population is known to be the nasal
carriers of this organism. Skin of 30% of food handlers is known to harbours
S.aureus. Therefore this organism is a useful indicator of human hygiene in a process
involving human handling. Shrimp processing is a good example of such a situation.
26
Food poisoning due to S. aureus:-

Staphylococcus food poisoning is due to consumption of various fishery products
like shrimps canned in brine, smoked cod in oil, fish sausage, salted herring, frozen
fish sticks have been reported. Food poisoning outbreak may happen if the product
is handled carelessly during later processing which leads to multiplication of these
organisms to dangerous level. Toxins once produced cannot be destroyed by heating
even at 1000C. So it is clear that if sufficient quantity of toxin is formed in a food
material, food poisoning can follow even if the material is consumed after cooking.
Hence hygeine and adequate refrigeration of the material during handling and
processing is highly essential in preventing multiplication and toxin production.
Diseases and symptoms
Nausea, vomiting, abdominal pain, diarrhea, absence of fever and sub-normal blood
pressure are the usual symptoms which start within 1-6 hours after consuming the
infected food. Complete cure is possible within 48 hours.
Control measures: Since Staphylococcus aureus is a useful indicator of human
hygiene in the process involving human handling, adequate control over the health
and hygiene of fish handlers, adequate refrigeration (always below 50C) of the material
during handling and processing is essential to prevent this bacterium from seafood.
Salmonella
Characteristics : Salmonella is aerobic, Gram negative, rod shaped, non-spore
forming mostly motile.
Primary habitat : The primary habitat is the gut of infected man, animals, birds,
insects, rodents, lizards and snakes. From the gut it is excreted out through faeces
and is found in sewage. Fresh fish collected from the open sea is free fromSalmonella.
However, fish from polluted coastal waters are usually infected.
Diseases and Symptoms
Salmonella food poisoning symptoms are nausea, vomiting, abdominal pain,
diarrhoea, fever and headache accompanied by prostration, muscular pain,
restlessness and drowsiness which last for 2-3 days. Complete recovery is possible
only in about 20 days. At this stage these organisms disappear from the intestinal
tract of most of the patients. But upto 5% of the victims may become the carriers of
the organisms for about 3 to 4 months. “Carriers” are known to be the main source
of Salmonella contamination in many types of food materials.
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Reference Book
Control measures: Since incidence of salmonella is associated with polluted coastal

waters, avoid fishing from polluted and near shore waters. Avoid sorting the catch
on sea beaches. Use only chlorinated water for processing and for ice manufacture.
Health check up can be carried out periodically to detect potential carriers and
avoid such carriers from handling food. Follow good sanitary practices and proper
hygiene in seafood factory.
Vibrio cholerae
Characteristics: Vibrio cholerae are shaped like coma or curved rods. They are
Gram negative, non-spore forming and motile. It is aerobic and the optimum growth
temperature is 300c.
Primary habitat:The only known natural habitat of V.cholerae is man and it is
transmitted from man to man through the environment. Usually food, water, flies and
contaminated hands play prominent role in the transmission of this organism.
Diseases and Symptoms: After an incubation period of 1-4 days, there is a sudden
onset of nausea , vomiting, profuse diarrhoea with abdominal cramps. The stools
resemble “rice water” and contain mucus, epithelial cells and large number of vibrios.
The morality rate, without treatment, is between 25 and 50%.
Control measures: Environmental hygiene and sanitation plays a significant role in
the contamination of seafood with Vibrio cholerae. So great importance should be
given for sanitation and hygiene. The surroundings of processing plant should be
kept clean and disinfected. Only potable water should be used and the water used
for different purposes should be properly chlorinated. Due importance should be
given to personal hygiene and periodical medical check ups of the workers are also
advised.
Vibrio parahaemolyticus
Characteristics: Vibrio parahaemolyticus is a Gram negative, non-spore forming
rodes. They are motile, facultatively anaerobic, halophilic and exhibit pleomorphism.
Slightly curved, coccoid and swollen forms are also observed. Its optimum growth
temperature is 30-350C.They are very heat sensitive and they cannot grow beyond
440c.
Primary habitat: This is of marine origin and can be found in seawater, sediments,
planktons, fin fishes and shell fishes of coastal and estuarine origin. It is not reported
from deep ocean since it cannot withstand deep ocean hydrostatic pressure.
28
Diseases and symptoms: In man V.parahaemolyticus causes either diarrhoea,

occasionally dysentery or gastroenteritis. The infection is limited for only a few days
with little evidence of spreading from one person to another.
Control measures: The natural reservoirs of V.parahaemolyticus is sea, estuaries
and animals harvested from there. Preventing contamination of raw material is
impossible. So much effort should be taken to prevent contamination of the finished
products. Time and temperature control is very essential to control its rapid
multiplication. V.parahaemolyticus is sensitive to heat, disinfectants, low pH. None
of these other than heat would inactivate V.parahaemolyticus to a safer level. The
most important means of controlling infection in human being lies in simple hygienic
measures to prevent multiplication and cross contamination. Freezing is the most
important method of preventing multiplication of V.parahaemolyticus in seafood.
Food poisoning would not occur if seafood is heated to 1000C before consumption.
Clostridium botulinum
Characteristics: Clostridium botulinum is an anaerobic, Gram positive, spore
forming, rod shaped bacterium. When it grows in food, it produces a toxin. This
toxin is elaborated into food from bacterial cell.It is an exotoxin. Chemically it is a
protein and when we ingest the food containing this toxin we get food poisoning.
This food poisoning is called ‘botulism’. Botulism toxin is a neurotoxin.
Primary habitat: This anaerobic bacterium is usually present in soil, aquaculture
farm sediments and sea bottom.During unfavourable conditions C. botulinum
produce spores which cannot be destroyed by heat treatment. Under favourable
anaerobic conditions, the spores grow and produce toxin which is heat labile.
Symptoms of botulism
Symptoms begin usually within 12-36 hours after ingestion. Nausea and vomiting
are the initial symptoms. In some cases, gastrointestinal disturbances follow. Thirst,
diplopia (double vision), difficulty to swallow and difficulty to speak may follow.
They may further be followed by breathing difficulty which may further lead to death.
There is no satisfactory treatment for botulism. Once the disease is recognised as
botulism, the only available remedy is to administer antitoxin injection.
Control measures: Clostridium botulinum is usually present in fish obtained either
by capture or by aquaculture. Bottom feeding fishes, crustaceans and molluscs
usually have highest level of contamination with Clostridium botulinum. Intestinal
tract of these species is the main reservoir of this bacterium. So the incidence is
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Reference Book
markedly reduced by gutting the fish. The source of botulism poisoning is usually
the preserved food such as meat and meat products, canned vegetables and fish,
salted and smoked fish and surimi. The spores of Clostridium botulinum are heat
resistant. If food is contaminated with the spores, they survive heat treatment. These
spores can germinate and produce toxins under favourable conditions. But the toxin
is heat labile (destroyed at 800C in 30 to 40 minutes and at 1000C in 10 minutes.).
Hence boiling the canned food for 10 to 15 minutes prior to eating can prevent
hazards due to botulism.\
Shigella
Characteristics: Shigella are Gram negative, rod shaped, non motile, non-spore
forming, facultatively anaerobes growing within a temperature range of 10 – 400C.The
optimum growth temperature is 370C.
Primary habitat: Man is the only known natural host for Shigella. The organism is
transmitted directly from hand to mouth through contaminated fingers, contaminated
food, water and ice, food handlers who are carriers of this organism, through flies
and contaminated contact surfaces.
Diseases and symptoms: Shigella is often associated with intestinal diseases like
bacillary dysentery. It is characterised by the passage of loose motion mixed with
blood and mucous.
Control measures: As the infection due to shigella is exclusively from human sources.
The measures like good personal hygeine, hygienic food handling practices, time
and temperature control, restricting known carriers from food handling and use of
properly chlorinated water and ice are followed to prevent or control this organism.
Microbial limits
Particulars Raw products Cooked Products
TPC 5x105/gram 1x105/gram
Faecal coliforms 20/gram Nil
Staphylococcus aureus 100/gram 100/gram
Salmonella Absent/25 gram Absent/25 gram
V.cholerae Absent/25 gram Absent/25 gram
30
Practicals
Identification and observation of different bacteria.
Identification and operation of various equipments used in seafood industry.
Field visit report and OJT report.
Class test and Seminar
TE Questions
1. ______________is a faecal indicator bacteria.
2. Select a bacteria found in the nasal cavity of man from the list below.
(E.Coli, Staphylococcus aureus, Clostridium, Vibrio cholerae)
3. Describe the sampling methods for Bacteriological analysis
4. Select the exact colony character of bacterium given in column A from column B.
A B
Staphylococcus aureus • Brown colonies with metallic sheen
• Red colonies with or without black centres
• Small black shiny colonies surrounded by an area
of clear zone
3 Briefly describe the method of enumeration of TPC
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Reference Book
Unit No. 3.4

Hygiene and Sanitation in fish processing plants
Introduction
This unit highlights the need for factory hygiene, personal hygiene and chlorination
schedule in processing plants. SSOPs and GMPs followed in Indian sea food industry
are also dealt here. In the early stages the quality of products processed and exported
by our sea food industry was heterogeneous in nature due to the lack of quality
standards. This unit highlights the quality aspects like GMP which includes factory
hygiene, personal hygiene, SSOP and chlorination schedule to be followed in seafood
processing plant.
Learning Outcomes
The learner :
• Practises personal hygiene.
• Explains factory hygiene.
• Evaluates the quality of raw material in a processing plant.
• Practises online processing.
• Records temperature maintenance during processing.
• Experiments on freezing and packing related to production and process control.
• Experiments on packing and storage of frozen foods.
• Explains shipment of processed material.
• Lists key points on SSOP.
• Sketches chlorination chart.
• Estimates available chlorine in process water
• Practises cleaning schedule in a processing plant
GOOD MANUFACTURING PRACTICES (GMP)
Protection of consumers against food borne diseases and maintenance of
manufacture’s reputation mainly depend on the levels of sanitation in the seafood
exporting unit. Seafood processing units handle highly perishable commodity which
need utmost care and hygiene. Elevated temperature, poor sanitary conditions of
the factory premises and inadequate hygiene of the workers will speed up the spoilage.
Any amount of money spent in the factory will result in only diminishing returns
32
unless well organised programme of sanitation is prepared and implemented. GMP

(Good Manufacturing Practices)is one such programme in which a series of
preventive measures and permanent controls are undertaken during food production
to ensure safe end product. The GMP regulations are as follows.
1. Personnels
Disease control : Any person who, by medical examination or supervisory
observation, is shown to have, or appears to have, an illness, infected wounds, or
any other abnormal source of microbial contamination shall be excluded from any
operations.
Cleanliness: All the workers are to be provided with clean outer garments and
boots/foot wears to wear before entering into the working area. They have to clean
their nails by brushing, washing hands thoroughly with the soap solution provided at
all entry points and disinfecting in the hand dip (20ppm chlorinated water) before
starting work. Remove all the unsecured jewellery which may directly come in contact
with food or food handling surfaces while in operations.Proper training is given to
workers of all sections. Proper man power is also to be allotted in each section.
2. Building and facilities
Building:
The building should be a strong permanent structure with smooth surface to facilitate
easy cleaning of dust particles adhering to it. The roof of the building is to be made
of concrete. Separate and adequate change room facilities are to be provided for
the male and female workers of pre-processing and processing section. A raised
platform is to be provided in the receiving section for unloading the material from the
trucks. Separate Chill rooms are to be provided for the storing of raw materials and
processed materials. Separate sections for pre-processing, sorting, grading and
processing are needed with sufficient spaces to avoid any cross contamination.
Separate areas are to be provided for the washing of pre-processing utensils.
Freezing, packing and storing facilities are to be provided in such a way as to facilitate
the flow of work in a unilateral direction. Floors are to be easily washable with
desired slopes towards the drainage line to avoid any stagnation of water. All walls
in the area should be cemented and polished or fitted with glazed tiles up to a height
of 6 feet from the floor to facilitate easy cleaning. The floor-wall joint shall be curved
to facilitate easy cleaning.
All the doors are to be tight fitting and self closing type. Sufficient number of toilets
with all facilities are to be provided. Toilets do not directly open into the pre processing
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Reference Book
and processing area.At the entry to the fish handling area, adequate number of wash
basins may be fitted to wash and disinfect workers' hands before entering the hall.
There shall be foot dip filled with germicides at the entry to the hall and workers shall
be instructed to enter the hall only through the foot-dip. There shall be sufficient
lights and ventilation in the hall.All doors of the processing unit opening to outside
shall be fitted with automatically working air curtains. Proper waste disposal facility
is to be provided. Adequate facilities are to be provided for microbiological and
organoleptic analysis of the product.
Floor : The floor inside the compound is to be concreted and maintained to avoid
any contamination due to dust and stagnation of water.
Adequate drainage is provided in such a way as to prevent the entry and breeding of
pests. Effluent Treatment Plant and its floor shall have proper slope so that the water
on the floor runs into the drain.The drainage openings shall be closed with grills of
proper size to prevent entry of rodents.
Other facilities: There shall be plentiful supply of potable water in the fish handling
hall. Ice shall be stored on raised platform in separate insulation room.
1. Production and process control
a. Raw material purchase and receiving to the unit.
Purchase only very fresh material landed in clean and neat landing centres. Purchase
only well iced material (Temperature of the material below +4ºC). After purchasing,
the materials are re-iced immediately with sufficient quantity of ice, layer by layer
(1:1 proportion) in good and clean containers for transporting to the factory by
insulated trucks. Material is unloaded to the raised platform, from there to the raw
material receiving area through chute.
b. Pre-processing
In the pre-processing centre after de-icing, the material is washed with chilled water
distributed to the peeling/ pre-processing table where peeling, beheading, removal
of entrails/gutting & cleaning, filleting etc. are carried out. Pre- processed material is
iced and shifted to the processing area for further processing.
c. Processing
After de-icing and washing the materials are graded and sorted, according to the
requirements of the buyers. Weighing, setting in trays, adding glaze and arranging in
the trolleys for shifting it to the freezer room or loading in to the plate freezer are
done.
34
d. Freezing
i) Plate Freezing: The freezer will be pre-cooled at +5°C and thereafter the
processed material is loaded into the plate freezers. The plate freezer will freeze
the product at –40°C in 90 minutes, for attaining the core temperature of the
products at -18°C.
ii) Blast Freezing: Here the trolleys in which the trays containing materials are
loaded in to the pre-cooled blast freezer and it is operated until the temperature
inside reaches up to –40°C. This procedure will take around 4 to 5 hours
e. Packing of the frozen products
Packing of both block frozen and blast frozen products are carried out in the packing
area. In the master cartons details such as Name of the product, Manufacture’s
address, Approval number of the Establishment, Type of packing, Brand, etc. are
printed.
f. Storage of the Product
After packing in the master cartons the same is stacked in a cold store where the
temperature is maintained at –18° C or below.
g. Inspections for quality assurance
All processing units should be equipped with an in-house laboratory to monitor
plant sanitation and to have an in-process check on the product.
SANITATION STANDARD OPERATING PROCEDURES
(SSOPs)
The sanitary procedures followed have to be clearly expressed by the seafood factory.
The areas covered are sanitary aspects of water, food contact surfaces including
equipments, machinery, utensils and employees, cross contamination with potable
and non-potable water, materials at different stages, ice, pest control measures,
sanitising and toilet facilities, protection from adulterants, storage of toxic chemicals
and employees health. The areas where daily sanitation monitoring needed should
be identified. Eight key sanitation conditions are explained below.
1. Safety of the water and ice that come in contact with food or food contact
surfaces, or used in the manufacture of ice should be ensured. Testing of
water is carried out once in a year, and once in 4months at EIC approved
laboratory for the parameters as per the EEC Directive.
• TPC at 37°C, 22°C; faecal coliforms and Vibrio cholerae are tested
fortnightly.
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Reference Book
• Water tanks are cleaned fortnightly or as when needed, as per the cleaning
procedure.
• The roof of the concrete water tanks are sealed so that there is no chance
for any external contamination due to bird droppings, dust, rodents etc.
2. Condition and cleanliness of food contact surfaces, including utensils,
gloves and outer garments.
All the equipments that come in contact with food are made of good grade
plastic, stainless steel /Aluminum alloy and GI
3. Prevention of cross contamination from sanitary objects to food, food
packaging material, other food contact surfaces, including utensils, gloves
and other outer garments and from raw material to final product.
The following precautionary practices are exercised to prevent cross contamination:
• The lay out of the plant is in such a way that the raw material received is in
the one end and the finished product handling is in the opposite end.
• There are separate sections for pre-processing and processing
• There are separate change rooms for male and female workers of pre-
processing and processing with all facilities.
• Separate facilities and utensils are provided for each sections like raw ma-
terial receiving, pre-processing, processing etc. and they are distinctly
marked by different colours.
• There are separate washing areas for utensils of pre-processing and pro-
cessing.
4. Maintenance of hand washing & sanitizing and toilet facilities.
Hand washing facilities are provided at the entrance of pre-processing and processing
sections, entrance of toilets and bath rooms. Foot operated taps for potable water,
sink, soap solution, soap filling cans and single use towels are provided. Basins
containing 20 ppm chlorinated water is kept before the main working areas for
sanitizing the hands by dipping for a contact time of one minute.Toilet facilities are
provided in the rest rooms and change rooms as well.
5. Protection from adulterants
Protection of food, food contact surfaces from adulteration with lubricants,
fuel, pesticides, cleaning compounds, sanitizing agents, and other chemical,
36
physical and biological contaminants. These are properly labelled and stored
in a separate chamber and also have separate entrance for storage.
6. Proper labeling, storage and use of toxic compounds.
7. Control of employee health conditions.
Before appointment of workers, the health conditions are assessed by a medical
practitioner. Those who have good health or those who are free from any
contagious diseases are appointed for the work inside the factory. Periodic
health check-ups are conducted and health card showing history of each worker
is maintained in a prescribed format.
8. Exclusion of pests from the plant.
Pests are excluded by providing air curtains and fly catchers at all entry points.
Rodent traps are placed to prevent the entry of rodents.
Chlorination
In plant chlorination has become popular in seafood processing industry for process
control and maintenance of good manufacturing practices. In processing plants sodium
hypochlorites are used as main source of chlorine. It can be directly added to the
water to be chlorinated. Chlorinated water is used for cleaning processing hall, utensils,
processing tables, walls and floors, crates, and all other contact surfces. Process
water as well as water used for glazing is chlorinated to disinfect. Some of the
chlorine added combines with organic matters. The chlorine remaining after satisfying
the demand of water will be available for germicidal action. The level of chlorine
required in water during the various stages of processing seafood are given below.
CHLORINATION CHART
Process water : Below 2 ppm
Ice : Below 2ppm
Glaze water : Below 2 ppm
Hand Dip : 20ppm
Foot dip : 50 ppm
Utensil : 50 ppm
Floor : 150 ppm
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Cleaning Schedule: All food contact surfaces including utensils and equipments
are cleaned before start and end of work as and when required as per the cleaning
procedure.
• Clean the food contact surfaces with water and thoroughly scrub using brush
for removing slime and solid particles, and wash with potable water.
• Scrub with alkaline liquids detergent –Teepol and Wash with potable water.
• Apply disinfectant, chlorine water of desired level for a contact time of 15
minutes.
• Final wash with potable water.
Practicals
1. Visit to fish processing plant, learn and practise
• Personal hygiene
• Factory hygiene
• Processing operation
Estimation available chlorine
Chlorinated water is used for manufacturing ice, as process water and glaze water
and for cleaning various contact surfaces in the processing hall. Definite specifications
are there for available chlorine in water used for different operations. Some of the
chlorine combines with organic matters. The remaining chlorine available for the
bactericidal and bacteriostatic property is of great importance in fish processing
industry. It can be determined titrimetrically by employing Na2S2O2 or As2O2 and
colorimetrically by O- toludine method.
Estimation of chlorine by thiosulphate titration
Principle: This method is based on the following reaction
CI2 + Na2S4O3 = Na2S4O6 + NaCI
When potassium iodide is used in the reaction, the CI2 liberates an equivalent amount
of I2 from KI. The end point is indicated by the discharge of blue colour using starch
indicator. If the available chlorine content is less than 15- 20 ppm, 1000 ml water is
used for estimation.
Reagents required
Sodium thiosulphate 0.025 N
Dissolve 25gm of Na2S2O3.5H2O in 1L to get 0.1N Na2S2O3, standardize against
38
0.1 N K2Cr2O7. Dilute it.

Glacial acetic acid
Potassium iodide
Starch Indicator
Procedure
Pipette 20 ml water sample in to a 250 ml conical flask.Add 2 g of Kl and 5 ml of
glacial acetic acid. Titrate it with std. 0.025N sodium thiosulphate till a light yellow
colour is obtained. Then add 1 ml starch indicator and continue titration till complete
disappearance of blue colour. Note down the volume of thiosulphate used.
Calculation
Available CI2 in water (mg/L)
= V x N x 35.5 x 1000
Vol. of water sample
V = Volume of thiosulphate consumed in titration
N = Normality of thiosulphate used in titration
35.5 =Equivalent weight of chlorine
Handling of apparatus in lab while titration
Calculation of available chlorine
Preparation of questionnaire on personal hygiene and factory hygiene
Summarize the cleaning procedure followed in processing plants
TE questions
1. Expand the following
GMP, SSOP
2. Match the following
2ppm Hand wash
20ppm Floor washing
50ppm Utensil washing
100ppm Ice and processing water
3. Briefly explain personal hygiene
5. Describe 8 points of SSOP
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Unit No. 3.5

QUALITY STANDARDS FOR FISH
AND FISHERY PRODUCTS
Introduction
Food standards have been introduced on a national and international level to
protect the consumer’s health and ensure fair practices in food trade. The formulation
of standards for fish and fish products became necessary to attain a minimum
standards of cleanliness and hygiene in fish handling, processing and exporting. Quality
requirements of different countries are also highlighted here. In order to assure the
quality of sea foods various inspection systems are in use. The guideline by these
inspection agencies ensures that marine products are safe to consume and are
produced under hygienic conditions. This unit highlights the various aspects of
inspection systems in India and abroad.
Learning Outcomes
The learner :
• Lists national and international standards in sea food industry.
• Evaluates various inspection systems.
• Works with HACCP in Sea food industry.
• Maintains various records in processing plants like Hazard analysis work sheet,
HACCP plan form, Tunnel freezer register, Plate freezer registers, Consolidated
daily production register, Daily sanitation check list, Check list for personal
hygiene, Chlorination register, Register for analytical report, Raw material
evaluation register, Register for pre-processing summary and Register for
processing.
National Standards
Government of India through an act of parliament passed a legislation on the Export
(quality control & inspection ) Act in 1963. Based on this act an Export Inspection
Council (EIC) was set up on January 1964 to conduct quality control and pre
shipment inspection. The EIC is assisted by Export Inspection Agency (EIA)
established by the Government under section of the act. Five such EIA were
established, one each at Mumbai, Kochi, Kolkatta, Delhi and Chennai.
From 1969 various inspection schemes of fish and fishery products were handed
over to EIA by CIFT. Today all types of marine products are subjected to compulsory
40
quality control and pre-shipment inspection before export. It has become mandatory
that a certificate of inspection accompanies all consignments.
Bureau of Indian standards ( BIS ):The system was initially known as Indian
Standards Institution ( ISI ). BIS published specifications for fish and fishery products.
The main objective is to formulate qualifying standards for various products including
fishery products and its components are as follows.
• To check physical specification of product such as weight, size etc.
• To check chemical parameters of the product and its composition such as food
additives, ingredients etc.
• To check microbial parameters and avoid contamination of the product.
BIS Specification for Frozen Fish
Raw material Fresh & clean
Signs of spoilage Nil
Freezing temperature Less than – 40o C
Freezing time Less than 2 hours
Organoleptic quality Superior
TPC Below 5 lakhs
The Food Safety and Standards Authority of India ( FSSAI )

It has been established under Food Safety and Standards Act, 2006 which
consolidates various acts and orders that have hitherto handled food related issues
in various Ministries and Departments. FSSAI has been created for laying down
science based standards for articles of food and to regulate their manufacture, storage,
distribution, sale and import to ensure availability of safe and wholesome food for
human consumption.
International standards
Codex Alimentarius Commission
It is an international organization for the formulation of food standards to use globally.
The aim is to protect consumer’s health and ensuring their trade practice. Those
standards are used by member countries to formulate their own standards. The
codex documents include proficiency in respect of good hygiene, contaminants and
food additives, labelling, presentation and sample selection.
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ISO 9000
It is an international organization for standardization, established in 1946 with
headquarters at Geneva, Switzerland. The purpose of ISO is to promote the
development of standardization globally to facilitate international exchange of goods
and services. ISO 9001, 9002, and 9003 are models for quality assurance in
organization . ISO 9004 provides detailed elements to consider when designing or
revising a quality management system. Companies can register their quality
management system to only ISO 9001, 9002, 9003. ISO 9000 is the short cut
name for the overall series of the 5 documents and the name for the first one in the
series.
USFDA
It is enforced by US Government for the safety of general public. It is intended to
ensure that food is pure, wholesome, safe and produced under hygienic conditions.
The requirements under USFDA are name and address of the manufacturer, net
weight, common name of food, ingredients in food, source of raw material, nutritional
label, production code indicating date of production and food additives.
EU Standards
It is prescribed by the countries of European Union. Microbial standards, heavy
metal standards and drug residual content prescribed in European standard make it
unique from other quality standards.
USFDA, EU and Japanese Standards for fish and fishery products
Particulars Raw products Cooked Products
TPC 5x105/gram 1x105/gram
Faecal coliforms 20/gram Nil
Staphylococcus aureus 100/gram 100/gram
Salmonella Absent/25 gram Absent/25 gram
V.cholerae Absent/25 gram Absent/25 gram
Various Inspection Systems

Consignment wise Inspection
It is the simplest form of inspection. Here the owner of the exporting unit submits an
export request for inspection after his consignment is ready for export. EIA performs
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inspection of the product by drawing random sampling. If the sample meets the
requirements and standards specified, a certificate of worthiness will be issued to
the consignment or otherwise it is rejected.
Drawbacks of the system are:
• The rejection of the consignment cause heavy loss to the processor.
• Leads to dislocation of shipping schedule.
Quality Control and Inspection in Approved units (QCIA)
According to this, each processing unit should fulfil certain minimum requirements
related to surroundings, construction, lay out, ceiling, floor, fly proofing, vermin and
animal control, ventilation, lighting, working table, utensils, machinery, cold storage
and warehousing, water and ice, sanitary facilities, sewage and waste disposal, toilet
facilities, personal health & hygiene and transportation facilities.
The unit decided to operate under this system will have to get an approval from the
competent authority before starting the processing. On request a panel of experts
visit the plant and approval will be accorded.
Continuous inspection at different stages of processing is followed. The quality of
water and ice, sanitary and hygienic condition of the plant and maintenance of
documents will also be monitored regularly. Certificate of inspection is issued by
EIA based on end product inspection. It ensures high quality product and losses can
be minimized since the defects are rectified at the production line itself.
In Process Quality Control (IPQC)
To get approval under this system the processing plant meets certain additional
requirements over those in QCIA that includes competent and qualified personnel
to supervise pre- processing operations, to conduct organoleptic evaluation and
bacterial analysis of the product and laboratory with all equipments and chemicals.
Inspection and monitoring at various stages of the processing are conducted by the
personnel of the unit. Based on declaration of the technologist regarding the export
worthiness of the consignment, EIA issues certificate of export.
Self certification Scheme
A unit performed under IPQC for a stipulated period without any problem and with
out any rejections are eligible for self certification. This system is extended to
processors who fulfil:
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• All infrastructural facilities.

• Strict quality control system in the plant.
• Regular auditing of the quality system
• Established reputation.
The technologist of the plant performs the end product inspection and processors
are permitted to certify the export worthiness of their product.
European Union Approval
European Union countries banned import of Indian seafood due to report of certain
pathogens in it during 1997. Government of India took up the matter and as a result
of bilateral negotiations a new system of approval to sea food processing plant was
introduced. The unit which wishes to export fish and fishery products to European
Union has to give a request to EIA. The preliminary panel, IDP (Inter Departmental
Panel) will inspect the plant. If it is approved by IDP a second high power panel,
SAT (Supervisory Audit Team) will carry out inspection. SAT will give
recommendation to EIC and EIC will approve the plant for exporting to EU.
Hazard Analysis Critical Control Point (HACCP)
Hazard Analysis Critical Control Point (HACCP)concept was proposed by USFDA
has been taken as a standard process control system for assuring food safety by
international bodies. This concept offers possibilities to secure the safe production
of food. It helps the processors to perform the analysis and control the process to
prevent known hazards that are likely to occur. It is a preventive strategy, based on
thorough analysis of the prevailing conditions in the processing factory. It is a study
related to the prevention of contamination and growth of micro organisms in all
stages of food chain. Through this system, the hazards that may occur at different
stages of processing are identified and prevent it or reduce it to an acceptable or
safer level by the implementation of Good Manufacturing Practices, Good Hygienic
Practices, Sanitation Standard Operating Procedures etc.
Hazard: A hazard is a biological, chemical, physical or economical factors with
potential to cause an adverse effect on health and wealth.
Biological hazard: This includes pathogenic bacteria, viruses and parasites. These
hazards can come from raw materials or from food processing steps.
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Physical hazard: It includes any physical substances like sand, stones, glass pieces,
insects etc. Decomposition, adulteration and economic fraud also come under
physical hazard.
Chemical Hazard: Naturally occurring chemical hazards including histamine
poisoning, ciguatoxin, PSP, DSP, ASP, unintentionally added chemicals like
pesticides, fungicides, intentionally added chemicals like antibiotics in aquaculture,
sulphites used to prevent melanosis in shrimp etc.
Control point: Control point is any step in a manufacturing process of a product at
which a biological, physical or chemical hazard can be controlled.
Critical Control point: Critical Control point is any step in a manufacturing process
of a product which if not controlled properly may result in the occurrence of a risk
so that the products are unwholesome or cause of economic fraud.
Principles of HACCP:
• Conduct a hazard analysis, identify, list the hazards and specify the control
measures.
• Identify the CCPs in the process.
• Establish the conditions necessary to control hazards at each CCP.
• Establish monitoring system to ensure control of CCPs
• Establish corrective action or preventive measures to be taken while monitoring,
indicates that a particular CCP is moving out of control.
• Establish verification procedure which include supplementary tests together
with a review which confirms HACCP is working properly.
• Establish a documentation system.
Practicals
Preparation of Hazard analysis Work sheet and Plan form for the given Product.
Give a product with its flow chart and prepare Work sheet and Plan form for that
particular product.
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Hazard Analysis Worksheet
Firm name Product Description

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Firm address Method of Storage & Distribution

Intended use & Consumer
HACCP Plan Form
Firm name Product Description

Firm address Method of Storage & Distribution
Intended use & Consumer
Signature of company Official Date

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Example
Product Description : Frozen Cuttle Fish Whole cleaned

Block Frozen 5 x 4 Kg pack
Method of Distribution : Frozen store at – 18o C
Intended use & Consumer : General Public
FLOW CHART
Receiving

De-icing & Washing

Sorting & Grading

Weighing

Setting in trays
 Q/C Inspection

Freezing

Packing in master cartons

Cold storage

 Q/C Inspection
Shipment
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HAZARD ANALYSIS WORKSHEET
Method of Distribution : Frozen store at - 18o C
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HACCP Plan Form

Method of Distribution : Frozen store at - 180 C
Signature of company Official Date

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3.5.4 Various Registers used for Documentation
Processing Register: This register contains the total quantity of raw material purchased with variety, quantity received, quantity
packed, filled weight, count when packed as well as bacterial condition of the raw material.
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Consolidated Production Register: This contains the data of total quantity produced grade-wise, quantity shipped and the
balance available at any time.
Packing register:This indicates the exact number of cartons produced each day, the cartons certified and balance to be
certified.
Inspection register:These contain the details of organoleptic and bacteriological analysis of each day’s production and details
of analysis of sanitary samples.
Register for non-conventional packs: This include stocks of all non-conventional packs stored in the cold storage.
FREEZER LOG
Date:
Shift: Tunnel Freezer
Date:
Shift: Plate Freezer
CONSOLIDATED DAILY PRODUCTION REGISTER
Type of Product………………… Type of Pack…………………….……..Date…………

Code……..
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DAILY SANITATION CHECKLIST
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CHECK LIST FOR PERSONNEL HYGIENE
Date:
Shift:
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CHLORINATION REGISTER
Chlorine level in ppm

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Date Signature of Supervisor

REGISTER FOR ANALYTICAL REPORT
Name of the Fishery product
Type of Product
No. of Cartons
No. of samples drawn code:
ORGANOLEPTIC ANALYSIS
Decision : Remarks : Place :
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RAW MATERIAL EVALUATION REGISTER
Date : Quantity :
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Source : Day code :

Type : Vehicle No :
Species :
REGISTER FOR PRE- PROCESSING SUMMARY
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REGISTER OF PROCESSING
Date ……….
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Practicals (detailing)
1. Chart preparation on physical, biological and chemical hazards.
2. Visit to processing plant and collect specimen copy of various records maintained
in processing plants.
Assessment activities
Participation in practicals
• Unit test
TE questions
1. Find the odd man out
USFDA FSSAI Codex Alimentarius ISO 9000
HACCP EIC BIS CCP FSSAI
Sl. No. A B
1 Physical Hazard Heavy metals
2 Chemical Hazards Pathogenic bacteria
3 Biological Hazard Metal and glass Pieces
4. Prepare an article on the quality standards of fish and other sea foods
5. List the seven principles of HACCP
6. List any five registers used in sea food processing plant
7. Describe Hazard and CCP
EXTENDED ACTIVITY
Seminar on Contamination , Spoilage, Preservation and Processing of Fish and
other Sea foods
PTC can be made service oriented by water quality analysis of adjacent water
bodies for TPC and E.coli; Checking quality of ice from nearby ice plants.
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LIST OF PRACTICALS
1. Draw the structure of a bacterial cell
2. Chart preparation on the different growth phase of bacteria
3. Preparation of stock buffer
4. Preparation of working buffer
5. Enumeration of TPC of Fishery products
6. Identification & Operation of lab equipments like Autoclave, Hot air oven,
Incubator, Colony counter, water bath, water still, BOD incubator
7. Chart preparation and exhibition on GMP and SSOP
8. Preparation of chlorination chart of a processing plant.
9. Estimation of available chlorine
10. Calculation of the amount of chlorine to chlorinate water as per required
concentration
11. Writing sample records and registers maintained in processing plants
12. Chart preparation on physical, biological and chemical hazards
OVERVIEW OF MODULE 4
Ready to eat, cooked fishery based products have now been popularised among
consumers in India. It can be produced with out much investment and sophisticated
technology. Production of fishery based products can be included in the rural
development programmes. Encouraging the production and marketing of fishery
based products through cottage industries can create self employment opportunities
at village level. This will enhance living standards of the rural poor of India.
Hence this module highlights the importance of fish and other sea foods by familiarizing
and developing skills in the production of various fish based products and other sea
foods.
ABOUT THE UNITS
UNIT 4.1 Value Added Fishery Products
Introduction
At present consumers prefer value added fishery products than traditional raw fish.
This value added fishery products can be prepared not only from value fishes but
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also from cheaply available trash fishes. Many value added fish products like fish
cutlets, fish wafers, fish sausage etc. can be prepared from fishes without much
investment and mechanical support. The learners develop skills in the preparation,
storage, and distribution of value added products under hygienic conditions through
practicals, field visits, PTC and OJT activities mentioned in this unit.
Learning Outcomes
The learner :
• Prepares fish marinades
• Prepares fish /clam/prawn pickle
• Prepares fish /clam/ prawn cutlet
• Prepares Fish wafers
• Prepares Fish sausage
• Prepares Fish Ball
• Prepares Fish Finger
• Prepares Fish momos
• Describes the preparation of Fish Protein Concentrate
• Prepares Fish soup powder
• Prepares Dried Prawn pulp
• Describes the preparation of Masmin flakes
Concepts (detailing)
FISH MARINADES
Marinades are fish or fish portions processed by treatment with edible acid and salt
and put up in brine or oil. Development of micro organisms are generally delayed in
acid medium having concentration of 1-2%. Salt extracts water out of the fish tissue
and cause the proteins to coagulate.
Types of Marinades
On the basis of process employed, the marinades are classified into Cooked
marinades and Fried marinades.
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Cooked marinades
Fish or fish portions are treated with edible acids and salt and are heat treated. The
combined effect of heat and acid gives the preservative effect.
Fried marinades
In the Fried marinades the fish after pre treatment with acid and salt is baked or fried
in the oil with or without breading and is covered with acetic acid or sauces. The
higher temperature of frying kills most of the bacteria in fish flesh.
Assessment activity
Group discussion
Class test
Preparation of a project report for starting a small scale fish pickle unit
Practical
PREPARATION OF COOKED MARINADES
Raw material – Good quality Raw material

Washing

Dressing – Gilling, beheading and filleting

Blanching – Blanching in 2% acetic acid and 6-8% salt at 850C for 10 -15 min

Adding spices – Coriander, cloves, pepper and bay leaves are added to final pack

Packing – Pack in a medium of 2% acetic acid and 3% salt

Sealing
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PREPARATION OF FRIED MARINADES

Raw material – Good quality raw material

Washing – To remove dirt, sand, etc.

Weighing

Dressing – Gilling, beheading and filleting

Brining – 5 % salt solution for 10 min

Frying – Deep fry at temperature 1600 C - 1800 for 5-12 min

Adding spices like coriander, cloves, pepper and bay leaves to the final pack.

Pack in a medium of 2% acetic acid and 3% salt
FISH CUTLET
This product is prepared from minced fish meat. Fish cutlet is a highly acceptable
consumer product. They can be flash fried and kept stored up to 6 months.
Preparation of fish cutlets
Cook the fish and separate the meat. Cook the potatoes, peel, mash and add the
cooked fish mince, salt, turmeric powder, kashmiri chilly powder, pepper powder,
masala and fried chopped onion, ginger and curry leaves. Mix them well. Mould the
mixture into round shape and dip in batter and rolled over bread crumps. This is
flash fried in vegetable oil maintained at 160-1700c for 5 seconds. They are then
packed in consumer packets and kept stored at -200 c. Cutlets are deep fried prior
to consuming. Storage life is 6 months at -200c.
Assessment activity
• Calculation of the economics of fish cutlet.
• Marketability of fish cutlet.
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Practical
Preparation of fish /prawn/clam cutlet
FISH WAFERS
Dried, ready-to-fry and ready-to-serve
wafers, with carbohydrate as main base
and incorporating salt and several other
ingredients with or without spices are
very popular in most parts of the Fish Wafers
country. Cheaper varieties of fishes like thread fin breams, sciaenids, cat fish etc.
can be used for the preparation of this product.
Practical activity
Preparation of fish wafers
The dressed and cleaned fishes are cooked in water for 30 minutes. It is then cooled
and edible meat alone is separated. Homogenize the processed fish meat with 1 litre
of water for 10 minutes in a mechanical grinding machine. Add corn flour, tapioca
starch, salt and water; blend the whole mass for one hour. Spread the homogenised
mass uniformly in aluminium trays in a thin layer of 1-2 mm thickness and cook in
steam for 3-5 mins. Cool to room temperature. Cut the cooked material into desired
shapes and dry under sun or preferably in artificial dryer (at 45° C to 50° C) to a
moisture content below 10%.Pack suitable lots of the dried product in sealed
polythene bags or glass bottles and store it in a cool and dry place till marketing. The
product can be stored in good condition for two years. Permitted food colours can
be incorporated, if needed, at the time of mixing the other ingredients with the
processed fish meat in order to get desired colour. Generally, this type of product is
used as side dish after frying in oil.
FISH SAUSAGE
Sausages are prepared from the mince of low value fishes along with ingredients like
starch, sugar, salt, spices, fat. These are packed
in natural casings, synthetic non-edible and edible
casings. Normally the sausages are stored at
refrigerated temperatures for two weeks, and for
more than six months in frozen storage. Heat
processed sausages can be stored at room
temperatures for a period of six months.
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The main ingredient is surimi or ground fish meat. The surimi is mixed with salt (3-
4%), sugar (2-3%), sodium glutamate (0.3%) starch, and soya protein in a silent
cutter. At the end of mixing, lard or shortening (5-10%), polyphosphate (0.2-0.3%)
and flavorings are added and the minced meat is placed in a casing tube made from
vinylidine chloride. Stuffing is done by an automatic screw stuffer. The casing tube is
closed by metal rings. The tube is heated in hot water at 85-90°C for 40-60 min.
After heating, it is cooled down slowly to avoid shrinking of the tube and then stored
at refrigerated temperature
Assessment activity
Prepare a write up on Fish sausage
FISH BALLS
There are several varieties of fish which do not
command a ready market as fresh fish, but are
comparable to many table fish in nutritive value.
One of the ways of ensuring effective utilisation
of such fish is to process ready-to-serve or
ready-to-cook value added products, for which
there already exists great demand from within the country as also from abroad. Fish
ball is one such product prepared using fish mince and starch.
Practical activity
Fish ball preparation
Mix fish mince with 1 % salt and 5% corn starch (if required, spices like garlic,
ginger etc. can be added). Prepare balls of 2-3 cm in diameter. The balls are
battered and breaded. Pack the balls preferably in thermoformed trays as such or
after flash frying in hot vegetable oil. Preserve by freezing and store at -180c.
Assessment activity
Prepare a write up on fish balls
FISH FINGERS
Fish fingers, also known as fish sticks is a
processed food made using a white fish, which
has been battered or breaded. They are commonly
available in the frozen food section of
supermarkets. They can be baked in the oven,
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grilled, shallow fried, or deep-fried. The fish used may be either fillets cut to shape
or minced/ground fish reformed to shape. Those made entirely from fillets are generally
regarded as the higher quality products and will typically have a prominent sign on
the box stating that the fish is 100% fillet. Minced fish is more commonly used in
store brand economy products. They may have either batter or breadcrumbs around
the outside as casing, although the coating is normally breadcrumbs. In addition to
white fish, fish fingers are sometimes made with salmon.
Practical activity
Preparation of fish fingers
Fish is washed in chilled water. It is weighed and meat is separated to a size of 1 x
1 x 5 cm. It is again washed in chilled water, soaking with 3% salt and lemon juice
for 1 hr. Drain for 10 minutes, Pierce thin bamboo needle or stick from coconut
leaves. Then batter (prepared by mixing egg, corn flour, wheat flour, Bengal gram,
dal powder, salt ginger, garlic, kashmiri chilly power etc.) is prepared. It is breaded
and quickly frozen for storage. Fry in oil before serving.
Assessment activity
Prepare a write up on Fish fingers
FISH MOMOS
Momos is a broad classification for a dish that
consists of small pieces of dough (made from a
variety of starch sources), often wrapped
around a filling. The dough can be based on
bread, flour, or potatoes, and filled with fish,
They may be cooked by boiling, frying,
simmering, or steaming. It can be consued as
such or with gravy / sauce, or in soups or stews.
Practical activity
Prepare fish momos
Ingredients
1. Flour (Maida) - 2 cup
2. Salt - ¼ tea spoon
3. Water - as needed
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Combine flour and salt in a large bowl. Add little water knead well for 5 to 6 mins.
to make nice soft dough. Cover the dough with a damp cloth. Cover the bowl with
a lid and keep aside for 10 min. or until use.
For stuffing
1. Fish ( Tuna,Seer fish,etc.) -500g
2. Onion -1 (finely chopped)
3. Ginger paste -1 tsp.
4. Garlic Paste -1 tsp
5. Chopped spring onion - 4
6. Pepper powder- ½ tsp
7. Lime juice -1 tbsp.
8. Salt to taste
Instructions
• Knead dough with maida, salt and water. The dough should not be sticky but
right for rolling out
• For the filling de-vein and mash the fish, add all the other ingredients and mix
well
• Divide the dough into small balls. Using dry flour roll each ball into a thin circle
(as thin as possible)
• Place a small amount of stuffing in the centre of the circle
• Start pleating from one side and join in the centre. Prepare all the momos,
cover with wet cloth and keep aside until use.
• Grease steamer pan with oil, arrange the momos in the pan (keep space between
them). Steam till the outer cover becomes transparent (for about 10-12 min ).
It depends on the thickness of the outer cover
• Serve hot with tartar sauce or tomato ketchup.
Assessment activity
Prepare a write up on Fish momos
FISH PROTEIN CONCENTRATE
Fish Protein Concentrate (FPC) is a food grade powder product designated primarily
for human consumption. FPC is a colourless, odourless powder product with medium
level of protein (50-70%) and contains some level of fat/oil (1-20%) in the powder
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form as well; prepared from fresh fish of almost any kind or size.
Preparation of FPC
Fresh fish is selected for the preparation of FPC. The raw material is washed well in
chilled water and weighed. The fish is beheaded, de-skinned and gut is removed.
The edible meat is picked and minced well and minced meat is suspended in water
in the ratio 1:1. Add glacial acetic acid at the ratio of 5% of the weight of minced
fish. It is heated at 70-800 C for 30 min. on a water bath. The mixture is filtered and
the left over is pressed to make press cake. The press cake is extracted with ethanol
which removes colour and moisture. This is again filtered and pressed in a cotton
cloth. The pressed cake is dried under sun or mechanically in a drier. The dried
material is powdered and packed properly. The packed material is stored at room
temperature.
Assessment activity
Prepare a write up on FPC
FISH SOUP POWDER
White flesh of many low value fish like threadfin bream, Sciaenids, perches, etc. can
be used to prepare fish soup powder. This product has high consumer acceptability
and is now produced by several manufacturers.
Practical activity
Preparation of Fish Soup Powder
The fresh fish is de-skinned and de-boned after cooking. The fried onion is added
to this meat and ground to a fine paste. Then coriander powder, cassava starch,
sugar, pepper powder, garlic, ascorbic acid, carboxy methyl cellulose and mono
sodium glutamate are ground to a fine paste. Mix with ground paste. Spread to a
thin layer, dry under vaccum, pulverise and sieve. Mix with milk powder and pack in
laminated pouches.
Assessment activity
Practical work on Fish soup powder.
DRIED PRAWN PULP
Usually small sized thelly prawns are used for making dried prawn pulp. Prawn is
cooked in salt water until it turns pink in colour. Dry in sunlight. Beating in gunny
bags. Winnowing to separate shell. The pulp is collected and packed properly.
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Practical activity
Preparation of Dried prawn pulp
MASMIN FLAKES
An innovative value added product is prepared by smoking and drying tuna meat.
Minced tuna meat is mixed with salt and liquid smoke, made into a paste and stuffed
inside a stainless steel mould, after which blocks are cooked and dried till the moisture
reaches below 15%. Using a flaking machine, masmin flakes are produced and
dried again to get the product moisture content below 10%. Flakes are then packed
in polyester/polythene laminated pouches and stored at room temperature. Masmin
flakes prepared by improved method has superior biochemical qualities compared
to traditional masmin. The lower moisture of masmin flakes assures higher shelf life.
Nutritional profiles such as protein content and lysine content are high. It shows
higher levels of PUFA especially EPA, DHA and can play a vital role in attracting
consumer health consciousness to this product.
TE QUESTIONS
1. Name the 2 types of Marinades
2. Name the preservation method in which the anaerobic fermentation in brine or
immersion in vinegar is practised
3. Given below are some fishery value added products. Select the breaded product
a. fish pickle
b. fish sausage
c. fish momos
d. fish cutlet
4. Lakshdweep is famous for this product
It is a smoked product.
It is made from Tuna fish.
Name the product.
5. Name the fishery value added product for which natural or artificial casing is
necessary for the preparation.
6. You are asked to prepare fish pickle in the practical examination. Write the
procedure to prepare it.
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UNIT 4.2
Fishery Byproducts
Introduction
Fish offal and trash fishes are the major sources for the production of fish byproducts.
Fish flesh on an average contains 15-20% protein. Some species of fish contain
very high amounts of body oil. Few species of fish like shark, cod etc. are good
sources of liver oil. Fish processing and filleting industries turn out large quantities of
fishery waste. All these are good sources of high quality protein, fat, minerals etc.
and are used to produce different fishery byproducts.
The traditional fishery byproducts are fish meal, fish body and liver oils, fish maws/
isinglass etc. Fish protein concentrate, pearl essence, fish skin leather etc. are some
other byproducts generally processed out of fish and fish waste. Chitin and chitosan
processed out of shrimp, crab and other crustacean shell waste are byproducts of
high economic value. Biochemical and pharmaceutical products like bile salts, insulin,
glucosamine etc. are byproducts of great significance. A brief account of some of
the important fishery byproducts is given below.
Learning Outcomes
The learner :
• Prepares chitin & chitosan
• Prepares shrimp extract
• Prepares Fish meal
• Prepares Fish body oil
• Describes the preparation of Pearl essence
• Describes the preparation of Isinglass
• Prepares Fish silage
Chitin and Chitosan
Chitin is the second most abundant biopolymer on earth next only to cellulose. It is
a white, hard, inelastic nitrogenous polysaccharide extensively used for several
purposes. In India, the single largest source of chitin is the shrimp shell waste. Chitin
is produced from the shell waste by deproteinisation and demineralization. Chitosan
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is produced by the deacetylation of chitin. Chitosan has several industrial and medicinal
uses.
Chitosan is used
• growth promoter in animals and birds, used as an ingredient in their feed.
• clarifying agent of fruit juices
• purification of drinking water
• treatment of waste water and sewage effluents
• sizing agent in textiles and paper
• pharmaceutical and cosmetic industry
Practicals
Preparation of chitin and chitosan
Chitin is prepared from shrimp or crab shell waste which involves two important
steps, demineralisation of the waste using a mineral acid followed by deproteinsation
of the demineralised mass using a dilute solution of caustic soda. The shell waste is
stirred well with dilute hydrochloric acid (1.2N) until it becomes soft. Demineralisation
may take upto 1-2 hours for completion and is indicated by stoppage of effervescence.
The liquid is decanted and the mass is washed with water until free of acid. Then the
residue is boiled in 5% NaOH for 30 minutes. Drain the solution and wash the
residue till free of alkali. Filter off the liquid and dry under sun or using mechanical
drier.
Chitosan is prepared by the deactylation of chitin with 60% NaOH or KOH in 1:1
ratio for 90 minutes at 95-100oC. The alkali is drained off and the residue is washed
repeatedly using water until it is free from alkali. The residue is then dried in sun or in
a mechanical drier. It is then packed in polythene bags.
Quiz
Draw chart for preparation of chitin
Shrimp extract
Large quantities of prawn waste are thrown away as waste. The high percentage of
protein present in this waste can be isolated for human consumption or as animal
feed.
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Reference Book
Practicals
Preparation of shrimp extract
Prawn waste is washed to remove dirt, sand, etc. Then it is boiled with 3% NaOH
for 30 minutes. It is then filtered and the filtrate is neutralized with acetic acid. The
filtrate is concentrated to obtain semi solid mass. It is packed in polythene bags and
stored in frozen condition.
Quiz
Port folio
Report on shrimp extract preparation
Fish meal
Fish meal is a commercial product made from fish offal and trash fish. It is a brown
powder or cake with high nutrient. Constituents of meal vary depending on the type
of raw material and the process used. Protein is generally around 65%. Moisture,
fat and ash content vary at 6-10%, 5-10% and 12-33% respectively. Fish meal is
also an important source for minerals such as calcium, phosphorus, copper, zinc,
manganese, iodine and selenium. Hence fish meal is considered to be a valuable
constituent of fish and poultry feeds.
Practicals
Preparation
Fish meal is prepared mainly by two processes – wet rendering and dry rendering.
Wet rendering is normally applied to fatty fish where it is boiled with water to render
the bones and meat portions soft. The aqueous portion decanted and the solid portion
is pressed in a canvas bag with screw press to remove further quantity of water and
oil. The filtrate and pressed out liquid together is called stick-water. The whole
liquid is then centrifuged to remove oil. The pressed cake is dried and then pulverized
in a grinder and sieved to get uniform size. Pack in polythene pouches. In wet rendering
some of the soluble nutrients like proteins, minerals and vitamins are lost in the stick
water. Most of the fat content is expelled out along with stick water in the wet
rendering.
Dry rendering is the process employed to lean fish where it is dried in the sun to
moisture levels of about 10% . It is then pulverized and packed. All nutrients are
74
retained in the dry rendering. In dry rendering fat is retained in the final product, it
gets easily oxidized and rancid, adversely affecting its quality and shelf life.
Quiz
Draw flow chart for preparation of fish meal by wet rendering method.
Port folio
Report on fish meal preparation
Field visit report
Fish body oil
Body oil is extracted from fatty fishes like Oil sardine. Fish body oil is also obtained
as a byproduct of fish meal production.
Uses
• Preparation of factice, an artificial rubber filling compound from sardine oil
• Fat liquoring in the leather industry
• Tempering of steel
• Batching of jute
• Manufacture of insecticidal soap
• Protective coat on wooden fishing crafts
Practicals
Preparation of fish body oil
The raw material is washed, cooked with equal quantity of water for 30 minutes
with occasional stirring till oil floats on the surface. The oil that floats on the surface
is collected. It is then boiled again for another half an hour with occasional stirring
and allowed to settle. The upper layer of the oil is decanted and water is kept
separately. The cooked mass is then pressed in a cloth bag using a screw press. The
press liquor and the liquid portion already decanted and kept earlier are mixed and
common salt is added and stirred. This helps quick separation of oil. The oil is then
heated on a water bath to remove adhering water and stored in air tight containers.
Draw chart for preparation of fish body oil
Quiz
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Reference Book
Pearl essence
Guanine is deposited in the epidermal layer and on the scales of most of the pelagic
fishes. Since those crystalline guanine are suspended in a suitable solvent the product
is called pearl essence. The scales are soaked in gasoline to separate pearl essence
from protein and water. The pearl essence is transferred into gasoline where it floats
to the surface. The separated pearl essence is then filtered to obtain the fine particles
of pearl essence.
Uses
• Artificial pearl
• Shiny coatings in ash trays, fishing rods, book covers, textiles, jewellery boxes,
umbrella handles and electric light switches.
Quiz
Isinglass / Fish maws
Dried air bladders (swim bladders) of catfish, carps, eels, polynemids, sciaenids,
sea bass, etc. is called Fish maws. They are rich in collagen and used as delicacy in
Chinese soups. The bladders are first removed from the selected fish and blood and
adhering fat materials are scraped off. They are then cut open and washed thoroughly
in running water. Then the outer black membrane is removed by scraping.
Subsequently the bladders are cut into pieces and are dried in an artificial drier or in
sun and stored in suitable containers. Isinglass, so prepared is used for clarifying
beverages like wine, beer and vinegar. Isinglass also reduces 2 to 0.05% of the
suspended solids in beer and increases filtration rate from 3000 to 11,000 liters. It
can also be used as an adhesive base and in confectionery product, Indian ink and
as an efficient adhesive for glass, pottery and leather. Products with less than 8%
moisture content are however, preferred for industrial purposes.
Quiz
Fish silage
Fish silage is a liquid product made from trash fish or fish offal that are liquefied by
the action of enzymes in the fish in the presence of an added acid. The enzymes
breakdown fish protein into smaller soluble units and the acid helps to speed up their
76
activity while preventing bacterial spoilage. Formic, propionic, sulphuric and

phosphoric acids are used. Normally about 3-4% of acid is added so that the pH
remains at or below 4.0.
Practicals
Preparation of fish silage
Fish or offal is ground and mixed well with 3.5% by weight of formic acid of 85%
concentration using a mechanical mixer. The quantity of acid used must be sufficient
to bring down the pH of the mixture to 4. Periodic agitation will assist the process of
liquefaction of protein that may take 1-2 weeks depending upon the freshness and
oil content of fish.
Uses
Fish silage is used as cattle feed.
Seminar on fishery byproducts
Unit test
Quiz
Port folio
Report on fish silage
TE questions
1. Name the two methods employed for preparation of fish meal.
2. Given below are the uses of a fishery byproduct. Name the byproduct.
• preparation of factice, an artificial rubber filling compound
• coating on wooden fishing crafts
3. Varun prepared a fishery byproduct from the scales of sardines, mackerels,
carps, mullets and ribbon fishes. Identify it.
4. In a pre- processing plant large quantities of prawn shell waste is available.
Can you use this for making any fishery byproduct?. If yes, name the product
and describe the method of preparation.
5. What is used for the preparation of isin glass?
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Reference Book
UNIT 4.3
MISCELLANEOUS AQUATIC PRODUCTS
Introduction
Though aquatic products are largely based on fish related products, plant origin
products also contribute substantial proportion to the aquatic products. Sea weeds
are the major plant items from sea and they have higher content of important minerals
like calcium and iron than fruits. It has important role in the food consumption of
people. This unit highlights the important plant and animal based aquatic products
and their usage. Some aquatic products like Ambergris has importance in perfume
industry.
Learning Outcomes
The learner :
• Explains the source and importance of Algin
• Explains the source and importance of Agar agar
• Explains the source and importance of Carrageenan
• Explains the source and importance of Beche-de-mer
• Explains the source and importance of Ambergris
Detailing of Unit
Algin
Algin, also called alginic acid or alginate,
is a polysaccharide distributed widely in
the cell walls of brown algae; binds with
water to form a viscous gum. Its colour
ranges from white to yellowish-brown. It
is sold in filamentous, granular or Brown algae
powdered forms. Alginates are refined from brown seaweeds. A wide variety of
brown seaweeds of the phylum Phaeophyceae are harvested throughout the world
to be converted into the raw material commonly known as sodium alginate.
Uses
Sodium alginate has a wide use across a wide variety of industries including food,
textile printing and pharmaceutical. Dental impression material utilizes alginate as its
means of gelling. Alginate is both food and skin safe.
78
• Manufacture of paper and textiles, water proofing and fireproofing fabrics.

• In food industry as a thickening agent for drinks, ice cream and cosmetics and
as a gelling agent for jellies.
• In pharmaceutical preparations, such as Gaviscon, in which it combines with
bicarbonate to inhibit reflux.
• Sodium alginate is used as an impression-making material in dentistry.
• Sodium alginate is used in reactive dye printing and as a thickener for reactive
dyes in textile screen-printing. Alginates do not react with these dyes and wash
out easily, unlike starch-based thickeners.
• Calcium alginate is used in different types of medical products including skin
wound dressings to promote healing and can be removed with less pain than
conventional dressings.
Preparation
Seaweed is broken into pieces and stirred with a hot solution of an alkali, usually
sodium carbonate, for about two hours. The alginate dissolves as sodium alginate
to give a very thick slurry. This slurry also contains the part of the seaweed that does
not dissolve, mainly cellulose. This insoluble residue is filtered. The goal of the
extraction process is to obtain dry, powdered, sodium alginate. The calcium and
magnesium salts do not dissolve in water; the sodium salt does.
Agar agar
Agar is a gel forming substance soluble in hot water. It is a complex mixture of
polysaccharides obtained from the cell wall of certain species of red algae. It is
mainly a mixture of two polysaccharides – Agarose and Agaropectin. The major
source of agar is agar yielding red algae like Gracilaria, Gelidium and Pterocladia.
The characteristics of agar includes the gelling power in aqueous environment. (It
gives gels without flavour) and it withstands thermal treatment above 100o C.
Agar plates for microbial culture Plant Tissue culture in agar
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Reference Book
Uses
• Thickening and gelling agent
• In bakery, it is used to cover cakes as in icing
• In bacteriology, it is used for the preparation of culture media
• In confectionery, it is used to prepare jellies
• It is used as plant tissue culture medium
Carrageenan
Red algae
Carrageenan or carrageenin is a polysaccharide extracted from red edible

seaweeds. They are widely used in the food industry, for their gelling, thickening,
and stabilizing properties. Their main application is in dairy and meat products, due
to their strong binding to food proteins.
Gelatinous extracts of the seaweed, Chondrus crispus (Irish Moss) is used as
food additives, an alternative to gelatin in some applications or may be used to
replace gelatin in confectionery.
Preparation
The seaweed is dried, ground and washed thoroughly. After treatment with hot
alkali solution (e.g., 5–8% potassium hydroxide), the cellulose is removed from the
carrageenan by centrifugation and filtration. The resulting carrageenan solution is
then concentrated by evaporation. It is dried and ground to specification.
Uses
• Desserts, ice cream, cream, milkshakes, yogurts, salad dressings, sweetened
condensed milks
• Sauces: used to increase viscosity
• Beer: clarifier to remove haze-causing proteins
80
• Pâtés and processed meats (e.g., ham): substitute for fat, increase water retention,
and increase volume.
• Toothpaste: stabilizer to prevent constituents separating
• Fruit Gushers: ingredient in the encapsulated gel
• Fire fighting foam: thickener to cause foam to become sticky
• Shampoo and cosmetic creams: thickener
• Air freshener gels
• Marbling: the ancient art of paper and fabric marbling uses a carrageenan mixture
on which paints or inks float; the paper or fabric is then laid on it, absorbing the
colours
• Shoe polish: gel to increase viscosity
• Biotechnology: gel to immobilize cells/enzymes
• Pharmaceuticals: used as an inactive excipient in pills/ tablets
• Soy milk and other plant milks: used to thicken, in an attempt to emulate the
consistency of whole milk
• Diet sodas: to enhance texture and suspend flavours
• Pet food
• Personal lubricants
• Vegetarian hot dogs
Beche-de-mer
The food product prepared from Sea cucumbers ( marine animals of the Phylum
Echinodermata, Class Holothuroidea, Genus Holothuria) is called Beche-de-
mer. They are used in fresh or dried form in various cuisines. In some cultural contexts
the sea cucumber is thought to have medicinal value.
Fresh sea cucumber Dried sea cucumber
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Reference Book
Ambergris
Ambergris is a compound excreted from
the intestine of sperm whales and found
floating on sea surface and on coastal
areas. It has a peculiar musk odour and
used in blending large number of exotic
perfumes. Ambergris is often spotted in
tropical and sub tropical sea shores of
many countries like Australia,
Newzealand, India and Bahamas.
Ambergris is now considered as a morbid material from the intestinal tract of sperm
whale. It comes from the stomach of dead whales. When sperm whale feeds on
cuttle fish, due to some injury or unknown reason ambergris is formed in the intestine.
This is based on the observation that often small fragments of cuttle fish are found in
the ambergris when collected freshly.
A good quality ambergris is soft, waxy and gray in color and is found to have
concentric layered structure resembling that of onion. It is mainly used in perfumery
as tincture and essence for fixing delicate odours.
TE Questions
1. Write short notes on agar agar
2. State the uses of algin.
3. Beche-de-mer is prepared from —————————.
4. Name the product obtained from sperm whale which is used in perfume industry.
5. Find the odd man out.
Laminaria, Macrocystis, Ascophyllum, Gelidium, Staphylococcus
82
UNIT 4.4
PACKAGING OF FISHERY PRODUCTS
Introduction
Packaging is an important part of production, storage and distribution of any product.
It facilitates the easier and safer transport of the product and protects it from
contamination and loss, damage or degradation etc. It also provides an opportunity
to the buyer to identify the product and of course persuades the buyer to purchase
the product. This unit helps to get basic idea of packaging material and packing
methods. Packaging may be defined as the means of ensuring the safe delivery of a
product to the end consumer in sound condition at the minimum overall cost. Food
packaging is an external means of preservation of food during storage , transportation
and distribution. They should facilitate storage, effective chilling, internal and long
distance transport, easy determination of quantities and display in whole sale and
retail markets. Packaging materials protect the product from contamination or loss.
The printing on the exterior of the package helps to identify the brand and attract the
buyer’s attention.
Learning Outcomes
The learner :
• Identifies packing materials like Glass containers, Metal cans, Types of paper
packages, Cellophane, LDPE, HDPE, Aluminium foil and Retort pouch
• Practises packing of Frozen Material like IQF products, Block frozen Products.
• Practises packing methods like, packing on stand pouch, packing in polythene
covers.
• Categorises the packing of various value added fishery products and by
products.
• Classifies the packaging of canned fish and fish pickle
• Evaluates modern packing methods like MAP, CAP, Vacuum packing.
Packing materials
Glass containers
Glass containers are one of the important materials for food packaging. It is strong,
rigid, chemically inert and can be moulded in to variety of size and shape. It is an
excellent barrier to solids, liquids, gases and gives protection against flavour and
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Reference Book
odour contamination. The main disadvantage is that it is fragile in nature.

Metal cans
It is mainly used for heat sterilized products. Different types of metal containers like
standard tin plate, light weight tin plate and tin free steel etc. are available in the
market. Metal cans have superior strength and can fill products easily. The main
disadvantages are weight, difficulty in reclosing and disposal.
Paper
Considerable quantity of packaged foods are stored and distributed in packages
made out of paper or paper based products. Because of its low cost, easy availability
and versatility it retains first position in packaging materials. It is permeable to gases
and moisture and loses its strength when wet. Ordinary paper is not oil resistant but
can be made resistant by mechanical process during manufacture. The different
types of papers used in packaging of seafood are listed below.
• Kraft paper : This is a strong paper and is used for the manufacture of corrugated
fibre board box.
• Parchment paper : The surface of parchment paper is more intact than kraft
paper and it has greater oil resistance and wet strength properties
• Grease proof paper : It is resistant to oil and fat but this property is lost when
the paper becomes wet. It is used for wrapping fish, meat and diary products.
• Paper board : Thick paper is called paper board. Paper boards are used for
carton making.
Cellophane
It is produced from highly purified cellulose. Uncoated cellophane is flexible, strong,
transparent, grease proof, hygroscopic and permeable to water vapour. When both
sides of the film are coated with moisture resistant lacquers, permeability to vapour
and other gases is greatly reduced. Polythene coated cellophane is available. It has
low permeability to odours so that the aroma is retained in the package itself.
Low Density Polyethylene – LDPE
Most widely used packaging material as it posses qualities such as transparency,
water-vapour impermeability, heat stability, chemical inertness and low cost of
production. It resists temperature between – 40 to 85 o C. It is made by the
polymerisation ethylene (natural state is gas) under high pressure and temperature.
The density of the finished product is low and it is called low density polyethylene.
84
High Density Polyethylene – HDPE

It is produced by low pressure process. The density of the finished product is high.
HDPE is stronger, thicker and less flexible than LDPE and has lower permeability to
gases and moisture. It can withstand temperature up to121o C.
Aluminium foil
Aluminium foil is a solid sheet rolled to a thickness less than 0.006 inches. It has
properties like reflectivity, thermal conductivity, light weight, corrosion resistance,
grease and oil resistance, tastelessness, odourlessness, heat and flame resistance.
Aluminium foil free from defects is a perfect barrier of moisture and oxygen. It is the
cheapest material to use for the said properties. Foils of thickness 8 to 10 micron
are used for food packing.
Retort pouch
Retort pouch is a type of flexible packaging material for canned products. It can
withstand thermal processing. It is made of three materials, an outer layer of polyester
for strength, a middle layer of aluminium foil as barrier for moisture, light and gas and
an inner layer poly propylene as the heat seal and food contact material. The pouch
is thinner than cans and takes less time to reach sterilization temperature . It can be
easily opened by cutting with scissors . The main disadvantage of pouch packing
could be that they are not robust like cans and special packaging system is required
for transportation.
Assessment activity
Collection and Exhibition of different types of packaging materials
Assignment on packing materials
Packaging of frozen Fish
In India Sea food industry has emerged as one of the major export oriented industry.
India exports ninety varieties of seafood products to various countries all over the
world. Of these, frozen products dominates the trade. Frozen shrimp, Frozen fish,
Cuttlefish and Squids are important marine products exported from India. A suitable
frozen fish package must be able to meet the following requirements.
• Reduction in moisture loss, oxidation and change of odour and flavour.
• Retention of volatile flavours
• Flexibility to fit the contour of the food.
• Resistance to puncture,brittleness and deterioration at low temperature.
• Ease of filling.
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Reference Book
The conventional system of processing shrimps is to in plate freezers as blocks of 2

kg and 4 kg. The material for packing comprises LDPE/HDPE films, duplex carton
and corrugated fibre board box. The problems with this packaging system are their
low mechanical strength and tendency to get wet due to deposit of moisture.
Shrimps are frozen as blocks of 2 kg each in duplex board cartons lined with low
density polyethylene (LDPE) and 10 such cartons are packed in master cartons
made of 5 ply or 7 ply corrugated fibre board box. Fishes, cuttlefish and squid
products are frozen as 2 kg or 4 kg blocks. 10 or 5 such blocks are packed in
master cartons made of 5 ply or 7 ply corrugated fibre board box lined with low
density polyethylene ( LDPE ).
IQF products are filled in a primary container (plastic mono film, co - extruded film
or laminated pouches) of capacity varying from 200 gm to 4 kg. After weighing the
primary pack is closed by heat sealing and further packed in master cartons for
storage and transportation. If and when duplex carton is used , it will be desirable to
use laminated plastic film on the inner side of the carton (The most effective film is 10
micron poly propylene).
Practical Activity
Preparation and packaging of 2 kg block frozen shrimp and fish
Assessment activity
Evaluate the personal skill of learners on packaging of various frozen fishery products.
Packaging of dried Fishery products
Baskets with braided coconut or palmyra leaves are the containers exclusively used
for packing this product both for export and internal distribution.An overwrap with
gunny fabrics is given as reinforcement in the case of products meant for export and
those which have to be transported over long distance inside the country.
But now the bulk of packaging material in use are waxed corrugated cartons, dead
wood or plywood boxes and high density polyethylene ( HDPE is impervious to
microbial and insect attack ). The commonly used packaging material for consumer
pack of dry fish are low density polyethylene or poly propylene.
Practical Activity
Preparation and packaging of dried fishery products such as dried anchovy and
dried shrimp
86
Assesment activity
Packaging of dried fishery products
Packaging of value added fishery products and byproducts
As the sea food industry in India started diversifying into the production of various
value added fishery products, packing of these products become necessary.
Processing technologies have been developed for preparing fish ready to cook and
ready to serve and value added products from many varieties of cheaper fish which
has less demand in the fresh fish market. The most important such products are
battered and breaded shrimp, Squid rings, stuffed squid, fish fingers, fish cutlet and
fish momos etc. The thermoformed trays produced from food grade PVC and poly
styrene are suitable for packaging value added fishery products. These thermoformed
trays are usually sealed with polyester based film and are useful in self service system.
Practical Activity
Preparation and packaging of value added Fishery products such as fish sausage,fish
cutlet and fish momos
Assessment activity
Packaging of value added Fishery products
Packaging of canned fish and fish pickle
An ideal canned fish package should be hermetically sealable, thermally conductive,
inexpensive and without affecting the odour, colour, texture or food value of the
content. Sulphur resistant lacquered cans are generally used for food products. Tin
plate cans and aluminium cans are also become popular. Today bulk of the canned
fish in the world is being packed in aluminium cans as it does not produce dark
sulphur stains.
The traditional material for packing of pickled products is glass bottles because of
its rigidity, inertness, non toxicity, durability and non permeability to gases and moisture.
But recently flexible packaging materials based on polyester laminated with LDPE –
HDPE co- extruded film are in use. In this flexible packaging materials pickle can be
kept for a period of 7 to 8 months at ambient temperature .These materials do not
have any bad effect on the product and can be fabricated as stand up packs with all
details printed. So this material can replace the glass containers and the cost is also
found to be less than that of glass containers.
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Reference Book
Practicals
Preparation and packaging of fish pickle
Assessment activity
Packaging of fish pickle
Modern Packaging Methods
Vacuum Packing
Vacuum Packing is a method of packaging that removes air from the package prior
to sealing. This method involves manually or automatically placed items in a plastic
film package, removing air from inside and sealing the package. Shrink film is used
to have a tight fit to the contents.
Modified Atmosphere Packaging (MAP)
The high ambient temperature of tropical countries favours rapid multiplication of
microbes and thereby accelerates spoilage. Presently ice and mechanical refrigeration
are the common methods to retard microbial and enzymatic spoilage. Modified
Atmosphere packaging ( MAP ) is a technologically viable method developed as a
supplement to ice and mechanical refrigeration to reduce the loss and extend the
storage life of fresh sea food products.
In MAP air is replaced with different gas mixtures to regulate / retard microbial
activity and discard discolouration of the product. The gases normally employed are
carbon dioxide, mixtures of carbon dioxide and oxygen, carbon dioxide and nitrogen,
oxygen and nitrogen. Packaging materials generally employed for this purpose are
flexible films of nylon, PVC moulded trays and low density polyethylene.
Controlled Atmosphere Packaging (CAP)
A controlled atmosphere is an agricultural storage method; an atmosphere in which
oxygen, carbon dioxide and nitrogen concentrations as well as temperature and
humidity are regulated. CAP is usually employed in the storage of fruits where the
respiration rate is retarded so that they do not mature as quickly, which helps to
maintain crispness and flavour. During this time, the starch also slowly changes to
sugar, so that the fruits coming out of CAP has that “just-picked” taste.
88
TE Questions
1. List out different packaging materials used for the packaging of fishery products
HDPE, LDPE, PVC
3. State the difference between kraft paper and parchment paper
a. Glass container i Fish and meat
b. Metal cans ii Fish pickle
c. Grease proof paper iii Canned foods
5. Prepare an article about the advantages of Retort pouch over metal can
EXTENDED ACTIVITY
Project proposal preparation for a small scale fishery value added product unit.
Seminar on Prospectus of Battered and Breaded products in Indian market.
LIST OF PRACTICALS
1. Preparation of fish /clam/prawn pickle
2. Evaluate the economics in preparation of fish /clam/prawn pickle
3. Preparation of fish /clam/prawn cutlet
4. Evaluate the economics in preparation of fish /clam/prawn cutlet
5. Preparation of fish wafers
6. Preparation of Fish sausage
7. Preparation of Fish Finger
8. Preparation of Fish momos
9. Preparation of fish wafers
10. Preparation of chitin & chitosan
11. Preparation of fish meal
12. Preparation of Fish body oil
13. Preparation of Fish Silage
14. Exhibition on packing materials like Glass containers, Metal cans, Types of
paper packages, Cellophane, LDPE, HDPE, Aluminium foil and Retort pouch.
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Reference Book
LIST OF REFERENCES
1. Fish Processing Technology – T.K.Govindan, Oxford &IBH Publishing
Company, New Delhi
2. Post harvest Technology of Fish and Fish products-Balachandran.K.K, Daya
Publishing House, Delhi
3. Text book of Fish Processing Technology – Gopakumar.K ,ICAR ,New Delhi
4. Training Manual on Sea food Quality Assurance -CIFT
5. Advances in Fish Processing Technology – Sen D P , Allied Publishers Pvt.
Ltd. New Delhi
6. Introduction to Fishery Byproducts -Barlaw
7. Fish Processing Technology, G M Hull,Blackie Academic and Professional,
London
8. Fish & Fisheries Products, Hazards & Controls Guide, Department of health
and Human services, Food and Drug Administration.
9. HACCP in Meat, Poultry and Fish Processing – Pearson A N & Duston T R
(Eds.), Blakie Academic &Professional, London
10. Quality Assurance in Seafood Processing – Bonnell A D, Chapman & Hall,
New York
11. Microorganisms in Foods, Their Significance and Methods of Enumeration –
ICMF, University of Toronto Press, London
12. HACCP User’s Manual – Corlett D A Jr., Av Aspen Publications, Maryland
13. Seafood Quality Determination – Krammer, D E and Liston, J (Eds.), Elsevier,
London
90

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Vocational Higher Secondary

State Council of Educational Research and Training (SCERT),

Unit No. Name of units Page No.

3.1 Basic Microbiology 10

Module 4 : FISHERY VALUE ADDED AND BYPRODUCTS

• Sampling methods for microbial examination, methods of sterilization,

Module 4 : FISHERY VALUE ADDED AND BYPRODUCTS

STRUCTURE OF A BACTERIAL CELL

CLASSIFICATION OF BACTERIA BASED ON SHAPE

CLASSIFICATION OF BACTERIA BASED ON TEMPERATURE

Thermophiles (Thermo =Temperature, Philes = Love)

CLASSIFICATION OF BACTERIA BASED ON SALINITY

PATHOGENIC AND NON PATHOGENIC BACTERIA

• Most of them are spore forming bacteria.

UNIT 3.2- FISHERY MICROBIOLOGY

pathogenic bacteria by contaminations. These are assessed by the

• Total plate Count

• Moist heat sterilization: This is done by autoclaving the items to be sterilized.

Temperature is controlled by hydraulic

Sources of contamination :- Near-shore waters, contaminated boat deck, fish

Food poisoning due to S. aureus:-

Control measures: Since incidence of salmonella is associated with polluted coastal

Diseases and symptoms: In man V.parahaemolyticus causes either diarrhoea,

3 Briefly describe the method of enumeration of TPC

Unit No. 3.4

unless well organised programme of sanitation is prepared and implemented. GMP

0.1 N K2Cr2O7. Dilute it.

Unit No. 3.5

The Food Safety and Standards Authority of India ( FSSAI )

Various Inspection Systems

• All infrastructural facilities.

Firm name Product Description

Firm address Method of Storage & Distribution

Firm name Product Description

Signature of company Official Date

Product Description : Frozen Cuttle Fish Whole cleaned

Product Description : Frozen Cuttle Fish Whole cleaned

Signature of company Official Date

Type of Product………………… Type of Pack…………………….……..Date…………

Chlorine level in ppm

Date Signature of Supervisor

Decision : Remarks : Place :

Source : Day code :

REGISTER FOR PRE- PROCESSING SUMMARY

PREPARATION OF FRIED MARINADES

activity while preventing bacterial spoilage. Formic, propionic, sulphuric and

• Manufacture of paper and textiles, water proofing and fireproofing fabrics.

Agar plates for microbial culture Plant Tissue culture in agar

Carrageenan or carrageenin is a polysaccharide extracted from red edible

Fresh sea cucumber Dried sea cucumber

odour contamination. The main disadvantage is that it is fragile in nature.

High Density Polyethylene – HDPE

The conventional system of processing shrimps is to in plate freezers as blocks of 2

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