In accordance with DS 040-2001-PE / 07-2004-PRODUCE and

harmonized in this regard with those of the EU AND THE USA

EXHIBITOR: ING. MARCELINA LEYTON GORDILLO

CIP 75295
 PART IV
MANUFACTURING PRACTICES
FRESH FISH
AND FROZEN
 PART IV.

Preliminaries: Legal basis. Good Manufacturing

Practices in freezing operations
1. Application of GMP in the processing of fresh and
frozen fish.
2 GMP control in the process of fresh and frozen fish
.

ML
G

NATIONAL LEGISLATION
SANITARY STANDARD FOR ACTIVITIES
FISHERIES AND AQUACILLARS DS040-2001-PE
Operators Responsibility
Article 83.- Processing plant operators must guarantee:
1. The use of fish and ingredients that are healthy, free of decomposition or
contamination, as well as fish from authorized areas.
2. The application of good hygiene and sanitation practices in all processing stages and
operations.
3. The application of processing practices in accordance with recognized scientific
principles and what is established in this Health Standard.
4. The application of health quality assurance systems to product safety and its
processing will be supported by the application of the Hazard Analysis and Critical
Control Points (HACCP) System.
5. Continuous and permanent training of personnel on issues related to the hygienic
handling and processing of fish and fishery products, as well as personal hygiene.

ML
 G
Definition. DS 040-2001-PE
HELLO GOOD PRACTICES OF
MANUFACTURING : A set of
appropriate hygiene practices, the
observance of which ensures the
sanitary quality or safety of food and
beverages. They are programs to
provide health safety to food by
preventing any potential source of
contamination.
ML
PREREQUISITE PROGRAMS: The series
of stages, measures or procedures that
must be applied to ensure compliance
with standards and regulations and
that must be met before implementing
any health quality assurance program
such as HACCP, with respect to:
1. Design, construction of
establishments and their
equipment.
2. Hygiene, sanitation of
establishments
3. Application of Codes of Good
Manufacturing Practices in the
healthcare field.
G

SUBCHAPTER III. PRACTICES OF

MANUFACTURE
PART I
OF FISH PROCESSING
FRESH AND/OR FROZEN

Article 93 of DS 040-2001-PE

Requirements and sanitary conditions that must be met by production

plants
processing classified as artisanal or industrial or
primary processing

ML
G

ARTICLE 59 OF DS 07-2004-PRODUCE

ML
G

MANUFACTURING PRACTICES
From the processing of fresh and frozen
fish.

The activities of
Processing of fresh and/or
frozen fish must be carried out
under hygienic conditions and
fish must be used permanently.
cooled
that fulfill with the
following requirements:

D.S. 040-2001-PE. Article 93°

ML
G

MANUFACTURING PRACTICES
From the processing of fresh and frozen
fish.
The DS health standard 040-2001-PE, provides in Article 93:

a) Control of raw materials

b)Control of fresh fish processing

operations prior to freezing.

c) Control of freezing operations

ML
 G

D.S. 040-2001-PE Article 93.a

FROM THE RAW MATERIAL
Only chilled fish of
good and consistent
freshness, healthy and
CAREFUL!!
suitable for human
consumption
should be used.

they to sid
must fishhave
susceptible to the formation of histamine
quickly refrigerated,
and maintained in
conditions that prevent
the formation of this
toxin, in terms of
temperature and time span.
3. Under no circumstances should fish from restricted or
contaminated areas be used.

ML
 G

D.S. 040-2001-PE.Article 93.b ei

RESCO FISH PROCESSING OPERATIONS PRIOR TO th
GROWTH LIMITS AND CONDITIONS
FREEZING
OF PATHOGENS
er
'
CAREFUL!! TEMP. TEMP. POTENTIAL TEMPERATURE MAXIMUM
PATHOGEN MINIMUM MAXIMA HAZARDOUS OF THE PRODUCT CUMULATIVE
These CONDITION EXPOSURE TIME
Escherichia coli 6.5°C 49.4°C Growth of pathogenic
operations must be strains of E. coli 6.6 -10°C
2 days
5 hours
11 –21°C > 21°C
carried out quickly so as to avoid 2 hours
Listeria
monocytogenes
increasing the
-0.4°C temperature
45°C Growth of Listeria
monocytogenes
7 days
-0.4 –5 °C 6 – 10°C 1 day
of the fish. 11 -21°C 7 hours
2. 22 – 30 °C > 30 °C 5 hours
Any fish parasitized or with 1 hour
Salmonella
obvious physical
5.2°C
damage,
46.2°C
it will be
Growth of Salmonella
species 5.2 –10°C
2 days
5 hours
discarded from the process line. 11 –21 °C > 231 °C
2 hours
Staphylococcus 10°C 48°C Growth and toxin 7 – 10°C 14 days
3. Defrosting the fish must be done
aureus toxin formation of S. aureus 11 – 21°C > 21°C 12 hours
formation 3 hours
controlling the
Vibrio time and temperature
5°C
parameters
45.3°C
in
Growth of Vibrio 21 days
order to reduce deterioration
parahaemolyticus and
parahaemolyticus 5–10 °C 11 –
6 hours
21°C 22 – 27 °C
avoid contamination. > 27 °C
2 hours
1 hour
Source: Fish and Fisheries Products Hazards and Control Guidance. April 2011
 Preliminaries :
Legal base. Good manufacturing practices
Freezing Operations
1. They must be carried out using equipment specially designed
for this purpose, which must ensure rapid freezing at
temperatures of -18º C or lower.
2. Fish should be packaged in such a way as to protect them from
contamination and dehydration . Only the
Large fish, such as tuna, that are intended as raw materials for
subsequent processing may be frozen and stored without
packaging.
3. Proper rotation of frozen products in storage must be ensured.

DS 040-2001-PE Article 93.c

 Preliminaries :
Legal base. Good manufacturing practices

OPERATIONAL REQUIREMENTS IN THE STORAGE OF FRESH

FISH
The temporary storage of fish must be carried out with ice in cold
or isothermal chambers, or in pools with refrigerated water at
temperatures close to 0º C or containers with ice, in order to
ensure its conservation.

D.S. 040-2001-PE. Article 33°

Preliminaries :
Legal base. Good manufacturing practices
OPERATIONAL REQUIREMENTS IN THE
STORAGE OF FROZEN FISH

Article 34.- Frozen products must be stored and transported at temperatures of

–18º C or lower with a minimum of fluctuation.
In addition, they must be packaged and properly identified. Large fish stored in
bulk should be placed on clean surfaces, never in direct contact with the floor,
and properly glazed.
Warehouse operators must keep records of data on origin, quantity, destination,
time and temperature conditions of storage and transportation of fishery
products. These records must be available for inspections by the health
inspection authority.
 Preliminaries :
Legal base. Labelled
D.S. 040-2001-PE.
Label content
Article 150°.- The label must declare the following:
a. Common name of the fish and the type of product
b. Net content in the National System of Measurements, commonly called “metric”.
c. Drained weight, when the product standard approved by the sector indicates it.
d. Name or company name and address of the producing, importing or distributing
company.
e. Ingredients and additives in descending order.
f. Identification of the lot, which could also be on the product packaging itself.
g. Country of origin in case of import.
h. Minimum duration date in accordance with the corresponding standard.
i. Storage conditions.
j. Instructions for use.

ML
G

PART IV
1. APPLICATION OF PRACTICES
MANUFACTURING OF
FISH PROCESSING
FRESH AND/OR FROZEN
Of species such as tuna, parakeet, horse mackerel,
mackerel, hake, anchovy

Whole, fillets, slices, headless

gutted, pulp
GOOD MANUFACTURING PRACTICES
 AND THE SELECTION OF TECHNOLOGY
PROSECUTION

□ REGARDLESS OF THE SELECTED FREEZING TECHNOLOGY, GOOD

PRACTICES ARE ACTIONS THAT, LIKE HYGIENE PROGRAMS,
SHOULD BE APPLIED WITH THE PURPOSE OF:
□ ENSURING COMPLIANCE WITH STANDARDS

□ PROVIDE HEALTH SAFETY TO FOOD BY PREVENTING ANY POTENTIAL

SOURCE OF CONTAMINATION
 OBJECTIVE OF THE APPLICATION OF FRESH AND FROZEN FISH
MANUFACTURING PRACTICES

Establish the different controls of possible dangers and defects

in the different production phases, describing technological
guidelines that can be used as control measures and corrective
actions.
Provide a reasonable guarantee that the provisions on quality,
composition, labeling and control of food safety hazards or
safety of fish and fishery products will be complied with.
QUALITY,
COMPOSITION CODEX ALIMENTARIUS
>
, LABELING
 DEFINITIONS

FRESH FISH : FISH OR FISHERY PRODUCTS THAT HAVE NOT RECEIVED ANY
CONSERVATION TREATMENT OTHER THAN COOLING. (Codex)

HAZARD: AGENT OR CONDITION PHYSICAL,

BIOLOGICAL OR CHEMICAL WHICH COULD CAUSE
ADVERSE EFFECTS HEALTH OF THE
CONSUMER (Codex33 Hygiene Committee Meeting)
 FROZEN FISH
Fish that has undergone a freezing process sufficient to reduce the
temperature of the entire product to - 18°C (0°F), or a lower temperature
in order to preserve the inherent quality of the fish and that has been
held at said temperature during transportation, storage and
distribution, until the moment of preparation.
 FREEZING PROCESS
That which is carried out with the appropriate equipment in such
a way that the maximum crystallization temperature limits are
quickly exceeded (–1°C and –5°C), and is considered finished
when the product temperature reaches -18. °C (0°F)

CRITICAL FREEZING ZONE OR MAXIMUM

CRYSTALIZATION TEMPERATURE
It is the temperature range between – 1°C and – 5°C ,
the area in which the largest amount of water (75 to
80%) contained in the food is transformed into ice
crystals.

ML
 DEFINITION OF FROZEN FISH
Whole fish or its various
presentations that have
been subjected to a
freezing process until the
thermal center reaches -
18°C or less.

THERMAL CENTER
Point inside a part of the food
where the highest temperature is
recorded at the end of the rapid
freezing process

ML
 COLD CHAIN

Term that indicates the continuity of the

means used successively to maintain the
temperature of food, as appropriate , from
reception, to processing, transportation,
storage and retail sale.
DEFECT: CONDITION OBSERVED IN A PRODUCT THAT
DOES NOT MEET THE ESSENTIAL PROVISIONS
REGARDING QUALITY, COMPOSITION AND/OR
 DEFINITIONS
LABELING OF THE CORRESPONDING LCODEX PRODUCT
STANDARDS. (24TH CODEX MEETING. FISH AND FISHERY PRODUCTS COMMITTEE)

POINT OF CORRECTION OF EFFECTS: PHASE IN WHICH

IT IS POSSIBLE TO CARRY OUT CONTROL AND
PREVENT, ELIMINATE OR REDUCE TO AN ACCEPTABLE
LEVEL OF EFFECT OR ELIMINATE A RISK OF FRAUD (24TH
CODEX MEETING. COMMITTEE ON FISH AND FISHERY PRODUCTS)

ML
 PROCESSING CONDITIONS

Before starting operations, you must ensure:

1. Product presentation
2. Processing technology
3. Quality factors: Smell, color, flavor, texture, or
others.
4. Health quality requirements.

ML
 PROCESSING CONDITIONS

Before starting the process, you must ensure:

1. Ensure compliance with drinking water requirements
2. Clean and disinfected environments
3. Clean machinery, equipment and instruments
4. Facilities of operating personnel
5. Correctly presented staff
6. Equipment and refrigerated warehouses at the required
temperature
7. Calibrated control instruments

ML
 PROCESSING CONDITIONS

8. Other necessary

ML
 PRODUCT FREEZING PROCESS
HYDROBIOLOGICAL
Receiving Washed/ selected/
raw material chilled/iced
Sheets/ Salt
bags Additiv
es
Classified/
brined/ Cut/devalved/
heavy/ immersion bare/
in conservative

d
Boxe
s
P r Packaging
U

Transport Stored
Defrosted
< -18°C < -18°C

Part I.1. PRE-FREEZE OPERATIONS

□IReception, gutting, filleting, fleshing
> - E.}

□lPre-Treatments to avoid quality

defects
RAW MATERIAL ACCEPTANCE
REQUIREMENTS: FISH

• Freshness

• Quality

> Non-toxic
 STAGE: Reception of fresh or frozen raw fish

POSSIBLE HAZARDS:
Microbiological pathogens, viable parasites, biotoxins,
chemicals (including veterinary drug residues) and
physical contamination.
POSSIBLE DEFECTS:
Decomposition, parasites, physical contamination.
TECHNICAL GUIDANCE:
□ . For raw fish, product specifications could include the following
characteristics:
V Organoleptic characteristics such as appearance, smell,
texture, etc.;
V Chemical indicators of decomposition and/or
 contamination, for example, TVN, histamine, heavy metals,
pesticide residues, nitrates, etc.
V Microbiological criteria, particularly for intermediate raw
materials, aimed at preventing the production of raw
materials containing microbial toxins.
V Physical characteristics such as the size of the fish.
' Homogeneity of the species.
 Reception of fresh or frozen raw fish
TECHNICAL GUIDANCE: TRAINING

□ . Training will be provided to fish handlers and competent personnel

in:
□ Species identification and communication to ensure that fish
received come from safe sources.
□ Sensory evaluation techniques
to ensure that the fish meets the
provisions
quality essentials.
□ Special attention to reception
and classification of fish species
scombrotoxic either
suspicious of introduce
parasites.
TECHNICAL GUIDANCE:
ML
 Reception of fresh or frozen raw fish
e.If the fish must be gutted upon arrival at the processing
establishment, this operation will be carried out
efficiently, without excessive delay and taking care to
avoid contamination.
f. Fish known to contain harmful, decomposed or
extraneous substances that will not be removed or
reduced to an acceptable level by normal grading or
preparation procedures will be rejected.
g. Information about the capture area will be provided.
 Sensory evaluation of fish

The best way to evaluate the

grade of freshness
either
Decomposition of fish consists
of applying sensory evaluation
techniques.

Apply appropriate evaluation

determine the acceptability of
fish and removing fish
criteria sensory so 463
that it does not comply with the
provisions on quality.
 Sensory evaluation of fish

For example, fresh white fish is considered unacceptable

if it has the following characteristics:
Skin/mucus: sandy, muted colors with
yellowish-brown mucus spots.
Eyes: concave, opaque, sunken, discolored.
Guts: grey-brown or whitish, mucus
yellowish-opaque, compact-coagulated.
Smell: meat with the smell of amines, ammonia,
milky, lactic, sulphurous, fecal, putrid, rancid.
 STAGE: GUTTING AND WASHING

POSSIBLE HAZARDS:
Microbiological pathogens
biotoxins.
POSSIBLE DEFECTS:
Presence of viscera, bruises,
bad smells, cut failures.
Gutted and washed

TECHNICAL GUIDANCE:
V The evisceration is considered
 complete when the intestinal tube and internal organs have been removed.
V A sufficient supply of clean seawater or drinking water shall be available
for washing.
> Whole fish in order to eliminate foreign matter and reduce bacterial
load before evisceration.
> The fish is gutted to remove blood and viscera from the ventral cavity.
> The surface of the fish in order to remove loose scales.
> The equipment and utensils used in evisceration to minimize the
accumulation of mucus, blood and debris.
Gutted and washed
 TECHNICAL GUIDANCE:

V Temperature regime In order to control histamine or a defect, gutted

fish shall be drained and completely covered with ice or
appropriately refrigerated in clean containers and stored in
specially designated suitable areas of the processing
establishment.
{ If you wish to preserve the milk, roe and liver for later use, you must
have separate and suitable facilities for their storage.
 STAGE: Filleting, skinning, trimming
and backlit examination
POSSIBLE HAZARDS:
Parasites viable,
microbiological
pathogens and
biotoxins, presence of
thorns.
POSSIBLE DEFECTS:
Parasites, presence of
thorns, subjects
objected (e.g. skin,
scales, etc.),
decomposition.
 Filleting, skinning, trimming and backlight
examination

TECHNICAL GUIDANCE:

To minimize waiting times, threading and backlighting

chains, as appropriate, should be designed to be
continuous and sequential so that there is a uniform
flow without interruptions or delays and / or waste can
be removed.

ML
 Filleting, skinning, trimming and backlight
examination
TECHNICAL GUIDANCE:

• A sufficient supply of clean seawater or drinking water shall be

available for washing:
• In the case of products that are marketed and labeled as boneless
fillets, the people who
handle the fish they will use techniques suitable for
inspection and will use the necessary instruments to eliminate
thorns that do not comply with the Codex standards or
commercial specifications.

ML
 Filleting, skinning, trimming and backlight
examination
TECHNICAL GUIDANCE:

V Backlit examination of skinless fillets by specialized personnel in a

suitable location that makes full use of lighting is an effective
technique for controlling parasites (in fresh fish) and should be
used when exposed species of fish are used.
V The table used for backlight examination should be cleaned
frequently during the operation to minimize microbial activity on
contact surfaces and prevent fish residue from drying out due to
the heat generated by the lamp.

ML
 Filleting, skinning, trimming and backlight
examination
TECHNICAL GUIDANCE:
V Where a prescribed critical limit has
been established for the operation and
temperature regime to control
histamine or effect, fish fillets should
be completely covered with ice or
appropriately refrigerated in clean
containers, protected from dehydration
and stored in suitable areas of the
processing establishment.

ML
 PREVENTIVE TREATMENTS:
To avoid quality defects

Prevention of defrosting rigor

Rust prevention Use of

Prevention of color changes additives
in meat Prevention of
denaturation in fish
\ of proteins
whole, or
FOOD fillets,
ADDITIVES
HG or correct
Only the use of the following
food additives is allowed in fish and fish products:
fresh
Any antioxidant indicated in food category 09.1.2 (fresh mollusks,
crustaceans and echinoderms) of the General Standard for Food
Additives. CODEX STAN 192-1995, Rev. 7, 2006, at levels that do
not exceed the BPM.

Frozen
Any antioxidant indicated in food category 09.2.1 (fish, fish fillets
and frozen fishery products, including mollusks, crustaceans and
echinoderms) of the General Standard for Food Additives. CODEX
STAN 192-1995, Rev. 7, 2006 at levels not exceeding BPM.
 PREVENTION OF THE . RIGOORR DEE DEESCONNGEELADOO)

In species such as: Tuna, skipjack, hake, horse mackerel and

sardine

Cause Effect Control measure

Freezing before Rapid ATP Thaw at -2 to -3°C until ATP

cadaveric rigidity degradation disappears

High level of ATP in Excessive defrost Defrost whole fish

frozen muscle exudate up to 40%

Loss of water
retention capacity
___________________________)
 • Formation of free fatty acids.
OXIDATION PREVENTION

F
CAUSE EFFECT
Inadequate conditions of • Aminocarbonyl formation
Pretreatment, freezing, that give yellowish color
packaging and storage \
\____________________________

CONTROL MEASURES
• Treatment with antioxidants?
• Vacuum packaging
•____Frosting of frozen product
___________________________________
 USE OF ANTIOXIDANTS

% APPLICATI
SOLUBLE IN WATER SOLUTION
OF USE EXHIBITHION ONS
TIME
Ascorbic acid Water 0.5 to 1 5 to 10 min. Prevents oxidation
Sodium ascorbate Water 0.5 to 1 5 to 10 min. of substances
Erysorbic acid and Water 0.5 to 1 5 to 10 min. water soluble
potassium
sodium erysorbate Water 0.5 to 1 5 to 10 min.
 PREVENTION OF PROTEIN DENATURALIZATION
In fish fillets and pulp

Cause
Inadequate pretreatment, freezing, packaging
and storage conditions

Effect
Actomyosin denaturation
Loss of water holding capacity
Dehydration/Sponging

TO TO
Control measure
Treatment with cryoprotectants:
Addition of phosphates and sugar
V J.

OTHER INGREDIENTS

The packing medium and all other ingredients

used must be of food quality and comply with the
applicable Codex standards, in cases where
national legislation does not contemplate it.
 STAGE: Wrapping and Packaging

POSSIBLE HAZARDS:
Unlikely

POSSIBLE DEFECTS:
Subsequent dehydration, decomposition
MAHI MAHI

FROZEN MAHI MAHI FILLET

SKINLESS
(Coryphaena hlppurus)
Size:
200/500g/
Net
pc
weight: 5
Kgs
 Wrapping and Packaging

TECHNICAL GUIDANCE:

1. Packaging material must be clean,

intact, durable, sufficient for its
intended use and of food grade.
2. Packaging operations should be
carried out in a manner that
minimizes the risk of contamination
and decomposition.
3. Labeling and weight of products should
comply with relevant standards.
 STAGE: Vacuum packaging or EAM

POSSIBLE HAZARDS:
Microbiological pathogens, physical contamination (with
metals).
POSSIBLE DEFECTS:
Post decomposition
Vacuum packaging or EAM

TECHNICAL GUIDANCE:

1. The storage time depends on the species, the

fat content, the initial bacterial load, the gas
 mixture, the type of packaging material used and, above all, the storage
temperature.
2. The meat of the fish should be outside the seam area.
3. Inspect packaging material before use to ensure that
is not damaged or contaminated.
4. Verify the effectiveness of the hermetic seal and the correct operation of the
packaging machine.
5. The hermetically closed containers will be transferred carefully and without
excessive delay to the refrigerator where they will be stored.
6. Ensure that the proper degree of vacuum is achieved, and that airtight seals are
intact.
 STAGE: Vacuum packaging or EAM: Heavy

POSSIBLE HAZARDS: Unlikely.

POSSIBLE DEFECTS:
Incorrect net weight

TECHNICAL GUIDANCE:
The scale used for weighing
will be periodically
calibrated with standardized weights to ensure
accuracy.
 CONTAINERS AND PACKAGING
It refers to all materials, such as aluminum sheets, plastic sheets, waxed
paper and cardboard boxes, used as:
 PACKAGING OF FILLET IN BLOCKS
Frozen mold

Size t b c
standard
16.5l o 481 60 measurements
bs 253 mm. mm
PART I.2

OPERATION
CONG ELA TION
 STAGE: Freezing process

POSSIBLE HAZARDS:
Viable parasites.
POSSIBLE DEFECTS:
Texture deterioration, rancid odor development,
freezer burn
 TECHNICAL GUIDANCE:

1. Freeze as quickly as possible , delays before freezing cause

the temperature to rise, increasing the speed of quality
deterioration and reducing conservation time.
2. Establish a temperature regime for freezing according to
available freezing equipment and capacity, nature of the
product, thickness, shape and volume of the production,
guaranteeing maximum crystallization temperatures as
quickly as possible.
 TECHNICAL GUIDANCE:
3. The thickness, shape and initial temperature of the product
will be as uniform as possible.
4. The production of the processing establishment will be a
function of the capacity of the freezers.
5. The frozen product will be moved as quickly as possible to
the place where it will be stored in the freezer.
6. The temperature in the center of the frozen fish will be
systematically monitored to check whether the freezing
process has been completed.
 TECHNICAL GUIDANCE:

7. Frequent checks will be carried out to verify that the freezers

are working correctly.
8. A comprehensive record of all freezing operations will be
maintained .
9. For the destruction of parasites harmful to human health,
freezing temperature and monitoring of freezing time should
be combined with adequate control to ensure sufficient
cooling
 EQUIPMENT
CAS
CELL ALIVE
SYSTEM

Spiral quick food freezer with C 1000

kg/h
 EQUIPMENT
Each freezer and compartment of cold storage places that are used to
store and retain food and that are capable of allowing the growth of
microorganisms, must be equipped with:
□ an indicator thermometer,
□ a temperature measuring device, or a temperature recording device,
installed so as to show the exact temperature in the compartment ,
□ and be equipped with an automatic control to regulate the
temperature, □ or with an automatic alarm system to indicate a
significant change in temperature in manual operation.
ML Source: 21 CFR. Part 110. Current good manufacturing practices.
G
 APPROVED FREEZING PROCESS
For parasite control
It is the rapid freezing process
established by the operator that will be
considered complete unless and until the
product temperature reaches –20ªC or
lower temperature in the thermal center.
The freezing time and temperature
will depend:
1. From the nature of the product
2. thickness and size
3. From the presentation Once established, it
4. Of the equipment used must be applied,
controlled and
recorded.
FREEZING CURVE (Temperature / Time)
 FREEZING SPEED

EQUIPMENT PRODUCT THICKNESS TIME

FREEZING METHOD

FORCED AIR AT -30 A TUNNEL 60mm 3 – 5 hours

Fish on trays. (blocks)
-40°C
Large and medium fish - 3-6 hours
in trays
- 6 – 10 hours
Sturgeon and other
large fish hanging
BY CONTACT PLATE FREEZERS Whole fish blocks, fillet 30mm 55 minutes
At -35°C blocks, pulp, surimi 50mm 75 minutes
65mm 135 minutes

Source: Frozen fish processing manual: BMBuikoba, ZIBelova

PART I.3

OPERATIONS AFTER
FREEZING
EQUIPMENT
 STAGE: GLAZING

POSSIBLE HAZARDS:
Microbiological pathogens, biotoxins.
POSSIBLE DEFECTS:
Subsequent dehydration, incorrect net
weight.
GLAZED

TECHNICAL GUIDANCE
SANIPES-
PCMBV
1. Use of drinking water .
2. The product is adequately covered by a protective
layer of ice ;
3. If additives are used, ensure proper proportions and
application conform to product specifications .
4. Consider on the product labeling information on the
amount or proportion of glaze information that will be
used to determine the net weight of the glaze.
5. When used, it is important to periodically replace the
glaze solution to minimize bacterial load and fish
protein buildup.

ML
 GLAZED
Allows training
of a thin layer
of ice throughout the
surface of the
product, for
immersion or
sprinkling of
frozen fish
in cold water at a
next temperature
at 0°C.
Glazing equipment
 STAGE:
PACKAGING

The packaging must

take place in
conditions such
to avoid the
defrosting and
the pollution of
 fish

STAGE: REFRIGERATED STORAGE

FRESH FISH

POSSIBLE HAZARDS:
Microbiological pathogens and biotoxins.
POSSIBLE DEFECTS:
Decomposition, physical damage.
 TECHNICAL GUIDANCE:

V The fish will be moved to the chilling facilities without excessive

delay.
V The facilities will be capable of maintaining the fish at a
temperature between (0°C and +4°C).
{ The refrigeration chamber will be equipped with a calibrated
thermograph. It is highly recommended that a thermometer with
temperature recording be installed.
{Stock rotation plans will ensure adequate setup for fish.
V The fish should be stored in shallow trays and surrounded with
sufficient quantities of crushed ice or a mixture of ice and water
before processing.
 TECHNICAL GUIDANCE:

V Fish shall be stored in such a way as to prevent damage from

stacking or overfilling of boxes.
V Fish known to contain harmful, decomposed or extraneous
substances that will not be removed or reduced to an acceptable
level by normal grading or preparation procedures will be
rejected.
V When appropriate, the ice covering the fish will be replaced or the
temperature of the premises will be modified.
 STAGE: FROZEN STORAGE

POSSIBLE HAZARDS:
Unlikely. Microbiological pathogens, toxins, viable
parasites.
POSSIBLE DEFECTS:
Dehydration, rancidity, loss of nutritional quality.
TECHNICAL GUIDANCE:

V The facilities shall be capable of maintaining fish at – 18°C or

lower temperatures, with minimum temperature fluctuations.
 Frozen storage

V The warehouse will be equipped with a calibrated

thermograph.
V A systematic stock allocation plan will be developed and
maintained.
V The product will be glazed and wrapped to protect against
dehydration and contamination.
V Fish known to contain defects that will not be subsequently
eliminated or reduced to an acceptable level by reprocessing
shall be rejected.

ML
 refrigerated warehouses
Insulated and refrigerated premises especially intended for the
storage of frozen products.

They must have refrigeration capacity

to maintain products at a temperature
of -18 °C or lower, but are not
intended for freezing or cooling them .
They must guarantee stable
temperature and humidity conditions.
Records of data on origin,
quantity, destination, temperature
conditions of the products must
be kept by the operators.
MLG
 RECOMMENDATIONS FOR BETTER
USE OF THE AREA
STORAGE
/7nn//hH09U//700Aa
Correct rudder stowage

111

Rum stowage NO
correct

The stowage must

—
to be made: p—
□ Distance from wall to load, without f 1- "*] refrigeration equipment: 0.3 – 0.25 m rm yes
□ Distance from roof to load, without refrigeration equipment: 0.5 m
□ Distance from the refrigeration equipment to the load: no less than 0.40 m
□ Corridors of 1.2 m for every 10 meters of
chamber length. Pallet
transport
system
 Auxiliaries for freezing
and refrigerated
warehouses
Protector
s
Shelves

curtains or reverse air flow Battery-powered

Freezing forklift
trays
 Refrigerated warehouses: Control instruments

.S. 040-2001-PE. Article 31

DICKSON

Thermorecorders
-—"ede-ha Only for Spain:
Registrar "not
submitted
in control
metrological"
according to

Digital order
Source
ITC/3701/2006
thermomet :
CAREL
ers
The CAREL Datalogger stores all the
temperature values from the last year,

D.S. 040-2001-PE. Article 31 automatically and in compliance with the EEC

MLG Have continuous temperature recording systems in each cold room or warehouse.
directives, allowing them to be transferred to
a PC using the download module.
 Stowage plan for frozen products
Duration time in
of
TIME OFstorage
LIFE chamber frozen fish in
UTIL Extension
or
storage
beyond the declared shelf life , the ITP - P II COLD AREA
Life of
product will be of fair to poor quality, although LOCATION PLAN OF PRODUCTS IN CAMERA
storageit may still be edible, it is not the quality that
It is definedthe
as the industry and A
Duration
Species sb k)) ,in months (*)
xRtcES
—
uvreciweS ,

period of timemust that

market . -12°C -18°C ed,
-30°C 5^ ( u 5
t«cHi
By Mq4co

the product
He case is
(67/
g
3,6 i Foe7u
Rl)
Mackerel 3 6 8
Se7u11
p7oezsa ( I 3.EE
remains in one
classified as non-compliance with GVHDhi
Be7/a
labeling
EUveR.A2G
3.H
IUZOéKSacVeg
condition that can Glazed mackerel ~ - 6 8
standards and ppo
—AL
6
A63
4dectos 890
be described as -
SNUE2Cio4C>

8 14 80 ns
I osqueo eHi r0

quality . Alaska Pollock HG

(u24Dos 6s9ucos

good quality 2u
IQF Steaks 6 10 ih 0e
- r
Samo (oweec-4/e.8
Steak blocks - 7
3-587ia (tiueicciAl 12
“Com6xd

fadudoy
Surimi - exar
<26 12 di4 AcNo

MACteA CWwbI
Pacific sole SuCi - 4
CaTa0/- IMP- 10 deoDo- Jeof#$ JEB
36B
Fountai CB see
n: HaEuo
Frozen fish preparation manual: BMBuikoba, ZIBelova.

Planning seafood cold storage. Edward Kolbe, Donald Kramer

(*) Life time as long as storage conditions are constant.

 CONTROLLED DEFROST

POSSIBLE HAZARDS:
Microbiological pathogens and biotoxins.
POSSIBLE DEFECTS:
Decomposition

DEFROST
Defrosting must be carried out
in conditions
controlled time and
temperature, avoiding exposing
the fish to contamination ML or G
adulteration
 Controlled defrosting

TECHNICAL GUIDANCE:
V The defrosting method will be clearly defined and the duration
and temperature of the process, the instrument used to
measure the temperature and the location of this instrument
will be taken into account.
V The defrosting program (time and temperature parameters) will
be carefully controlled.
V Critical limits for suitable defrosting time and temperature will
be selected to avoid the development of microorganisms,
histamine, or clear and persistent odors or flavors indicating
decomposition or rancidity.

ML
 Controlled defrosting

TECHNICAL GUIDANCE:

V When water is used as a defrosting medium, it must be

of potable quality.
V When recycled water is used, efforts will be made to
avoid the accumulation of microorganisms.
V When water is used, circulation should be sufficient to
achieve uniform defrosting.

ML
 Controlled defrosting

TECHNICAL GUIDANCE:
V During defrosting, and depending on the method used,
the products will not be exposed to excessively high
temperatures.
V Special attention will be paid to the control of
condensation and exudate from the fish, and effective
drainage must be provided.
V The fish will be processed immediately after thawing or
refrigerated and kept at the appropriate temperature
(melting ice temperature).

ML
 STAGE: LABELING

POSSIBLE HAZARDS:
Unlikely
POSSIBLE DEFECTS:
Incorrect labeling
LABELLED
 TECHNICAL GUIDANCE:

• Labels will be checked before affixing to ensure that

all the information they contain conforms to Codex
Labeling Standards.
• In many cases, products that have not been correctly
labeled will be relabeled and the PCD plan will be
modified.
 STAGE: Metal detection

POSSIBLE HAZARDS:
Metal contamination
POSSIBLE DEFECTS:
Unlikely
 metal detection

TECHNICAL GUIDANCE:

• Adjust the chain so that it allows the metal detector to

function correctly.
• Ordinary procedures will be established so that when
the detector rejects a product, the cause of this
rejection is studied.
• If a metal detector is used, it will be periodically
calibrated to a known standard to ensure proper
operation.
 FINAL PRODUCT
Frozen fish or fishery products must meet the requirements
of:

a) Healthcare quality
b) Quality: Freshness, Smell, color, texture

The lots will be subjected to sampling plans and

examined by the methods established by the
Health Authority in order to accept them or
reject them for trade and consumption
 FOOD SAFETY CRITERIA FOR FISH AND
FISHING PRODUCTS ESTABLISHED IN THE REGULATIONS OF
THE EUROPEAN UNION.
PRODUCTS INDICATOR BOUNDARIES Status/Action
Fishery products from fish w,n,r
HISTAMINE m= 100 mg/kg
species associated with a
high histidine content M = 200 mg/kg
Sampling plan n=9, c=2
HPLC method

Fishery products subjected w,n,r

HISTAMINE
to enzymatic ripening m= 200 mg/kg
treatment in brine, M = 400 mg/kg
manufactured from fish Sampling plan n=9, c=2
Associated with a high HPLC method
histidine content

Fish species of the families: Scombridae, Clupeidae, Engraulidae,

Coryfenidae.
 EC Regulation No. 2073/2005

INTERPRETATION OF RESULTS
to accept or reject batch

SATISFACTORY, IF THE FOLLOWING REQUIREMENTS ARE MET

1) The observed mean value is less than or equal to

2) A maximum of c/n observed values lie between m and M
3) No value is observed that exceeds the limit M

UNSATISFACTORY, IF THE OBSERVED AVERAGE VALUE IS GREATER

THAN m
or more than c/n values are between m and M or one or more observed
values
are > M
 STAGE: Transport of fresh fish
and frozen

POSSIBLE HAZARDS:
Development biochemical
(histamine), microbial
proliferation and
contamination
POSSIBLE EFFECTS:
Decomposition, physical
damage, chemical
contamination (fuel)
 Transport

TECHNICAL GUIDANCE:
1. Check the temperature of the product before loading.
2. Avoid excessive exposure to high temperatures during loading and
unloading of fish, shellfish and their products.
3. Load in a way that ensures good air flow between the product and the
walls, floor and ceiling panels; load stabilizing devices are recommended.
4. Monitor air temperatures inside the transport vehicle during transport;
The use of a thermometer with temperature recording is recommended.
TECHNICAL GUIDANCE:
During transportation:
1. Frozen products should be kept at –18°C or lower temperatures
(maximum fluctuation +3°C);

ML
 Transport
2. Fish, shellfish and fresh products should be kept at a temperature as
close to 0°C as possible.
3. Fresh whole fish should be kept in low layers and surrounded by finely
crushed ice at melting temperature; Adequate drainage shall be provided
to ensure that water runoff from melted ice does not come into contact
with products or that melt water in one container does not contaminate
products in another container;

ML
 Transport
TECHNICAL GUIDANCE:

During transportation :
4. Where appropriate, consideration should be given to transporting
fresh fish in containers with ice packs instead of ice;
5. Where appropriate, consideration should be given to transporting fish
in watered ice , chilled or refrigerated seawater (e.g. e.g. Pelagic fish). Cold
or refrigerated sea water should be used under appropriate conditions;
6. Refrigerated processed products should be kept at the temperature
specified by the manufacturer, but generally should not exceed 4°C;
Reception and Storage of ingredients, additives,
containers and packaging material

ML
 Transport
POSSIBLE HAZARDS:
Chemical and physical contamination, microbiological
pathogens.
POSSIBLE DEFECTS:
Loss of quality characteristics of packaging materials
or ingredients

Technical guidance

1. Ingredients and containers will be stored in appropriate

temperature and humidity conditions.

ML
 Transport
2. A systematic stock rotation plan will be developed and
maintained to avoid material expiration.
3. Ingredients and packaging will be properly protected and
kept separate to avoid cross contamination.
4. Defective ingredients or packaging will not be used.

PART IV

2. CONTROL OF PRACTICES
MANUFACTURING IN THE
FISH PROCESSING

ML
 Transport
FRESH AND FROZEN

In processing plants
frozen

ML
 PART III.2

CONTROL OF MANUFACTURING PRACTICES IN THE

FRESH AND FROZEN FISH PROCESSING

OBJECTIVE: Demonstrate “Self-control”

Operators Responsibility
CONTROL OF MANUFACTURING PRACTICES IN THE
PROCESSING OF FRESH AND FROZEN FISH

How to Demonstrate “Self-Control”?

ML
 PART III.2

Through the application of Programs

BPM Control that:

Secure the application and document

the actions carried out, the ones that
will be available for inspection or
verification by the Authority
National and international health

ML
 PART III.2

WHICH SHOULD CONTAIN A CONTROL PROGRAM

MANUFACTURING PRACTICES IN THE PROCESSING OF
FROZEN FISH

Describe the purpose, scope and responsibilities

Describe the operations or stages of the process
and those responsible for its execution
Establish possible defects, correction
defects and technical guidance
The description of the control actions in each
stage of the production process and instruments
of control
What, who, how, when to control, register, MLG
 validate, verify and act

BPM records
Freezing plant operators must document and record Good Manufacturing
Practice controls, among others:
1. Order and Production Report.
2. Sensory evaluation of raw materials and quality of the process and
product.
3. Reception and storage of ingredients, additives, containers and
packaging material.
4. Time and temperature conditions of the process stages
5. Packaging and labeling weight controls.
6. Report on the origin, quantity, destination, time and temperature
conditions of storage and transportation of fishery products. Article
34 ° . DS 040-2001-PE
7. Product traceability ML
G
 BPM CONTROL AT ALL STAGES

PACKING

-T°esp.susc.hist Records. -Drinking -Packaging hygiene

water and ice
-Freshness -Daily and personal
-Daily and hygiene
-Internal temperature personal
hygiene -Labeled/labeled
-Transport
-Time and temperature
-Cross contamination
-Filling weight
-Uniformity of cuts

-Time and temperature

EXPORT PACKED/ -Lots
CERTIFICATION STORAGE
-Packaging hygiene
- Self-control records
-Daily and personal
-MP/PT performance
hygiene -Tunnel/cong hygiene.
-Temperature records
-Labelling/labeling
-Quality and C. Product sanitary

MLG -Lots
-Coded batches -Time and storage temperature.

-Process approved cong.

-Freeze time and

temperature.
MLG -Lots
 ………..besides

1. Processing plants that export to the EU

or Argentina or Brazil must be on the
List of registered establishments in the
EU. PP/Aq
TEMPERATURE MANAGEMENT IN THE COLD CHAIN

Personnel, Control Instruments and Records

2. Air 3. Non- 4. Destructive

1. Inspection temperature destructive product
visual of recording product temperature
food examination temperature measurement
measurement • Evaluator
Evaluator • Equipment • Frozen product
Formats and • Evaluator
operators and
• Thermometers: thermometers
records evaluator Resolution 0.1 °C
Resolution 0.1 °C
• No. Sensors Scale: -20 to +
Scale: -20 to +
according to 30°C
30°C Flat sensor
storage capacity • Calibration
• Calibration
and continuous • Formats and
• Formats and
recording
registration
equipment
temperature
 TEMPERATURE MANAGEMENT IN THE COLD CHAIN

Temperature control
2. Exam 4.
3. Non-
record Measurement
destructive
1. " temperature of temperature of
product
Inspe air product
temperatur
Check ifction
itfois well frozen Destructive
Upon entry, during,
e
Presentsvisua
o upon exit, when the
Defrosting measureme
ldofor Frosting non-destructive
Upon entry, during (-18°C), nt examination registers
upon departure. (-21 °C or signs of deviations. (-
lower) 18°C or lower).
Upon entry, during, upon
departure: (-18°C or lower),
 Other defects

TOLERANCES: Short-term fluctuations in product temperature

in the cold chain, within the limits allowed in this Code and that
do not affect the
MLG safety or product quality.
OFFICIAL TEMPERATURE CONTROLS OF FROZEN PRODUCTS
OFFICIAL TEMPERATURE CONTROLS OF FROZEN FISHERY PRODUCTS SHOULD INCLUDE:

A. CONTROL OF THE
TEMPERATURE OF FREEZING A. TEMPERATURE CONTROL
EQUIPMENT PRODUCT INTERNAL

B. CONTROL OF FRESH AND B. TEMPERATURE CONTROL

FROZEN STORAGE CHAMBERS EXTERNAL CONTAINERS
C. SHARE REGISTRATION
c. CONTROL OF MEANS OF CALIBRATION OF THERMOMETERS
TRANSPORTATION AND THERMORELOGERS

OFFICIAL CONTROLS OF FISHERY PRODUCTS

 OFFICIAL CONTROLS OF FISHERY PRODUCTS SHOULD INCLUDE AT LEAST THE
FOLLOWING ELEMENTS

A. ORGANOLEPTIC EXAMINATION
B. FRESHNESS INDICATORS
C. HISTAMINE AND TEMPERATURE CONTROL
D. WASTE AND CONTAMINANTS
E. MICROBIOLOGICAL TESTS
F. PARASITES
G. TESTING FOR POISONOUS FISHERY PRODUCTS
DECISIONS FOLLOWING OFFICIAL CONTROLS OF FISHERY PRODUCTS
FISHING PRODUCTS WILL BE DECLARED UNFIT FOR HUMAN CONSUMPTION YES.
A. THE EXAMS ORGANOLEPTIC, SUITABLE FOR HUMAN CONSUMPTION.
CHEMICAL, PHYSICAL AND MICROBIOLOGICAL
OR PARASITES HAVE SHOWN THAT THEY DO NOT
COMPLY WITH THE LEGISLATION
COMMUNITY

B. THEY CONTAIN IN THEIR EDIBLE PARTS

POLLUTING AGENTS OR WASTE IN QUANTITIES
HIGHER THAN THE ESTABLISHED LIMITS OR IN
QUANTITIES IN WHICH THE CALCULATED FOOD
INTAKE EXCEEDS THE HUMAN INTAKE, DAILY OR
WEEKLY, ACCEPTABLE FOR MAN.
C. THEY DERIVE FROM:

I) OF POISONOUS FISH

II) THEY CONTAIN TOXINS OR BIOTOXINS

IN TOTAL QUANTITIES THAT EXCEED THE
ESTABLISHED LIMITS

D. THE AC CONSIDERS THAT THEY MAY PRESENT A

RISK TO PUBLIC HEALTH OR ANIMAL HEALTH OR
THAT, FOR ANY OTHER REASON, THEY ARE NOT
 for your
Thank you very much

attention

I n g. Marcelina LeytonGordillo
CIP 75295
 E-mail: m
ML leyton@itp.gob.pe
G