Page 1 of 40

RURAL FISHERIES WORK EXPERIENCE PROGRAME

2024-25

SUBMITTED BY
Dodiya Roshani 2021030210071139
Pansuriya Krisha 2021030210071157
Rathod Khushi 2021030210071164

SUBMITTED TO
DR. J. B. SOLANKI SIR
ASSISTANT PROFESSOR OF DEPARTMENT OF FISH PROCESSING TECHNOLOGY

COLLEGE OF FISHERIES SCIENCE, VERAVAL

KAMDHENU UNIVERSITY, GANDHINAGAR
 Page 2 of 40

MODULE: 2
FISH PROCESSING PLANT EXPERIENCE
(H. M. G. INDUSTRIES)
 Page 3 of 40

INTRODUCTION:
JINNY MARINE TRADERS has a sophisticated, modern EU seafood plant on the
west coast of India, in the small and traditional fishing town of Veraval in the
Saurashtra region of Gujarat. Jinny Marine Traders was founded by Mr. K.P.
Thomas, a well-known fishery scientist in 1996. It is the largest exporter
company from Veraval, currently managed by Mr. Kenny Thomas and Mr. Benny
Thomas.

1. COMPANY PROFILE:

Company Name H.M.G Industries

Address 1306/1311, GIDC Estate, Veraval- 362269
Gujarat.
E-mail jinnymarine@[Link]
Contact No. 02876-232702, 02876-232390
02876-232781, 09925032456
Year of Establishment 1996
Founder Name Mr. K. P. Thomas
Owner Name Mr. Kenny Thomas
CEO Mr. Benny Thomas
Production Manager Mr. Sachendra Singh
Q/C In charge Mr. D.S. Bisth
Status of Organization Private
Activity Processing and Exporting Frozen Marine
Products
EIA Approval No. 241
Exporting Country All Countries including EU
Products Shrimps, Squid, Cuttlefish
 Page 4 of 40

Source of Raw Material Wild Catch from Sea Water (FAO-51)

Origin of products Indian
Ice plant 30 m ton/day
R.M. Chill room 20m ton/day
Freezing facility 2- Blast freezer, 2-IQF Units
Water treatment plant 12000 Ltr/hr
R.M. capacity 20 ton/day
Block ice plant 25 ton/day
Flake ice plant 15 ton/day
Tube ice plant 25 ton/day
Whole R.M. freezing capacity 38 ton/day

Tunnel freezer 4 ton/ 8 hrs.

IQF NO.1 18.5 MT/day
IQF NO.2 2.0 MT/day
Production capacity 20 ton
Cold storage NO.1 175 M ton
Cold storage NO.2 275 M ton
Cold storage NO.3 150 M ton
Cold storage NO.4 240 M ton
Store room 3 No. (For Packaging materials, Chemicals,
Cleaning agent
No. Of Workers 700.
 Page 5 of 40

2. COMPANY POLICY:

• Aim: To achieve and maintain the highest standard of quality and food safety for
all of its fish and fishery products and strive to continually quality standard in
order to improve its competitive position in the market place.
• The essence of all fish and fishery products is its flavor, taste and nutrition.
• They serve safe food without losing its original nutrients.
• The management & work for recognize the importance of generation and
ensuring customer satisfaction by the provision of a consistent quality product.
Therefore, their organized resources and totally committed to achieving this by
producing a quality and food safe product which meets the demands and need
of the customer and Consumer.
 Page 6 of 40

HACCP Jinny Marine Traders Fisheries Quality

CGMP Management Work Under This SSOP
Three Types of Policy

• HACCP (Hazard analysis critical control point) is a logically practically, common

sense technique used to control food safety hazard worldwide in the food
processing industry.
• It is an important safety management system and can be interpreted in to any
operation.
• This is not zero risk system, but it is designed for minimizing the risk of food
safety hazard.

HACCP system built up on the CGMP (Current good manufacture practice) and SSOP
(Sanitation standard operating procedure)

• A combination of these two-prerequisite programmed (CGMP and SSOP) with

HACCP makes up to deliver safe products to consumer.

HACCP (Hazard Analysis and Critical Control Point):

➢ Hazard – any biological, chemical or physical property that may be expected to

cause an unacceptable health risk to consumers if present in the product. It may
be either physical, chemical or biological.

• Biological – bacteria, microorganism and parasites

• Chemical – natural toxins, and chemical contaminants (pollutants,
pesticides, sanitizers)
• Physical – Hair, glass, stones, metal etc.
 Page 7 of 40

➢ Risk – an estimate of the likelihood of the occurrence of a hazard

➢ Severity of risk – the seriousness of a hazard if not properly controlled (e.g.,
metal or toxic)
➢ Critical control point (CCP) – a specific point in a process where control can be
applied to eliminate or reduce the risk of a hazard to an acceptable level.

 HACCP (Hazard Analysis and Critical Control Point) Steps:

• Assemble the HACCP team

• Describe the product
• Identify intended use
• Construct flow diagram
• On side verification of flow diagram
• List all potential hazards conduct a hazard analysis determine control
measures
• Determine CCPs and describe the measures to control the hazards
• Establish critical limit for the control measure at each CCPs
• Establish a monitoring system for each CCPs
• Establish corrective action for deviations that may occur
• Establish verification procedures
• Establish record keeping and documentation

GMP (Good Manufacturing Practices):

• Personal health: Dieses control, Cleaning, Education and training

• Building facilities: Building, receiving area, ceiling, walls and floors, high
ting, ventilation.
 Page 8 of 40

• Sanitary operation: General cleaning and maintained, Substance use in

cleaning and sanitizing, Pest and rodent control, Sanitation of food
contact surface.
• Sanitary facility & control: Water and ice management, Plumbing,
Effluent and waste water management, Change room, toilets, Hand
washing and foot dip facilities, Fish waste disposal.
• Equipment and utensils: Cold room/storage, Laboratory.
• Production and process control
• Ware house and distribution: Cold storage, Vehicle breakdown

SSOP (Sanitation Standard Operating Procedure):

 General principle of SSOP:

• Safety of water and ice

• Area of SSOP
• Prevention of cross contamination
• Maintenance of hand washing, hand sanitizing and toilet facility
• Protection of food from adulterants
• Proper labeling, storage and use of toxic compounds
• Control of employee health conditions
 Page 9 of 40

• Exclusion of pests

Chlorination schedule in company:

Area Level of chlorine Frequency

Floor washing 100 – 200 ppm Every Break
Utensil washing 50 – 100 ppm Every Break
Freezing equipment 50 – 100 ppm Every defrosting
Hand sanitation dip 20 ppm Every 3 hours
Foot dip 50 ppm Every 3 hours
Processing < 2 ppm Every 3 hours
Glaze water < 2 ppm Every 3 hours
Ice production < 2 ppm Every 3 hours
 Page 10 of 40

DOCUMENT MAINTAINED IN COMPANY:

i. Daily sanitary check list

ii. Vehicle washing check list
iii. Raw material entry register

iv. Pre-processing checklist

v. Processing check list

vi. Freezing checklist

vii. Packing checklist

viii. Metal detector check list

ix. Flake ice/ Block ice production record

x. Log book for machinery

xi. Bacterial test record

xii. Stock report

xiii. Production report

DOCUMENT ENCLOSED WITH EXPORT PRODUCTS:

i. Health certificate (Approved by EIA)

ii. Catch certificate (Issued by MPEDA)
iii. Invoice (Detail about products)

iv. Testing report of company/ company/ another laboratory

v. Q- Certificate (For quality & all detail)

 Page 11 of 40

DIFFERENT SECTIONS OF PLANT:

A. Raw Material Receiving Section

B. Pre-Processing Section

C. Agitating Section

D. Processing Section

E. Freezing Section

F. Packaging Section

G. Storage Section
Page 12 of 40
 Page 13 of 40

RAW MATERIAL RECEIVING SECTION:

In this section, raw material is unloading. Here it’s weighing at the raw material
weighing room & then transferring at the chill room. Raw material is coming from
the different centers like VERAVAL, OKHA, PORBANDAR, MANGAROL, JAFRABAD,
NAVABANDAR, VANAKBARA etc. in insulated vehicles. There are different varieties
of raw material including shrimp, Cuttle fish, squid, and octopus are purchase here.
Before the raw material is receiving, the raw material is checked for the different
parameters like, Temperature of product, Appearance, Odor, Proper icing,
Freshness, Cleanliness, Skin rupturing, Broken piece, Texture, Black spots mainly in
shrimps and sulphide residue in shrimps. If the material is spoiled or deteriorated
than its rejected only good quality material is receiving. Price of the material is
decided according to quality. After all the process is finished, raw material is
transferred in to the raw material chill room where material is store for proper
icing.
Page 14 of 40
 Page 15 of 40

Different species of shrimp, squid, cuttlefish & octopus that processed in this
company are:
SHRIMP:

Scientific Name Common Name Local Name

Parapenaeus stylifera Kiddi Prawn Tiny

SQUID:

Scientific Name Common Name Local Name

Loligo duvaucelli Indian Squid Narsinga
Loligo durytuthis Needle squid Nidal
Loligo indica Semi needle squid Semi needle

CUTTLE FISH:

Scientific Name Common Name Local Name

Sepia pharaonis Cuttlefish Makul
Sepia aculeate Needle cuttlefish Dedaka, Kabra
Sepia prasadi Cuttlefish LB (Long bone)
Sepiella inermis Spineless cuttlefish IndaGoti

OCTOPUS:

Scientific Name Common Name Local Name

 Page 16 of 40

Octopus memranicus Octopus Salak

Octopus vulguris Octopus Hikavro

PRE-PROCESSING SECTION:

In this section, raw material comes for preprocessing activity like separation of
different spp, peeling, removing of cuttle bone and pine bone etc. After
preprocessing activity, the material is rewashed and first grading is done. Grading is
done by manually or mechanically. Grading is done based on size, shape, weight
etc. The material is stored with proper icing and maintains temperature at 4 degree
Celsius. Mainly observed the grading of Uroteuthis duvacelli and sepia acculata
along with octopus membranous.
After this the processed material is transferred for agitation and treatment.
Page 17 of 40
Page 18 of 40
 Page 19 of 40

AGITATING SECTION:

In this process agitating material is used like salt, phosphate, & citric acid (Q-100, T- 40 & T-
67 is agitating chemical). Agitation is done for the firmness, whiteness, & long-term
preservation of the pre-processing material at 40 RPM. This process is done by manually or
mechanically for 20-24 hrs. or less period of time. The proper chilled preprocessed material
is transferred to the processing section. In this section Workers wear a pink dress code,
Supervisor wear a White dress with blue color, Sanitation workers wear a red dress code and
Waste collector wear a green dress code

• Agitation: For texture and firmness (add with 2 to 3% salt in 100 lit waters.)
• Blanching: To stoppage enzymatic activities, color maintain, bacteria load
destroyed etc. It is done into the boiled water ideal temperature=67+3 for 8-10
sec.
• Cooking: Cooked product, temp. 95°C, cooking time 90-110 sec.
• Glazing: To prevent dehydration, good appearance, temp 0 to -1° c
 Page 20 of 40

PROCESSING SECTION:
In this section, final grading of material is done by size. Separating of the broken piece,
discoloration, dehydrated, black spot piece & big-small pieces. After the final grading is
finished, the material is particularly weighed & arranged for packing. Product prepared at
the plant is given below.
• SQUID & CUTTLE FISH: Frozen SQW, CFW, SQWC, CFWC, SQRG, SQTN, SQT,
Cuttle fish strips, Stuffed Squid and Its Products.
- Single Stuffed Squid: Blanched Tentacle, Brocken pieces of squid
(Only one tube is used for making stuffed)
- Double Stuffed Squi: Two piece of tentacle, Brocken piece of squid
(Two tubes are used for making stuffed)

• SHRIMPS: H/O Shrimp, HL shrimp, PUD, PD, Blanched.

Page 21 of 40
 Page 22 of 40

GRADES OF DIFFERENT PRODUCTS

Species Product Types Product Grades / Sizes

Cuttle Fish F/CFW U/50, 50/100, 100/150,
150/300, 300/500, 500/700,
Squid F/SQW U/3, 3/6, 6/10, 10/20, 20/40,
40/60, 60/80
F/SQW/C 20/40
IQF/SQW/C 10/20, 20/40
IQF/SQRG RAW/BLANCHED 60/UP, 400/500, BKN
IQF/SQTN RAW/BLANCHED 60/UP
IQF/SQT RAW/BLANCHED 40/60, 60/80
F/BABY SQW 100/UP
Octopus IQF/OCTOPUS/ W/TUBES --
Shrimp PUD (PEELED AND UN 10/25, 20/40, 40/60, 60/80,
DEVEINED) 80/100, 10/200 200/300,
300/600.
10/30, 30/50, 50/70, 70/100,
100/200
HL (HEAD LESS) 21/30, 31/40, 41/50, 51/60,
61/70.
HO (HEAD ON) 11/16, 16/20, 21/25, 26/30,
31/35, 36/40, 41/50.

FREEZING SECTION:
 Page 23 of 40

The processed material is transferred to freezing section for freezing. Freezing is one of the
preservation methods by avoiding spoilage of product. There are different types of freezers
are used for freezing of the products like, Plate freezer, IQF, Blast freezer & Tunnel freezer
which are freeze the product at -40c̊ and below. When the inter part of the product has
temperature reach -18c̊ so every water drop has converted into ice.

• IQF: It is used for small material freezing like the PUD, Stuffed, Ring, Tentacle and
etc. The product is freeze at -35 to 40c̊. The product is put over the belt of IQF
and belt speed is maintained on the size of the product. The freeze product is
collecting and the glazing is done with chilled water (1-4c̊) for hardening of the
product. Hardener has temperature -30 to -33c̊. Glazing is helps against to the
dehydration of the product and gives good appearance of the products. Capacity:
1 IQF (6MT/ Day).

BLAST FREEZER
It’s used for individual freezing.

Temperature: -35 to -40c̊

Time duration: 8- 12hrs
Capacity: 20 tons or more/day

TUNNEL FREEZER
 Page 24 of 40

It is used for blocks and tray freezing

Temperature: - -35 to -40c̊
Time duration: -10-12hrs
Capacity: - 20 tons or more per day

TYPES OF ICE MAINLY USED IN PLANT

Tube ice
Flake ice
Block ice

PACKING SECTION (ANTE ROOM):

Finally freeze product is transferring for the packing in packing section. Final packing and
cartooning of the product are done in ante room. 1st product come from freezing is sorted
and if any broken and damage piece is there then it’s removed. First product is packed in to
polythene bags and sealed it with enclosing slip of product detail. Then master carton is
prepared. Product code which is maintained from raw material is writing on carton which
helps to trace back the material. Date of production is also writing on carton.
 Page 25 of 40

METAL DETECTOR:
Metal detector is used to find out the metal inside the product. Firstly, the slabs are
put under the metal detector and it is passed through tracks for specification of machine,
then pass the packed products, if the metal residue is present then the machine will stop
automatically and detect the metal from track.

LABELLING:
Detail of the product like MFG date, Expiry Date and Name of the exporter, Name of
importer, variety, grade, Net weight, Gross weight and Glaze % are prepared in language of
importer. Then it is transferred into cold storage at -18 degree Celsius.
 Page 26 of 40

CODE LIST:

For packing they use 5 ply corrugated carton. When the products are packed in
cartons, information about product is printed on carton in a code form.
a) Product name

b) Grade

c) Production year

d) Production month

e) Production date

f) Type of packing

g) Supplier code

h) Shift (Day, Night)

For production year month wise alphabets are used and these are accepted universally.
Only “I” is not used in this.

CODE MONTH
A January
B February
 Page 27 of 40

C March
D April
E May
F June
G July
H August
J September
K October
L November
M December

COLD STORAGE:
At this section, the last pack product is stored at less than -18.̊
No. of Cold storage = 4

3. FLOW CHART OF DIFFERENT PRODUCTS:

Raw Frozen Cephalopods Whole (SQW, CFW) Block / IQF

Raw material

Unloading, deicing, washing, examine & Weighing

Icing

Deicing & segregation

 Page 28 of 40

Washing and examine

Grading & icing

Washing Weighing & setting

Blast freezer/IQF/ Plate freezer

Glazing

Master cartooning & labeling

Frozen storage

Shipment
 Page 29 of 40

Raw / Blanched / Cooked / Frozen Crustaceans (Shrimps) (Head On / Head less / PUD /
PD) block / IQF

Raw material
Unloading, deicing, washing, examine &
Weighing

Icing

Deicing & segregation

Beheading, peeling, cleaning, & icing

Washing & grading

Washing and examine

Cooking &Blanching

Weighing & setting Chilling

Glazing
 Page 30 of 40

Weighing, packing & labeling

Master carton packing

Frozen storage

Shipment
 Page 31 of 40

Raw / Blanched / Cooked / Frozen Cephalopods Whole Cleaned /Tentacles Tubes / Fillet /
Rings / Roe / Block / IQF

Raw material

Unloading, deicing, washing, examine & Weighing

Icing

Deicing & segregation

Peeling, Trimming, cutting & cleaning

Washing &Icing

Hardening & Icing

Washing and examine

Grading & icing

 Page 32 of 40

Weighing & setting

Blast freezing/ Plate freezing

Glazing

Weighing

Master carton packing &Labeling

Frozen storage

Shipment
 Page 33 of 40

Steps of Water Houses and Distribution and Water Treatment:

Water from outside River/Dam/Deep well Underground tank

Water Treatment Plant

Chlorination

Pressure Sand filter

Activated Carbon filter

U.V. sterilization

Micro soft filter Horse power pump

Auto chlorine dossier (< 2 ppm chlorine level maintain)

Flow meter

U.V. sterilization
 Page 34 of 40

Overhead tank Centex tank Distribution

Distribution

MICROBIOLOGY TEST:
At company microbiological test of the raw material and final products are done
regularly. Every day sample of product which prepared yesterday is taken from cold storage
with hygienic way. Sample for antibiotic, cadmium, led, etc. are send to the other private
laboratory. (If buyer demand then all test is carried out at other lab except company lab).

• FOLLOWING MICROBIOLOGICAL TEST ARE CARRIED OUT:

Total Plate Count
Salmonella
Escherichia coli ([Link])
Enterobacter
Vibrio cholera
Staphylococcus aureus
 Page 35 of 40

• AGAR FOR DIFFERENT BACTERIA:

Bacteria Agar
Total Plate Count Tryptone Glucose Beef Extract Agar (TGBE)
Salmonella Lactose Broth (LB) Selenite Cystine Broth (SCB) Tetra
Thionate Broth (TTB) Bismuth Sulphite Agar (BSA)
Hektoen Enteric Agar (HEA)
Xylose Lysine Deoxycholate Agar (XLD)

Escherichia coli ([Link]) Tergitol – 7 agar ( T–7 agar)

Entrobacter Violet Red Bile Glucose Agar (VRBG)
Vibrio cholera Thiosulphate Citrate Bile Salt Sucrose (TCBS) agar
Alkaline Peptone Water (APW)
Staphylococcus aureus Baird Parker (B.P.)
Page 36 of 40
 Page 37 of 40

EFFLUENT TREATMENT PLANT:

It is located separately in the premises in which sewage water is treated as follows:

Screening Tank: Sewage is passed through the stainless-steel screen. The solid wastes ad
solid wastes and sand particles are collected in those chambers.
Equalization Tank: Effluent from screening tank is allowed to flow through equalization tank
where it is allowed to equalize pH & other parameter.
Aeration Tank: Sewage is passed through activated sludge and aerated by providing
compressed air through air sparer system. In this COD and BOD of effluent is normalized.
Hopper Bottom Settling Tank: Aerated sewage is allowed to settle off its sludge along with
suspended solid particles and sludge is recycled to aeration tank. Settled sediment is
disposed.

Disposal: So treated effluent is allowed drain to the common drainage system of Veraval
industrial association in GIDC.
TRACEABILITY:
• Receive the raw material.
• Put the supplier code on raw material box.
• The raw material box goes to pre-processing section / chill room with code slip.
• After Pre-processing activity product goes to processing section.
• At the time of freezer load setting we put code slip with product name, factory
approve origin, grade and raw material supplier code.
• After freezing frozen products are packed in master cartoons.
• Master cartoons are labeled with following details
• Factory approval No. or name
• Product name
• Type of pack
• Production code
• Raw material supplier code
 Page 38 of 40

• Packing supervisor code

• Time of packing (D) day or (N) night
• Country of origin
• Grade
• For sea food product – Capture zone (FAO 51)
• A detail of specific code which has been shipped to a destination is recorded on
exposer
• Thus, the traceability should work from the raw material to shipment. So, we
can trace back out anywhere.
• On the basis of packing date, we can trace the packing material. Frequency for
checking traceability: - six monthly

TYPE OF POST-HARVEST LOSSES:

• Lose in Nutritional Value: Fish that has decomposed to such a degree that it is
unfit or unsafe for human consumption. As fish spoil, its nutritional value
decreases as the bacteria causing the spoilage degrade the protein.

• Quality Loss: Quality loss refers to fish that has undergone changes owing to
spoilage or physical damage and has suffered quality deterioration. Lack of proper
chilling.

• Economic Loss: The losses of material will involve a loss in value, as the fisherman,
processor or distributor has less weight of material to sell.
Page 39 of 40
Page 40 of 40