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5. PROCESSING EQUIPMENT
Some of the most important equipment used for canning and pre-treatment of fish is
described in this chapter. The items selected are chosen, more to give an impression
of the processing principles, rather than to recommend particular equipment.

5.1 General Canning Equipment

5.1.1 Retorts
As briefly described previously retorts are used to sterilize the contents of the cans.
Horizontal retorts, which are commun within the fish canning industry, have the
following general features :
The major components of such retorts are the retort shell (body), crates and various
controllers.
The capacity of the retort is .optional and depends on the output of the cannery,
however as a guide a retort which holds 1 400 cans (850 ml) per batch would suit most
medium sized batch operations. In this case the retort would be approximately 4 000
mm long and have a diameter of 1 200 mm. The size of each crate would be 800 mm x
700 mm x 700 mm.
Approximate steam consumption would be 400 kg per batch while water consumption
during cooling would be approximately 10 000 l per batch. Consumption of electricity
would be approximately 5 kWh per hour for circulation pump etc.
Stainless steells mainly used in the construction of retorts.
Normally the retort can be operated by one person, who in many cases is in charge of
a batch of retorts.

5.1.2 Seaming machines

There are several automatic seaming machines specially designed for closing filled
square, oval and round aluminium or tin plate cans. Characteristics of a common
machine are shown in Figure 22.
Automatic machines are fitted with can end and can body feeding devices and also
with equipment for automatic code marking of can ends.
In addition they may also be linked with the following devices:
Automatic filling device
The device is designed for filling of oil, tomato sauce and other liquid sauces into cans.
It is pneumatically operated and fills precisely measured quantities into each can.
Lidplunger and control closing device

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The device is mounted on the closing machine and is particularly useful for overpacked
cans. It presses the lid down on the can, and if the lid is not lying on the can, the
seaming operation is automatically stopped.
Automatic seaming machines can operate at speeds of 3 500-4 000 cans per hour.
Diateters of cans that may be seamed range from approximately 50 to 195 mm. The
height of the cans may range from 15 to 120 mm. Multiple code markings are available.
Approximate length of the seaming machine will be 2 000 mm while width will be 2 000
mm .

Figure 22 Automatic seaming machine

Approximate consumption of electricity is 30-35 kWh per 8 hours.
The machine can be operated by two workers.

5.1.3 Can washing and drying machine

Can washing and drying machines are used to clean cans after sterilization in order to
remove residual oils that may have adhered to the can surfaces during filling and
retorting.
These machines are frequently fitted with a variable speed drive to regulate the speed
of the conveyor-belt.
Approximate dimensions of these machines are 3 600 mm (length), 1 500 mm (height)
and 1 600 mm (width).

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The drive motors will consume approximately 60-70 kWh per 8 hours when fully used.
If steam battery is used for heating it will consume approximately 200 kg steam per
hour. If the machine is heated by electricity it will consume approximately 100 kWh per
8 hours.
All parts are made from stainless steel.
The machine is automatic, but may be fed by one or two workers. See Figure 23.

5.1.4 Cartoning machine

Cartoning machines are used for packing cans into individual cartons. The main
characteristics of an air operated cartoning machines are given below.

Figure 23 Can washing and drying machine

They may be equipped with a rotating infeed table. The cartons are separated and
opened by use of vacuum and the machine is equipped with a pump for this purpose.
The machine has two electric motors each of 0.25 hp.
The capacity of the machine shown in Figure 24 is up to 65 cans per minute.
Dimensions of cans that may be operated by the cartoning machine: length (85-180
mm), width (50-100 mm), and height (12-40 mm). Length of the machine is 2 400 mm
and width is 800 mm. The motors will consume approximately 3-5 kWh per 8 hours.
Consumption of compressed air is 160-200 litres per minute. The machine may be fully
automatic or it may be fed by one or two workers. There are on the market other types
of cartoning machines with capacity 120 or more cans per minute.

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CARTONING MACHINE:
A: Feeding conveyor for product
B: Cardboard boxes stack and extraction
C: Infeed attachment for product
D: Closing station for boxes
E: Discharge of finished cardboard boxes
Figure 24 Automatic cartoning machine

5.2 Equipment for Canning Tuna

5.2.1 Racks
Racks are used in the pre-cooking process. Baskets with tuna are placed on the racks
before they are loaded into the cooker.
The main characteristics of racks used for tuna are given in the following:
The racks are equipped with two fixed and two swivel wheels.
The holding capacity of each rack is determined by the requirements of production .
Approximate dimensions of a rack are 760 mm, width 838 mm and height 1 400
mm wheel.
The material used in construction is either galvanized or black iron
Two workers are used to fill the baskets and load the cooker.

5.2.2 Baskets for cooking tuna

Baskets filled with tuna are placed in racks and loaded into the cooker.
The main characteristics of baskets often used for pre-cooking tuna are given below:
The holding capacity of each basket is approximately 15-16 kg fish.

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Dimensions of the baskets used for the racks described above are 810 mm x 380
mm x 100 mm and the net weight of each basket is 4 kg.
Galvanized wire is often used .to construct these baskets.
Two workmen can fill the baskets and load the cooker.

5.2.3 High speed tuna filler

A high speed tuna filler is a fully automatic machine designed to cut and fill pre-cooked
tuna meat into round and/or oval cans.
The main components are the feeding unit, the cutting unit and the filling unit.
The machine fills tuna tablets ranging from 100 g to 1 kg. Mass speeds are shown in
Table 14. Length of the machine is 3 600 mm, width is 1 700 mm and height is 1 250
mm. All contact parts are made from stainless steel. Only one person is required to
feed tuna loins into the machine.
Table 14 Summary of operating parameters for automatic filling of round and oval tuna
cans
Can
description

Can dimensions

Fish tablet diameter

Filling speed

Diameter
(mm)

Height
(mm)

Minimum
(mm)

Maximum
(mm)

(c.p.m.)

Standard
round

60 to 90

24 to 45

54

82

up to 150

Large round

80 to 110

48 to 106

75

93

up to 70

Oval

65 x 105

20 to 40

56

92

up to 100

5.2.4 Exhaust box

Exhaust boxes are used for heating cans to ensure that when sealed and cooled a
vacuum is produced in the container.
The main characteristics for a typical exhaust boxes used for tuna are given in the
following:
They are equipped with can feeding and discharge belts and electric motor.
The capacity of the exhaust box should be approximately 10 tons per 8 hours with
an exhausting time varying between 1-10 minutes in steam open to the
atmosphere.
Length of the box is 3 600 mm and width is 600 mm.
The motor will consume approximately 25 kWh per 8 hours. Consumption of steam
is 70-80 kg per hour.
Material used in construction is mainly stainless steel.

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The machine can be operated by one or more worker, depending on the degree of
automation used at the infeed and exist stations.

5.3 Equipment for Canning Sardines

5.3.1 Grading machines
The machine is designed to automatically grade sardines into various sizes.
The main characteristics of a typical grading machine for sardines are given below:
The machine shown n Figure 25 is powered by a 1.0 hp motor. If greater
segregation is demanded than is achievable in a single grading operation, the
machine can be equipped with a double set of grading rollers, the second
mounted underneath the first. In this manner a double grading of the fish will be
achieved. The capacity of the machine is 1 500-2 000 kg per hour, when
grading sardines of a size ranging from 20 to 100 fishes per kg.
The approximate dimensions of the machine are length 2 700 mm, width 1 100
mm, and height 700 mm.

Figure 25 Grading machine for sardines

The motor will require approximately 5-6 kWh per 8 hours.

Aluminium alloy is mainly used in the construction of the machine.

5.3.2 Brining unit

The main characteristics of an automatic brining unit. used for sardines are described
below and shown in Figure 26.

The main components are a drum made of perforated plate, which is connected
to a variable speed drive and a 1.0 hp motor.

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The capacity of a brining unit varies from 1 000 to 5 000 kg per hour an the
speed of the drive controls the brining time from between 1 and 15 minutes.

The approximate dimensions are length 4 000 mm, width 1 550 mm and height
1 700 mm.

The motor will require approximately 5-6 kWh per 8 hours.

The machine is manufactured from stainless steel.

5.3.3 Nobbing machine

A nobbing machine as described previously and illustrated in Figure 27 is used for
head cutting, nobbing (which means pulling the viscera out of the belly), cleaning and
tail cutting and/or fixed body cutting.
The characteristics of a nobbing machine used for sardines and herring are given
below.

The main components of the machine are the feeding unit, fish magazine, head
cutting unit, nobbing unit, cleaning unit and cutting unit for the tails.

The capacity of the machine described is 400-550 fishes per minute depending
on fish length, which may vary from 110 to 260 mm.

Approximate dimensions are length 2 700 mm, width 2 200 mm and height 1
600 mm.

Power consumption is approximately 20 kWh per 8 hours and water

consumption is approximately 12 litres per minute.

Figure 26 Brining unit

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Figure 27 Cutting and nobbing machine

Materials used in construction are stainless steel and aluminium alloy

The machine shown may be operated by one supervisor.

5.3.4 Continuous flash cooker

The flash cooker is used for pre-cooking and drying of sardines before exhausting and
closing the cans.
The main components of the cooker shown in Figure 28 are the automatic charge and
discharge section, the steam chamber, the draining section and the drying section. Two
chains carry approximately 800 crates in which the cans are placed.

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Chain speed and thereby cooking time is variable. Different types of cans can be
cooked without adjustments to the cooker. Up to 12 500 club cans per hour can be
processed.
Approximate dimensions are length 15 500 mm, width 1 600 mm and height 3 900 mm.
The cooker will require approximately 50-60 kWh per 8 hours if it is used fully while
depending on load steam consumption is approximately 500 kg per hour. The cooker is
mainly constructed from stainless steel. Being fully automatic one operator is required
to supervise the machine.

5.3.5 Smoking kiln

The smoking kiln is also used for drying, pre-cooking and smoking sardines. The main
components of a kiln are the drying unit, the smoking chamber, the fans, the heat
exchanger and two motors, a 4-hp motor for the fans and a 1.5-hp motor for the chains.
The capacity of the automatic kiln shown in Figure 29 is 6 000-8 000 kg per 8 hours.
Approximate dimensions are length 11 650 mm, width 2 200 mm and height 2 170 mm.
The kiln requires approximately 30-40 kWh per 8 hours and consumption of oil is
approximately 5 litres per hour. Material used in construction is mainly black iron. Being
fully automatic the kiln is operated by one worker.

5.4 Equipment for Canning Fish Paste Products

5.4.1 Meat separator
Fish meat separators are used to recover meat from split and washed fish.
The main components of a separator are normally a rotating perforated drum/cylinder,
mounted horizontally, and a rubber belt. The perforated drum and the rubber belt
rotates in the same direction, and the fish is squeezed in between the rubber-belt and
the drum. The separator is equipped with a 5 hp motor.

Figure 28 Flash cooker

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Figure 29 Smoking kiln

The capacity is 10 tons washed and split fish per 8 hours, with an approximate yield of
7 tons minced fish and 3 tons offal. Approximate dimensions of a typical separator are
1 060 mm x 1 127 mm x 1 050 mm. The diameter of the holes in drum are 2 1/2- 3 mm.
The motor will require approximately 30 kWh per 8 hours. All contact parts are made
from stainless steel. The machine is operated by one worker.

5.4.2 Bowl chopper/mincer

The ingredients (fish, salt, milk starch, etc.) must be mixed and finely minced. The
mincer-bowl rotates, and the ingredients have to pass under vertical high speed cutting
knives.
The main components of the machine are the bowl, the mincer and a 50-100 hp motor.
Mincer/cutter capacities vary from approximately 25 litres to several hundred litres. The
bowl capacity is approximately 325 litres. Approximate dimensions of the
chopper/mincer are (2 200 mm x 1 800 mm x 1 350 mm). The motor will consume from
approximately 300 to 600 kWh per 8 hours. All contact parts are made from stainless
steel. The machine is operated by one worker.

5.4.3 Pumps for minced materials

The mixture of fish and ingredients is emptied from the bowl mincer into a container
with a built-in screw and pump at its base. From this container the mass can be
pumped, either to the ball former, or the fish cake former. The fish balls and cakes are
extended through stainless steel pipes.

The main components are the container, the pump with a 2 hp motor and the pipes.
Approximate capacity is 40-50 litres per minute, with variable speed. The dimensions
are 1 550 mm x 1 100 mm. The motor will require approximately 12 kWh per 8 hours.
All contact parts are made from stainless steel. One operator is required.

5.4.4 Cooking equipment for fish balls

The cooker for fish balls may vary in size however an example of a cooker with a 2 000
kg/h capacity is given below.

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The main components of the machine are normally a ball former and cooking
chamber.

Approximate dimensions are length 6 000 mm, width 1 250 mm and height 400
mm.

For the size quoted steam consumption is approximately 500-700 litres per
hour.

The cooker is made from stainless steel and it is usually operated automatically.

5.4.5 Fryer for fish cakes

As the cakes have to be fried on both sides, they have either to be turned manually
otherwise the machine can do this automatically.
A description of an electrical fryer for fish cakes is given below and shown in Figure 30.

The main components of the machine are normally the cake former, a belt and
a heating element.

Capacity is 650 kg fried cakes per hour (13 000 cakes x 50 g per cake).

Approximate dimensions are length 6 000 mm, width 1 500 mm and height 1
500 mm.

The fryer described requires 900 to 1 000 kWh per 8 hours when it is used to
full capacity.

The machine may be operated by one worker.

Figure 30 Frying machine with fish cake former

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