Snippet…

• We are going to learn about entire process in which the processing

plant go through from receiving raw material to storage of that
processed material...
• Also about laboratory like what the actual process is conducted in day
to day basis…
• And about effluent treatment plant ( ETP ) …
CCP - 1
• Raw material receiving supplier declaration
• Tests :
• Sulphate
• Antibiotics
• Visible checking :
• Count
• Softness
• Temp <4 degree celcius
• Hanging meat
• Texture
• Decomposition
• Black spot
Raw material receiving
• Raw materials are received in Ash colour boxes
• Those crate boxes are indicated by different Batch number
• Those crate also contain date, variety, count, batch number
• Materials are received by insulated containers
Filth wash
• Received materials are washed with chill water
• ( FILTH : Waste material, dirt )
• Dirt mixed with chill water and form a orange coloured foam
• orange colour foam is formed due to dirt colloid with water with the
help of air bubbles forms under the filth wash machine
Grading
• After filth wash those material is again washed with chill water
• Then the material is passed into grading machine
• Which separate the material ie. Shrimp, into different size
• The grading machine contain 6 different belts
• The belts are adjusted based on the requirements of buyer
• Then the graded material is filled in orange colour crate box
• Each box ( 2 crate ) weigh about 34 kg
• 2 crate weight ( 4 kg )
• Water ( 0.400 kg )
• The material weight ( 30 kg )
Pre - processing ( beheading )
• The Material are received ( headon material )
• Received in ash colour crate box
• Then the head of the material is pulled out with the help of
manpower
• Calculation :
• Waste : 31 %
• Yield : 69 %
• Then the beheaded material is shifted into brown colour crate box
Value addition
• Variety
• Peeled and deveined ( PD ) - 82 %
• Peeled and deveined tail on ( PDTO ) - 88 %
• Pull vein peeled deveined ( PVPD ) - 83 %
• Pull vein peeled deveined tail on ( PVPDTO ) - 88 %
• Butterfly - 88 %
• Easy to peel ( EZPL ) - 99 %
• PD : Shell, tail, vein all removed ( knife is used )
• PVPD : shell, tail, vein are removed ( needle is used )
• PVTO : Shell, vein are removed, tail is not removed ( needle is used )
• PDTO : shell, vein are removed, tail is not removed ( knife is used )
• EZPL : Only vein is removed ( scissor is used )
Waste
• PVPD : 6 KG
• EZPL : 1 KG
• PVTO : 5 KG
• PDTO : 5 KG
Soaking
• Meaning
• Some kind of chemical and water is added to the material to benefit
the yield, taste and texture of the material
• Two methods
• / treated
• /untreated
• Treated ( method -1 )
• Chemicals : salt and sodium tripolyphosphate
• Water
• Process :
• Chill water + salt + sodium tripolyphosphate are mixed well with
particular amount of material
• Stir it for 1 ½ hours
• Stalking – 1 ½ hours
• Treated ( method – 2 )
• Chemical : salt
• Water
• Process :
• Chill water + salt are mixed well with particular amount of material
• Stir it for 1 ½ hours
• Stalking - 1 ½ hours
• Untreated
• The material is mixed well in water
• Stir it for 45 mins
• Stalking - 45 mins
Benefits
• Enhance the sensory quality
• Prevent driploss
• Increase the weight of the product
Individual quick freezing ( IQF)
• CAPACITY :
• Infeed - 925 kg/hr
• Hardener - 1.2 tons/hr
• BELT SPEED :
• Speed of the belt depend on the grade and variety which pass in
infeed.
• Hardener – ( - 40 degree celcius )
Working principle
• IQF
• It freeze the product extremely quickly
• By quickly freeze the product, the cells within the food are
undamaged and preserved so that a higher quality result is acquired
every time
• Crystalize the water molecules present inside the shrimp
• HARDENER
• Freeze the chill water ( glaze )
Belt speed
• 8/12 - 8 mins
• 13/15 - 7 mins
• 16/20 – 6 mins
• 21/25 – 5 mins
• 26/30 – 4.5 mins
• 31/40 – 4 mins
• 41/50 – 4 mins
• 51/60 – 4 mins
• Glaze % = frozen weight – deglaze weight / frozen weight x 100
• Purpose of using glaze :
• Act as a protective layer
• Prevent the brokening of shrimp ( after iqf process )
Block ( plate freezer )
• Temp – (- 40 degree celcius )
• Capacity – 418 and 384 pans
• One slab – 1.816 kg ( big pan ) and 1.260 kg ( small pan )
• Time – 1 hr
• Chemical for freezing purpose – ammonia
CCP – 2
• Packaging and labelling :
• Food additives – include phosphate in the ingredient list
• Significant hazard – food additives
• Critical limit – label includes additives with high impact
• Monitoring – visual examination
• - finished product label
• Corrective action – if the packaged units do not have labels or labels
with additives in ingredient statements , it gets reviewed
• verification and record keeping
Metal detection
• After weighing and sealing the packets are passed through the metal
detector
• If any metal detected, the machine stops process automatically
• METAL SIZE :
• Ferrous – 1.5 mm
• Non ferrous – 2 mm
• Stainless steel – 2.5 mm
• Entire process is monitored by supervisor and quality control person
CCP – 3
• METAL DETECTION :
• Significant hazard :
• Ferrous – 1.5 mm
• Non ferrous – 2 mm
• Stainless steel – 2.5 mm
• Corrective action :
• If metal piece is identified reprocess the product or destroy the
product
Packaging and labelling
• Label colour : vannamei
• Broken – orange
• Cooked – pink
• Dc – red
• G1 – radium
• G2 – dark green
• Label colour : Black tiger
• Broken – orange
• Cooked – pink
• Dc – red
• G1 – radium
• G2 – green
Packaging dummy type ( tape colour )
• PD – Plain
• PVPD – black
• PDTO – yellow
• EZPL – green
• HL – orange
Ante room and cold storage
• Cold storage Temp – ( - 18 degree celcius )
• Ante room Temp - ( 15 degree celcius )

• Why – 18 degree celcius ?

• At this temperature all bacteria such as thermophiles, mesophiles,
psychrophiles, psychrotrophs get arrested .
• More over it increase the shelf life of the product, by reducing its
temperature.
Effluent treatment plant ( ETP )
• Basically four treatments are there,
• Preliminary – removal of solids, oil and grease
• Primary – removal of floating suspended solid, organic matter
• Secondary – removal of biodegradable organic matter ( BOD )
• Tertiary – removal of residual suspended solids, dissolved solids
How does ETP work ?
• The operation of the effluent treatment plant is divided into three
categories,
• Primary treatment involves separating sludge from the liquid using
sedimentation tanks and then
• Secondary treatment involves the removal of biological or organic
matter to reduce bacterial population
• Tertiary treatment involves removal of harmful microbiological
contaminants from wastewater