SEA FOOD PLANT SANITAT

ION

Presented by
Navya D R UGS17BFT145
Naveen G V UGS17BFT144
Seafood plant sanitation
Seafood sanitation has been defined as the controlling
of all conditions or practices within the plant so th
at seafood processed is free from disease causing mic
roorganisms and foreign matter.
It is essential to provide the processor with guideli
nes that will give the consumer a high quality ,whole
some food.
Seafood processor should familiar with
 Microorganisms that cause spoilage and foodborne illn

ess
 Characteristics of various types of soil

 Effective cleaning compounds and sanitizers

 Cleaning equipments and effective cleaning procedures

Sanitation construction considerations

A hygienically designed plant can enhance the wh

olesomeness of all foods and dramatically impro
ve the effectiveness and efficiency of the sani
tation program.
In a hygienic operation ,the employer or manage
ment team should ensure
 good housekeeping
 should be constantly vigilant against ineffecti

ve sanitary practices for all physical faciliti

es ,unit operations ,employees and materials .
site requirements
 It should be clean and attractive .
 Clean premises should be maintained .
 Should be adequately drained .
 Should be free from excessive dusty roads ,yards
.
 Should be equipped with capability to dispose of
f the seafood plant waste.
 Must supply an ample amount of potable water
 Adequate provisions should be made for wastewate
r discharge.
Construction requirements
 Materials that do not absorb water and are easil
y cleaned ,resistance to corrosion and other det
erioration
 Openings should be equipped with air or mesh scr

eens to prevent entry of insects , rodents , bir

ds and other pests.
Floors
 Should be constructed of an impervious material su

ch as waterproof concrete or tile.

 The material should be durable with a surface i,e
; even enough to prevent accumulation of debris bu
t Smooth enough to cause slipping and falling.
 A rough finish or use of embedded abrasive particles can re
duce accidents.
 A frequently used surface is water based acrylic epoxy resi

n that provides a durable ,non absorbent, easy to clean sur

face that can double the life of the concrete floor.
 Finish should contain an abrasive material to provide a ski

d-resistant surface.
 Acid brick floors are known to satisfactory and durable.

Floor drains
 A drainage outlet should be provided in processing area for

each 37 m2 of floor space .

 Floors in the processing area should have a slope to a drai

nage outlet of 2% and be uniform ,with no dead spots to tra

p water and debris.
 All drains should contain traps.
 Drainage line should have an inside diameter at least 10cm and
should be constructed of cast iron , steel or polyvinyl chlorid
e .
 Drainage lines should be vented to outside air to reduce odors

and contamination.
 All vents should screened to prevent entrance of pests into the

plant.
 Connection of drains lines from toilets directly into sewage sy

stem can further reduce contamination.

Ceilings
 Should be constructed at least 3m high in work areas with mater

ial impervious to moisture .

 Acceptable material is portland cement plaster .

 A false ceiling prevents debris from overhead pipes ,machinery

and beams from falling onto exposed products.

Walls and windows
 should be smooth and flat with a nonabsorbent material such as

glazed tile , glazed brick , smooth surface portland cement pl

aster or other non toxic material.
 Concrete walls are satisfactory if they contain smooth finish.

 Painting is discouraged a nontoxic paint not lead based can be

applied.
 Window sills, if present , should be slanted at 45 degree angl

e to reduce debris accumulation.

Entrances
 Should be constructed of rust resistant materials with tightly

soldered or welded seams .

 Double entry screened doors should be provided for outside ent

rances as well as air curtains over side doorways in the proce

ssing areas .
Processing equipment
 should have a durable , smooth finish that is easily cleane
d .
 Surface should be free of pits ,cracks and scale.

 Equipment should be designed to prevent contamination of pr

oducts from lubricants ,dust and other debris.

 Hygienic design for cleaning ease .

 Should be installed and maintained to facilitate cleaning o

f equipment surfaces and surrounding areas.

 It should be made up of stainless steel .

Cutting boards
 should be fabricated of a hard, non porous , moisture resi
stant material .
 Should be easy to remove for cleaning and should be kept sm

ooth.
 Cutting board should be abrasion and heat resistant , shat
terproof , and nontoxic.
 Should not contain material that will contaminate products.

Conveyor belts
 Should be constructed of moisture resistant material and ea

sy to clean .
 Should be designed to eliminate debris catching corners and

inaccessible areas.
Drive belts and pulleys
 Should be protected with guard shields that are easily remo

ved during cleaning .

 Motors and oiled bearings should be located so that oil and

grease will not come in contact with the product.

 A satisfactory equipment should be located w
ithin 0.3 m of walls and ceilings so that ac
cess for cleaning is available.
 Equipment should be mounted at the same dist
ance above the floor or have water tight se
al with the floor .
 All waste should be discharged through flume
s or tanks , so that it is delivered with an
uninterrupted connection to the drainage sys
tem without flowing over the floors.
Contamination sources
 Environment conditions at seafood plant location
 The processing equipment, containers and work surfaces
 Raw fish and processing environments are potential source of lis
teria monocytogenes .
 Raw product if improperly harvested and subjected to unsanitary
practices on vessel or truck , delayed refrigeration , improper
handling
 Workers
 Equipments ,boxes, belts, tools ,walls , floors , utensils , sup
plies , and pests .
 Scombroid contamination is associated with some of dark fleshed
, fast swimming fish. This is also called histamine poisoning an
d causes allergic reaction.
 Undercooked shellfish can be contaminated with vibrio vulnificu
s and contain viral infections from hepatitis A.
 Sanitation principles
A seafood sanitation program must encompass proper han
dling of the sanitation tasks as well as personnel a
llocation.
Sanitation Inspection Critical Factors
Stanfield (2003) suggested the following critical fact
ors to remember when a sanitation inspection of a pr
ocessing plant for fresh or frozen fish is conducted
:
1. Look for evidence of rodents, insects, birds, or pe
ts within the plant.
2. 2. Observe employee practices including hygienic pr
actices, clothing cleanliness,and use of proper str
engths of handdip solutions.
4. Determine if equipment is washed and sanitized durin
g the day and at the beginning and end of the daily
5. Check to determine if the fish arewashed with a spra
y after evisceration
and periodically throughout the process prior to packagi
ng.
6. Determine the method and speed of freezing or frozen
fish and fish products.
7. Check the use of rodenticides and insecticides to ass
ured that no contamination occurs.
8. Observe handling from boats to finished package and o
bserve any significant objectionable conditions.
Manufacturing inspection
 The following manufacturing inspection suggestions we
re adapted from those provided by Stanfield (2003):
1. The flow plan and manufacturing procedure should be
evaluated.
2. Processing equipment should be evaluated for constru
ction, materials, and ease of cleaning.
3. Equipment cleaning and sanitizing procedures should
be observed and evaluated to determine their adequacy
.
4. All butchering procedures should be observed and eva
luated.
5. Water source should be determined and evaluated to c
onfirm that only potable
6. If a long production delay occurs during processing fish
at room temperature, the product should be checked for deco
mposition.
7. All handling steps and intermediate steps in processing t
hat may cause contamination should be examined.
8. Holding times and temperatures during processing should b
e determined.
 9. If battering and/or breading of fish are involved, the p

rocess should be reviewed carefully, including temperature

and possible contamination sources.
 10. Compliance with good manufacturing practices (GMP) shou

ld be evaluated.
Personnel allocation
 In addition to the need for adequate clean
ing methods and seafood facilities, a well
qualified sanitarian is required.
 seafood plant manager is ultimately respo
nsible for an effective sanitation program
and the production of wholesome products,
sanitation employees who are trained to ma
intain a clean plant must be provided.
 Employees should be adequately instructed
in seafood product knowledge and in proper
sanitary techniques, so that they are info
rmed of the importance of the effect of pr
 Any employee with a contagious illness shoul
d not work around processing areas, even dur
ing cleanup
 The typical seafood processing plant should

have one or more employees responsible for d

aily inspection of all equipment and process
ing areas for hygienic conditions.
 Any sanitation deficiencies should be correc

ted
before production operations are initiated.
 Cleaning Schedule
 A cleaning schedule with sequential cleaning steps is essential.

The schedule should be adopted for each area of the plant and shoul
d be followed.
 Continuous-use equipment, such as conveyors, flumes, filleting m

achines, batter and breading machines, cookers, and tunnel freeze

rs, should be cleaned at the end of each production shift.
 If there are no refrigerated areas, batter machines and other equ

ipment in contact with milk or egg products should be cleanedat

4-hour intervals by draining the batter, flushing the batter rese
rvoir with clean water,and subsequently applying a sanitizer.
 At the end of the production shift, this equipment should be dis

assembled, and all parts should be cleaned and sanitized. These p

arts, as well as portable equipment, should be stored off of the
floor in a clean environment to protect against splash water, dus
t, and othercontamination sources
The following steps apply when cleaning seafood plants:
1. Cover electrical equipment with polyethylene or equivalent
film.
2. Remove large debris and place it in receptacles.
3. Manually or mechanically remove soil deposits from the wall
s and floors by scraping, brushing, or by the action of a h
ose from mechanized cleaning
equipment. Proceed from the top to the bottom of the equipment
and walls, toward the floor drains or exit.
4. Disassemble equipment as required.
5. Conduct a prerinse for wetting action and removal of large
and water-soluble debris, with water at 40°C or lower. This
temperature is important. A higher temperature can cause de
naturation of seafood residues and other proteins, with sub
6. Apply a cleaning compound that is effective against organ
ic soil (usually an alkaline cleaner) by portable or centra
lized high-pressure, low-volume, or foam equipment. The tem
perature of the cleaning solution should not exceed 55°C.
7. After the cleaning compound has been applied and given ap
proximately 15 minutes to aid in soil removal, rinse the eq
uipment and area with water that is 55 to 60°C. 8. Inspect
equipment and the facility for effective cleaning, and corr
ect deficiencies.
9. Ensure plant sanitation through application of a sanitize
r.
10. Avoid contamination during maintenance and equipment set
up by requiring maintenance workers to carry asanitizer and
to use it where they have worked.
sanitation checks
The following sanitation checks should be conducted:
1. Compliance with good manufacturing practices (GMP
s) should be confirmed
2. Effectiveness of equipment cleaning and sanitizin
g should be inspected.
3. Hand washing and sanitizing facilities and the ap
propriate solution strength should be checked.
4. The correct usage and storage of pesticides shoul
d be verified.
5. The proper processing and storage temperature sho
uld be verified to ensure reduced microbial growth.
High Hydrostatic Pressure Treatment

High hydrostatic pressure (HHP) processing is a viab

le treatment technique for use in reducing pathoge
nic microorganisms associated With food and in ex
tending shelf life.
HHP has been applied to a variety of foods, includin
g seafoods, fruit juices, sauces, and meats.
HHP was effective in killing microorganisms in raw f
ish fillets, but its significant effect on the col
or and overall appearance of the product limits it
s application to the processing of fish for raw fi
sh markets.
 HHP offers seafood processors advantages suc
h as reduced process time; retention of fre
shness,flavor, texture, appearance, and col
or; and reduced functionality alterations c
ompared to traditional thermal processing.
HHP of 250 to 300 MPa for 120 seconds curtail
s many of the disease risks (such as from V
ibrio parahaemolyticus, V. cholera, and V.
vulnificus) associated with the consumption
of raw oysters .
Ozone Generation

 ozone has utility in aquaculture to disinfect wa

ter and assist in filtration and for cooling towe
r water.
 Production units are available that concentrate
oxygen from the air using pressure swing absorpti
on (PSA), use air directly, or feed pure oxygen f
rom another source.
 The most common is PSA, because the feed gas must
be dried away (to prevent formation undesirable b
y-products from ozone formation) and the drying p
rocess is similar to the concentration process
RECOVERY OF BY-PRODUCTS
Waste management, including the recycling of seafood waste pro
ducts, has become increasingly important. In addition to th
e economic considerations, an effective recovery system can
contribute to a more hygienic operation.
Today, many food processors are recycling and/or reducing thei
r liquid discharges.
Innovations in water conservation are:
● Wastewaters used for noncontaminating purposes in one area
of a food processing operation are now being redirected to
other areas that do not require potable water.
● Closed water system food processing operations in which all
process waters are continuously filtered to remove solid ma
terials have been established.
● Dry conveying equipment has been utilized to replace water
transport of solids.
Hazard Analysis Critical Control Point
Models

Seafood processing regulations, which became effective on Dece

mber 18, 1997, require that a seafood processing plant (dom
estic and exporting foreign countries) represent a preventi
ve system of food safety controls known as hazard analysis
and critical control point (HACCP). The basic concept of HA
CCP is to:
(1) identify food safety hazards that, in the absence of contr
ols, are likely to
occur in products
(2) establish controls at those operations in the process tha
t will eliminate or minimize the possibility that an identi
fied hazard will occur.
HACCP provides a systematic approach for taking those measure
s that demonstrate to the Food and Drug Administration (FD
A), customers, and consumers that food safety and design ar
e being practiced
 Four raw fish workshops conducted by the National Mar
ine Fisheries Service developed HACCP models for each
region that identified between 23 and 26 steps with 5
to 11 critical control points.
 The HACCP model for breaded shrimp production identif

ied 30 process steps, with 9 identified as critical.

 Similar evaluations were made through analysis of coo

ked and raw shrimp processing.

 This surveillance model is designed to develop a seaf

ood products inspection program to protect consumers,

based on the HACCP concept.A