B: DETAILED VESSEL INSPECTION REPORT
3.1 INTRODUCTION
a re a in a p ro p e r insulated co n ta in e r, w hich is m a d e u p o f slush ic e a n d salt w a te r. Tuna is to b e properly h a n d le d in a safe a n d p ro p e r m anner. The te m p e ra tu re o f th e tu n a is very im p o rta n t a n d th e re should b e a form th a t shows th e re co rd e d te m p e ra tu re th a t has b e e n in sp e cte d a t tim e o f discharge.
S ection 4.2.3 shows th e ty p e o f form s w h ich is required to b e c o m p le te d a t p o in t o f d isch a rg e . These form s will also show if th e re is a p ro b le m w ith th e te m p e ra tu re o f th e tuna. If th e re is an y problem s a t tim e o f discharge, then w hen th e p ro d u c t arrives to th e receiving a re a it c a n b e co rre c te d .
Points o f C o n ce rn
No tuna is to b e taken into th e receiving area th a t has b e c o m e d e co m p o se d , unw holesom e a n d /o r co n ta m in a te d .
No tu n a w hich has n o t b e e n properly g u tte d is perm itte d .
No tuna is to b e a c c e p te d a t th e receiving a re a w hich has b e e n transported by th e m eans o f a n o p e n truck.
No tu n a is to b e p la c e d o n th e flo o r o f th e receiving a re a . Tuna w h ich is p la ce d on th e floor will b e c o m e c o n ta m in a te d very easily. It is u n a c c e p ta b le to have a p ro d u c t th a t is b e in g processed fo r hum an co n su m p tio n h a n d le d in this m anner. There are to o m any ways for th e floor to b e c o n ta m in a te d , a n d in turn ca u se co n ta m in a tio n to th e pro d u ct.
3.1.2 G rading o f Tuna
The g ra d in g o f tu n a is d o n e a t this stage for colour, c o n d itio n a n d size. Tuna m ust b e p la c e d on a proper g ra d in g ta b le w hen being in sp e cte d fo r these procedures.
Section 5 details th e system th a t is used for th e g ra d in g o f Bigeye a n d Yellow Fin Tuna for co lo u r a n d c o n d itio n a n d th e form s w hich should b e c o m p le te d w hen inspection o f tuna Is being carried out.
During quality inspection for co lo u r a n d co n d itio n , th e tuna should b e m arked as to w hat m arket it is in te n d e d for by p la cin g a ta g with th e p ro p e r m arkings on them .
Points o f C oncern
Tuna are not to be p lac e d on floor, for fe a r o f co n ta m in a tio n a n d d a m a g e to th e outer a re a o f th e fish.
Tuna are not to b e d ra g g e d on floor a rea for fe a r o f d a m a g e .
Tables fo r th e Inspection a n d processing o f tu n a are to b e co n stru cte d o f a sm o o th surfa ce w hich is free from cracks a n d crevices. The ta b le should b e co n stru cte d o f a p p ro ve d m aterials.
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During inspection all a tte m p ts m ust b e taken to preven t th e co n ta m in a tio n o f th e tu n a from fore ign m aterial.
All utensils used during th e inspection p ro ce d u re m ust b e c le a n a n d safe.
3.1.3 C ooling
Tuna m ust b e kept c o o l a t all tim es to ensure th a t th e re is no rise in th e c o re te m p e ra tu re o f th e tuna.
Tuna Is not to b e le ft exposed fo r a long p erio d o f tim e .
Tuna should only b e rem o ved from th e slush tanks as th e y a re g o in g to b e processed.
The c o re te m p e ra tu re o f th e tuna should b e a t 0°C a t all tim es.
Tuna for dom estic markets must b e m aintained a t a prope r c o re te m p e ra tu re . The air te m p e ra tu re in th e processing a re a should b e m a in ta in e d a t 18°C or less.
Points o f C oncern
Tuna w hich has a high te m p e ra tu re is n o t p e rm itte d to b e exported.
Tuna Is n o t to b e rem o ved from slush tanks until tim e o f p a ckin g fo r shipping.
Tem perature b e fo re b eing rem o ved from th e tanks m ust b e a t 0°C.
If tem perature o f tuna rises a b o v e 7°C th a n th e m e a t is b e in g exposed to th e process o f increasing chances o f histamine. The only w ay th a t this c o m p o u n d c a n b e co n tro lle d is by e lim ina ting th e c h a n ce s o f a rise in th e te m p e ra tu re . 3.1.4 Processing o f W hole Fresh Tuna
Tuna is to b e p la c e d on ta b le s w hereby th e process o f rem oving th e fins is ca rrie d out. All fins should b e rem oved properly a t this sta g e in produ ction.
The belly ca vity is in spected fo r w orkm anship to ensure th a t th e re a re no g u t rem nants le ft in th e belly w all o f th e tuna.
The a re a aroun d th e h e a d w here th e gills ha ve b e e n rem o ved m ust b e in sp e cte d to ensure th a t it is properly c le a n e d . If th e re a re a n y d e a d b lo o d present it m ust b e rem oved im m ediate ly. The section o f visible b o n e around th e head section must, if not already during c a tc h in g b e in g c le a n e d properly, b e c o m p le te d a t this tim e.
The inner belly lining m ust b e properly trim m e d . Any p ie ce s o f th e m e m b ra n e w h ich a re han gin g or loose m ust b e rem o ved properly. W hen th e tu n a has b e e n in sp e cte d for workm anship, if th e tu n a a re to b e held fo r a n y p erio d o f tim e b e fo re b e in g p a cke d a n d shipped, th e y m ust b e p la c e d in properly co n stru cte d slush tanks, w hich have c le a n a n d safe slush ic e a n d salt w ater.
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If th e tem perature o f th e wash w ater is high, it is re c o m m e n d e d th a t th e w ater b e co o le d before co m in g in c o n ta c t with the tuna. O ne m e th o d is to pass th e w ash w a te r thro ugh a c o il o f c o p p e r p ip e w hich has b e e n p la c e d in a ice /w a te r slurry.
Points o f C o n ce rn
No tu n a w h ich is d e c o m p o s e d , ta in te d or unw holesom e shall b e processed.
No tuna is to b e inspected or processed o n th e flo o r surfa ce o f th e processing area. The reason for this is to prevent co n ta m in a tio n .
No tuna is to b e d ra g g e d across th e floor. Tuna is a very d e lic a te fish. It is very easy to d a m a g e th e skin surface o f th e tuna. If th e scales a re d a m a g e d a n d th e skin is torn, th e c o n d itio n o f th e tu n a will b e a ffe c te d b y this m e th o d o f h a n d lin g tu n a . The outer m e a t w hen th e tu n a is being d ra g g e d will also b e d a m a g e d causing a decrease in th e usable m e a t. R em em ber th a t th e buyer is only paying fo r th e a m o u n t o f p ro d u c t th a t he c a n use.
No tu n a is to b e exposed to th e h e a t fo r a long p erio d o f tim e . If th e tem perature o f th e m e a t o f th e tu n a is p e rm itte d to rise it will c re a te a qu a lity problem ,
No tuna should b e p la c e d in im properly designe d slush tanks.
No blood is perm itted to rem ain in th e tuna. This will ca u se ra n cid ity to form in th e m e a t o f th e tuna, causing health a n d qu a lity problem s.
If these measures are follow ed, tuna will be protecte d from co n ta m in a tio n a n d d a m a g e to th e scales, skin, a n d outer m eat.
3.1.5 Processing a n d Packing o f Fresh Tuna Loins
Tuna w hich is being d ire cte d for processing as fresh tu n a loins m ust b e processed im m e d ia te ly prior to shipping.
Tuna loins m ust b e processed and inspected for an y d e fe c ts as quickly a n d as carefully as possible. All d e fe cts m ust b e rem oved a t tim e o f processing.
Tuna loins m ust b e co ve re d im m e d ia te ly in a prope r a p p ro ve d p o ly sheet Im m ediate ly a fte r being in spected.
Tuna bins are to b e packed in a proper shipping box whic h m ust c o n ta in either frozen gel-p acks or dry ice.
Tuna bins should only b e p ro d u ce d in a specially designe d te m p e ra tu re co n tro lle d room . The air te m p e ra tu re should n o t e xce e d 18°C .
Points o f C o ncern
No tuna bins th a t is unsafe, d e co m p o se d , or unw holesom e is p e rm itte d to b e p a cke d or shipped.
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Tuna loins m ust m aintain a te m p e ra tu re o f 0°C .
No fresh tuna loins destined fo r sashimi are p e rm itte d to b e processed from tu n a th a t does not m e e t th e co lo u r a n d c o n d itio n score o f 40 a n d higher.
No tuna loins are to b e transported in an unrefrigerated truck.
3.1.6 Packing an d Shipping o f W hole Fresh Tuna for Exporting
Tuna m ust have a c o re te m p e ra tu re o f 0°C b e fo re it is p la c e d into c a rto n for shipping.
Tuna is to b e rem oved from th e slush tanks just prior to packing.
The o u te r surface m ust b e w iped c le a n with a spon ge a n d cle a n safe salt w ater.
The belly section m ust b e w iped c le a n from an y w ater or foreign m aterial.
The belly wall m ust be packed with frozen g e l packs to help in m aintainin g th e c o re te m p e ra tu re o f th e tuna.
The outer skin surface must b e covered with green tu n a p a p e r w hich has been previously soaked in salt water. This will prevent th e skin o f th e tu n a from losing its m oisture; a n d also, w here th e re are m ore th a n o n e tuna in a ca rto n , it will p ro te c t e a c h tuna from th e other.
The tuna a fte r being properly co ve re d is to b e p la c e d ge n tly into th e carto n.
The c a rto n m ust c o n ta in tw o sheets o f 10 m il poly w hich is large e no ugh to co m p le te ly co ve r th e tuna.
Before closing the plastic you m ust p la c e frozen g e l packs around th e tu n a to help m aintain the proper te m p e ra tu re . If dry ic e is used, it m ust b e p la c e d in the container so as not to cause freezer burn to th e skin surfa ce a n d th e outer m e a t.
The c a rto n m ust be constru cte d o f w a ter tig h t m a te ria l a n d have strength to w ithstand p a cka ges stacked on to p o f e a c h o th e r w ithout b eing crushed.
The ca rto n m ust also b e co n stru cte d o f m ate rial th a t prevents th e transfer o f te m p e ra tu re . It m ust b e designe d for c o ld retention a n d b e insulated from external tem peratures.
Transporting o f fresh tuna p a cke d for air shipm ent. The truck m ust c o n ta in a chill unit so as to m aintain th e air te m p e ra tu re a t 0°C during transportation to th e airport.
Points o f C o ncern
Tuna which is decom p osed or unwholesom e is not p e rm itte d to b e p a cke d for export.
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Tuna, a t no tim e is to b e rem oved from the slush tanks a n d p la c e d on th e floor prior to or during th e processing operation.
Tuna th a t is im properly ch ille d shall not b e p a cke d for shipping.
No tu n a is to b e shipped unless e a c h c o n ta in e r contains eithe r frozen ge l packs a n d /o r dry ice.
No tu n a is to b e p la c e d in to ca rto n w ithout proper p ro te ctio n o f th e skin.
No tuna is to b e packed w ithout the belly section co n ta in in g a prope r a m o u n t o f frozen g e l packs.
No c a rto n to b e used w hich does not reach th e requirem ents m e n tio n e d abo ve.
No tuna to b e transported to th e airpo rt in n o n -co o la n t trucks.
3.1.7 Processing o f Frozen Tuna Loins and Sticks
Tuna which is destined for frozen production must b e processed as quickly an d as carefully as possible as soon as it is received. Sections 3.1.7.1 a n d 3.1.7.2 show parts o f tuna loins a n d section 3.1.7.3, th e dressing o f eviscera te d tuna.
Fresh Tuna w hich is destined for frozen loin p ro d u ctio n m ust b e properly handled. The tuna must be transferred to th e loin p ro d u ctio n a re a in a proper m a n n e r. The fish m ust b e m o ved into th e p ro d u ctio n area by m eans o f containers or trolley.
All c a re m ust b e taken to ensure th a t during th e p ro d u ctio n process th a t no tuna co m e s in c o n ta c t with a ny co n ta m in a tio n ,
Frozen loins a n d sticks m ust b e processed in a prope r c le a n a n d safe environm ent. The p ro d u ctio n facilities m ust b e properly co n stru cte d so as to p ro d u c e th e best qua lity p ro d u ct w ith th e utm ost o f ca re . The w orkm anship o f th e p ro d u c t m ust b e co n tro lle d a t all tim es.
Tem perature m ust b e reduced as quickly as possible a fte r th e p ro d u ctio n has b ee n c o m p le te d .
A ir-blast freezing is re co m m e n d e d b e ca u se low tem p era tures c a n be obtained very quickly. The blast freezer should b e a b le to re d u ce th e produ ct's co re te m p e ra tu re to -60°C within 6 hours. After th e p ro d u c t is properly frozen it must be stored in the co ld storage. The tem perature o f the c o ld stora ge m ust b e m a in ta in e d a t -50°C or lower.
Both th e blast freezer a n d th e c o ld storage should have a recorder to continuously record th e tem p era tures.
During th e processing o f tuna there are to b e no ch e m ica ls a d d e d to enrich the c o lour o f the bins or sticks, unless they have b e e n previously a p p ro ve d for hu m a n consu m p tion by th e c o m p e te n t authority having jurisdiction. A
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description o f the chem icals should a c c o m p a n y th e frozen p ro d u ctio n w hich contains th e additives.
A fte r freezing a nd during th e rem oval o f o u te r skin, only th e a m o u n t o f p ro d u ctio n w hich c a n b e properly h a n dle d is to b e rem oved from th e c o ld storage.
During th e rem oval o f th e skin a n d d e fects, all c a re m ust b e taken to ensure th a t th e p ro d u ct does not c o m e in c o n ta c t w ith any co n ta m in a tio n .
Before the produ ct is p la ce d into the carton, it is required to b e p la c e d through a m e ta l d e te c to r to ensure th a t there is no m etals present in th e m eat.
Each tuna b in is to be p la c e d into a sleeve a n d th e sleeve properly sealed to ensure th a t th e frozen loin or sticks are p ro te c te d from co n ta m in a tio n .
During th e tim e th a t th e frozen p ro d u ct is o u t o f th e c o ld stora ge for final processing, all c a re m ust b e taken to m inim ize th e c h a n c e o f rise in tem p e ra tu re .
Points o f C oncern
No tuna w hich is tainted, decom posed, and unwholesom e shall b e processed.
No tuna is to b e p la c e d on th e floor b e fo re processing co m m e n ce s.
No tuna is to b e rem oved from th e slush tanks until ready for processing.
No tuna is to b e d ra g g e d across th e p ro d u ctio n floor.
No p ro d u c t is to be rem oved from th e blast freezer until prope r c o re te m p e ra tu re has b ee n reache d.
All products are to b e properly co ve re d with plastic sleeves a n d p la c e d into a proper shipping carto n.
No frozen product is to be transported from the processing plant by o p e n truck.
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3.1.7.1: Tuna AKAMI a nd TORO
Source: Narasaki
3.1.7.2: Proportion o f A k a m i a nd Toro
Source: Williams: Queensland Fishing Industry Training Council
From INFOFISH Technical Handbook 1, Handling and Processing of Tuna for Sashimi.
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3.1.7.3 Dressing o f Eviscerated Tuna
Place the fish on a cle a n cu ttin g -b o a rd on on e side with th e head to your left.
• Hold th e p e c to ra l fin a n d raise it slightly. Insert knife n e a t th e base o f pectoral fin and c u t dow n tow ards th e dorsal line, an d m ove th e knife gen tly follow ing th e line o f th e ope rcu lum .
• C ut just behind the isthmus to th e base o f th e p e cto ra l fin also follow ing th e line o f th e o p e rcu lu m to c o m p le te th e cut.
Som etim es, th e pelvic fins a re rem oved a t this stage by cu ttin g from th e isthmus.
• Turn th e fish o n to th e other side, a n d re p e a t th e a b o v e steps, followed by chop pin g the backbone by holding th e h ea d an d using a heavy knife or hacksaw until th e h e a d is cu t.
• The fully dressed tuna is then quarter filleted by inserting a sharp knife through th e b a c k until reaches th e b a ckb o n e , an d cu ttin g a lo n g th e dorsal line as shown in th e follow ing diagram s.
• The four quarter-fillets are then carefully sliced into thinner fillets, or dire ctly c u t into blocks o f 300-400 m m in length fo r th e wholesale market. Upon proper chilling cond ition , these blocks c a n b e stored u p to o n e week.
Filleting o f
D ressed Tuna fo r Sashim i
Source: Narasaki, 1986
From INFOFISH Technical Handbook 1, Handling and Processing of Tuna for Sashimi.
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3.1.8 Processing o f Tuna for Dom estic Market
No tu n a w hich is ta in te d , d e c o m p o s e d or unw holesom e shall b e processed for th e d o m e stic m arket.
Tuna m ust b e properly chille d b e fo re being shipped.
Tuna is to b e properly stored in slush ic e a n d salt w ater prior to shipping.
Tuna is to b e properly transported to th e m arket.
Points o f C o ncern
No tuna fo r th e d o m e stic m arket is to b e le ft o n th e processing floor.
Tuna w hich is im properly gutted or is n o t g u tte d is n o t p e rm itte d to b e shipped to th e m arket.
No tuna for th e d o m e stic m arket is to b e le ft in th e o p e n air with no covering, No tuna is to b e shipped to th e m arket in o p e n trucks.
No tu n a is to b e shipped w ithout b eing properly ice d . 3.1.9 Summary
The m ain p o in t to re m e m b e r is th e w ay in w hich tuna is to b e ha n d le d a t all tim e.
Tuna is g ra d e d by b o th th e co lo u r a n d co n d itio n o f th e w hole fish.
The freshness a n d co lo u r are th e m ain fa cto rs th a t are considered in d e te rm in in g th e p rice w hich is to b e p a id for tuna. The next fa c to r is d e te rm in e d by th e Yield Recovery o f th e m e a t. This is d e te rm in e d b y th e c o n d itio n o f th e o u te r surface. By looking a t th e scales a n d skin they d e te rm in e how m u ch o f th e outer m e a t will b e used.
W hen w e sell a w hole tuna, w e sell th e w hole fish w hich includes th e scales, and skin as well as th e m e a t. The e nd user will only p a y fo r w h a t usable m e a t he will recover from the tuna. For every tim e th a t a tuna is d ra g g e d , pulled, or slides across a floor there is not only d a m a g e to th e loss o f scales or torn skin, b u t also d a m a g e to th e outer m e a t area, b oth in c o n ta m in a tio n a n d in loss o f u na ble pro d u ct.
Tuna must b e handled very carefully a t all tim es, it is not to b e d ra g g e d across a processing floor. The floor is n o t to b e used as p a rt o f th e processing ope ra tion.
W e m ust im prove th e w orkm anship o f th e tuna w herever a n d w henever possible. If w e show th e buyers th a t w e a re im proving our work m ethods an d
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decreasing any d a m a g e to the tuna then w e c a n b e in a position to d e m a n d m ore return on th e en d pro d u ct.
3.2 EMPLOYEE REQUIREMENTS