• Contents

    • Section 1 Good Manufacturing Practices for the On-Board Handling and Processing of Fresh and Frozen Tuna
      • 1.1 Introduction
      • 1.2 Processing Steps
      • 1.3 Method of Catching
      • 1.4 Temperature of Tuna
      • 1.5 Handling
      • 1.6 Clubbing and Killing
      • 1.7 Bleeding
      • 1.8 Gutting and Gilling
      • 1.9 Lowering of Temperature
      • 1.10 Icing of Tuna
      • 1.11 Discharging of Tuna
      • 1.12 On-Board Freezing of Tuna
      • 1.13 Summary of Fish Handling Procedures
      • Annex 1 Flowcharts for On-board Handling of Fresh and Frozen Tuna
        • Annex 1.1 Flowchart for the On-board Handling of Fresh Tuna
        • Annex 1.2 Flowchart for the On-board Handling of Frozen Tuna
      • Annex 2 Tuna Missile
      • Annex 3 Diagrams of Proper Handling Procedures and Descriptions
    • Section 2 An Integrated Quality Management Program (IQMP) for On-Board Handling of Tuna
      • 2.1 Introduction
      • 2.2 Establishment of Control Points or Inspection Points
        • 2.2.1 Process Flowchart for Inspection or Control Points
        • 2.2.2 Potential Critical Control Points
        • 2.2.3 Identification of Control Points
      • 2.3 Fish
        • 2.3.1 Requirements
        • 2.3.2 Defect Deficiency
        • 2.3.3 Monitoring Procedures
        • 2.3.4 Corrective Action
        • 2.3.5 Inspection of Tuna as it is Being Taken On-board
        • 2.3.6 Corrective Action Report
        • 2.3.7 Inspection of Tuna as it is Being Received On-board Vessel
        • 2.3.8 Information to be Supplied by Fishing Vessel
      • 2.4 Ice
        • 2.4.1 Requirements
        • 2.4.2 Ingredients
        • 2.4.3 Defect Definitions
        • 2.4.4 Monitoring
      • 2.5 Cleaning Agents, Sanitisers, Lubricants
        • 2.5.1 Requirements
        • 2.5.2 Specifications
        • 2.5.3 Monitoring Procedures
        • 2.5.4 Forms for Data Collection and Reporting
        • 2.5.5 Guidelines for Corrective Action
        • 2.5.6 Incoming Chemical Inspection Report
        • 2.5.7 Information to be Supplied by the Fishing Vessel Owner/Operator
      • 2.6 Vessel Design, Production Facilities
        • 2.6.1 Requirements for Vessel Design
        • 2.6.2 Production Facilities
        • 2.6.3 Corrective Action
        • 2.6.4 Guidelines for Corrective Action
      • 2.7 Operation & Sanitation
        • 2.7.1 Requirements
        • 2.7.2 Inspection of Vessel
        • 2.7.3 Forms for Inspection
        • 2.7.4 Guidelines for Corrective Action
        • 2.7.5 Action Reports
      • 2.8 Process Control
        • 2.8.1 Requirements
        • 2.8.2 Defects and Deficiencies
        • 2.8.3 Inspection Requirements
        • 2.8.4 Forms for Collection Data
        • 2.8.5 Corrective Action
      • 2.9 Fresh Storage Facilities
        • 2.9.1 Requirements
        • 2.9.2 Inspection Requirements
        • 2.9.3 Corrective Action
        • 2.9.4 Fresh Tuna Temperature Recovering Log
      • 2.10 Frozen Storage Facilities
        • 2.10.1 Requirements
        • 2.10.2 Inspection
        • 2.10.3 Corrective Action
        • 2.10.4 Frozen tuna Cold Storage Log
      • 2.11 Final Product
        • 2.11.1 Requirements
        • 2.11.2 Defect Tolerance
        • 2.11.3 Sampling Plan
        • 2.11.4 Corrective Action
      • 2.12 Recall Procedures
        • 2.12.1 Requirements
        • 2.12.2 Monitoring Procedures
        • 2.12.3 Guidelines for Corrective Action
        • 2.12.4 Shipping Record Report for Fresh/Frozen Tuna from Fishing Vessels
      • 2.13 Employee Qualifications on Fishing Vessels
        • 2.13.1 Requirements
      • Annex 4 Definitions
      • Annex 5 Potential Critical Control Points for the On-Board Handling of Fresh and Frozen Tuna
    • Section 3 Good Manufacturing Practices for the On-Shore Handling and Processing of Tuna
      • 3.1 Introduction
        • 3.1.1 Receiving
        • 3.1.2 Grading of Tuna
        • 3.1.3 Cooling
        • 3.1.4 Processing of Whole Fresh Tuna
        • 3.1.5 Processing and Packing of Fresh Tuna Loins
        • 3.1.6 Packing and Shipping of Whole Fresh Tuna for Exporting
        • 3.1.7 Processing of Frozen Tuna Loins and Sticks
          • 3.1.7.1 Tuna AKAMI and TORO
          • 3.1.7.2 Proportion of Akami and Toro
          • 3.1.7.3 Dressing of Eviscerated Tuna
        • 3.1.8 Processing of Tuna for Domestic Market
        • 3.1.9 Summary
      • 3.2 Employee Requirements
        • 3.2.1 Health
        • 3.2.2 Hand-Washing
        • 3.2.3 Hand Covering, Disinfection
        • 3.2.4 Outer Garments and Head Gear
        • 3.2.5 Smoking and Spitting
      • 3.3 Plant Facility Requirements
        • 3.3.1 Building
        • 3.3.2 Floors
        • 3.3.3 Drains
        • 3.3.4 Walls
        • 3.3.5 Ceilings and Overhead Protection
        • 3.3.6 Overhead Lighting
        • 3.3.7 Toilet Facilities
        • 3.3.8 Water Supply
        • 3.3.9 Floor Tanks for the Holding and Cooling of Tuna
        • 3.3.10 Overhead Pipes
        • 3.3.11 Processing, Grading and Packing Tables
        • 3.3.12 Conveyers Used in the Production of Loins
        • 3.3.13 Chutes, Containers Trolleys
        • 3.3.14 Animals
        • 3.3.15 Rodents and Insects
        • 3.3.16 Trays and Trolleys Used in the Frozen Production
        • 3.3.17 Freezing Facilities
        • 3.3.18 Freezing Facility Temperature Recorder
        • 3.3.19 Packing Material for Fresh Tuna Shipping and Material Used in Shipping
        • 3.3.20 Offal Removal
        • 3.3.21 Room Temperature in Processing Room
        • 3.3.22 Hot Water Supply
        • 3.3.23 Ice
        • 3.3.24 Plant Surroundings
        • 3.3.25 Sewage
      • 3.4 Proper Cleaning Procedures
        • 3.4.1 Clean-up Procedures
    • Section 4 An Integrated Quality Management Program for the On-Shore Handling and Processing of Fresh and Frozen Tuna
      • 4.1 Introduction
        • 4.1.1 Process Flowchart for Determining Inspection/Control Points
        • 4.1.2 Potential Inspection/Control Points
        • 4.1.3 Identification of Inspection/Control Points
      • 4.2 Fish
        • 4.2.1 Requirements
        • 4.2.2 Fish Defect Deficiency
        • 4.2.3 Monitoring Procedures
        • 4.2.4 Corrective Action
          • 4.2.4.1 Corrective Action Report
          • 4.2.4.2 Inspection of Tuna At Receiving Site
          • 4.2.4.3 Raw Product Inspection Report
          • 4.2.4.4 Information to be Supplied by Fish Processing Company
      • 4.3 Other Ingredients
        • 4.3.1 Requirements
        • 4.3.2 Ingredients
        • 4.3.3 Defect Definitions
        • 4.3.4 Defect Tolerances
        • 4.3.5 Monitoring Procedures
        • 4.3.6 Corrective Action
        • 4.3.7 Data Collection and Reporting Forms
          • 4.3.7.1 Incoming Ingredient Inspection Report
          • 4.3.7.2 Information to be Supplied by the Processing Company, Monitoring Procedures
      • 4.4 Ice
        • 4.4.1 Ice Requirements
        • 4.4.2 Ingredients
        • 4.4.3 Defect Definitions
        • 4.4.4 Monitoring
      • 4.5 Cleaning Agents, Sanitisers, Lubricants
        • 4.5.1 Requirements
        • 4.5.2 Specifications
        • 4.5.3 Monitoring Procedures
        • 4.5.4 Corrective Action
        • 4.5.5 Forms for Data Collection and Reporting
          • 4.5.5.1 Incoming Chemical Report
      • 4.6 Plant Construction/Production Facilities/Plant Equipment
        • 4.6.1 Building
        • 4.6.2 Floors
        • 4.6.3 Drains
        • 4.6.4 Walls
        • 4.6.5 Ceilings
        • 4.6.6 Overhead Lighting
        • 4.6.7 Overhead Pipes
        • 4.6.8 Toilet Facilities
        • 4.6.9 Water Supply
        • 4.6.10 Floor Tanks
        • 4.6.11 Equipment
        • 4.6.12 Freezing Equipment
        • 4.6.13 Guidelines for Corrective Action
        • 4.6.14 Plant Rating Forms
        • 4.6.15 Guidelines for Corrective Action
      • 4.7 Operation and Sanitation
        • 4.7.1 Requirements
        • 4.7.2 Sanitation
        • 4.7.3 Plant Rating Forms
        • 4.7.4 Corrective Action
      • 4.8 Process Control
        • 4.8.1 Requirements
        • 4.8.2 Defects and Deficiencies
        • 4.8.3 Inspection Requirements
        • 4.8.4 Corrective Action
      • 4.9 Fresh/Frozen Storage Facilities
        • 4.9.1 Fresh Storage Facility
          • 4.9.1.1 Requirements
          • 4.9.1.2 Inspection Requirements
          • 4.9.1.3 Corrective Action
          • 4.9.1.4 Fresh Tuna Temperature Recording Log
        • 4.9.2 Frozen Storage Facility
          • 4.9.2.1 Requirements
          • 4.9.2.2 Inspection Requirements
          • 4.9.2.3 Corrective Action
          • 4.9.2.4 Frozen Tuna Cold Storage Log
      • 4.10 Packaging Material
        • 4.10.1 Requirements
        • 4.10.2 Specifications
        • 4.10.3 Defect Definitions
        • 4.10.4 Defect Tolerances
        • 4.10.5 Monitoring Procedures
        • 4.10.6 Corrective Action
        • 4.10.7 Packing Material Inspection Report
      • 4.11 Final Product
        • 4.11.1 Requirements
        • 4.11.2 Defect Tolerances
        • 4.11.3 Sampling Plan
        • 4.11.4 Corrective Action
      • 4.12 Recall Procedures
        • 4.12.1 General Requirements for Fresh and Frozen Tuna Products
        • 4.12.2 Specifications for the Documentation of Shipments
        • 4.12.3 Monitoring Procedures
        • 4.12.4 Corrective Action
        • 4.12.5 Shipment Record Form
      • 4.13 Employee Qualifications
        • 4.13.1 Requirements
      • Annex 6 Potential Critical Control Points for Fresh/Frozen Tuna Products
      • Annex 7 Detailed Plant Inspection and Rating Report
      • Annex 8 Employee Hygienic Practices Checklist
      • Annex 9 Detailed Plant Hygienic Inspection Report
      • Annex 10 Action Report
    • Section 5 Grading of Bigeye and Yellowfin Tuna
      • 5.1 Introduction
      • 5.2 Nomenclature
      • 5.3 A Point Score System for Grading of Tuna
        • 5.3.1 Colour
        • 5.3.2 Condition
        • 5.3.3 Grading
      • 5.4 Colour Scores for Bigeye Tuna
      • 5.5 Colour Scores for Yellowfin Tuna
      • 5.6 Condition Scores for Bigeye and Yellowfin Tuna
      • 5.7 Quality Grading Form for the Inspection of Colour
      • 5.8 Quality Grading Form for Condition
      • 5.9 Flow Chart for Tuna Grading; At Sea, On-Shore
    • Section 6 The Proper Unloading of Fresh Tuna from Fishing Vessels
      • 6.1 Procedures in Place At Present in Indonesia
        • 6.1.1 Improvements
        • 6.1.2 Hatch Size and Vessel Design
      • 6.2 Proper Procedures in the Unloading of Fresh Tuna
        • 6.2.1 Temperature
        • 6.2.2 Fish Hole Chart
        • 6.2.3 Temperature Inspection
        • 6.2.4 Equipment
        • 6.2.5 Proper Fish Unloading System
        • 6.2.6 Unloading Requirements
        • 6.2.7 The Age of the Tuna
        • 6.2.8 Insulated Containers
        • 6.2.9 Transportation Procedures
        • 6.2.10 Cleaning of Fish Storage Area
        • 6.2.11 Icing of the Vessel
        • 6.2.12 Fish Hole Chart
        • 6.2.13 Temperature Recording Log Unloading Operation
      • 6.3 Inspection Points
        • 6.3.1 Discharging
        • 6.3.2 Temperature
        • 6.3.3 Unloading System
        • 6.3.4 Transportation
        • 6.3.5 Unloading Sites - Surroundings
        • 6.3.6 Ice
      • Annex 11 Fish Unloading Systems and Description
    • Section 7 Bibliography

Acknowledgements

The contribution of the Canadian International Development Agency (CIDA) for providing funds to assist the development of this work and its publication is gratefully acknowledged.

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