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