File no. 2.4

FI: DP/IND/75/038 Field 06cument 9 January 1980

INDIA

SALTING OIL SARDINE (Sardinella longiceps) BY MEDITERRANEAN METHOD AND PRODUCTION OF NON-STERILIZED CANNED FISH PRODUCTS

A report prepared for the Pelagic Fishery Investigations on the Southwest Coast - Phase II - Project

FOOD AND AGRICULTURE ORGANIZATION OF THE UNITED NATIONS Rome, 1980

W/N6060 This is one of a series of reports prepared during the course of the FAO/UNDP project identified on the title page. The conclusions and recommendations given in the report are those considered appropriate at the time of its preparation. They may be modified in the light of further knowledge gained at subsequent stages of the project.

The designations employed and the presentation of the material in this document do not imply the expression of any opinion whatsoever on the part of the United Nations or the Food and Agriculture Organization of the United Nations concerning the legal or constitutional status of any country, territory or sea area, or concerning the delimitation of frontiers. ACKNOWLEDGEMENTS

This is one of a series of field documents prepared and issued by the project (Phase II). This report is based on the work and findings of L. Kucic, Fish Processing Consultant (salted non-sterilized canned products), in collaboration with the fish processing staff of the Integrated Fisheries Project. Special recognition is due to G.E. Samuel, Fish Processing Technologist at IFP, and also to Dr M.S. Prabhu, Director of the Pelagic Fishery Project and Integrated Fisheries Project for his full cooperation which enabled the experiments to be carried out without delay.

Any comments· are welcome and should be addressed to:

The Director FAO/UNDP Pelagic Fishery Project P.O. Box 1791 Cochin 682016 India v

TABLE OF CONTENTS

1. INTRODUCTION 1

1.1 Terms of Reference 1 1.2 Background information 2

2. RESOURCES AND PROCESSING METHODS 2

2.1 Resources in Southwest India for Salted Non-sterilized Canned 2 Fish Products

2.1.1 Sardines 2 2.1.2 Anchoviella 3

2.2 Fish Handling and Transportation 3

2.2.1 Handling on Board the Vessels 3 2.2.2 Icing 4 2.2.3 Chilled Sea Water 4 2.2.4 Salting on Board the Vessel 4 2.2.5 Half Salting on Board the Vessel 5

2.3 The Process of Salting and Maturation 5

2.3.l Barrels 5 2.3.2 Salt 6 2.3.3 Weights - Press 6 2.3.4 Grading and Sorting the Fish 6 2.3.5 Salting Plant Floor Plan 7 2.3.6 The Brine Basins 7 2.3.7 The Brine Generator 7 2.3.8 Dalmatian (Yugoslavian) Method 7 2.3.9 Dutch Method 8 2.3.10 Portuguese Method 8 2.3.11 Salting of Sardines in 5 and 10 kg Containers 9

2.4 Salted Fish Products 9

2.4.1 Salt Fish Fillets 9 2.4.2 Flat Fillets 9 2.4.3 Rolled Fillets 10

3. SALTING EXPERIMENTS CONDUCTED AT THE INTEGRATED FISHERIES PROJECT 10

3.1 Oil Sardine 10 vi

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3. 2 Equipment/Material Used in the Experiment 10

3.3 Salt 11

3.4 Flow-sheet for Salting of Sardines 11

3.5 Variations of Salting Methods Used 12

3.6 Production of Rolled Fillets 13

3.7 Training of Personnel 14

4. MATUFATION, CHEMICAL AND BACTERIOLOGICAL SAMPLING AND CONTROL 14

4.1 Experiments Conducted by the Central Institute of Fisheries 14 Technology (CIFT)

4.2 Chemical Analysis 14

4.3 Maturation and Organoleptic Evaluations 14

5. CONCLUSIONS AND RECOMMENDATIONS 15

LIST OF TABLES

Table 1 Bacteriological analysis of fresh sardines 20 Table 2 Bacteriological analysis of salted fish and brine used in experiments 20 Table 3 Total plate counts for brine and salted S. pilchardus during maturation 21 at 15 0 -20 0 C temperature Table 4 Chemical analysis of salted fish (Sardinella longiceps) 22 Table 5 Chemical analysis of.§... pilchardus: typical data for sardines used 23 for non-sterilized salted products in Yugoslavia Table 6 Maturation and organoleptic evaluation of salted fish 24 (4 weeks after salting) Table 7 Maturation and organoleptic evaluation of salted fish 28 (7 weeks after s.alting) Table 8 Maturation and organoleptic evaluation of salted fish 32 (9 weeks after salting)

LIST OF FIGURES

Figure 1 Barrel for salting the fish 36 Figure 2 Cover for weights 36 Figure 3 Schematic drawing of barrel filled with fish 37 Figure 4 Section through the barrel hoop 38 Figure 5 Hand press 38 Figure 6 Work station for salting 39 Figure 7 Rolled fillet of sardine 39 vii

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Figure 8 Flat fillet of sardine 39 Figure 9 Scissors for cutting the head of fish 40 Figure 10 Basin for oil and brine separation 41 Figure 11 Brine generator 41 Figure 12 Arranging of barrels in salting storage 42 Figure 13 Floor plan of salting and storage areas 43 1

1. INTRODUCTION

1.1 TERMS OF REFERENCE

The Government of India, assisted by the United Nations Development Programme and the Food and Agriculture Organization of the United Nations, have been engaged in the Pelagic Fishery Investigations on the Southwest Coast - Phase II - Project (IND/75/038), whose main purpose is estimating the characteristics, size and location of the pelagic fishery resources, determining the most efficient gear and methods for efficient and economic exploitation, and determining for industrial application the most economic ways of processing and marketing pelagic fish.

The project was operational from 1 January 1976 to 30 March 1979.

As part of the project operation FAO assigned Mr L. Kucic, Fish Processing Consultant (salted non-sterilized canned products), from 13 January 1979 to 26 April 1979, with the following terms of reference:

Under the general supervision of the Project Manager and in close collaboration with the Industrial Processing Adviser and the Marketing Management Adviser of Project IND/75/038, the consultant should:

- make himself familiar with the results already obtained within the project on the trials of salting Sardinella longiceps using the Mediterranean method of salting small pelagic fish; - continue the above mentioned experiments with an aim to obtaining a commercially viable salted product and experiment with salting selected other pelagic species; - develop the production method of salted fillets packed in oil in cans but not sterilized, using the above mentioned salted pelagic fish; - supply technological input to the Marketing Management Adviser, for a feasibility study on the commercial production of canned, but not sterilized, salted sardinella fillets in oil for export markets; - prepare the layout, with a brief description of the process, for facilities required for commercial scale production of the above mentioned salte'd fish and salted canned fillets; - train counterparts in the techniques of salting pelagic fish using the Mediterranean salting method; - train by demonstration a few foremen in the above mentioned salting and salted fillet production practices, if requested to do so by the Project Manager.

The Consultant made two field trips, one north to Mangalore, the other south to Tuticorin; the remaining time was spent at the Integrated Fisheries Project (IFP), Cochin, where the experiments were carried out. 2

1.2 BACKGROUND INFORMATION

A variety of fish products known under the common name of salted fish products is produced and marketed in many countries of the Mediterranean region including Spain, France, Italy, Greece and Yugoslavia.

These products are derived mostly from sardines and anchoviella. Salting is a simple method of preserving large quantities of fish from spoilage and, because of its popularity in this form, the product commands a fairly good price on the market. These products are very much appreciated in Western Europe and the USA. Owing to the high cost of labour, the quantity produced in relation to all sterilized fish products in Mediterranean countries is only 1:20.

Prior to the development of modernday canning techniques in the afore-mentioned countries, most fish was preserved by salting, but with the development of the processing industry and frozen fish products, preservation by this traditional method is very much on the decrease even though demand for this product remains very high.

Along the narrow belt of the west coast of India, sardines, one of the most important species, are caught extensively by local fishermen. As large modern fish processing plants, large capacity freezing plants and cold storages to not exist, salted fish production could be very important particularly when the investment required in the processing of salted products is very low.

2. RESOURCES AND PROCESSING METHODS

2.1 RESOURCES IN SOUTHWEST INDIA FOR SALTED NON-STERILIZED CANNED FISH PRODUCTS

2.1.l Sardines

There are about ten different species of sardines in the Indian Ocean; the most important of which are: Sardinella longiceps - oil sardines; .§_. fimbriata - lesser sardinej S. gibossa; S. melanura; Dusstimieria hasselti ~ rainbow sardine. The oil sardine (~. longicep;) is the most abundant. All species of sardines, especially those of commercial value, are caught along the southwest coast and the lower east coast of India.

Spawning for oil sardine peaks in July and August, but is evident from April to September. The fishing season begins immediately after the southwest monsoon subsides and lasts from September to March with the peak season from September to December. The oil sardine has a very rapid growth; during the first year it reaches 14 cm and in the second year up to 19 cm.

The present data show that the traditional fishery for oil sardine exploits mainly the 0 year-class; during the first ye,ar of life and the one year adult fish do not contribute significantly to this fishery. The traditional artisanal fishery (nonmechanized) extends in a narrow belt within 10 miles along the coast. As the fish grow in size they generally tend to move to deeper waters, so the oil sardine of 16-18 cm length, most suitable for the salting and later producing the salted rolled fillets, are not being caught by the present fishing effort. 3

In order to fish further offshore, purse seine fishing should be developed so that the range and season of fishing operations for the oil sardine, particularly to harvest larger sizes, can be made less variable. The resources of oil sardines have been estimated at around 350 000 t. The possibilities of annual landings are estimated at 200 000 t, while annual landings during the last few years totalled about 150 000 t.

2.1.2 Anchoviella

There are three main species of anchoviella in the India Ocean:

Anchoviella bataviensis Anchoviella cheteroba Anchoviella zollengeri

All the species are most abundant in dense concentrations in the Gulf of Mannar/Cape Cormorin area during July and August and later spread to the north where they disperse in scattered layers over a wide area to 17°N lat. near Ratnagiri, returning south around April.

The resource of anchoviella has been estimated as at least 300 000 t. The landings during the last few years were approximately 35 000 t annually, showing that the resource . is hardly exploited.

2.2 FISH HANDLING AND TRANSPORTATION

2.2.1 Handling on Board the Vessels

The time from catching until landing is about 6 hours which in moderate climate condi­ tions is a very short period,btit at temperatures between 30°-35°c spoilage is rapid, each hour without proper chilling being equal to a decline of one day in the keeping time of most fresh fish.

The gillnet catch is sometimes left in the net and the fish removed more easily by spreading the net on the beach, while the purse seine catch is scattered on the deck of the vessel, usually a few tons of fish at a depth of about 40 cm. The fish are not covered and are exposed to the sun while transported to the fish landing site. It is possible to obtain only second and third quality products from such fish, especially if it is salted product. Fish is not sorted aboard fishing vessels and the extra handling required ashore to sort for size and species further deteriorates quality of uniced fish.

Poor fish handling from time of catch to the landing site is one of the most serious problems of the Indian fisheries, Without good quality raw material, it is impossible to obtain a top quality processed product. Since the fishing industry (excludi.ng shrimps) is oriented around a daily turnover of fresh fish for local consumption, and the surplus is utilized for low quality cured products or for non-human consumption, quality is not a prime market requirement for most fishes.

There is consequently no incentive to the fishermen to work harder to keep the fish in better condition. All handling operations - sorting, washing, icing and storing in fish boxes - are considered unnecessary by the fisherman given the present situation. 4

Most countries have the same problem, and proper quality control at the primary producer level takes a long time to evolve if a government agency is not authorized to enforce strict standards. In Yugoslavia, similar problems were overcome when fishermen and buyers eventually realized that good quality pays dividends to both. For example, sardines for salting and canning fetch double the price when sorted, iced and boxed as compared to bulk landings that are neither sorted nor iced. Until the fishermen, buyer and processor appreciate the advantages of predicating price for quality as well as for supply and demand, there will be little improvement in quality. The catalyst to induce such a change should be provided by government in the form of education programmes and practical demonstrations directly with the parties concerned.

2. 2. 2 Icing

A typical and proven method of handling sardines in Yugoslavia is outlined below, and would be easily adaptable to the purse seine fishery being developed inKarnatakaand Kerala. Purse seine vessels of 14-17 m length can carry from 500 to 1 000 plastic nesting boxes 60 x 33 x 12 cm, each with a capacity of 8 kg fish. These can be stowed on top of the wheelhouse, and secured by lashing a piece of netting over them. The vessels have an insulated hold below deck of capacity suitable for storing ice only. Ice is used in the ratio of 4:1 since the catch is aboard for short periods of time, seldom exceeding 8 hours. After catching (the catch rate is similar to that of India - up to 6 t per purse seine set), the fish are sorted as to species and size, placed in boxes, ice is sprinkled on top, the full boxes stowed on deck then covered with a tarpaulin. In Yugoslavia, fish held in ice for more than 24 hours do not make top quality salted fish products.

2.2.3 Chilled Sea Water

A demonstration unit was recently put into operation by the Pelagic Fishery Project in a 32 ft sardine carrier vessel operated by the Karnataka Fishery Development Corporation, Mangalore, A detailed report is to be published by the Pelagic Fishery Project and initial results, retaining first grade quality from catching to the landing site over a 24 hour period, were excellent, This vessel can carry only 4 t in the insulated fish hold (3 t fish, 1 t ice and water). By using the same air blower in the hold of a 45 ft seiner, a more optimum sized unit of 8 to 12 t fish capacity could be built for a slightly higher cost, yielding 3 to 4 times the revenue, Such a unit is under installation in a 45 ft Kerala Fisheries Corporation Vessel. Details are available in the Pelagic Fishery Project, Phase II,Field Document IND/75/038/10.

2.2.4 Salting on Board the Vessel

The most satisfactory method of achieving a high quality salted fish fillet is to salt the fish on board immediately after catching, However in the case of the oil sardine, salting whole fish (with head and scales) has not proved successful, and would not tharefore be feasible under conditions in India, However, this method might be possible with other sardines having a much lower fat content. An attempt was made to catch other species of sardine, such as a~· fimbriata (lesser sardine) or Dussumieria hasselti (rainbow sardine), but during the 100 days of catching by the Integrated Fisheries Project vessels, too few were found to be able to carry out the experiment. The data for S. fimbriata showed that the landing of this species in India in 1977 was about 65 000 t. ~· fimbriata is caught from the northern part of the east coast to the southern part of the west coast, mainly in Tamil Nadu. The season of catching~· fimbriata is from September to January. Recently, catches by purse seiners in Karnataka have been falrly significant. 5

2.2.5 Half Salting on Board the Vessel

One method of avoiding spoilage of sardine is to place the fish in non-drainable boxes on board the vessel. Fish is mixed with salt, one fisherman shaking out the fish into fish boxes and the other putting salt over the fish until it is thoroughly mixed with salt,

The proportion of fish and salt is 10:1. The fish thus protected can remain with salting up to 3 days under Mediterranean conditions and up to 24 hours in tropical climate conditions. Before salting, the half-salted fish should be washed and then salted in the same way as fresh fish, but with less salt. Another partial salting procedure used ashore is to store fish in large containers or tanks filled with cold brine, usually + l0°c and brine strength 24°Bo. This fish as a rule maturates later, the period of maturation extending for further two weeks in Mediterranean conditions. It is not recommended to keep fish in cold brine for more than 24 hours, as it appears to retard or prevent the release of fat from tissue in a normal manner.

2.3 THE PROCESS OF SALTING AND MATURATION

Salting is the most simple way of preservation of fish. The concentrated salt solution or dry salt in contact with the wet fish produces a saturated solution which will penetrate from the surface to the inside of the fish body and at the same time, force the water out of the tissue and the cell by osmosis. Putting weights on salted fish releases water even more efficiently and, in the case of fatty fish, also squeezes out the fish oil.

Strong concentrations of salt (over 20 percent) retard decomposition of fish and almost completely eliminate the possibility of spoilage. It is possible to salt fish in many different ways, but depending on the quantity of salt, there are three main methods:

- mild salting 10-15 percent of salt ~vith fine salt) - medium salting 15-20 percent of salt (with fine salt) - strong salting 20-40 percent of salt (large granulated salt).

During the time of maturation of salted fish, many different chemical and bacteriological processes take place and the protein is slowly decomposed. This reaction is closely related to salt concentration and temperature. In cold climates where the temperature is between 5 and l0°c mild salting is used; in moderate climates where the temperature is around 15°c, medium salting is used; and with a temperature over 25°C, strong salting is necessary using more than 20 percent and sometimes even 40 percent of salt.

2.3.1 Bartels

Barrels must be expertly made of solid wooden staves of about 2 cm thickness, without knots or cracks (Fig. 1). A deciduous hardgrain wood is most suitable.

Hoops must be made of green not dry wood, fastened by jute cord, which is preserved with tar (Fig. 4). Each barrel is constructed from 12-14 wooden staves with a height of about 50 cm - bottom diameter 32 cm and top diameter 34 cm, The volume is about 40 1 when filled with salted fish and the weight about 56-60 kg. Barrels usually have 8 wooden hoops but may have more if they are to be transported long distances. Before using, the barrel must be hooped and then filled with fresh or sea water for several hours until it becomes completely watertight. 6

If hold barrels are used for salting, they should be washed in boiling water, then dried. Any odour must be eliminated. If the barrel is not watertight, the brine leaks out, the fish dry out and will soon spoil.

2.3.2 Salt

Clean, white sea salt, in large and granulated crystals should be used. Experience has shown that powder salt penetrate~ faster into surface tissue and impregnates the fish, whereas the activity of large size crystals is moderate and does not scorch the surface of the fish.

The slow activity of large crystal salt could affect its preservation action; however too fine salt causes too rapid removal of water and "glues" the fish, sometimes resulting in a hard and abnormally dry final product. The best size of salt crystal is about 2.5 mm. The quantity (weight) of crystals of more than 3 mm should not be over 15 percent.

Sea salt almost always contains some quantity of sand and undissolved materials that form colloids, decreasing the substitution of water and salt. The other chemicals in sea salt result in high hygroscopy; for example, magnesium salts cause an increase in humidity of over 19 percent when the relative humidity is over 75 percent, retarding maturation activity in the tissue of fish.

The recommendable humiditY, in salt is about 3-4 percent and that is generally salt with less than 0.1 percent of MgC1 . Salts which contain large quantities of Mgso or MgCl 2 4 2 penetrate extremely slowly into fish tissue.

The standard chemical composition of white sea salt used for salting sardines and anchoviella in Yugoslavia is:

% Humidity 2-12 NaCl 85-98 MgC1 0.1-1.5 2 MgS0 0.2-1,64 4 CaC1 0,47 2 Caso 2,28 4 A full barrel (58-60 kg gross weight), takes about 54-55 kg of fish and 21-22 kg of salt.

2.3.3 Weights - Press

The salting room should have a sufficient number of cement weights of about 30-32 kg 2 each (the pressure on 1 cm of salted fish is about 0.03 kg (see Fig. 3). Wooden covers with handles for pressing the fish during salting (Fig. 5) and a sufficient number of plastic boxes for washing the fish before salting are required.

2.3.4 Grading and Sorting the Fish

The barrel must be filled with fish of the same size and quality. Second quality fish or fish awaiting salting should be put in concentrated brine of 24°Bo and later washed and salted. 7

2.3.5 Salting Plant Floor Plan

The floor of the salting plant should be arranged so that it is possible to store barrels in rows two abreast, with a passage of about 50 cm wide and the floor of the passage about 3-4 cm higher than that on which the barrels are placed. In this way the brine which spills over the barrel flows along the deeper part of the floor and into a drain to the brine basins, where it is collected for re-use. The floor must be concrete, sloped to permit draining of the brine into the brine basins (Fig. 13).

2.3.6 The Brine Basins

The brine basins work on the principle of settling, connected containers. The basins are built with a raised margin and one filling pipe from the floor which can be closed when the floor is washed and a suitable cover (Fig. 10).

The dirty brine mixed with fish oil and blood flows into the first basin. The blood and heavy pieces of fish sediment drop to the bottom of the basin, and fish oil floats on the surface. Periodically basin No. 1 should be cleaned and freed of oil. The brine which flows from the first basin to the second is fairly clean, providing it has sufficient time to settle. It is therefore recommended to build a third basin to ensure that all sediment is removed since contaminated brine can easily spoil salted products.

2.3.7 The Brine Generator

It is recommended to install one brine generator, since the consumption of brine (especially in warm climate conditions) is fairly high, particularly during the first few weeks after salting. This is a very simple device, as shown in Fig. 11. It can be built in different capacities, depending on the cubic content, the production being directly related to cubic capacity. The one shown is 4.5 mm and produces approximately 4 500 kg of fully saturated brine every 24 hours.

2.3.8 Dalmatian (Yugoslavian) Method

Clean, washed fish is distributed in boxes to each worker. Each work station has the empty barrel in front, the boxed fish on the left side, the salt on the right side and the worker is seated. The production is directly related to the work position layout (Fig. 6). Starting at the bottom of the barrel the worker puts a handful of salt and then a layer of sardines on their sides, closely and horizontally one to the other so that the backs of the sardines in each row are parallel to the stomachs of the next row. The fish should be placed at the end of each row with the head next to the edges of the barrel.

When one layer is arranged, a handful of salt is added, pressed with the wooden press and then more salt is added. The layer of salt must be spread so that it is possible to see the thickest part of the fish above the salt level and the greatest quantity of salt is over the head of fish. The second layer is arranged transversly to the first and so on until the barrel is full. When the barrel is fi.lled more salt must be spread on the top and covered with a wooden lid. Lastly a cement weight of 32 kg is put on the top of the lid. The length of time required for the weighting depends on the season in which the fish was caught and on the fat percentage in tissue. The maturation time in Mediterranean climate conditions for salted sardines is between 14 and 30 weeks, depending on the time of salting. Springtime salting (March, April, May) maturates after 15 to 20 weeks, but autumn salting sometimes maturates after more than 30 weeks if the winter temperature is under 15°c, So maturation depends on catching season, temperature and fatness (fish is thinnest after spawning time) and the length of time the weights are kept on barrels.

For Mediterranean climate conditions, weighting times are as follows:

March, April (salting) 4-5 weeks May, June (salting) 6-7 weeks October, November (salting)8-9 weeks

The weight on the barrels and the activity of the salt separate a large quantity of water from the fish. After a few days the volume of fish in the barrel is reduced, so it is necessary to fill up with more fish. To make up the deficiency, fish of the same size and same production batch should be used. If fresh fish is used, it should never be added to batches that are more than two weeks in maturation.

First remove the weight from barrel, then with wooden plate, press the top fish down and remove the fat and blood liquid on top. Then remove the top layer of salt and wash the top layer of fish with fresh brine. Then fill up with fish and salt as before then cover and put on the weight. The barrel is usually filled up seven days after salting but it also depends how fat the fish is. It is very important in wintertime salting because in cold weather the separation of oil from tissue is much slower.

2.3.9 Dutch Method

Fish are nobbed, and placed back up, with the headless end toward the barrel edge and all tails in the centre. The proportion of salt between layers is previously described. The barrel is left for seven days without a weight, then the contents are removed, the fish rinsed in clear brine, and resalted as before.

2.3.10 Portuguese Method

The salting method is that already described, but using fish with head and intestines removed. The most simple means of cutting the head manually (if nobbing machine is not available) is to use scissors, as shown in Fig. 9. It is possible to make the scissors in any workshop from thin metal plate. To salt one barrel averaging 58-60 kg the following quantity of fish is necessary:

~ Fresh fish 70-79 Head and .intestines (25%) 17-20 Nobbed fish in barrel 55-58 Salt in barrel 21-23

The labour for hand-nobbing is about double that in the case of whole fish requiring about four working hours per one barrel. However, savings in salt, barrels and filleting labour more than offset this initial labour cost, as one barrel of nohbed fish will yield 9 about 16 kg of fillets compared to 10 kg from whole fish. Filleting rates increase from about 140 pieces from whole fish to 230 pieces per hour for nobbed fish. So in final analysis of the total costs for barrels, fish, salt and labour, the total saving using nobbed fish can be as high as 35 percent, Also, there is a better salvage value from fresh compared with salted offal.

2.3.11 Salting of Sardines in 5 and 10 kg Containers

Adopting the same methods as for salting in barrels, small tinplate containers can be used, using about 15 kg fish for 10 kg containers and about 6-8 kg for 5 kg containers. The use of metal containers is not recommended as corrosion is excessive a few weeks after filling with brine.

2.4 SALTED FISH PRODUCTS

Salt fish products in cans have a short storage life. These containers are not sterilized, and are commonly referred to as non-sterilized cans. Their durability is 18 months after closing, but in tropical conditions it would be reasonable to reduce this to 12 months. After this period the product is not dangerous to health, but the surface of fillets becomes white with crystallized salt, and eventually the fillets will become very soft and only suitable ·for production of salted fish spread. It is very important to produce only as much as the market demands.

2.4.1 Salt Fish Fillets

After maturation an organoleptic test should be carried out on the product before filleting. When the product has to be stored for a long time it is recommended to produce fillets from salted fish which is not completely maturated.

Before removing fish from the barrels, a long, sharp wooden probe is forced through the salted fish to the bottom of the barrel, and an experienced inspector checks to determine whether the fish is maturated or has a strange odour. A further product taste inspection is necessary when the fillets are arranged into the cans. After the fish is taken from the barrel the workers remove the salt and skin and take out the backbone. The inside part of the fillet must be cleaned to remove small bones and stomach membrane (Fig. 8).

2.4.2 Flat Fillets

The flat fillets are arranged along the container such that the back part of fillets is toward the opening of the can. The layers must be arranged orderly and densely. As the fiilets are thickest in the middle, the end of can is sometimes empty, and this space has to be filled with one small fillet placed transversely. If the fillets are packed in large containers, a piece of perforated parchment paper should be inserted between th~ layers. The fillets become dry and may turn rancid if left in the open air, so the packing in cans should be performed quickly, the .oil added and the cans closed immediately. The fish used for the production of fillets may not be completely maturated, as maturation will still continue inside the closed can, thus increasing the storage life of the canned product. 10

2.4.3 Rolled Fillets

The production is the same as for flat fillets except that the fillets are rolled with one piece of red or green capsicum placed in the middle of the rolled fillet (Fig. 7).

3. SALT!NG EXPERIMENTS CONDUCTED AT THE INTEGRATED FISHERIES PROJECT

Experiments on salting of sardines by the Mediterranean method were conducted mainly with oil sardine (Sardinella longiceps) with the objective to produce finished products similar to those produced in the Mediterranean. Trials were also carried out with Sardinella fimbriata and Dussumieria acuta (rainbow sardine) for comparison purposes since these two fishes have a different chemical composition and less fat than the oil sardine. Anchoviella, one of the important resources found by the pelagic Fishery Project, was also tried for making salted fish spread.

3.1 OIL SARDINE

The oil sardine used in the experiment was taken from the landings at the Integrated Fisheries Project, Cochin. The oil sardine was caught by 9.7 m and 13 m long purse seine vessels·· These vessels fished daily, leaving for the fishing ground around 06.00 hours and returning to port about 14.00 hours. No icing was done on board the fishing vessel and the catch was carried on deck. The time between catching and landing of the fish was not more than 3-4 hours and the fish accepted for the experiment was of fairly good quality.

Immediately after landing, the fish was washed in chilled water and stowed with ice in small fish boxes (length: 600 mm x width: 330 mm x height: 100 mm) and kept in the chill room, from where they were taken for the salting experiments. The number of pieces of sardines used in the experiment varied from 10 to 21 per kg, or an overall length of 150-180 mm.

CHEMICAL COMPOSITION OF OIL SARDINES USED IN THE EXPERIMENT COMPARED TO MEDITERRANEAN SARDINES

Oil sardines Mediterranean sardines (%) (%) Moisture 72. 78 71.50 Protein 18.2 20.31 Fat 7.2 5.59 Ash ---0.5 ---o·,6 98.68 98.00 ======

3.2 EQUIPMENT/MATERIALS USED IN THE EXPERIMENT

Containers - Wooden barrels were not available, and since the experiment had to be completed during the 3-month assignment of the FAO Consultant, it was not possible to make wooden barrels. Instead, tin containers (imported from Norway by the Pelagic Fishery Project for use in the IFP canning plant) of capacity 5 1, 220 mm diameter ·x 135 mm height were used. The containers were lacquered on both sides with sulphur-resistert lacquer. 11

Wooden Press ,.. The wooden press (205 ll11l) diameter x 20 nun thickness) used for pressing the fi~h C\nd salt in the container had a wooden handle to make pressing easier. "Plav" (local wood) was used for making the press.

Wooden lid - The wooden lid for placing over the salted fish to bear the weight of the stone was similar to the wooden press mentioned above but without the handle.

Weights - Weights were used for placing over the salted fish to exert pressure for the easy removal of moisture and fat from the fish. The weights were made of concrete, length: 150 mm .x width: 150 nun x height: 200 mm, and weiP,hed 10 kp;.

3,3 SALT

Crystallized sea salt (coll]JUon salt, larger crystals) size 2-3 mm on sides was used in the experiment. The salt was fairly white in colour, with the following chemical composition:

% Sodium 84.8 Moisture 8.1 Magnesium chloride 0.72 Magnesium sulphate 0.74 Calcium sulphate 0.39 Sand 0.00

Method of salting

The containers, wooden lids, wooden press, and the concrete stones were washed and cleaned thoroughly. The fish to be salted (oil sardine, whole or nobbed, or scaled and nobbed) was washed with potable water. A handful of crystal salt was spread at the bottom of the container and the fish were regularly arranged on the salt bed, the head of the fish always pointing toward the side of the can. The fish were laid flat side ·down and, when one layer was complete, pressed with the wooden press. Again a thin layer of salt was spread over the fish layer and pressed hard a few times with the wooden press. The second layer of fish was arranged, with the direction of the second layer exactly at right angles to the first layer and this process was continued till the level of salted fish reached the brim of the container, A thick layer of salt was spread on top and the wooden lid put in position and the concrete weight placed on top. The salted fish cans were stored in this condition in the salting building of the Integrated Fisheries Project, where the ambient temperature was between 28 and 33°C and relative humidity from 70 to 95 percent (during the period January to April).

3.4 FLOW-SHEET FOR SALTING OF SARDINES

I pre-treatment J, raw material fresh sardines

water, ice------washing.. t. in chilled. water waste water 12

fish box, ice icing J, knife scaling scales knife w nabbing head, viscera, knife

water washing waste water

salting .!, container, fish, arranging fish regularly salt, wooden press in. layers, al~ernating with layers in salt J, wooden lid covering with wooden lid '1- concrete weight keeping concrete stone ,J; arranging salted fish cans regularly in the salting yard

3.5 VARIATIONS OF SALTING METHODS USED

Various methods of salting were employed in the experiment to determine the best way for salting the oil sardine:

(1) Salting sardines with head and scales (2) Salting sardines after nabbing but with scales (3) Salting after scaling and nabbing - changing the brine every day for first four days - changing the brine on the fifth day - without changing the brine, but merely pouring the brine to fill the can every day - filling the can with brine only when the level is low 0 - keeping the can in the chill room at o c (4) Salting after scaling and nabbing and brining fish for 24 hours in cold brine - changing the brine every day for first four days - changing the brine on the fifth day - without changing the brine, but merely pouring the brine to fill the can every day - filling the can with brine only when the level is low 0 - keeping the can in the chill room at o c (5) Salting after scaling and.nabbing but applying a smaller weight (about 2 kg only) (6) Salting after scaling and nabbing but without applying any weight (7) Salting sardines after scaling and nabbing placing in larger plastic container (50 kg capacity) and applying larger stones (8) Salting after scaling and nabbing using the Dutch method (9) Salting after scaling and nabbing, the salt being mixed with tamarind extract, cloves and cardamum (10) Salting sardine fillets, skinned by "TRIO skinning machine, using powdered salt 13

Salting of Other Species of Fish

(11) Salting Sardinella fimbriata with head and scales, changing brine on the fourth day (12) Salting rainbow sardines (Dtissumieria acuta)with head and scales and changing brine on the fourth day (13) Sal ting Anchoviella with head and scales

3,6 PRODUCTION OF ROLLED FILLETS

The salted sardines which were sufficiently maturated were taken out of the containers after draining out the brine, and salt removed from them, The sardine was placed on a wooden plank, and the lower edge of the belly was cut with a sharp knife. Then a slit was made along the length on the dorsal side with the knife and the fillets were separated from the bone. Skin from the fillet was removed, peeling by hand. Each fillet was cut in the middle lengthwise in such a way that each fillet was divided into two equal halves. Each half fillet was rolled into a spiral and a caper or piece of capsicum was placed in the middle of the spiral.

Arrangement of Fillets in the Can

The rolled fillets were arranged regularly inside the can. The can used was 1/8 round aluminium can with tear-off lid, 100 g net weight, imported from Norway. Fillets were arranged in three layers inside the 1/8 round cans and perforated parchment paper was placed between the layers to avoid one layer of fillet sticking to the next.

Double refined groundnut oil was used in the packing. Sixty-seven g of salted rolled fillets (with caper) and 33 g of oil were packed in each 1/8 round can. The cans were seamed using the LOVATI semi-automatic seaming machine available at the IFP canning plant.

Production Data for Salted Fillets (Oil Sardine)

Raw material used - whole fish 75 kg Equivalent nabbed and fillets 35 kg Quantity of salt used 20 kg Maturation time 9 weeks Weight of finished (salted) fish 40 kg Weight of salted fillets 10 kg Quantity of oil used 5.12 kg Number of 1/8 round cans obtained (product) 160

Contents in each can

Weight of fillets 63 g Number of fillets 42 Weight of caper 8 g Weight of oil 32 g Number of layers 3 Total weight of contents 103 g 14

3.7 TRAINING OF PERSONNEL

The IFP staff made available to assist in these experiments consisted of E.G. Samuel, Fish Processing Technologist, 2 assistant technologists, 10 female and 2 male workers, and 15 students. Using similar methods the technologists and workers are capable of producing further samples that prove successful, but thorough familiarity with the maturation process can only be developed through long practical experience.

4. MATURATION, CHEMICAL AND BACTERIOLOGICAL SAMPLING AND CONTROLS

4.1 EXPERIMENTS CONDUCTED BY THE CENTRAL INSTITUTE OF FISHERIES TECHNOLOGY (GIFT)

The salting of the sardines· was performed in thrae ways:

(i) on whole sardine; (ii) on sardine with head, viscera and scales removed (iii) on sardine with head and viscera removed but not scales.

The analysis consisted of taking samples of fresh sardines (one day iced),and the above three salted samples after day one and day four of maturation. An analysis of the salt used for the brines in the three types of salting was also made.

Total plate count, total halophilic bacterial count (tolerating 20 percent salt), total coliforms and total streptococci were determined.

Results are given in Tables 1 and 2 of Appendix. 2. There were no halophilic bacteria in the fresh fish or brines or the salted fish up to 4 days. But halophilic bacteria were found to be present in brine 8 days after salting. Red halophiles were also present, Table 3 (Appendix 2}. shows acceptable and non-acceptable total plate counts for brine and salted~· pilchardus maturating under Mediterranean conditions.

4.2 CHEMICAL ANALYSIS

The change in moisture, fat and salt content of the three categories of oil sardines used (whole, nobb,ed and nobbed without scales) were monitored by GIFT during the first four days, then on the 7th, 15th, 24th and 38th days during maturation. Results are tabulated in Table 4 (Appendix 2), and can be compared to typical results obtained fron S. pilchardus under Mediterranean conditions (see Table S,Appendix 2).

4.3 MATURATION AND ORGANOLEPTIC EVALUATIONS

In Tables 6, 7 and 8 (Appendix 2), maturation and organoleptic evaluations were made after 4, 7 and 9 weeks in maturation. The result , after 9 weeks, is shown in the "Remarks" column.

Summary of Observations

Proper maturation in tropical ambient conditions was not possible unless the sardines were nobbed, scaled and heavily weighted for long periods. AlthoBghnot fully maturated the samples to which tamarind and two spices were added appeared to give a more constant an~ faster maturation. The skinless fillets maturated soonest, but could have poor texture and colour as compared to those filleted after maturation. 15

5. CONCLUSIONS AND RECOMMENDATIONS

5.1 The experiments on salting have indicated that it is possible to salt Sardinella longiceps by the Mediterranean method and to produce canned, unsterilized salted fish fillets. The experiments show that the basic criteria to be respected must include:

- nobbing - scaling 2 - use of weights not less than 0.03 kg/cm for at least 6 weeks - changing brine daily for first 4 days - quantity of salt: 35 percent salt by weight relation to fresh fish placed in the barrel . 0 - b rine must be fully saturated, 24 Bo - salt crystals for dry salting should be about 2.5 mm crystal diameter, with no more than 15 percent oversize - fish size should be around 24 pieces per kg.

5.2 The experiment lasted only 3 months, based on preliminary experiments conducted earlier that indicated full maturation in 45 days. Further experiments should be conducted for salting sardines of different species, in different seasons, in order to standardize the salting procedure and to determine the duration of maturation of fish salted in different seasons and also storage of salted fish in different temperature conditions. Fisheries research organizations such as CIFT, Cochin; Fisheries College, Mangalore; and CFTRI, Mysore, should actively participate in a programme on salting, using variations of methods evolved from these experiments.

5.2.1 Follow-up

The follow-up programme could consist of:

- 9 m/m consultancy from September through May - continuation of successful methodology with variations. using oil, lesser and rainbow sardines, under ambient conditions - experiments as above but under controlled temperature and humidity conditions - conducting experiments at Mangalore and Tuticorin in collaboration with the College of Fisheries and Technological Units in addition to IFP, Cochin

5.2.2 Immediate follow-up of processing

Immediate follow-up of the S. fimbriata, Dussumieria actita and Anchoviella presently in maturation since March should be completed by IFP and CIFT staff analysing the product during maturation, and producing canned fillet samples for consumer acceptance analysis. 16

5.2.3 Immediate follow-up of produced product samples

I The FAO/UNDP Consultant on salting will give samples of canned, salted fillets to buyers of this product to ascertain their opinion and to have their reaction to its quality, price, marketabilityt etc. This information will be forwarded to FAO at the earliest date for publication. If the potential buyers in the international market accept this product, and it can be produced at a competitive price, then the Indian Government should assess the market potential, and institute pre-investment studies for developing this sector of the fishing industry.

Appendix 1 contains information on possible areas for such development, a pro f6rma product cost and pro forma capital cost schedules.

At least two technologists from the industry should have 6 months training in the salting process in a few large commercial fish-salting factories in Europe. These technologists will continue the work on salting of fish, and organize and advise the industry when commercial production of this product commences in India.

The poor handling of fish in India, and the consequent immediate deterioration of quality and loss of monetary and food values is a serious problem for Indian fisheries. Proper handling at time of catch is indispensable for the type of products described in this report. Proper and adequate handling methods are a prerequisite for future development. 17

Appendix 1

A. DEVELOPMENT CONCEPT

A. l Plant locations

Since the prime requisites for Mediterranean-type salted products are sardines and anchoviella in prime condition, and experiments to date indicate that the longest storage period before salting under ideal conditions in the tropics is 24 hours, the processing plant should be located as close as possible to the supply of fish. In 1977, the total landings of oil sardines in the project area from Tuticorin in the south to Ratnagiri in the north were 149 783 t. Kerala state accounted for 78 percent of the landings, and Karnataka 20 percent. The major districts and landing sites are given below:

District Tonnes Major landing sites Karnataka (State) 31 135 Karwar, Tadri, Kornta, Honavar, Alvekodi, Gangolly, Coondapoor, Hangarkatta, Malpe, Mulki, Mangalore

Cannanore 15 471 Kasaragod, Lannanore, Calicut l 31 057 Calicut (Khozikode), Ponnani (Kerala) Malappuram 17 483 - Trichur 16 866 - Ernakulam 16 340 Cochin, Ernakulam Alleppay 9 722 Alleppay Quilon 10 059 Quilon

Apart from those areas with heavy oil sardine landings, if the experiments on lesser and rainbow sardines and whitebait prove successfu~ consideration should be given to locating processing plants further south; the area from Trivandrun (Kerala) to Tuticorin (Tamil Nadu) would be ideally situated for acquiring these species.

A.2 Analysis of a production unit

On the assumption that the species of sardines and whitebait and processing methodology can be adapted under ambient climate conditions in India so that the product is acceptable for established foreign markets, a processing unit to salt about 900 t of fish, yielding 3 million cans of 100 g size non-sterilized rolled fillets, is suggested as a viable unit. Given Indian conditions, this would be an attractive development proposition since:

(a) It is labour-intensive - labour accounts for 36 percent of the product cost (b) Capital costs are minimal, there is no expenditure for sophisticated equipment and most of the capital costs are for the building and simple equipment; the ratio of capital cost to total value of product is 1:2 (c) Most equipment can be fabricated locally, or be of Indian m::i.n.ufacture 18

(d) Power requirement - there is no electrical power or other type of energy required for processing (e) Potable water - requirements are minimal, and a supply of clean salt water could substitute for much of this requirement.

Based on the above, and the trend of increasing short supply and rising costs of production by traditional Mediterranean producers, the cost of production and capital cost estimates are given in Proformas A.3 and A.4 below. A unit cost of I.Rs. 3 per 100 g can is a competitive price compared to the production costs in the Mediterranean.

Since the round, aluminium, 100 g, raised, pull-top can is not at present used for this product, no attempt has been made at this preliminary stage to assess marketing aspects or compare pricing with the various types and sizes of cans used. The information will be elaborated if results from the samples to be consumer-tested are encouraging.

The possibility of incorporating a salting operation with a sterilized canned products production unit could also be examined, This has several advantages; including reducing overheads and giving flexibility to the work force, since filleting and canning of salt fish can be performed after the peak fishing season.

A.3 Proforma schedule of production costs for 3 175 000 x 100 g salted non-sterilized cans per annum

Direct costs Total Cost (I.Rs.) per can Sardines - 910 t at I.Rs. 800 728 000 Salt - 280 t at I.Rs. 200 56 000 Cans and lids - round, aluminium, 100 g, 2 560 000 raised pull-top at I.Rs. 0.80 Refined vegetable oil - 102 t at I.Rs. 10 000 1 020 000 Capsicum - 26 t at I.Rs. 4 000 104 000 Labels - 3 200 000 at I.Rs. 0.10 320 000 Master cartons 3 32 000 at I.Rs. 4.0 128 000 Water - 5 000 m at I.Rs. 0.10 500 Electricity - 2 500 kW at I.Rs. 0.20/kW 500 Sub-Total: materials 4 917 000 1.549 Labour - female - 620 for 12mo at I.Rs. 400/mo 2 976 000 - male 55 for 12 mo at I.Rs. 500/mo 330 000 - seamer operator at I.Rs. 800/mo 9 600 - drivers - 2 at I.Rs. 500/mo 12 000 - technologists - 4 at I.Rs. 1 200/mo 57 600 - supervisors - 7 at I.Rs. 800/mo 67 200 - manager - 1 at I.Rs. 2 000/mo 24 000 - admin. officer - 1 at I.Rs. 1 500/mo 18 000 - clerk/typist - 3 at I.Rs. 600/mo 21 600 Sub-Total: labour 3 516 000 1.107 19

Total Cost Direct costs (I.Rs.) per can Total material and direct/indirect labour costs 8 433 000 2.656 Depreciation and maintenance (see Appendix 2, 414 200 0.131 Proforma A4 Return on investment - 10% of I.Rs. 4 510 800 451 000 0.142 Interest on working capital - turnover x 3 per annum 10% x 1/3 of I.Rs. 8 433 000 278 000 0.087 Total break-even cost of production I.Rs. 9 576 200 3.016

A.4 Proforma schedule of capital costs and depreciation for a salting and non-sterilized products canning plant of 3 175 000 x 100 g cans per annum

Years Annual cost of Capital costs Cost depreciation depreciation & maintenance 2 2 Land - 5 000 m at ~.Rs. 25/m 125 000 Buildings - 3 250 m x I.Rs. 800 2 600 000 20 130 000 Barrels - 10 000 at I.Rs. 100 1 000 000 5 200 000 Weights - 500 at I.Rs. 12 60 000 20 3 000 Brine generator 8 000 10 800 Forklift trucks - 2 at I.Rs. 150 000 300 000 10 30 000 Wooden pallets - 100 at I.Rs. 50 5 000 5 1 000 Aluminium tables ·- 100 at I.Rs. 800 80 000 20 4 000 Aluminium trays - 200 at I.Rs. 100 20 000 10 2 000 Wooden filleting boards - 600 1 000 5 2 400 at I.Rs. 20 Knives - 600 at I.Rs. 10 6 000 1 6 000 Plastic trays - 600 at I.Rs. 8 4 800 5 1 000 Seaming machine, automatic 160 000 10 16 000 Can washing machine 80 000 10 8 000 Pallet hand lifts - 10 at 50 000 5 10 000 I.Rs. 5 000 TOTAL I.Rs.4 510 800 I.Rs. 414 200 20

Appendix 2

Table 1

Bacteriological analysis of fresh sardines (1 day in ice)

5 Total plate count 2 x 10 Jg Total halophilic count nil Total coliform nil Total streptococci nil

Bacteriological analysis of salt med.

5 Total plate count 1 x lo Is Total halophilic count not detected in 100 times diluted sample Total coliform nil Total streptococci nil

Table 2

Bacteriological analysis of salted fish and brine used in experiments

Head, viscera & Head, and viscera Days after Whole fish Bact. count scales removed removed but not salting salted and salted scales, or salted Fish production BacL No.l No.2 No.3 1/ 5 5 6 TPC Z/ 6 x 10 /g 7 x lQ /g 1 x 10 /g 1 day THC - nil nil nil Coli forms nil nil nil Streptococci nil nil nil 3 3 3 TPC 1 x 10 /g 2 x 10 /g 4 x 10 /g 4 days THC nil nil nil Coliforms nil nil nil Streptococci nil nil nil 1/ TPC - Total plate count 2/ THC - Total halophilic count 21

Table 2 (cont'd)

Head, viscera & Head, and viscera Days after Whole fish Bact. count scales removed removed but not salting salted and salted scales,or salted Fish production Bact. No.l No.2 No.3 Brine only 6 5 6 8 days TPC 2 x 10 /ml 9 x 10 /ml 1 x 10 /ml Total 25/ml 20/ml 6/ml halophiles Red halophiles nil nil nil Coli forms nil nil nil Streptococci nil nil nil

Table 3

Tot~l p!ate counts for brine and salted li:. Eilchardus during maturation at 15° -20°c temperature

Numbe.r of bact. /ml of brine Acceptable first grade Not acceptable days after salting 6 1 3 x 103 6 x 105 2 5 x 102 2 x 2 105 5 7 x 103 1 x 105 10 4 x 104 1 x 105 20 8 x 104 3·x 104 90 4 x 102 2 x 104 120 4 x 102 5 x 104 - 180 2 x 10 4 x 10 Number of bact.in salted fish Ma tumti()Jl __ tj!!!_e in days 105 ___ "' 1 5 x 102 2 x 6 5 4 x 103 5 x 10 3 10 6 x 10 5 x 105 3 3 20 1 x 4 x. 10 102 2 90 4 x 102 4 x 102 120 2 x 101 1 x 102 180 1 x 10 1 x 10

Note: A qualitative analysis of the above counts has not been made, and there are few published data. In the first phases of maturation, predominant forms were multiform (palisades of different size and form). At the end of maturation bacterial flora consisted predominantly of different types of Bacillus sporogenis. 22

Table 4

Chemical analysis of salted fish (Sardinella longiceps)

No. of days Description of Moisture Fat NaCl after salting salted fish % % % 0 whole fresh fish 72. 78 6.2 0.34 before salting 1 - whole fish 58.13 6.27 6.52 - nobbed fish 54.69 7.43 9.60 - scaled and nobbed 51. 70 11.62 11.32

2 - whole fish 50.00 11.05 9.65 - nobbed fish 47.60 9.33 12.96 - scaled and nobbed 47.43 9.25 13.15

3 - whole fish 48.24 8.44 13.02 - nobbed fish 47.84 8.40 12.90 - scaled and nobbed 47.93 8.80 13.86

4 - whole fish 46.06 8.52 13.59 - nobbed fish 47.25 9.51 13.86 - scaled and nobbed 47.42 7.78 14.67

7 - whole fish 46.53 8.37 14.53 - nobbed fish 47.14 8.14 14.96 - scaled and nobbed 47.26 6.92 14.93

15 -, whole fish 46.68 6.94 15.52' - nobbed fish 47.26 6.97 16.45 - scaled and nobbed 47.64 7.02 16.47

24 - whole fish 46.19 - 16.69 - nobbed fish 47.34 7.87 17.49 - scaled and nobbed 47.37 7.36 17.15

38 - whole fish 47.81 -- -.nobbed fish 45.42 -- - scaled and nobbed 45.18 - - 23

Table 5

Chemical analysis of S. pilchardus: typical data for sardines used for non-sterilized salted products in Yugoslavia

Moisture Fat NaCl % % % Fresh sardines before salting 61.4 15.8 2.0 One day after salting 71.5 5.6 2.5 30 days after salting 46.7 7.2 25.5 180 days after salting 53.0 6.1 23.3 24

Table 6, Maturation and organoleptic evaluation of salted fish (4 weeks after salting)

SIZE OF OBSERVATION OF POSSIBILITY OF TYPE OF SALTING FISH SALTED FISH SKINNING AND APPEARANCE COLOUR APPEARANCE . SMELL FILLETING 1. Salting sardines with head Large Satisfactory Very bad, Satisfactory Bad Red to dark brown and scales rancid 2. Salting sardines after Small Satisfactory Strong, Satisfactory Bad RE>ddish nobbing but with scales rancid & unpleasant 3. Salting after scaling and nob bing 3.1 changing the brine every Medium Good Bland Satisfactory to good Satisfact, White to light brown day for first four days 3.2 changi°ng the brine on the Medium Good Bland Satisfactory to good Good White to light fifth day 3.3 without changing the brine, Medium Good Bland Bad to satisfactory Bad to Light to light brown but merely pouring the · satisfact. · . brine to fi 11 the. can. every day 3.4 filling the can with brine, Small/ Good Slightly Satisfactory to good Satisfact. Light to light brown only when the level is low medium rancid 3.5 keeping the can in the Medium Good Bland Good Good Light chill room at o0 c ' 4. Salting after scaling and nobbing and brining fish for 24 hours in cold brine :-4 .1 changing the brine every Medium/ Good Slightly Good Satisfact. Light day for first four days large rancid 4.;.2 changing the brine just Medium/ Good Slightly Satisfactory to good sa:tisfact_. Light to light brown qn the fifth day large rancid 4.3 without changing the brine, Medium/ Good Slightly Satisfactory to good Satis"fact, Light to light brown but merely pouring the large rancid brine to fill the can every day 4.4 filling the can with brine, Medium/ Good Slightly Good to very good Satisfact. Light to light brown only when the level is low large rancid 4.5 keeping the can in the Medium Good Bland Good Good Light chill room at o0 c 5, Salting after scaling and Large Good Rancid Very good Satisfact, Light brown nobbing but applying a smaller weight (about 2 kg only) 25

OBSERVATION OF FILLETS OVERALL QUALITY REMARKS SMEr:;L CONSISTENCY TASTE SALTINESS MATURATION EVALUATION Very bad, strongly Crumbling, pasty Finished + rancid Bad and unpleasant Satisfactory Bad Less Finished +

Slightly rancid Satisfactory Rancid Less Not finished ++/+++

Very slightly Good Good, but not Less Not finished +++ rancid characteristic Very slightly Satisfactory Good, but not Less Not finished ++ rancid to good characteristic

Very slighty Satisfactory Good, but not Less Not finished ++ rancid to good characteristic Bland Good Bland Slightly less Not yet started ++++

Slightly rancid Good Bland, not Slightly less· Not maturated ++ characteristic Slightly rancid Good Bland, not Slightly less Not maturated ++ characteristic Slightly rancid Good Bland, not Slightly less Not maturated ++ characteristic

Slightly rancid Very good Bland, not Slightly less Not maturated ++/+++ characteristic Slightly rancid Good Bland, not Slightly less Not yet started ++++ characteristic

Rancid/slightly Good Not characteri- Less J:lot finished ++ rancid stic

------·---- 26

Table 6 (cont'd)

SIZE OF OBSERVATION OF POSSIBILITY OF TYPE OF SALTING FISH SALTED FISH SKINNING AND APPEARANCE COLOUR APPEARANCE SMELL FILLETING 6. Salting after scaling and Large Good Rancid Good to very good Good Light brown nabbing but without applying any weight 7. Salting sardines after Large Good Bland Bad Bad Pink scaling and nabbing placing in larger plastic container (50 kg capacity) and applying larger stones 8, Salting after scalingand nob. Large Good Rancid Very good Good Light to light brown using the Dutch method 9. Salting after scaling and Medium/ Good Pleasant Very good Good Red to light brown nabbing, the salt· being mixed large good with tamerind extract, cloves and cardamum 10. Salting sardine fillets, White inside, brown skinned by TRIO skinning outside machine, using powdered salt Salting of other species of fish 11. Salting Sardinella fimbriata with head and scales, ; changing brine on the fourth day 12. Salting rainbow sardines The fish were salted at the end of March; (Dussumieria acuta) with maturation process has just begun head and scales and changing brine on the fourth day 13. Salting Anchoviella with head and scales

Note: + Bad ++ Satisfactory +++ Good ++++ Very good 27

OBSERVATION OF FILLETS OVERALL QUALITY SMELL CONSISTENCY TASTE SALTINESS MATURATION REMARKS EVALUATION

Slightly Good, but not Characteristic Less Beginning ++/+++ rancid more water in for of fillets unmaturated maturation Strong, but not Bad Sweet strange Less Finished + characteristic

Rancid Good/ Rancid Slightly less Not maturated ++/+++ very good Pleasant Very good Pleasant, Slightly less Middle ++++ good maturation

Bland Very good Bland Too salty Beginning +++/++++ maturation 28

Table 7. Maturation and organoleptic evaluation of salted fish (7 weeks after salting}

SIZE OF OBSERVATION OF POSSIBILITY OF TYPE O~' SALTING FISH SALTED FISH SKINNING AND APPEARANCE COLOUR APPEARANCE SMELL FILLETING 1. Salting sardines with head Spoiled and thrown out and scales 2. Salting sardines after Small/ Good Good and Satisfactory Good Pink to red nobbing but with scales medium strong 3, Salting after scaling and nob bing 3.1 changing the brine every Medium/ Good Bland to Good Good Fresh fish colour day for first four days large mild, pleasant 3.2 changing the brine on the Medium/ Good Good, but Good Good Light brown, good fifth day large top layer rancid 3. 3 without changing the brine, Medium/ Good Good to Good Good Light red, but merely pouring the brine large v.good characteristic to fill the can every day 3.4 filling the can with brine, Medium/ Good Good Satisfactory Good Light brown only when the level is low large 3.5 keeping the can in the No maturation 0 chill room at o c 4. Salting after scaling and nobbing and brining fish for 24 hours in cold brine 4.1 changing the brine every Small/ Satisfactory Bland to Bad/ Satisfact. Light brown day for first four days medium slightly satisfactory rancid 4.2 changing the brine just Small/ Good Bland to Good Good Light brown on the fifth day medium slightly rancid 4.3 without changing the brine, Small/ Good Slightly Good Good Light brown but merely pouring the medium rancid brine to fill the can every day 4.4 filling the can with brine, Small/ Good Slightly Good Good Light brown only when the level is low medium rancid 4.5 keeping the can in the No maturation chill room at o0 c 29

OBSERVATION OF FILLETS OVERALL QUALITY SMELL CONSISTENCY TASTE SALTINESS MATURATION REMARKS EVALUATION

Characteristic but Not enough Satisfactory Less Almost ++/+++ too strong good to good complete

Bland to mild Good Not maturated Less Half ++!+++ but good maturated

Bland Good Good Less Half +++

Good to very good Good to Good to Good Half ++++ characteristic very good very good

Good Satisfactory Good Less Half +++

Bland to slightly Satisfactory Not Less Half ++ rancid to bad characteristic

Bland to slightly Good Good to Less Half ++ rancid satisfactory

Bland to slightly Satisfactory Too dry, Less Half rancid satisfactory

Bland to slightly Satisfactory Bland, slightly Less More than half ++ rancid to good rancid maturated 30

Table 7 (cont'd)

SIZE OF OBSERVATION OF POSSIBILITY OF TYPE OF FISH FISH SALTED FISH SKINNING AND APPEARANCE COLOUR APPEARANCE SMELL FILLETING --t- 5. Salting after scaling and Medium/ Good, but little Satisfactory to good Satisfact, Light brown/red nabbing but applying a large too fleshy rancid/ smaller weight (about 2 kg good only) 6. Salting after scaling and Medium/ Good/ Bland/ Satisfactory to good Satisfact, Light brown· nobbing but without large satisfact, storage applying any weight 7. Salting sardines after Very Good Good Satisfactory Good Brown red scaling and nabbing placing little in larger plastic container (50 kg capacity) and applying larger stones

8. Salting after scalingand nob. Small/ Bad Rancid/ Good Satisfact./ Light to light bro~m using the Dutch method medium highly bad rancid 9. Salting after scaling and Large/ Good Good and Good to satisfactory Good Light to bright pink nobbing, the salt being medium strong mixed with tamerind extract, smell of cloves and cardamum tam,& card, 10. Salting sardine fillets, Good Light to light brown skinned by TRIO skinning machine, using powdered salt Salting other species of fish 11. Salting Sardinella fimbriata with head and scales, chang­ ing brine on the fourth day 12. Salting rainbow sardines The fish were salted at the end of March; (Dussumieria acuta) with maturation process has just begun head and scales and changing brine on the fourth day 13. Salting Anchoviella with head ancl scales

Note: + Bad ++ Satisfactory +++ Good. ++++ Very Good 31

'OBSERVATION OF FILLETS SMELL CONSISTENCY TASTE SALTINESS MATURATION OVERALL QUALITY REMARKS EVALUATION Not characteristic Too fleshy and Satisfactory Less More than +/++ crumbling half

Bland, not Too fleshy and Satisfactory Less More than +/++ characteristic crumbling half

Good, Good Good Less Nearly +++ characteristic

Rancid, Too dry, Rancid Less Half + highly rancid satisfactory

Pleasant, of Soft, and Good Less Nearing half +++/++++ tamarind and characteristic maturation cardamom

Bland to slightly Good to Slightly dry, Good Less than half +++ rancid satisfactory good, but not maturation characteristic 32

Table 8. Maturation and organoleptic evaluation of salted fish (9 weeks after salting)

SIZE OF OBSERVATION OF POSSIIlILITY OF TYPE OF SALTING FISH SALTED FISH SKINNING AND APPEARANCE COLOUR APPEARANCE SMELL FILLETING 1. Salting sardines with head Large Spoiled and thrown out and scales 2. Salting sardines after Small Satisfactory Charact, Bad Bad Reddish nabbing but with scales 3. Salting after scaling and nob bing 3.1 changing the brine every Medium/ Good Bland to Good Good Fresh fish colour day for first four days large mild, pleasant 3.2 changing the brine on the Medium/ Good Good, but Good Good Light brown and good fifth day large top layer rancid 3.3 ·without changing the brine, Medium/ Good Good Good Good Light red, but merely pouring the brine large v.good characteristic to fill the can every day 3.4 filling the can with brine, Medium/ Good Good Satisfactory Good Light brown only when the level is low large 3.5 keeping the can in the The maturation is not beginning and it is impossible to expect it 0 chill room at o c 4. Salting after scaling and nabbing and brining fish for 24 hours in cold brine 4.1 changing the brine every Small/ Satisfactory Bland to Bad to Satisfact. Light brown d·ay for first four days medium slightly satisfactory rancid

4 •. 2 changing the brine just Small/ Good Bland to Good Good Light bro~m on the fifth day medium slightly rancid 4.3 without changing the brine, Small/ Good Bland to Good, Good, Light brown but merely pouring the medium slightly satisfactory satisfact. brine to fill the can every rancid day 4.4 filling the can with brine, Small/ Good Bland to Good Good, Light brown only when the level is low medium slightly satisfact .. rancid 4.5 keeping the can in the 0 chill room at o c 33

OBSERVATIONS OF FILLETS SMELL CONSISTENCY TASTE SALTINESS MATURATION OVERALL QUALITY REMARKS EVALUATION

+ Rancid

Bad and Satisfactory Bad Less Finished + Not acceptable unpleasant

Bland to mild Good Not Less Nearly maturated ++/+++ Filleted maturated but good Bland Good Good Less Nearly maturated ++/+++ Filleted but all the fish have unacceptable long maturation Good to. very Good to Good to Good Over half maturated ++++ Acceptable but it is good character. very good very good necessary to keep the weight for at least 4 weeks Good Satisfactory Good Less Nearly maturated +++ Never maturated to bad

Bland to slightly Satisfactory Not Less Over half maturated ++ Not acceptable rancid to bad character.

Bland to slightly Good Good to Over half maturated ++ Acce!'table rancid satisfactory Less

Bland to slightly Satisfactory Too dry to Less Little over hald ++ Acceptable rancid satisfactory maturated

Bland to slightly Satisfactory Bland, Less Nearly maturated ++ Borderline rancid to bad slightly rancid Never maturated 34

Table 8 (cont'd)

SIZE OF OBSERVATION OF POSSIBILITY OF TYPE OF SALTING FISH SALTED FISH SKINNING AND APPEARANCE COLOUR APPEARANCE SMELL FILLETING 5. Salting after scaling and Medium/ Good, but Little Satisfactory Satisfact, Light brown nobbing but applyinp, a large too f reshy rancid/ smaller weight (about 2 kg only) good 6. Salting after scaling and Medium/ Satisfactory Bland Satisfactory Satisfact, Light brown nabbing but without large storage applying any weight 7. Salting sardines after Very Good Good Satisfactory Good Brown red scaling and nabbing placing little in larger plastic container (50 kg capacity) and applying larger stones 8. Salting after scaling and nob. Spoiled and thro1m out ·using the Dutch method 9. Salting after scaling and Large/ Good Good and Good to satisfactory Good Light to light pink nobbing, the salt being medium strong mixed with tamerind extract, smell of cloves and cardamum cardamum 10. Salting sardine fillets Good Light to pink skinned by TRIO skinning machine, using powdered salt Salting of other species of fish 11. Salting Sardinella fimbriata with head and scales, chang-, ing brine on the fourth day ' 12. Salting rainbow sardines The fish were salted at the end of March; (Dussumieria acuta) with maturation process has just begun head and scales and changing, brine on the fourth day , 13. Salting Anchoviella with head and scales

Note: + Bad ++ Satisfactory +++ Good ++++ Very good 35

OBSERVATION OF FILLETS SMELL CONSISTENCY TASTE SALTINESS MATURATION OVERALL QUALITY REMARKS EVALUATION

Not Too fleshy and Satisfactory Less Hore than half +/++ Not acceptable characteristic crumbling

Bland not Too fleshy and Satisfactory Less More than half +/++ Not acceptable characteristic crumbling

Characteristic Good Good, Less Nearly maturated +++ Satisfactory character.

Early rancidity

Pleasant tamarind Soft and Good Less Over half +++/++++ Good cardamum characteristic maturation

Bland Good Slightly Good Half maturation +++ Maturation good dry

No rancidity and maturation, appears normal but too early to assess No rancidity and maturation, appears normal but too early to assess

No rancidity and maturation, appears normal but too early to assess ~ 0 N•/:.fS 0 ~ ;:!!: Material: Wood '' \ r-1 QI ...... ¢.340 i:. (!) -+" al :;:: r r I () ! I I ~ I I I ~I 1 w ~1 CJ'> l I I ' ·- t I : Cl f <::>'~' q p l '"' ~ i 40 '. /00 : 40. "' j _,_ t- -+ r- I j

Fig. 1 Barrel for salting the fish Fig. 2 Cover for weights 37

t I

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Fig. 3 Schematic drawing of barrel filled- with fish 38

Jute impregnated with _tiff.

Fig. 4 Section through the barrel hoop

,,,,. ... ,,.. ., Material : Wood 1~~ "JiJO ~-~o I-·. --- ··-· -- .. ··-- ·--t l I '; ' ! I ' I

Fig. 5 Hand press '39

R

A - Workers B - Barrels S - Salt containers Fig. n Work station for salting R - Fish Boxes

Cut here to make roll fillet ~I.

Caper or capsicum I

Fig. 7 Rolled fillet of sardine Fig. 8 - Flat fillet of Scale - 2:1 sardine Scale 1:1 40

I Phase

II Phase

III Phase

IV Phase

Fig, 9 Scissors for cutting the head of fish 41

/, / . / ' ~- /.

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I j

F1g.. 10 Basin for oil and brine Construction - square sided, separation concrete sides and bottom Dimensions - millimetres

...... r ~. :... : l: .~ ~:. .':: >::: ... ~'N,>o I ~·...... ·~·-~;:: ·~·: ~1 r ~1 I I • ~i

I r' t /.soo ~---·--· - ~' 1 - Shower Material - 20 nun mild steel plate 2 - Salt container Capacitiy - 4,5 t fully saturated 3 - Salt (24°Bo) brine for 24 hours 4 - Linen filter Dimensions - millimetres 5 - Perforated container bottom 6 - Brine basin 7 Draining pipe Fig. 11 Brine generator Front view View from side

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, , / / . // ,// ·' /,//. / //,',·/··//// i. /~/./

\ Raised pas sag: area, sloped to drain 9

Fig. 12 Arranging of barrels in salting storage ... ______------...... ------~~_ tSS.~-'~""'~· -----·- - -- _. ------~!'"·.

F

____ J.__. _-!!!!! __ _ ~---· -·· - ·-- ·-· ·-~,4 ,... ------·-- -~,-··------. -- ~,,,. ·-.

A Main passage E Brine collecting canal I - Disinfection tank B Space with salting fish F Barrels store house J Passage to the production space c Manipulation passage G Salt store house K Barrels repairing work shop D Basin for oil and brine H Brine generator separation

Fig. 13 Floor plan of salting and storage areas

Dimensions - metres