Good Manufacturing Practice (GMP) for Small and Medium-Sized Traditional Fish Products Processing Establishments in ASEAN

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishments in ASEAN

Edited by: Yeap Soon Eong I Denise Thong Bai Hui

Marine Fisheries Research Department Southeast Asian Fisheries Development Center

The Southeast Asian Fisheries Development Center is a technical organization devoted to the accelerated development of ﬁ sheries in the region. The member countries of SEAFDEC are Japan, Brunei Darrusalam, Cambodia, Indonesia, Lao PDR, Malaysia, Myanmar, Philippines, Singapore, Thailand and Vietnam. SEAFDEC has four Departments, namely the Aquaculture Department in the Philippines; the Training Department in Thailand, the Marine Fisheries Resources Development and Management Department in Malaysia and the Marine Fisheries Research Department in Singapore.

Southeast Asian Fisheries Development Center, Marine Fisheries Research Department, 2 Perahu Road, Singapore 718915

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without the prior written permission of the publisher. ISBN 978-981-08-6894-9

2 Ù Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Table of Content

Introduction 5

Background on selected Traditional Fish Products Processing Establishments (TPE) 7

GMP for selected TPE (by country) Brunei Darussalam 17 Tiny shrimp paste – Belacan 17 Indonesia 25 Salted boiled fi sh – Pindang 25 Laos PDR 35 Dried fi sh – Pa heang 35 Malaysia 41 Fish cracker - Keropok lekor 41 Myanmar 47 Fermented fi sh – Ngachin 47 Fish sauce - Ngan pya ye 55 Philippines 61 Shrimp sauce – Alamang 61 Smoked fi sh – Tinapa 72 Singapore 81 Fish balls/fi sh cakes 81 Thailand 97 Dried shrimp 97 Fish sauce – Nam-pla 105 Vietnam 111 Fermented tiny shrimp paste - Mam tom 111 Fish sauce – Nuoc mam 117

Appendix 125

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Ù 3 4 Ù Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Introduction

Many small and medium-sized fi sh processing the importance of a safe food supply to food establishments (SME) in ASEAN member security, it is imperative that the TPE apply countries fi nd it diffi cult to implement quality appropriate GMP programs to assure quality assurance systems due to economic and and safety of these products. Therefore, to help technical constraints. They comprised largely the small and medium-sized fi sh processing of pre-processing establishments (PPE), which establishments (SME) in the ASEAN member produce semi-processed raw materials for main countries meet food safety and quality processing establishments and traditional fi sh assurance requirement, MFRD proposed a products processing establishments (TPE). PPE project in 2007 under the Japanese Trust Fund supply semi-processed raw materials such as II (JTFII) programme on ‘Quality Assurance shrimp, crab, squid, fi sh and bivalve mollusc Systems for Small and Medium-sized Fish to main fi sh processing establishments. The Processing Establishments in ASEAN member processes carried out in these establishments countries’ to develop GMP in PPE and TPE as may include peeling, de-heading, degutting, a fi rst step towards implementation of HACCP- de-skinning, cooking, picking, filleting or based quality assurance systems. shucking depending on the raw materials The fi rst regional project activity to develop involved. Thus, PPE can play a signifi cant role GMP for selected PPE was conducted in in determining the quality and safety of raw 2007/2008 and in 2008/2009, MFRD in materials and subsequently of the fi nished collaboration with nine ASEAN member products. In the ASEAN region, traditional countries, namely, Brunei Darussalam, fi sh products represent a signifi cantly large Indonesia, Lao PDR, Malaysia, Myanmar, part of total fi sh utilization and are a major Philippines, Singapore, Thailand and Vietnam, source of animal protein. As a result, conducted a second regional project activity traditional fi sh products are vitally important to develop GMP for selected TPE in these to food security, especially considering that countries. The selected TPE were involved the marginalized and poorer segments of the in the processing of various traditional fi sh population consume most of these products. products as shown in Table 1. In view of the importance of these products to the people’s diet in the ASEAN region and

Table1: List of ASEAN Countries and selected TPE

Country TPE Brunei Tiny shrimp paste (Belacan) Indonesia Salted boiled fi sh (Pindang) Lao PDR Dried fi sh (Pa heang) Malaysia Fish cracker (Keropok lekor) Myanmar Fermented fi sh (Ngachin), Fish sauce (Ngan pya ye) Philippines Shrimp sauce (Alamang), Smoked fi sh (Tinapa) Singapore Fish balls/fi sh cakes Thailand Dried shrimp, Fish sauce (Nam pla) Vietnam Fermented tiny shrimp paste (Mam tom), Fish sauce (Nuoc mam)

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Ù 5 This publication is the output of the second GMP for the other areas are also covered when regional project activity and it describes the they have an impact on the production and GMPs developed for the selected TPE as well processes involved. This publication should as outlines of the processing steps involved. be used in conjunction with other important references such as the Codex Alimentarius GMP can cover every aspect of food production, Commission’s Recommended International employee/personnel hygiene and training, Code of Practice- General Principles of Food plant and equipment/utensils design and Hygiene (CAC/RCP 1-1969, Rev 4-2003) and speciﬁ cations, cleaning and sanitation, and US FDA’s Code of Federal Regulation Title even warehousing and distribution of the 21 Part 110 Current GMP in Manufacturing, finished products. In this publication the Packing or Holding Human Food, as well as emphasis is on GMP for production and process other relevant national regulations. controls, which are speciﬁ c to the selected TPE. ON TI C DU O INTR

6 Ù Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Background on Selected Traditional Fish Product Processing Establishments (TPE)

Brunei Darussalam Indonesia

Tiny shrimp paste (Belacan) Salted boiled ﬁ sh (Pindang)

Tiny shrimp paste or Belacan in the local In Indonesia, most of the fish processing language is a semi-fermented/cured shrimp industries are TPE commonly operated by product in the form of a paste. The species small to medium scaled processors and cater of tiny shrimp used is the Acetes spp. Belacan mostly to the needs of the domestic market. is used as a condiment or ingredient in many They are scattered all around the provinces vegetable dishes and dips. It can be chilled, of Indonesia with sixty percent of them in frozen or stored at room temperature. It is the Java Island. often packaged in polyethylene plastic bags or A large portion (40%) of the 7.71 million containers for sale at local markets in Brunei tonnes of catch each year are processed in Darussalam. TPE. These TPE are predominantly engaged The major concerns for Belacan include in fi sh curing methods such as salting/drying reducing microbial counts, and preventing (85%), salting-boiling (11%), smoking (3%) oxidation, discoloration and desiccation. and fermentation (1%). Approximately 50% The majority of traditional establishments of the catch is sold as fresh fi sh while another producing Belacan are cottage industries. 10% is processed by large-scale processors and These cottage industries not only lack the sold as frozen fi sh, canned fi sh or others. appreciation and understanding of the It is common that traditional fi sh products importance GMP for food safety and quality, fail to meet the hygiene requirements of they also lack the capability to enforce such Indonesia. These traditional fi sh products are strict manufacturing practices. In an effort to predominantly consumed by the middle level improve the safety and quality of the Belacan, of society. The inability to meet the hygiene governmental agencies in Brunei have made requirements is mainly attributed to the special effort to improve the monitoring and many constraints faced by processors. These surveillance of products and practices. Focus constraints include the lack of infrastructure is now being placed on providing enhanced and equipment and the lack of appropriate and group-directed technical assistance and handling and processing area that comply guidance. In order to disseminate information with the hygiene requirements. more effectively, training programs are currently being conducted for all relevant In order to improve the quality of traditional stakeholders. fi sh products such that they comply with the hygiene requirements and are safe for human consumption, the TPE must be provided with adequate and appropriate processing equipment. TPE must also be trained on how to implement GMP. In order to achieve

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Ù 7 that, it is essential that the GMPs are fi rst Table 1: Production of Pindang established. No. Year Production (tonnes) In Indonesia, salted boiled fi sh is known as 1 2000 66,475 Pindang. Pindang plays an important role in 2 2001 134,071 the staple diet of the local population due to its low cost and high nutritional value 3 2002 124,826 particularly that of proteins. The storage life 4 2003 121,491 of Pindang can however, be compromised 5 2004 122,807 by poor sanitation and hygiene during the 6 2005 95,776 processing steps. 7 2006 124,260 Salted boiled fi sh is preserved in a process 8 2007 131,560 that involves boiling fi sh in the presence of salt. This traditional preservation technique is relatively easy to do and does not depend on the natural drying conditions or mechanical Lao PDR drying equipment that may sometimes pose a problem in the production of salted boiled Dried fi sh (Pa heang) fi sh. The Government of Lao places a strong The GMP for salted boiled fi sh is created emphasis on economic growth of the with the intention that they be applied to agricultural and food production sector small-medium sized establishments to allow of the economy. It seeks to promote rural them to meet the standard of processing development as a key component in its effort and to improve the quality of their products. to reduce poverty in the country. Similarly, the training and supervision of In the past decade, the fi sheries have played these small-medium sized traditional product a major role in providing a crucial source of establishments is expected to help produce income and employment for the rural men and fi sh products of higher quality that are safe women. They have also contributed greatly to for consumption and are more competitive the national food supply. In the year 2006, the in the market. fi sheries produced more than 97,400 tonnes The production fi gures of salted boiled fi sh in of fi sh and fi shery products. This is expected D Indonesia, mostly in the Java Island is shown to increase at around three to fi ve percent in Table 1. However, data on the export each year. volume is currently not available. The main The fi shing industry of Lao is particularly reason for this is that most of the products are active during the rainy season of the year. The consumed in Indonesia, in particular that of rainy season usually spawns an abundance the Java Island. The export volume is almost of fish and fishery products. As such the negligible. collection of aquatic animals is an important

ROUN activity for the country folk during the raining season. Most of the ﬁ shes are caught from

G natural fresh water resources which originate from the Mekong River, reservoirs and its tributaries (40%); ponds, swamps, wetlands, ﬂ ood plains (26%); rice ﬁ elds (32%) and cage culture (2%). BACK

8 Ù Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Although the fish and fishery products parasites and disease testing and certifi cation produced in Lao have increased, most of these of the safety of meat products units of the products are consumed domestically due to government. the high domestic demand. As such, very Moreover, the technical personnel often lack little are exported. The surplus products are the knowledge of methods in food analysis preserved in a variety of methods according and quality assurances. They also lack the to cultural preferences and prevailing local essential and specialized equipment required traditions. for more specialized tests. Therefore, they These TPEs are predominantly small scaled are unable to test for pesticide residues and and its processors belong to traditional fi sh mycotoxins. They are also unable to test processing families or communities. The and monitor chemical contamination in food most common forms of traditional products products. are fi sh sauce, fermented, pickled, dried and The lack of trained manpower, food inspectors smoked fi sh. and skills in terms of food analytical techniques The Government of Lao greatly supports the pose a major problem in ensuring food safety small and medium sized food processing in Lao. This is particularly true in places enterprises. In recent years, many food where there are rough terrains, and an absence factories have been established to ensure of proper roads. Communication with the suffi cient food for the domestic population remote rural areas is diffi cult in such areas. as well as for exports. Communication is made even more diffi cult by the presence of inadequate operational Nonetheless, the fish processing industry funding. in Lao is yet to be well established. This could be attributed to the underdeveloped The villages in Lao PDR started fi sh processing management system of fish processing in 1978 after the Nam Ngum reservoir was industries in particular that of traditional built. As part of the FAO project initiative, the processing enterprises. fi sh-processing group was offi cially established between 1998-1999. As there are three main Processors’ and consumers’ knowledge and kinds of traditional fi sh processing methods, understanding of food quality and safety, the fi sh-processing group targets to provide food-borne diseases is still very low. This lack three kinds of training to twelve particular of awareness has become the leading cause

villages. The group also provide equipment D of illness and death. These, accompanied by to these villages. other food safety related issues continue to N have a negative impact on public health and In addition to that, the ﬁ sh-processing group economic development. The outbreaks of food has tried to incorporate GMP in four targeted borne and food-transmitted diseases continue villages. The four villages are Tha Heua Tai, to rise. As such, the government of Lao has Tha Heua Neua, Seng Savang and Donxary OU to address an expanded list of possible food- Oudom.

borne diseases. R In Lao PDR, the most common forms of Unfortunately, at the present moment, the traditional processed products are fi sh sauces, necessary regulatory tools are still not in fermented fi shes, pickled fi shes, dried fi shes G place. There are only some regulations and and smoked fi shes. Dried fi sh or Pa heang, decrees related to food safety control. Though as it is known locally, are produced by the K there is currently a laboratory, the animal following procedure. The fresh fi shes are fi rst C disease diagnosis laboratory situated at the washed in fresh water. They are then gutted National Animal Health Center, it is currently and washed again before being mixed with being shared amongst the fi sh testing, animal seasoning. The seasoned fi shes are then dried BA

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Ù 9 under the sun and smoked. The completed Pa and are estimated to produce 2.5 tonnes of heang are hung on bamboo strings and sold Keropok lekor a day. The total production in the markets. of Keropok lekor in Malaysia is estimated to be about 30,000 to 60,000 a month. Though The fi sheries industry of Lao PDR is not highly most of these are sold domestically, some are developed. As such, the export of fi shes to exported to Brunei and the Middle East. foreign markets is insignifi cant. There are also very limited fi sh processing activities Keropok lekor is made from a mixture of occurring in the country. The trade of fi shes is fi sh, shrimp and starch. The fi shes used in predominantly domestic and this commodity the production of Keropok lekor are mainly is a very important source of protein for the low value pelagic fi shes such as Dussumieria local population. hasellti (Round hering, Ikan Tamban), Chirocentrus dorab (dorab wolf herring, The Department of Livestock and Fisheries Ikan Parang), Decapterus maruadsi (Round (DLF) has decided to place its emphasis Scad, Ikan Selayang), Decapterus macrosoma on improving the hygiene practices in fi sh (slender scad, Ikan Selayang) and Atule mate handling and processing. Presently, there (Yellow tail Scad, Ikan Selar). are no national standards for fi sh products However, DLF is considering using the national Keropok lekor is known for its versality and standards of Thailand or other neighboring ability to be formed into many different shapes countries as the basis for establishing the and sizes. These forms include oval, cocktail, national Lao standard. ball or sliced. There are also the newly formulated crispy and spicy forms. These new versions of Keropok lekor are already sold in Malaysia markets. The Department of Fisheries and a University are now conducting a joint study Fish cracker (Keropok lekor) on the product development and packaging of Keropok lekor. Keropok lekor is a traditional Malaysian fi sh product. It is a popular snack food that is widely consumed by all communities Myanmar in Malaysia. Keropok lekor is produced predominantly in the coastal areas of Malaysia Myanmar is endowed with an extended coast in particular the east coast of the Malaysian line that stretch along the Indian Ocean, Bay Peninsula mainly in the states of Kelantan, of Bengal and Andaman Sea. This extensive Terengganu and Pahang. coast line provide Myanmar with diverse fisheries resources. As of 2009, Myanmar At present, there are about two thousand has a population of 56 million. The people operators involved in the production of Keropok of Myanmar rely heavily on fi sh and fi shery lekor in Malaysia. Keropok lekor is traditionally products as their main source of animal made in small backyard operations in fi shing protein. Due to signifi cant growth in the fi shery villages. However, in recent years, some of these industry, the per capital domestic consumption operations have been up scaled up using large of fi sh has also increased signifi cantly in the semi-automatic machinery to produce large past two years. amounts of Keropok lekor. At present, there are about two thousand operators involved As a result of the favorable geographical in the production of Keropok lekor. Currently, conditions of Myanmar, the fisheries in there are fi ve establishments practicing GMP Myanmar have expanded. This is true for in the production of Keropok lekor. These fi ve the marine (coastal and off-shore) fi sheries, establishments are located in Kuala Lumpur inland fi sheries and aquaculture industry in

10 Ù Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Myanmar. Apart from ensuring food security Though the GMP for each of the production for the people, the government also places steps has been formulated, there are still strong emphasis on developing its fi sheries as problems and challenges involved in the they play an important role in earning foreign implementation of the GMP. For one, the income for the country through export. budget set aside for the implementation of GMP is limited. There is also insufficient As a result of strong governmental support, resources and time to train the personnel the fi shery production of Myanmar reached involved in the production of Ngachin. Some about 3.168 million metric tonnes in 2008. recommendations to overcome these issues Of these, marine fi sheries account for almost include providing more and frequent training 1.679 million metric tonnes of the fishes, to the TPE to increase awareness of GMP. freshwater fi sheries account for another 0.625 million metric tonnes, 0.675 million metric Fish sauce (Ngan pya ye) tonnes from aquaculture, and 0.189 million metric tonnes from less able fi sheries. These Fish sauce, or Ngan pya ye in Myanmar, is one values indicate that the marine fi sheries play of the basic ingredients in Myanmar cooking. It an important role in ensuring food supply is used liberally in nearly all Myanmar dishes. security and the livelihood of the community It is often used as a marinade for fi sh and people in the coastal regions. meat. It is also often mixed with fresh-cut or dried chilli and used as a condiment. Ngan In Myanmar there are 496 licensed and registered pya ye has a rich and translucent reddish- small and medium sized establishments. Of golden brown color. these 496 establishments, 117 are small sized establishments, while 379 are medium sized As of 2010, the division fi shery offi ces has establishments. These 379 medium sized recorded 56 registered fi sh sauce processors. establishments have been trying to develop The annual production for fish sauce is the GMP for the TPE of Myanmar. approximately 130,000 -190,000 tonnes.

A total of 136 fi sh processing plants including Fish sauce is made from a mixture of fi sh and TPE were licensed between the period of 2009- salt that has been allowed to ferment over a 2010. The factories that complied with the period of six months to a year. Traditionally, rules and regulations of the EU were permitted freshwater fi shes are used in the production to export their products to the EU countries of Ngan pya ye. However, some fi sh sauces

especially United Kingdom that has a bilateral are made using marine ﬁ sh or even squids. D agreement with Myanmar. The basic ingredients of Ngan pya ye are

fi sh, water and salt. Sugar may also be added N Fermented fi sh (Ngachin) for extra taste, though it is not a necessary ingredient. As Ngan pya ye is fermented, it As recorded by the division fi shery offi ces in does not require refrigeration and is best stored the years 2009 and 2010, there are104 Ngachin

in a cool, dark place. OU producers registered in the states of Pegu and

Tanintheri. Annual production of Ngachin is R approximately 900-1000 tonnes. The product Philippines

is produced from small whole ﬁ shes or marine G shrimp (Metapeneaus spp.) The fish or Shrimp sauce (Alamang) shrimps are mixed with salt and boiled rice. K The product may be consumed as cooked/fried Shrimp sauce is one of the popular traditional

Ngachin as well as raw Ngachin mixed with ﬁ sh and ﬁ shery products of the Philippines. C onion, chilli, garlic and oil. The shelf life is It is used as a condiment in many Filipino about a week at ambient temperatures. recipes. It is also used as a dip and as a BA

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Ù 11 flavoring agent in many Filipino noodle with rice. The average rate of consumption of dishes. dried and smoked fi sh in the Philippines is 4 kilos per capita per annum. Shrimp sauce is particularly popular in the Cavite areas of the Philippines. Despite it’s Salted, dried and smoked fi shes are widely popularity, the production of alamang is produced by a system of small-scale units and mostly confi ned to cottage industries. These cottage industries. These fi sh products account homemade Alamang are sold within the Cavite for a signifi cant proportion of the national areas and also to visiting clienteles from other production of fi shery products. parts of the Philippines. They are also sold Though the sale of smoked fish occur directly to restaurants or sent overseas to predominantly at central markets, the process Filipino Overseas Workers. of smoking the fish occur mostly at the Alamang’s main raw material, the tiny shrimp villages, towns and cities. As transport of Acetes spp., is only abundantly available smoked fi sh is fairly inexpensive and easy to during the months of May and September. As do, the smoking process can occur at a site such, there is a need to assist producers by away from the point of sale. teaching them how to sustain the supply of Based on the Bureau of Fisheries and Aquatic shrimp sauce all year round. There is also a Resources (BFAR) Fisheries Profile 2007, need to offer assistance to the industry to allow smoked fish has a very low FOB value it to fl ourish and become more competitive compared to other fi shery exports. This could in the market. be attributed to the fact that many small To ensure that the Alamang produced is of and medium-size fish smoking plants in high quality and safe for human consumption, the Philippines fi nd it diffi cult to implement it is very important to impart GMP to the GMP due to their economic and technical TPE. The government plans to achieve this by constraints. not only providing technical support but also To date, the safety standards for smoked fi sh fi nancial support. This is in consideration of has already been prepared and submitted for the fi nancial status of these small and medium- consultation with the industries and other size producers. institutions. After the standards have been reviewed, they will be submitted to the Bureau Smoked fi sh (Tinapa) of Product Standards for approval. D Smoked fi sh, known locally as Tinapa, is fresh fi sh that has been soaked in brine, sun-dried and treated with hot smoke generated from Singapore burning hardwood inside a smoke house. The smoke house is usually constructed using Fish balls and fi sh cakes drums or concrete tiles. Fish balls and fi sh cakes are widely consumed in Singapore as ready to eat snacks as well as ROUN Tinapa is one of the most popular ready-to- ingredients in many local dishes especially that of noodles and vegetable dishes. Traditionally,

G serve fi sh product available in the market all year round. This statement is particularly fish balls and fish cakes are made from true in the Tagalog region; Manila, Malabon, fresh fi sh but inconsistent and insuffi cient Navotas and some municipalities of Vacite, supplies of fresh fi sh has led processors in Bulacan, Batann and Quezon. It is believed Singapore to favor the use of surimi as the that it is in Quezon that smoked fi sh is fi rst chief raw material. Surimi is fi sh meat that accepted as a common dish to be consumed has been minced, leached by washing with water, thoroughly mixed with sugar and BACK

12 Ù Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN polyphosphate and then frozen. The surimi Dried shrimp is a traditional fi shery product is imported predominantly from Thailand, that is popular not only amongst the Thais but Vietnam, Indonesia, Malaysia, India and also amongst the people of South East Asia. Myanmar. It can be made from either marine shrimp, aquaculture shrimp or freshwater shrimp. The The scale of production varies from one- production of dried shrimp is located at coastal man stalls that are fully manually operated, provinces such as that of Trad, Chantaburi, to large plants producing up to ten or more Chonburi, Samuthsakorn, Samuthprakarn tonnes per day. The large amount of fish and some regions in the south of Thailand. balls and fi sh cakes produced are for both the Dried shrimp are usually produced in cottage domestic and export markets. About 45-50 fi sh industries where the processing practices and processing establishments in Singapore are hygiene practices are less than ideal. involved in the production of fi sh balls and fi sh cakes. They produce an estimated 30,000- Fish Sauce (Nam-Pla) 50,000 tonnes of products annually valued at S$80-90 million and are mainly for domestic There are three main groups of fermented consumption. However, in recent years, there fi shery products in Thailand. They are liquid are a few companies that have increased their products, paste products and products that exports to neighboring countries, US, EU and retain the original size and form of the raw Australia. materials. Fish sauce (Nam-pla) belongs to the fi rst group of fermented fi shery products. The core of the industry lies in the production Shrimp paste (Kapi) is a common example of of fi sh balls and fi sh cakes for the numerous product belonging to the second group and noodles stalls in Singapore. Fish balls and fermented fi sh products such as Pla-ra, Pla-jao, fi sh cakes are sold to noodle stalls and served and Pla-jom are examples of the third group with noodles. Fish cakes are usually cut into of fermented fi shery products. thin slices and added to noodles, soup and vegetables dishes. Deep-fried fi sh balls and Fish sauce is a major fermented product which fish cakes are also sold as snacks. These is consumed daily in almost every household snacks have become increasingly popular in and restaurant in Thailand. There are many Singapore.The use of fi sh balls and fi sh cakes small and medium scaled cottage factories in other dishes is also gaining popularity. Fish producing fi sh sauce in Thailand. In 1991, balls and fi sh cakes are also sold directly to there were 110 fi sh sauce manufacturing plants household consumers at wet markets and in Thailand. The quantity of raw material D supermarkets. Fish balls and fi sh cakes sold in used was 127,152 metric tonnes in weight supermarkets are usually packed in styrofoam with a value of 308.7 million baht (Dept. of N trays wrapped with polyethylene (PE) sheet. Fisheries, 1993). Fresh fi sh balls are packed in PE bags with Both marine and freshwater fi shes such as chilled water and displayed on refrigerated

anchovies, sardine and mud carp (Cirrhina OU cabinets. jullieni) can be used in the production of ﬁ sh

sauce. In 1986, the National Statistical Ofﬁ ce R conducted a survey on household expenses

Thailand and found out that approximately 37% of the G total money spent on condiments was on ﬁ sh Dried shrimp sauce. As such, the study concluded that ﬁ sh K Salting and drying are probably the oldest and sauce was the condiment that incurred the C easiest methods of food preservation. highest expenses no an average household’s expenditure on condiments. BA

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Ù 13 The Department of Business Economics under is that the productivity is not high. Only about the Ministry of Commerce also conducted a one to fi ve tonnes of fi nished products are survey on fi sh sauce consumption on the Thai produced per household per year. There are population and found that the average Thai also large-scale production establishments. consumed approximately twenty milliliters This group of production units has an annual of fi sh sauce a day. If we assume that the yield of about 10 tonnes per unit. This is population that consumer fi sh sauce is 50 signifi cantly higher than that of the household million, the amount of fi sh sauce required establishments. would be approximately 1,330,000 bottles of 750 milliliters a day. Fermented Tiny Shrimp Paste (Mam Tom)

Fermented tiny shrimp paste (Mam tom) is produced predominantly in the costal areas Vietnam of Vietnam. The ingredients of mam tom are In recent years, the annual average rate of tiny shrimps and salt added at a percentage of growth for the fi sh processing industry in 10-13%. The fermentation time is about two Vietnam has reached seven to twenty percent. to six months. The fermented shrimp paste There are over 530 large-scale processing produced should have a very fi ne texture. establishments and 4 billion US dollars Depending on the technology used in its worth of exports in 2008. Though there is production, the product can be very fi ne and a push to export fi shery products, over fi fty have a distinct fl avor. Though it is produced percent of the fi shery products are consumed mostly for domestic consumption, Mam tom domestically. is also exported.

In Vietnam, the technologies used in the Fish sauce (Nuoc mam) processing of fi shery products include, freezing, frying slating, fermenting and the production Fish sauce or nuoc mam, as it is known of fi sh sauce. Up to date, there are thousands locally, is also produced in the coastal areas of establishments of different scales. These of Vietnam and its islands. The ingredients establishments are predominantly located used to produce Nuoc mam are marine fi shes along the coastal areas and southern delta. and salt. The latter is mixed to the fi sh and Fish paste and fi sh sauce are also produced the mixture left to ferment for a period of six in these establishments. to twelve months. The fi nished product is a D liquid that has a light or reddish brown color There are two main types of production depending on the method used during its methods. The majority of fish processing production. Fish sauce also possesses a clear establishments are household establishments. and distinct fl avor. Fish sauce is produced for The major setback for this production method domestic consumption and export. ROUN G BACK

14 Ù Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN GMP FOR SELECTED TPE 16 Ù Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Brunei Darussalam

Product Name

Tiny shrimp paste – Belacan

Product Description

Shrimp paste is a traditional product that is commonly used in Brunei Darussalam as a condiment or an ingredient in many dishes, particularly that of vegetable dishes. It is a semi-fermented/ cured shrimp product in paste form.

The tiny shrimp Acetes spp. is ﬁ rst washed and sorted. After that, the shrimp is mixed with salt and stored for 8 to 10 hours before it is being dried in the sun for 7 to 9 hours, depending on the product and the heat of the sun. After drying the shrimp is put in a grinder machine before being pounded into a paste. Lastly, shaping or forming is done and the product is packaged according to market requirements.

Process Flow Diagram

Receipt of Acetes shrimp

Washing and Sorting

Mixing with Salt

Curing Overnight

Sun Drying

Grinding and Pounding

Forming /Shaping

Packing

Storage

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Ù 17 BRUNEI DARUSSALAM 18 Washing andSorting 2. Receipt ofRaw Materials 1. Outline ofProcessingSteps

Ù processing. portable waterandsortedbeforefurther it. Theshrimpsarethenwashedwith to allowforwaterdrainthrough container orinabasketwithsmallholes The shrimpsareplacedinaplastic Receipt ofSalt b. a. Receipt of

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN The saltusedmustbeoffoodgrade. temperatures notexceeding5˚C. shrimps ispreservedwithiceatlow ﬁ Fresh shrimpsarereceivedfrom Washing andSortingof Acetes shermen inplasticcontainers.The Figure 1A&1B Acetes spp. shrimps 3. Mixing with Salt 4. Curing Overnight the shrimps. Salt isaddedandmixedthoroughlywith shrimps. of thisstepistopreservethetaste fermentation totakesplace.Thepurpose its bottomandleftovernighttoallowfor placed inacontainerwithsmallholesat After mixingwithsalt,theshrimpsare Placed incontainerwithsmallholes Mixing withsalt Figure 3A &3B Figure 2 taste to preserve the Cured overnight Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN 5. Sun Drying omn Pcig trgi ree Storage inChiller Storagein Freezer Packing Forming the suntodryfor79hours. covered withplasticnetsandleftoutin The semi-fermented/curedshrimpsare Figure 4A&4B Sun drying Figure 6A,6B,6C&6D Forming/Shaping, Packing andStorage 7. 6. Grinding and Pounding customers. (-18˚C orless)beforebeingsoldtothe stored refrigerated(5˚Corless)frozen or containersofshrimppastearethen bags orplasticcontainers.These sizes andpackagedinfoodgradeplastic manually intotherequiredshapesand The shrimppasteisthenmoulded called using atraditionalpoundingequipment shrimps arethenpoundedintoapaste put intothegrindingmachine.Theground After thedryingprocess,shrimpsare lesung Grinding andPounding Figure 5A&5B .

BRUNEI DARUSSALAM BRUNEI DARUSSALAM 20 Theiceusedmustbemanufactured using 1. Compliance of contaminationtheﬁ substances. Thiswillinturnreduce possibility of contaminationwithbacteriaortoxic in amannerthatreducesthepossibility product duringprocessingmustbeproduced Ice thatcomesintodirectcontactwiththe Reason water fromapprovedsources. Ice mustbemanufacturedusingfrompotable Manufacture ofIce GMP 1A.2 Shipmentsoficedelivered inunsanitary 3. Icecontainersmusthavetightfitting 2. Icecontainersmustbemadefromnon- 1. Compliance of contamination. unsanitary containerswillbecomeasource Ice containedandtransportedindirty Reason clean andwell-designedcontainers. Ice shouldbecontainedandtransportedin Receipt ofIce GMP 1A.1 GMP forShrimpPaste( Section 1

Ù approved portablewater. to thesupplier. containers willberejected andreturned covers thatarenotdamaged. and easytoclean. corrodible materials,whicharedurable

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN

Receipt ofRawMaterials nal product. nal Belacan Compliance fails tomeetspecifi identify specifi used forprocessing.Recordsshouldbekeptto decomposed orunwholesomeshrimparenot should beevaluatedtoensurethattainted, The conditionandqualityoftheshrimp Reason properly. shrimp shouldbemaintainedandstored records ontheconditionandqualityof be evaluatedonreceipt.Documentationand The conditionandqualityoftheshrimpshould ReceiptofShrimp GMP 1B.1 involved inspoilage. down manyoftheenzymatic reactions reduces bacterialgrowth rateandalsoslows Storage ofrawshrimps at lowtemperatures Reason containers atlowtemperatures. Raw shrimpsaretobestoredinsuitable HandlingofShrimp GMP 1B.2 Therequirementsforthe quality ofthe 2. Thefollowingdetailsoftheshipmentare 1. ) . Natural smell, withnooff-odors b. a. Freshness shrimp areasfollows: Qualityoftheshrimp f. Averagetemperatureofshrimpupon e. d. Date of catch c. Name of transport Nameandaddressofsupplier b. Dateofreceiptfromsupplier a. recorded andkept: receipt c lotsincasethefi cations. nal product nal Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN Saltindamagedpackaging withoutproper 2. Onlyfoodgradesaltwithappropriate 1. Compliance the correctingredientisused. identifi should haveclearlabelstohelpinthe foreign extraneousmaterials.Thepackaging by micro-organisms,insects,chemicalsand salt andmayleadtocontaminationfrom will notprovidethedesiredprotectionto material shouldberejected.Damagedpackaging contamination, saltwithdamagedpackaging In ordertominimizeotherformsofmicrobial the subsequentsalted which maycontinuetoliveinthesaltand sources maycontainhalophilicbacteria, fi Contaminated saltcanaffectthequalityof Reason be intactandundamaged. requirements. Packagingofthesaltmustalso and hasconformedtosafetyquality prove thatthesaltisoffoodgradestandard The suppliermustprovidecertifi ReceiptofSalt GMP 1C.1 Shrimps should bekeptattemperatures 2. Shrimpsarestoredatlowtemperatures 1. Compliance nished product.Salt produced frommarine in processing. labelling shouldnotbeacceptedforuse used. certification shouldbeacceptedand not exceeding5˚Catalltimes. ice. by refrigerationorchillingwithwaterand cation ofthemsaltthusensuringthat acetes . cto to cation . SaltmustbeusedonaFirst-In-First-Out 4. Saltthathasbeenremovedfrom their 3. Propernon-woodenshelvingracksshould 2. deterioration ofthequalitysalt. dust, dirt,sandetc).Itmightalsoleadtothe insects, chemicalsandforeignmaterials(e.g. extraneous materialssuchasmicroorganism, manner mayresultincontaminationby Storage ofsaltinanopenareaahaphazard Reason and tidymanner. dry room.Theyshouldbestoredinaneat ground levelinaspeciallyassignedcleanand Boxes orbagsofsaltshouldbestoredabove StorageofSalt GMP 1C.2 Labelsshouldincludethefollowing 3. . Acleananddry roomthatisinsect 1. Compliance used bydate. used shouldnotbebeyond theirexpiry/ rotation/inventory control schedule.Salt (FIFO) basisoraccordingtothefactory’s labels dry containerswithpropercoversand packaging shouldbestoredincleanand ground level. be putinplaceforstoringofthesaltabove . Expirydate/useby date d. c. Country of origin Nameofmanufacturerorimporter b. a. Name of ingredient information: iii. E Avoidpestaccessandharbourage ii. Permitadequate maintenanceand i. construct to: salt. Thisroomshouldbedesignedand free mustbeprovidedforthestorageof contamination cleaning nable minimallikelihoodof

BRUNEI DARUSSALAM BRUNEI DARUSSALAM such ashalophilicbacteriaandmoulds. help controlthegrowthofmicroorganisms temperatures topreventcontaminationand hygienically incleancontainersatlow Mixing withsaltshouldbecarriedout Reason product. be carefullycontrolledtoattainthedesired amount ofsalt,timeandtemperatureshould ﬂ Shrimps shouldnotbeplaceddirectlyonthe a coolandcleanareaatlowtemperatures. Mixing shouldbecarriedouthygienicallyin MixingwithSalt GMP 3.1 22 the washingprocess. prevent orreducemicrobialgrowthduring washing process.Usingchilledwaterwill contamination oftheproductduring potable watersourceswillpreventpossible foreign materials.Theuseofapproved contamination byremovingallextraneous The purposeofwashingistominimize Reason materials. sources andsortedoutfromunwantedforeign chilled waterfromapprovedpotable The rawshrimpsshouldbewashedusing WashingandSorting GMP 2.1 oor orindirectcontactwiththewalls.The Section 3 Section 2

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN MixingwithSalt WashingandSorting

. Washing containers ortanksshouldbe 3. Thetemperatureof the watershouldbe 2. Thewaterusedmustbefromanapproved 1. Compliance . Utensilsandcontainers usedmustbe 4. Utensilsandcontainersusedformixing 3. Allworkersmustobservegoodpersonal 2. Mixingwithsaltshouldbecarriedoutin 1. Compliance allows thedrainage ofexcess water. change ofwater withgoodcirculation that designed properly toallow foraconstant made ofnon-corrodible materialsand or withtheadditionofice. maintained atbelow5˚Cbyrefrigeration potable source. free from corrosion. constructed from foodgrade materialsand after use. must beproperlysanitizedbeforeand hygiene practices. temperatures below10˚C. a cleanandproperlysanitizedareaatlow Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN directly onthefl contamination. Shrimpsshouldnotbeplaced a cleanenvironmentandprotectedfrom The sundryingshouldbecarriedoutin SunDrying GMP 5.1 environment isnecessarytoprevent The carefulcontroloftemperatureand Reason room atlowtemperatures. Curing shouldbecarriedoutacoolandclean GMP4.1 Curing Overnight reduce growthofmicroorganisms. necessary topreventcontaminationand The carefulcontroloftheenvironmentis Reason product quality. should becarriedoutquicklytomaintainthe reduce growthofmicroorganisms.Theprocess necessary topreventcontaminationand The carefulcontroloftheenvironmentis Reason environment andasquicklypossible. a pasteshouldbecarriedoutinclean Grinding andpoundingoftheshrimpsinto GrindingandPounding GMP 6.1 Section 5 Section 4 Section 6 Sun Drying Curing Overnight GrindingandPounding oor. . Allutensils, containers andmaterialsused 3. Theshrimpsshouldbecoveredwith 2. Theprocessingareashouldbefreefrom 1. Compliance Curingshouldbecarriedoutinacleanand 1. Compliance microorganisms. contamination andreducegrowthof . Thetraditional poundingequipmentused 2. Theprocessingareashouldbefreefrom 1. Compliance must beeasy tocleanandoffoodgrade. custom-designed netsfordrying. as dogsandcats. insects aswellrodentsandanimalssuch pests suchascockroaches,fl below 10˚C. properly sanitizedareaatlowtemperatures are easy toclean andmaintain. should bemadeofsuitablematerialsthat such asdogsandcats. insects aswellrodentsandanimals pest suchascockroaches,fl ies and other and ies ies and other

BRUNEI DARUSSALAM BRUNEI DARUSSALAM 24 Allworkersmustobservegoodpersonal 2. Plasticbagsorplasticcontainersused 1. Compliance microbial contamination. extraneous foreignmaterials,insectsand against mechanicaldamage,dust,dirt,other of theproductandtoprotect materials aredesignedtopreservethequality to maintaintheproductquality.Packaging The processshouldbecarriedoutquickly Reason containers. food gradeplasticbagsorsuitable and packedasquicklypossibleintoclean The shrimppasteshouldbeformed/shaped Forming/Shaping, GMP 7.1 Section 7

Ù hygiene practices. grade. in packingshouldbecleanandoffood

Good Manufacturing Practice (GMP) forSmall andMedium-sized Traditional Fish Products Processing Establishment inASEAN Forming/Shaping,PackingandStorage Packing . Theshrimppasteshouldbestored 1. Compliance shelf-life oftheproduct. Storage atlowtemperatureswillextendthe Reason at lowtemperatures. The shrimppasteshouldbeproperlystored Storage GMP 7.2 (-18˚C andbelow). refrigerated (10˚Candbelow)orfrozen Indonesia

Product Name

Salted Boiled Fish – Pindang

Product Description

Pindang is a traditional salted boiled ﬁ sh product in Indonesia. Pindang plays an important role in the staple diet of the local population due to its low cost and high nutritional value particularly that of proteins. Fresh whole ﬁ sh is washed, gutted, salted and boiled in brine to make the product. The production of Pindang is mainly in the Java Island and largely meant for local consumption. The export volume is almost negligible.

Process Flow Diagram

Receipt of Packaging material (bamboo baskets) Receipt of Whole Fish Receipt of Ice

Washing (I)

Gutting

Salting

Boiling

Washing (II)

Cooling

Packing, Storage and Distribution

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Ù 25 INDONESIA Outline ofProcessingSteps 26 Receipt ofRaw materials 1.

Ù ) Receipt ofWholeFish d) Receipt ofSalt c) Receipt ofPackaging material b) Receipt ofIce a)

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN ice. temperatures notexceeding 5˚Cusing processing. Fishispreserved atlow the fishesare safeandsuitablefor its organoleptic qualitytoensure that should berecorded andevaluated for Every shipmentofraw wholefish into theboilingwater (brine). in between thelayers offi for thesaltingoffi Food grade saltisusedasaningredient for storage anddistribution. the packaging ofthesaltedboiledfi traditional packaging materialsusedin Bamboo baskets orcontainers are the occurring. to preventanycontaminationfrom handled inasanitarymannersoas of non-corrodiblematerialsandare designed containers,whicharemade establishments incleanandwell- Ice istransportedtothepre-processing temperature notexceedingthatof5˚C. the temperatureofwatertoa the washingofrawfi Ice functionsasacoolingagentduring Receipt ofWholeFish Figure 1 sh. Saltisadded sh. It reduces sh andalso sh 4. Salting 3. Gutting 2. Washing (I) between thelayersoffi (15 –25%offi are arrangedinbamboobasketsandsalt In thisstep,thefi This stepisusuallyperformedmanually. the gutcavityorbellyoffi This stepwillremoveallthecontentsof of thewater. and iceisaddedtolowerthetemperature processed. Thiscanbedoneinbatches potable icedwaterbeforetheyarefurther The fishesarewashedincleanand Washing offi Salting offi Figure 3 Figure 2 sh weight)isaddedin shes,togetherwithsalt, sh sh. sh sh.

5. Boiling Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN 7. Cooling 6. Washing (II) salt) for15to30minutes. into theboilingbrinewater(20–25% bamboo basketcontainingthesaltedfi The fi and cooledontheshelvesinair. Each basketofsaltedboiledfi brine water. Salted boiledfi Cooling ofsaltedboiledfi shes areboiledbyimmersingthe Boiling ofsaltedfi Figure 4 Figure 5 sh arewashedwithhot sh sh isdrained sh sh . Packing,StorageandDistribution 8. prior todistribution. cartons) andstoredatroomtemperature made frombamboo(bamboobaskets/ Pindang Pindang packedinbamboocartons ispackedinpackagingmaterials Figure 6

INDONESIA INDONESIA 28 Theiceusedmustbemanufactured using 1. Compliance of contaminationtheﬁ substance. Thiswillinturnreducepossibility of contaminationwithbacteriaortoxic in amannerthatreducesthepossibility product duringprocessingmustbeproduced Ice thatcomesintodirectcontactwiththe Reason from approvedsources. Ice mustbemanufacturedusingpotablewater Manufacture ofIce GMP 1A.2 Shipmentsoficedelivered inunsanitary 3. Icecontainersmusthavetightfitting 2. Icecontainersmustbemadefromnon- 1. Compliance of contamination. unsanitary containerswillbecomeasource Ice containedandtransportedindirty Reason clean andwell-designedcontainers. Ice shouldbecontainedandtransportedin ReceiptofIce GMP 1A.1 GMP forSaltedBoiledFish Section 1

Ù approved portablewater. to thesupplier. containers willberejected andreturned covers thatarenotdamaged. and easytoclean. corrodible materials,whicharedurable

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN Receipt ofRaw Materials nal product. nal (Pindang) the otherpackaging materials. so astopresent noriskofcontaminationto be rejected andrefused entryintotheplant Dirty ordamagedpackaging materialsshould Compliance of contamination. contamination andmayitselfbecomeasource not providethenecessaryprotectionagainst Dirty anddamagedpackagingmaterialwill Reason rejected/refused. that aredirtyand/ordamagedshouldbe Packaging madeofbamboo(bamboocartons) GMP1B.1 Receipt of Packaging . Packaging materialsusedshallbekept in 1. Compliance the product. dirty packagingmaterialsmaycontaminate will notprovidethedesiredprotectionand contamination. Damagedpackagingmaterials of protectingthefinishedproductsfrom Packaging materialshaveanimportantfunction Reason through storageunderproperconditions. be keptcleanandsafefortheirintendeduse intended tocontaintheﬁ Packaging materials(bamboocartons)thatare StorageofPackaging GMP1B.2 clean andhygienic conditions.

Materials Materials nal product should product nal Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN from theplant. and/or contaminatedsalt shouldberemoved microbial contamination insaltedfi and saltedfi bacteria, whichcontinuestoliveinthesalt marine sourcesmaycontain the fi Contaminated saltcanaffectthequalityof Reason and withproperlabels. packaging intactandundamageduponreceipt Every shipmentofsaltshouldalsohavetheir the fi the processingplant.Saltasaningredientin be donebeforethesaltisacceptedforusein from anyphysicalcontaminants).Thismust quality requirements(i.e.microbiallimit,free that thesalthasconformedtosafetyand provided foreveryshipmentofsalttoindicate A certifi Receipt ofSalt GMP 1C.1 Acleananddryroom thatisinsect- 2. . Packaging materialsshallbeusedona 4. Proper shelvingrack shallbeputinplace 3. . Enableminimallikelihood fromc. Avoid pestaccessandharbourage; b. Permit adequatemaintenanceand a. should bedesignedandconstructedto: packaging material.Thestorage room free shallbeprovided forthestorage of schedule. to thefactory’s rotation/inventory control First-In-First-Out (FIFO) basisoraccording from away for thestorage ofthepackaging materials nal productneedstobeoffoodgrade. nished product. Saltproducedfrom cation from the salt supplier should be cation fromthesaltsuppliershouldbe are handled. from areas where raw orfoodproducts room forpackaging materialsaway contamination by locatingthestorage and cleaning, sh. Inordertominimisesuch the ground. halophilic sh, used sh, assigned cleananddryroom. level inaneatandtidymannerspecifi Bags ofsaltshouldbestoredaboveground Storage ofSalt GMP 1C.2 Saltinbadlydamagedpackaging without 2. Onlysaltshipmentswiththeappropriate 1. Compliance correct ingredientisused. in theiridentifi dirt, sandetc).Clearlabellingwouldhelp insects, chemicalandforeignmaterials(dust, extraneous materialssuchasmicroorganisms, protection andmayleadtocontaminationby Damaged packagingwillnotprovidethedesired . Saltthathave beenremoved from its 3. Proper non-wooden shelvingracks should 2. Acleananddryroom thatisinsect-free 1. Compliance in thequalityofsalt. dust, dirt,sandetc)aswelldeterioration insects, chemicalsandforeignmaterials(e.g. extraneous materialssuchasmicroorganisms, manner willresultincontaminationby Storage ofsaltinanopenareaahaphazard Reason for useinprocessing. proper labellingshouldnotbeaccepted the plant. certifi labels. dry containers withproper covers and packaging shouldbestored incleanand from thefl be putinplaceforthestorage ofsaltaway Enableminimallikelihood fromc. Avoid pestaccessandharborage b. Permit adequate maintenanceand a. should bedesignedandconstructedto: must beprovided forthestorage ofsalt.It contamination cleaning cation shouldbeacceptedforusein oor. cation thusensuringthatthe

Ù cally cally

INDONESIA INDONESIA 30 Thefollowing detailsare recorded and 1. Compliance not meetspecifi documented inordertoidentifylotsthatmay is utilisedforfurtherprocessing.Recordsare tainted, decomposed,orunwholesomefi should beevaluatedtoensurethatno The incomingshipmentofrawmaterials Reason properly kept. quality receivedshouldbemaintainedand noted onreceipt.Documentedrecordsofthe and quality.Theconditionoffi whole fi Every incomingshipmentofunprocessed ReceiptofWholeFish GMP1D.1 SaltmustbeusedinaFirst-in-First-Out 4. . Thefollowing qualityparameters should 2.

Ù . Average temperatures oftheﬁ f. Dateofharvest e. Nameofdelivery vessel ortransport d. Nameand address ofsupplier c. Dateofreceipt ofshipment b. a. Species name maintained: use-by date. should notbeusedbeyond theirexpiry/ rotation/inventory control schedule. Salt (FIFO) basisoraccording tothefactory’s Presence ofstaleodourassociatedwith a. Odour : be evaluated: . Qualityintheshipment g.

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN company taint ordecomposition. receipt sh shouldbeevaluatedforcondition cations. sh should be should sh sh upon sh Lotswiththepresence oftheseobservations 2. Whole 2. fi 1. Whole fi Compliance spoilage. also theenzymaticreactionsinvolvedin slows downtherateofbacterialgrowthand Storage ofwholefi Reason 5˚C. containers attemperaturesnotexceeding Whole fisharetobestoredinsuitable Handling ofWholefi GMP 1D.2 should berejected. Presence ofuncharacteristic and f. Gills : Presence ofsunken, dullwhiteorred e. Eyes Presence ofsoftandmushy texture.: d. Texture : Presence ofsplittingormutilation Physical damage: c. Presence ofburnsthrough toskinsor Bellycavity : b. not exceeding 5˚Catalltimes. cooling withice. achieved through refrigeration orby colour andslimy appearance ofgills. brown toyellow brown orwhite-yellow or decomposition.Presence ofdark stale odours associatedwithtaint eye orcentre ofeye liquefi the fi breakdown ofbellywall. sh shouldbe kept atatemperature sh are stored atlow temperatures sh. sh atlowtemperatures ed. sh Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN Arranging andsaltingof fi Reason peeling duringboiling. on thefi added inbetweenthelayersoffi possible undersanitaryconditions.Saltis and saltingshouldbedoneasquickly Arrangement ofthefi Salting GMP 4.1 of contaminationforthefi belly cavitiesofthefi Remaining guts,bloodandorgansfrom the Reason belly cavity. all remnantguts,bloodandorgansfromtheir approved, portablewatersupplytoremove contents. Theyarethenwashedinan The fishesareguttedtoremovethegut Gutting GMP 3.1 growth isreduced. the product.Atlowtemperatures,bacterial potable waterwillpreventcontaminationto any foreignmaterials.Theuseofapproved possibility ofcontaminationbyremoving The purposeofwashingistominimisethe Reason supply. or icedwaterfromanapproved,potable The wholefi GMP 2.1–Washing Section 2 Section 4 Section 3 sh surfacetopreventtheskinfrom sh should be washed using chilled sh shouldbewashedusingchilled Washing (I) Salting Gutting sh inbamboobaskets shes canbeasource sh intothebamboo shes. Theuseof sh and spread sh andspread . Washing containers ortanksshouldbe 3. Thetemperature ofthewater ismaintained 2. Thewater usedmustbefrom anapproved 1. Compliance practices. strong emphasisongood personalhygiene of contamination,thus thereshouldbe In additiontothat,humans canbeasource growth andspoilage. as quicklypossibletoreducemicrobial Therefore, thisprocesshastobecompleted will thusspeedupbacteriagrowthrate. temperature abuseoffi basket isaslowprocessthatwillmake contamination. of wasteisimportanttopreventcross- contamination totheproduct.Properdisposal approved potablewatersupplywillprevent . Waste shouldbecollectedincovered2. Theequipmentandutensilsusedshould 1. Compliance cleaned. permits drainage. Ithastoalsobeeasily water withagoodcirculation system that designed toprovide aconstantchangeof made ofnon-corrodible materialsand addition ofice. below 5˚Cby refrigeration orwiththe potable source. and emptiedregularly. pedal-operated bins, whichare removed are easy tocleanandsanitize. be madeofnon-corrodible materialsthat sh morelikely. This

INDONESIA INDONESIA The formulaconcentrationofsaltinwater prolonged periodsoftimeinboilingbrine. fi This isdonetoacceleratethecookingof immersing ofthebamboobasketsfi The brineisheatedtoaboilpriorthe Reason according tothesizeoffi for 30minutes.Theboilingtimemayvary bamboo basketsareplacedinsideittoboil salt. Thebrineisheatedtoaboilbeforethe The concentrationofbrineusedis20-25% arranged bamboobasketsintoboilingbrine. The fi Boiling GMP 5.1 to theproducts. brine waterisusedtopreventcontamination process istoremoveanyforeignmaterials.Hot The purposeofwashing(II)aftertheboiling Reason brine toremoveallforeignmaterials. The boiledsaltedfi Washing GMP 6.1 . Thebamboobaskets usediseasy to 2. 32 1. The fi Compliance shessothatthefi Section 6 Section 5

Ù is accompaniedby thepresence ofother clean andsanitize. Ifthebambooused carried outundersanitaryconditions. quickly andsaltinginbetween thelayers are

shes areboiledbyimmersingneatly Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN shes are arranged intothebamboo Washing (II) Boiling shesarenotimmersedfor sharethenwashedinhot sh. sh. sh. . Thehotbrinewatermustbemadefrom 2. Washing(II)iscarriedoutusing hot 1. Compliance . Thepersonal hygiene ofworkers iswell 3. . Thetimeallocatedfortheboilingof 3. Theconcentration ofbrineusedcontains 2. . Thebrineisfi 1. Compliance of fi microbial growthandtopreservethetaste parameters tocontrolinorderreduce and theperiodofboilingareveryimportant sh. potable water. contaminant. brine watertominimisethepossibility hygiene practices. workers shouldcomplywithgoodpersonal maintained andmonitored accordingly. All easy toclean. to remove from thebambooorshouldbe materials, thosematerialsshouldbeeasy fi time may vary according tothesizeof fi growth andtokeep thetasteoffi 20-25% ofsalt;thisistoreduce microbial the fi shes. shes isapproximately 30 minutes. This shes inbamboobaskets are added. rst brought uptoaboilbefore sh. prolonged periodsoftime. However, thestorageshouldnotbefor under sanitaryconditionspriortodistribution. cartons andstoredatambienttemperatures Salted boiledfi Packing,storageand GMP 8.1 minimize thepossibilityoffungusgrowth. should bedrainedorcooledinorderto After boiling,thehotsaltedboiledfishes Reason conditions. ambient room temperature andsanitary is drained andcooledontheshelves under Each bamboobasket ofsaltedboiledfish Cooling GMP 7.1 deterioration inthequalityofproduct. periods oftimepriortodistributionwillcause Holding ofsaltedboiledfi Reason Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN Section 8 Section 7 Packing, Storage andDistribution Cooling shes arepackedintobamboo distribution sh forprolonged 3. Distribution vehicles should be maintained Distributionvehiclesshouldbemaintained 3. Eachbamboopackofsaltedboiledproduct 3. Workersshouldobservegoodpersonal 2. Packingandstorageshouldbecarriedout 1. Compliance Thehotsaltedboiledfi 2. Thecoolingstepiscarriedoutinan 1. Compliance in acleanandsanitarycondition. Nameandaddressofprocessor c. b. Date of production a. Species name information: should belabeledwiththefollowing hygienic practices. in acleanandenclosedareaorroom. maintained. area orroom thatiscleanandproperly fungus. to minimizethepossibilityofgrowth of sh mustbecooled

INDONESIA 34 Ù Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Lao People Democratic Republic

Product Name

Dried Fish – Pa heang

Product Description

Dried fi sh or Pa heang, as it is known locally, are produced in the following procedure. The freshwater fi shes are fi rst washed then gutted and washed again before being mixed with seasoning. The seasoned fi shes are then dried under the sun and smoked. The completed Pa heang are hung on bamboo strings and sold in the markets.

Process Flow Diagram

Receipt of raw whole fresh ﬁ sh

Washing

Gutting

Drying/Smoking

Packing

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Ù 35 LAO PEOPLE DEMOCRATIC REPUBLIC . Receipt ofWholeFish 1. 36 Outline ofProcessingSteps

Ù two hours,thefi boat forapproximatelytwohours.Inthese the TPE,fi the afternoon.Priortobeingdelivered second timeatapproximately3-4pmin at about9aminthemorningand The fi used toensureconsistencyinfi local fi Fresh fi processed withinthesameday.Thefi The fi This iceisdeliveredeveryafternoon. – producingcompanyinHuamoVillage. by theTPE.Itispurchasedfromanice The iceusedbythefi by storingtheminiceboxesandicesacks. insulated boxesuntilthenextday. purchased intheafternoonarekept Insulated boxeswithwholefi

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN shes are delivered twice a day – once shes aredeliveredtwiceaday–once shes purchasedinthemorningare shermen. Thesamesuppliersare shes arepurchaseddailyfromthe shes arekeptonthefi Figure 1 shermen keepthefi shermen is provided sh inice sh quality. sh cool shing shes 2. Washing 3. Gutting Washing thefi usually bedoneinbatches. before beingfurtherprocessed.Thisis The fi then washedincleanwater. performed manually.Theguttedfi contents areremoved.Thisstepisusually spinal fi cavities. Thefi fishes areremovedfromtheirbelly In thisstep,theinternalorgansof shes arewashedincleantapwater Gutting ofthewholefi ns totheirtailsandall gut shes arecutopen fromtheir sh withcleantapwater Figure 2 Figure 3

sh shes are Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN 4. Drying/Smoking they arereadyforselling. smoked forapproximately6-8hoursbefore fi The fi shes arearranged onabamboonetand Washing ofthefi sh isdriedbysmoking.Thegutted Gutted andwashedfi Figure 5 Figure 4 sh aftergutting

sh 5. Packing additional packagingisrequired. for saleinthetraditionalmarkets,no As thedriedﬁ Dried ﬁ Dried Fish,Pa heang Fish drying/smoking sh hungonstringforsale shes arehungonstrings Figure 8 Figure 7 Figure 6

LAO PEOPLE DEMOCRATIC REPUBLIC LAO PEOPLE DEMOCRATIC REPUBLIC GMP forDriedFish . Shipmentsoficedelivered inunsanitary 3. of contaminationtheﬁ substances. Thiswillinturnreduce possibility of contaminationwithbacteriaortoxic in amannerthatreduces thepossibility product duringprocessing mustbeproduced Ice thatcomesintodirect contactwiththe Reason water from approved sources. Ice mustbemanufactured usingfrom potable ManufactureofIce GMP 1A.2 Icecontainers musthave tightﬁ 2. Icecontainers mustbemadefrom non- 1. Compliance of contamination. unsanitary containers willbecomeasource Ice containedandtransported indirtyand Reason clean andwell-designed containers. Ice shouldbecontainedandtransported in Receipt ofIce GMP 1A.1 38 Section 1

Ù to thesupplier. containers willberejected andreturned that are notdamaged. and easy toclean. corrodible materials, whichare durable

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN Receipt ofRaw Materials nal product. nal tting covers (Pa heang) not meetspecifi documented inorder toidentify lotsthatmay is utilisedforfurtherprocessing. Records are tainted, decomposed,orunwholesome fi should beevaluated toensure thatno The incomingshipmentofraw materials Reason properly kept. quality received shouldbemaintainedand noted onreceipt. Documentedrecords onthe and quality. Theconditionoffi whole fi Every incomingshipmentofunprocessed processing. to ensure thatthey are safeandsuitablefor be evaluated fortheirorganoleptic quality red spotsundertheirskin.Thefi totally whiteonitsstomach.Spoiltfi to bedeterminedfresh, the fi to ensure thatthefi on theunderside ofthefi Before acceptingeachlotoffi Compliance M B1 ReceiptofWholeFish GMP 1B.1 Theiceusedmustbemanufactured using 1. Compliance

approved portablewater. sh shouldbeevaluated forcondition cations. shes are fresh. Inorder shes are conducted are shes shes have tobe sh shouldbe se, checks shes, shes should shes shes have sh growth isreduced. the product. At low temperatures, bacterial potable water willprevent contaminationof any foreign materials. Theuseofapproved possibility ofcontaminationby removing The purposeofwashing istominimisethe Reason supply. or icedwater from anapproved, potablewater The wholefi Washing GMP 2.1 Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN reduce spoilageofthe product. necessary toprevent contamination and The careful control oftheenvironment is Reason directly onthefl contamination. Fishesshouldnotbeplaced in acleanenvironment andprotected from The dryingby smokingshouldbe carriedout Drying/Smoking GMP 4.1 The useofapproved potablewater supplywill can beasource ofcontaminationtothefi Remaining guts, bloodandorgans bellycavity Reason belly cavity. all remnant guts, bloodandorgans from their approved, portablewater supplytoremove contents. They are thenwashed inan The fi Gutting GMP 3.1 Section 3 Section 4 Section 2 shes are guttedtoremove theirgut sh shouldbewashed usingchilled Gutting Drying/Smoking Washing oor. sh. cross-contamination. disposal ofwaste isimportanttoprevent prevent contaminationoftheproduct. Proper Washing containers ortanksshouldbe 3. Thetemperature ofthewater ismaintained 2. Thewater usedmustbefrom anapproved 1. Compliance . Waste shouldbecollectedincovered2. Theequipmentandutensilsusedshould 1. Compliance . Allutensils, containers andmaterials 2. Thedrying/smokingarea shouldbefree 1. Compliance cleaned. permits drainage. Ithastoalsobeeasily water withagoodcirculation system that designed toprovide aconstantchangeof made ofnon-corrodible materialsand addition ofice. below 5˚Cby refrigeration orwiththe potable source. and emptiedregularly. pedal-operated bins, whichare removed are easy tocleanandsanitize. be madeofnon-corrodible materialsthat maintained. used mustbeeasy tocleanandwell animals suchasdogsandcats. and otherinsectsaswell asrodents and from pestsuchas cockroaches, flies

LAO PEOPLE DEMOCRATIC REPUBLIC 40 Ù Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Malaysia

Product Name

Fish cracker – Keropok lekor

Product Description

Keropok lekor or Keropok batang is a traditional Malaysian fi sh product that is popular amongst the Malay community especially in the east coast of Peninsular Malaysia particularly in the states of Trengganu, Kelantan and Pahang. Keropok lekor is a popular snack food which has become widely accepted not only amongst the Malay community but also amongst all other races in Malaysia. Keropok lekor is a tube-shaped product and resembles sausages but is usually cut or sliced into smaller and shorter pieces. It is made of fi sh, fl our, salt and other ingredients and can be deep fried to make it crispier. It can be eaten alone or with local chilli sauce or dip.

Process Flow Diagram

Fish Flesh/ Fish Minced Meat Ingredients

Mixing

Forming

Boiling

Cooling / Drainage

Packaging

Storage In Freezer

Delivery

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Ù 41 MALAYSIA 42 Records aremaintainedforaminimumof 3. Non-conformingrawmaterialsare2. Selectionisconductedoneachbatchof 1. Compliance during thereceivingprocess. have gonethroughgoodhandlingpractices important toensurethattherawmaterials specifi and gradedtoensurethattheyconformthe meat andrawmaterialshouldbeinspected delivered shipment,thefi Therefore, inordertoensurethequalityofeach dependent onthequalityofrawmaterials. The qualityofthefi Reason recorded neatlyandorderly. material qualityassurancerecordsshouldbe suppliers withqualityguarantee.Allraw materials areorderedonlyfromregistered fi raw materialsreceived,eachshipmentof To ensurethequalityandsafetyof ReceiptofRaw GMP 1.1 GMP forFishCracker s fl sh Section 1

Ù ) Percentage ofnon-conformingraw i) h) Quality of load/shipment. Averagetemperatureofrawmaterial g) NameofDeliveryCompany. f) Nameandaddressofsupplier e) d) Delivery date Natureofrawmaterial c) b) Date of catch a) Species of ﬁ the followinginformation: three (3)years.Therecordsshouldcontain rejected. raw materialreceived.

esh/fi cations. Theinspectionprocessisalso Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN material, whichhavebeen rejected. received sh mincedmeatandotherraw Raw Materials Materials sh nal productisheavily sh fl esh/fi sh minced (keropok lekor) monitored. properly andthetemperaturesshouldbe The freezerorchillermustbefunctioning as handlingmediumsfortherawmaterials. Stainless steeltraysandHDPEboxesareused quality andtominimizethegrowthofbacteria. at suitabletemperaturestomaintaintheir Wet rawmaterialsreceivedshouldbestored Reason not exceeding5˚C. while chilledrawmaterialsattemperatures stored attemperaturesnotexceeding-18˚C raw materialssuchasfishfleshmustbe adhere togoodhandlingpractices.Frozen stored insuitableconditionsorderto All wetrawmaterialsreceivedshouldbe StorageofWet Raw GMP 1.2 and alsotoavoidcross contamination. temperature toprevent them fromspoilage etc. mustbekeptinaspecial storeatambient bicarbonate, monosodiumglutamate(MSG) Dry rawmaterialslikefl StorageofDryRaw GMP 1.3 Thetemperatureoftherawmaterialsis 3. Theequipmentusedinthehandling 2. Therawmaterialsreceivedthatarenot 1. Compliance 5˚C (chilled)or-18˚C(frozen). maintained attemperaturesnotexceeding contamination. of therawmaterialsisfreefrom pending usage. used immediatelyarestoredproperly Materials Materials our, salt, sugar, sodium our, salt,sugar,sodium Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN Themixingprocess isdoneaccordingto 1. Compliance similar processes. all theproductsproducedaremadethrough formula arebeingadheredtoensurethat Standard operatingproceduresanddesignated it canbeeasilywashedandisrustresistant. quality andsafeproductsisstainlesssteelas The bestmaterialtouseintheproductionof Reason to thedesignatedformula. The mixingprocessshouldbedoneaccording that hasbeenapprovedbythegovernment. through arinsingprocessusingpotablewater the cleaningprocess,machinemustgo clean itusingapprovedchemicals.After Before usingthemachine,itisessentialto process ismadeentirelyofstainlesssteel. The mixingmachineusedduringthe Mixing GMP 2.1 Theequipmentusedinthehandlingofraw 2. Therawmaterialsreceivedthatarenot 1. Compliance HDPE pallets. be keptinfunctioningordercompletewith kept inacleanstore.Thestoremustalso mediums. Thedryrawmaterialsshouldbe HDPE containersareusedashandling temperature tomaintaintheirquality.Airtight Dry rawmaterialsshouldbestoredatambient Reason Section 2 the designatedformula. materials isfreefromcontamination. pending usage. used immediatelyarestoredproperly Processing(Mixing,Forming,Boiling,Cooling/Drainage) . Rawmaterialswiththeclosestexpirydate 1. Compliance beyond theirexpirydate. it canalsopreventtheusageofrawmaterials material usageisinorder.Inadditiontothat, The FIFOprinciplecanhelpensurethatraw Reason be applied. the FirstInOut(FIFO)principleshould When usingdryrawmaterialsinthestore, UsageofRaw GMP 1.4 in thefullyautomaticprocess, aconveyor- machine isusedtoform thedough.Finally, hands. Inthesemi-auto method,ablender should bedoneonstainless steeltablesusing The manualprocessof formingthedough gloves. to that,theymustalsowearnon-toxicrubber their handsusingbactericidalsoap.Inaddition involved intheformingprocessmustwash before andafterused.Workerswhoare made ofstainlesssteelandmustbecleaned involved intheformingprocessshouldbe operating equipment.Allequipmentthatis methods dependingontheavailabilityof using manual,semi-autoorfullyautomatic The formingprocessshouldbedoneeither Forming GMP 2.2 . Thesourceofwaterandiceusedis 3. Themachine/equipmentiscleanedbefore 2. . Properandaccurateinventories 2. are usedfi by thegovernment. approved assafeforhumanconsumption and afterthemixingprocess. records ofrawmaterialusagearekept. rst. Materials

MALAYSIA MALAYSIA quality. the watermustbechangedtoensure is 30minutes.Aftercompletingeachbatch, recommended boilingtimeforeachbatch be recordedatsuitablefrequencies.The by thegovernment.Watertemperaturemust using potablewaterthathasbeenapproved from stainlesssteel.Thisprocessmustbedone all times.Theboilermachinemustbemade water thatmustbemaintainedat100˚C The boilingprocessshouldbedoneusing Boiling GMP 2.3 Workers whoareinvolvedintheforming 3. Cleaning isdoneaftercompletingevery 2. Theformingprocessisdoneusingthe 1. Compliance also followgoodpersonalhygiene. contamination. Inadditiontothat,theymust and wearrubberglovestoavoidcross the manualprocessmustwashtheirhands easy toclean.Workerswhoareinvolvedin Stainless steelmachinesarerust-resistantand Reason is arrangedonstainlesssteeltrays. process. Aftertheformingprocess,dough forming machineisusedinthe 44

Ù processing procedure. gloves eachtimetheyproceedtoadifferent process washtheirhandsandchange load. method. manual, semi-automaticorfullyautomatic

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN must observegoodhygienicpractices. separated fromtheotherrooms.Allworkers Cooling/Drainage roommustbeclosedand at roomtemperatureorbyusingfan.The method allowsthedoughtocoolbyitself out onastainlesssteeldrainagetable.This The cooling/drainageprocesscanbecarried Cooling/Drainage GMP 2.4 Boilingiscarriedoutat100˚Cforleast 1. Compliance that hasbeenformed. be absorbedintothemiddlepartofdough each batchis30minutessothattheheatcan spoilage. Therecommendedboilingtimefor of thedoughbindingthuspreventingeasy This processcanalsoincreasethestrength 100˚C toensurethatthebacteriaiseliminated. water temperaturemustbemaintainedat easy toclean.Duringtheboilingprocess, Stainless steelmachinesarerust-resistantand Reason . Stainlesssteeltable(s) andglovesare 2. The process iscarriedoutasquickly 1. Compliance products. without causinganydamagetothefi the excessboilingwatercanfl of usingadrainagetableistoensurethat resistant andeasytoclean.Thepurpose The stainlesssteeldrainagetableisrust- Reason 30 minutes. used. possible inacleanroom. o smoothly ow nished Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN Productsshouldnotbeleftintheopen 1. Compliance practices. by temperatureabuseorimproperhandling cross contaminationandproductdeterioration Proper handlingduringdeliverywillprevent Reason during delivery. Finished productsshouldbehandledproperly Delivery GMP 5.1 and tolengthenitsshelflife. or frozentoensurethequalityofproduct Finished productsshouldbestored,chilled Reason or frozen. Finished productsshouldbestored,chilled Storage GMP 4.1 product. of productsandtoextendtheshelf-life packaging isessentialtoensurethequality products topreventcrosscontamination.Good room fromrawmaterialsandsemi-processed Packing shouldbecarriedoutinaseparate Reason the product information onthestorageandhandlingof the labellingonpackagingmustprovide after thecooling/drainage.Inadditiontothat, Packing ofproductsshouldbedoneimmediately Packing GMP 3.1 Section 5 Section 3 Section 4 Delivery Packing Storage 2. Frozen products are stored at temperatures Frozenproductsarestoredattemperatures 2. Chilledproductsarestoredattemperatures 1. Compliance 4. Temperature recorders should be available Temperaturerecordersshould beavailable 4. Frozenproductsshouldbetransported 3. Chilled productsshouldbetransportedin 2. 4. 3. 2. Packingoffi 1. Compliance not exceeding-18˚C. not exceeding5˚C. on alldeliveryvehicles. exceeding -18˚C. in freezervehiclesattemperaturesnot exceeding 5˚C. refrigerated vehiclesattemperaturesnot should beleftinthecoldante-room. periods duringloading/delivery.They at ambienttemperaturesforprolonged contamination andmicrobialgrowth. delay tominimizeanypossibilityofcross- carried outquicklyandwithminimal always beused. New, cleanpackagingmaterialsshould products. masks andhandglovestopackthefi uniforms, disposableheadcovers,facial Staff shouldbeproperlyattiredwithclean steel tables. Products shouldbepackedonstainless nished productsshouldbe nished nished

MALAYSIA 46 Ù Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Myanmar

Product Name

Fermented ﬁ sh – Ngachin

Product Description

Fermented fi sh or Ngachin, as it is called locally, is a traditional fermented fi sh product of Myanmar. The main raw materials for Ngachin are fi sh, salt and rice. This product is produced through the salting and fermentation of the fi sh. At room temperature, Ngachin has a shelf life of about a week. However, if it is refrigerated, its shelf life can be extended up to a month. Ngachin is considered a delicacy in Myanmar and when it is ripened it has a sour taste.

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Ù 47 MYANMAR Process FlowDiagram Fermentation (3days) Storage Labelling Packing withPlasticSheet & Distribution Packing MixingwithSaltand toremove water) (cylindrical with Forming/Shaping (Pressing withstoneweight Cooked shape) Rice De-watering Grinding/Mincing Filleting Dressing Receipt Packaging Washing of Materials Receipt ofWholeFish Receipt ofSaltandRice 48

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN Taung son leaf Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN . Receipt ofRaw Materials 1. Outline ofProcessingSteps . Washing, Dressing andFilletingof2. . Receipt ofpackaging materials d. Receipt ofRice c. Receipt ofSalt b. Receipt ofFish a. fi then guttedandtheirscalesremoved.The with waterandde-headed.Thefi The wholefi Fish shes arethenfi they are cleanandnotdamaged. recorded andchecked toensure that Every lotofpackaging material is undamaged. rice mustalsobeclean,intactand its qualityandgrade. Packaging ofthe documents orcertifi and checked fortheappropriate Each batchofricereceived isrecorded also beclean,intactandundamaged. and grade. Packaging ofthe saltmust or certifi checked fortheappropriate documents Every lotofsaltreceived isrecorded and safe andofgoodquality. parameters toensure thatthey are and evaluated fororganoleptic Every lotoffi cates attestingtoitsquality shes arewashedthoroughly lleted. sh received isrecorded cts tetn to attesting cates shes are shes 4. De-watering 3. Grinding/Mincing De-watering ofground/minced fi a screwpress. hour todrainoffexcesswaterorbyusing (stone) ontoptopressitforhalfan out eitherbyplacingaheavyweight in acleanclothandde-wateringiscarried The ground/mincedfi fi grinder/mincer toproduceground/minced The fishfilletsarepassedthrougha sh meat sh Grinding/Mincing offi using screw press Figure 1 Figure 2 shmeatiswrapped sh fi sh llets sh meat sh

MYANMAR MYANMAR 50 6. Forming/Shaping MixingwithSaltandCooked Rice 5.

Ù into acylindricalshape. The fi required. note thatifthefi meat iskneadbyhand.Itimportantto Normally, 1-1.5%ofsaltisaddedandthe used, thelowerqualityofproduct. required. Thehighertheproportionofrice of thefi with cookedriceintherangeof35-65% The ground/mincedfi

Mixing withSaltandCookedRice Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN Forming intocylindericalshape sh andricemixtureisthenformed sh weightaccordingtothequality Figure 3 Figure 4 sh isfresh,lesssalt sh meatismixed

8. Fermentation . Packing andLabeling 7. insects. protecting theproductsfromfliesand a periodof3daysintheshade,while The packedproductsarefermentedover (preferably of Products arepackedingreenleaves and labels. before beingwrappedwithplasticsheets sugar cane)andtiedwithbamboosstrips Wrap inplasticsheetsandlabels Packing inTaung-son leaves Figure 5 Figure 6 Taung-son orbanana Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN provide thedesired protection tothesaltand fi Contaminated saltcanaffect thequalityof Reason must alsobeintactandundamaged. in theprocessing plant.Packaging ofthesalt is safeandofgoodqualityacceptedforuse for every batchof saltdelivered. Onlysaltthat The saltsuppliershouldprovide acertifi ReceiptofSalt GMP 1B.1 Thefollowing detailsare recorded and 2. Any lotoffi 1. Compliance fails tomeetspecifi identify specifi used forprocessing. Records shouldbekept to decomposed orunwholesome fi should beevaluated toensure thattainted, The conditionandqualityofthefishes Reason properly. the fi and records ontheconditionandqualityof be evaluated onreceipt. Documentation The conditionandqualityofthefi ReceiptofFish GMP 1A.1 GMP forFermentedFish(Nga-chin) nished product. Damagedpackaging willnot Section 1 • Quality ofthefi harvest of • Date • Name ofdelivery vessel oftransport • Name andaddress ofsupplier • Date ofreceipt ofshipment name • Species kept forfuture reference: or unwholesome shouldberejected. shes shouldbemaintainedandstored company Receipt ofRaw Materials c lotsincasethefi sh thatistainted,decomposed cations. sh shes are not are shes shes should nal product nal cation cation . Packaging labelsshouldcontainthe3. Saltinbadlydamagedpackaging and 2. Onlyfoodgrade saltwithappropriate 1. Compliance ingredient isused. of thesaltthusensuringthatcorrect have clearlabelstohelpintheidentifi extraneous materials. Thepackaging should organisms, insects, chemicalsandforeign may leadtocontaminationfrom by micro- . Saltmustbeusedonafi 2. Aninsect free cleananddryroom must 1. Compliance chemicals andforeign materials. in contaminationby microorganisms, insects, Storage ofsaltinanopenarea mightresult Reason specifi be stored inaneatandtidymanner come intocontactwiththefl During storage, thebagsofsaltshouldnot StorageofSalt GMP 1B.2 • Expiry Date • Expiry Manufacturer of • Name Ingredient of • Name following information: in theprocessing. without proper labelingshouldnotbeused used certification shouldbeacceptedand date. (FIFO) basisbefore they reach theirexpiry be provided forthestorage ofsalt. cally assignedcleananddryroom. oor. They should rst in-fi rst out rst cation

MYANMAR MYANMAR . Riceinbadlydamagedpackaging and 2. Riceshouldbeofgoodqualityand 1. Compliance quality andsafetyofthefi product, contaminatedricecanaffectthe As riceisanimportantingredient forthis Reason must alsobeintactandundamaged. in theprocessing plant.Packaging oftherice is safeandofgoodqualityacceptedforuse for every batchofricedelivered. Onlyricethat The ricesuppliershouldprovide acertifi ReceiptofRice GMP 1C.1 52 process. Cleanandsuitablecontainers should contamination ofthefi water sources shouldbeusedtoprevent any from thesurfacesoffi the microbial andphysical contamination The purposeofwashing thefi Reason running water. The fi Washing ofFish GMP 2.1

Section 2

Ù used. without proper labelingshouldnotbe be free from allpesticideresidues. sh shouldbewashed inclean,potable

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN Washing, Dressing andFilletingofFish shes from thewashing shes. Only approved nished product. nished shes istoremove cation cation

2. Damagedanddirtypackaging materials 1. Compliance contamination totheproduct. contamination andmay beasource of are unabletoprotect thefoodagainst Damaged anddirtypackaging materials Reason be rejected. materials (especially All damagedanddirty(moldy)packaging Receiptofpackaging GMP 1D.1 and chlorination. treatment process shouldinvolve fi is beingusedtocleanthefi adequately treated andsanitizedbefore it ground orwell water isused,itshouldbe The water usedshouldbepotablewater. If Compliance the fi also beusedtominimizecontaminationof sanitized before use. Taung-son should notbeused. shes. leaves shouldbewashed and materials Taung-son shes. Thewater leaves) should ltration Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN the products. may becomeasource ofcontaminationto Dirty and/orpoorlymaintainedequipment Reason maintained. process shouldbekept cleanandwell The equipmentusedinthegrinding/mincing Grinding/Mincing GMP 3.1 help control thegrowth ofmicroorganisms. clean containers toprevent contaminationand Mixing shouldbecarriedouthygienically in Reason and sanitarymanner. be carriedoutincleancontainers inahygienic Mixing ofthefi MixingwithSaltand GMP 5.1 the products. may becomeasource ofcontaminationto Dirty and/orpoorlymaintainedequipment Reason shall bekept cleanandwell maintained. The equipmentusedinthede-watering process De-watering GMP 4.1 Section 5 Section 4 Section 3 MixingwithSaltandCooked Rice De-watering Grinding/Mincing Cooked Rice sh meat,saltandriceshould 2. The food-contact surfaces of the equipment Thefood-contactsurfacesoftheequipment 2. Theequipmentmustbethoroughly washed 1. Compliance Thefood-contact surfacesoftheequipment 2. Theequipmentmustbethoroughly washed 1. Compliance . Utensilsandcontainers usedmustbe 3. Utensilsandcontainers usedformixing 2. Allworkers mustobserve goodpersonal 1. Compliance smooth andfree from crevices. way. Thefoodcontactsurfacesmustbe should notbecorroded ordamagedinany must bemadeofnon-toxic materialsand day andasoftennecessary. and sanitizedattheendofeachprocessing smooth andfree from crevices. way. Thefoodcontactsurfacesmustbe should notbecorroded ordamagedinany must bemadeofnon-toxic materialsand day andasoftennecessary. and sanitizedattheendofeachprocessing free from corrosion. constructed from foodgrade materialsand use. must beproperly sanitizedbefore andafter hygiene practices.

MYANMAR MYANMAR product anddeterioration inproduct quality. necessary toprevent contaminationofthe The careful control oftheenvironment is Reason directly ontheﬂ from contamination.Itshouldnotbeplaced ferment inacleanenvironment andprotected The packaged product shouldbeallowed to Fermentation GMP 8.1 54 packaging materialsare unabletoprotect the contaminate theproduct. Damaged anddirty Dirty anduncleanpackaging materialsmay Reason hygienic andsanitarymanner. Taung-son Packing shouldbecarriedoutwithclean Packingwith GMP 7.1 of microorganisms. contamination andhelpcontrol thegrowth hygienically incleancontainers toprevent Forming/shaping shouldbecarried out Reason manner. clean containers inahygienic andsanitary Forming/shaping shouldbecarried outin Forming/Shaping GMP 6.1 Section 6 Section 8 Section 7

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN leaves andplasticsheetsina Forming/Shaping Fermentation Packing andLabeling sheets son oor. leavesandplastic Taung- Compliance source ofcontaminationtotheproduct. food againstcontaminationandmay bea . Allutensilsandcontainers usedmustbe 2. Theprocessing area shouldbefree from 1. Compliance Allworkers mustobserve goodpersonal 3. 2. Onlycleanandundamagedpackaging 1. . Utensilsandcontainers usedmustbe 3. Utensilsandcontainers usedformixing 2. Allworkers mustobserve goodpersonal 1. Compliance

clean andoffoodgrade. such asdogsandcats. insects aswell asrodents andanimals pest suchascockroaches, fl hygiene practices. sanitized before use. Taung-son materials shouldbeused. free from corrosion. constructed from foodgrade materialsand use. must beproperly sanitizedbefore andafter hygiene practices. leaves shouldbewashed and ies andother Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN Process FlowDiagram It isusedliberally innearlyallMyanmar dishessuchasinfi mixed withfresh-cut ordriedchilliandisoneofthebasicingredients inMyanmar cooking. shelf lifeof months toayear andthefi is madefrom amixture offi Fish sauceisoneofthetraditional fi Product Description Fish sauce– Product Name Ngan pyaye Ngan pyaye atroom temperature isaboutsixweeks. Itisconsumedas a condiment nal product hasarichtranslucent reddish-golden brown color. The sh andsaltthathasbeenallowed tofermentover aperiodofsix Fermentation inconcrete tanks Mixing fi Sun-drying inearthenjars sh products ofMyanmar. Itslocalnameis Bottling &Capping (3-6 months) (1-2 weeks) sh andsalt(3/4:1) Labeling sh/poultry curriesandsalads. Ngan pyaye

. It 55

MYANMAR MYANMAR 56 . MixingofFishandSalt 1. Outline ofProcessingSteps Mixture ofﬁ

Ù fi to weighdownthefi Bags ofsaltareplacedoverthefi of salt,andtoppedwithalayersalt. tank linedonthebottomwithalayer days beforetheyarefi of saltbyweightandleftforonetotwo four partsoffi usually cutintosmallerpieces.Threeto fi materials infishsauceproduction.If length arecommonlyusedastheraw Small marinefi fermentation processoccurs. fl shes from fl uids withinthemareextractedandthe shes oflargersizesareused,they

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN tank withbagsofsalton top Mixing offi sh andsaltplacedinconcrete oating to thesurfaceas sh aremixedwithonepart Figure 1 Figure 2 shes of2to5inchesin sh andsalt shes andtokeepthe lled intoaconcrete sh pile sh 2. Fermentation 3. Sun-drying Fermentation process from 6–12months to theupperlayerandmixedwell. from thebottomoftankaresiphoned pleasant aromaoffi months, themixturestartstodevelop for aboutsixmonthstoayear.Afterthree Natural fermentationisallowedtooccur in asunnylocationforonetotwoweeks. into cleanearthenjars,coveredandleft out. Thefi of fishremainsbeforebeingsiphoned for thefi the bottomoftank.Thisistoallow preferably bydrainingthroughaspigoton sauce) isremovedfromtheconcretetank After afurthersixmonths,theliquid(fi Sun-drying inearthenjars sh saucetopassthroughlayers ltered fi ltered Figure 3 Figure 4 sh sauceisthenfi sh sauce,theliquid lled sh

Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN product, itisimportanttoensure thatonly To ensure thequalityandsafetyof the Reason - shouldbechecked anddocumented. incoming lotofraw materials–fi The qualityandsafetyparameters ofeach Rawmaterials–Fish GMP 1.1 GMP forFishsauce( Section 1 sauce toripen. fi of weeksinordertodissipatethestrong sauce toairoutinthesunforacouple direct sunlight.Thisprocessallowsthefi allow forthefi From timetotime,theyareuncovered sh odors. Thisalsoallowsforthefi Fish sauce-Nganpyaye MixingofFishandSalt and Salt sh saucetobeexposed Figure 5 sh and salt and sh ngan pyaye sh sh sh . Bottling,CappingandLabeling 4. . Fishshouldbeevaluated forfreshness and 1. Compliance temperature abuse. histamine contentduetopoorhandlingand Fish shouldbefresh inorder toprevent high good qualityandsaferaw materialsare used. carried outmanually. Bottling, cappingandlabelingisusually or decomposed. histamine content.Fishshould notbestale ) Labeling offi Bottling offi Figure 6 Figure 7 sh sauce sh sh sauce sh

MYANMAR MYANMAR fi prevent contaminationandspoilageofthe of hygiene andenvironment isnecessaryto (from 6monthstoayear), thecareful control As thefermentationprocess isreasonably long Reason hygienic mannerandenvironment. Fermentation should becarriedoutinaclean, Fermentation GMP 2.1 . Saltusedshouldbecleanandcertifi 4. 58 prevent microbial contamination.Theamount Mixing shouldbecarriedouthygienically to Reason amount ofsaltshouldbeused. in aclean,hygienic mannerandadequate The mixingoffi Mixing GMP 1.2 Fishcontainers andallutensilsshouldbe 3. Fishshouldbeadequatelyicedorsalted 2. sh sauce. sh Section 2

Ù and notrusty. and undamagedpackaging. food grade. Itshouldbeinclean, intact made ofnon-corrodible materials, upon arrival.

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN Fermentation sh andsaltshouldbedone

ed as ed clean

. Utensilsandcontainers usedmustbe 4. Utensilsandcontainers usedformixing 3. Mixingshouldbecarriedoutinacleanand 2. Notmore thanfourpartsoffi 1. Compliance during thefermentationprocess. growth ofpathogenicandspoilagebacteria of saltusedmustbesufficienttocontrol . Allutensils, containers andequipment used 3. Thefermentationcontainers/tanks should 2. Theprocessing area shouldbeprotected 1. Compliance free from corrosion. constructed from foodgrade materialsand before andafteruse. must beproperly washed andsanitized and cats. well asrodents andanimalssuchasdogs as cockroaches, fl hygienic environment free from pestssuch part ofsaltshouldbeused. damage. any rust,cracks orcrevices orany other degree ofsaltandwell maintainedwithout materials capableoftolerating ahigh must beclean,madeofnon-corrodible and afteruse. be washed andsanitizedproperly before and animalssuchasdogscats. fl and free from pestssuchascockroaches, ies andotherinsectsaswell asrodents ies andotherinsectsas s t one to sh Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN will alsoresult inproduct contamination fi is necessarytoprevent contaminationofthe the careful control ofhygiene andsanitation As theseprocesses are carriedoutmanually, Reason environment. carried outinaclean,hygienic mannerand Bottling, cappingandlabelingshouldbe Bottling,Cappingand GMP 4.1 fi is necessarytoprevent contaminationofthe careful control ofhygiene andenvironment As thisprocess occurs outintheopen, Reason hygienic mannerandenvironment. Sun-drying shouldbecarriedoutinaclean, Sun-drying GMP 3.1 sh sauce. Theuseofuncleanbottlesandcaps sh sauce. sh Section 3 Section 4 Sun-drying Bottling,CappingandLabeling Labeling . Theprocessing area shouldbeprotected 3. Allworkers mustobserve goodpersonal 2. Allbottlesandcapsmustbewashed and 1. Compliance . Theearthenjars must have proper, tight- 2. Theprocessing area shouldbeprotected 1. Compliance and animalssuchasdogscats. fl and free from pestssuchascockroaches, covers. disposable gloves, facemasksandhair hygiene practices andproperly attired with sanitized properly justbefore use. fi and animalssuchasdogscats. fl and free from pestssuchascockroaches, materials pests, rain, dirt,dustandotherextraneous ies andotherinsectsaswell asrodents tting lidstoprotect thefi ies andotherinsectsaswell asrodents sh sauce from sauce sh

MYANMAR 60 Ù Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Philippines

Product Name

Shrimp sauce – Alamang

Product Description

Shrimp sauce or Alamang, as it is locally called, is a condiment that is widely used in Filipino cuisine. It gives Filipino food its own unique character and rich taste. Alamang is made from from the tiny shrimp Acetes spp. and is the salty ﬂ avouring that has become one of the most popular traditional products of the Philippines. During the months of abundance in catch (May and September), fresh tiny shrimps are salted and allowed to ferment for a period of one and a half months to a year. After fermentation, the ﬁ shes are pressed to extract the sauce. They are then cooked and sieved to produce a clear and richly aromatic shrimp sauce.

Currently, Alamang is still prepared in its traditional way that is predominantly manual with the use of some equipment/utensils. Most of the shrimp sauce are consumed locally though some are exported heavily to overseas Filipino communities.

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Ù 61 PHILIPPINES 62 Process FlowDiagram

Ù Packaging Materials

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN Receipt of Cleaning /Removing of Foreign Materials Raw Materials Distribution 2 Fermenting 1 2 1 Receipt of nd st nd Pressing st Packing Storing Cooking Salting Cooking Sieving Sieving Receipt ofSalt Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN . Receipt ofRaw MaterialsandPackaging 1. Outline OfProcessingSteps 3. Mixing 2. Cleaning . Receipt ofsalt c. b. Receipt of Receipt ofpackaging materials a. Materials spoilage, cleaningisdonewithoutdelay. To reducechancesofcontaminationand materials suchasstones,leavesandwood. Fresh processing of Only fresh ﬁ ensure goodqualityandsafetyinthe production of the fermentationof Only foodgradesaltsareusedfor until they are ready fordistribution. are stored inthecardboard cartons sauce. Thesebottlesofshrimpsauce are usedtocontainthebottlesofshrimp poured intoandcardboard cartonsthat bottles where theshrimpsauceare packing ofshrimpsauceincludeclean The packaging materialsusedinthe nished product. nished Acetes Mixing Acetes withsalt Acetes are sorted to remove all foreign aresortedtoremoveallforeign andSalt Acetes Acetes Figure 1 Alamang Alamang shrimps areusedinthe Acetes . . Thisisto inthe

0 1-3 3 12 4. Fermentation 50 2 3 ½ - 50 2 1 8 3 50 ½ ½

(io) glo) (gallon) (month) (kilos) uniyo muto Durationof Amountof Quantity of on Table1. the quantityparametersarelistedbelow producers andcommercialestablishments, with differentprocessors, household stage. Astheamountofsaltaddedvaries and preparethemforthefermentation and fermentationprocedures. year, dependingondifferentprocessors stretch fromoneandahalfmonthsto aroma. Thefermentationdurationcan it developsacharacteristicﬂ Acetes in earthenjarsorplasticcontainers.The The fermentationof to fermentationhelppreservethe The mixingofsaltwith Acetes Fermentation inplasticcontainers isstoredatroomtemperatureuntil sl Fermentation salt Figure 2 Table 1 Acetes Acetes iscarriedout is done prior isdoneprior aor and avour Acetes

PHILIPPINES PHILIPPINES 64 5. Extraction

Ù traditional product-shrimppaste. solid residueisincorporatedintoanother equipment. Aftertheextractionisdone, by handorwiththeuseofimprovised shrimp sauce.Thepressingcanbedone fermented mixtureispressedtoextractthe After fermentationiscompleted,the Pressing withimprovised equipment

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN Pressing byhand Figure 3 Figure 4 7. 1 6. 1 fl is usedbymanyasanothertraditional solid particle,isnotawasteproduct.It the clearsaucefrom using averyfi The cookedshrimpsauceisthensieved vats. The cookingisdoneinearthen under moderatefi The extractedshrimpsauceiscooked avouring orcondiment. st st Sieving Cooking Earthen cookingvat Alamang sauce ne whitecloth,toseparate Figure 5 Figure 6 re for two to three hours. re fortwotothreehours. hecko . Hecko , afi ne Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN 8. 2 9. 2 for packing. produce averyclearshrimpsauceready The shrimpsauceisthensievedagainto crystals appearatthesurface. slow fi The sievedsauceiscookedagainunder nd nd Sieving Cooking Sieving withfi re forseveralhoursuntilwhite salt Figure 8 Figure 7 Hecko ne white cloth 11. Storage 10. Packing/Bottling direct exposuretosunand intenseheat. distribution. Goodsarekeptawayfrom temperature incappedbottlesbefore Finished goodsarestoredatroom by hand. Shrimp sauceispackedintocleanbottles Finished product–Alamang Bottling ofshrimpsauce Figure 10 Figure 9

PHILIPPINES PHILIPPINES . Records ofevery batchofpackaging3. Packaging materials thatdonotmeet 2. Onlycleanandundamagedpackaging 1. Compliance from anysourceofcontamination. properly containingandprotectingtheproduct specifi packaging materialsthatdonotmeetthestated can beasourceofcontaminationwhile Damaged anddirtypackagingmaterials Reason fi and otherunwantedcharacteristicstothe materials shouldnotpassonanyodour,taste specifi packaging materialsthatdonotmeetthestated such asbottlesandcapswellother Damaged anddirtypackagingmaterials ReceiptofPackaging GMP 1A.1 GMP forShrimpSauce 66 12. Distribution nal product. nal Section 1

Ù for reference. materials received shouldbeﬁ rejected. the required specificationsshouldbe processing establishment. materials shouldbeallowed toenterthe twenty-four bottlesoffishsauce.A packed intocartons.Eachcartoncontains The bottlesofshrimpsaucearethen

cations maynotservetheirpurposein cations shouldberejected.Packaging Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN Receipt ofRaw MaterialsandPackaging Materials Materials led andkept (Alamang) Reason materials. be removed before storingthepackaging storage room. Dirtyoutercovering should be stored immediatelyinacleandesignated Upon reception, packaging materialsshould StorageofPackaging GMP 1A.2 3. 2. Packaging materialsshouldbeimmediately 1. Compliance product. which inturnmay contaminatethefi contaminants tothepackaging materials To prevent any possibilityofintroducing market. is soldat35Philippinespesointhelocal approximately 360mlofshrimpsauce.It bottle ofshrimpsaucetypicallycontains of contamination. possible pestinfestationandothersources be cleanedregularly andmonitored for easy cleaningandmonitoring. They should Storage rooms shouldbedesignedtoallow will beuseinafi be indicatedsothatpackaging materials observed andthedateofreceipt should packaging. Proper labellingshould be shelves tostore thedifferent typesof A storage room shouldbeprovided with stored inacleandesignatedroom. Materials rst-in-fi rst-out basis. rst-out nished Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN safety andqualityofthefi Any contaminationtothesaltcanaffect Reason cleaning agents, pesticidesandinsecticides. plant. Thesesources ofcontaminationinclude of contaminationthatmay bepresent inthe room shouldbeprotected from allsources a designatedcleanstorage room. Thestorage Immediately afterreceipt, the saltisstored in StorageofSalt GMP 1B.2 Records forevery batchofsaltreceived 3. Saltshouldbecontainedincleanandfood 2. Every batchofsaltreceived inthe1. Compliance fi of saltwillaffectthequalityandsafety shrimp sauce. Therefore, any contamination Salt isamajoringredient intheproduction of Reason grade packaging materials. Salt shouldbecontainedincleanandfood matter andpurity. terms ofmicrobial load,beingfree offoreign to meetsthesafetyrequirements forsaltin processing establishmentshouldbecertifi Every batchofsaltthatisreceived inthe ReceiptofSalt GMP 1B.1 nished product. nished in casesafetyconcernsarises. should befi grade packaging materials. certifi should beaccompaniedby necessary with thesetspecifi processing establishmentshouldcomply cation. led andkept fortraceability cations forsaltand nished product. nished ed establishment. before they are acceptedintotheprocessing the qualitycriteriasetby themanagement upon receipt. Shrimpsshouldalsopass contained incleanandappropriate containers and usedforprocessing. They should be Only very fresh shrimpsshouldbereceived Receiptof GMP 1C.1 Saltshouldbeproperly labelledandthe 3. Thestorage room shouldbedesignedto 2. Saltshouldbestored inacleandesignated 1. Compliance . Very minimal delays shouldbepermittedto 3. Shrimpsshould becontainedinclean, 2. Onlyvery fresh shrimpsshouldbeused 1. Compliance unsafe forhumanconsumption. inferior qualityfi Shrimps thatarenotfreshwillproducean Reason to adhere to thefi date ofreceipt shouldbeproperly indicated possible contamination. for possiblepestinfestationsandany other should becleanedregularly andmonitored allow foreasy cleaningandmonitoring.It storage room. time ofreceipt tostartofprocessing. ensure aquickandsmoothtransition from food grade containers. in production ofshrimpsauce. in theusingofsalt. Shrimps nished productthatmaybe rst-in-fi rst-out principle rst-out Acetes

PHILIPPINES PHILIPPINES Any delays can cause irreversible deterioration Any delayscancauseirreversibledeterioration Reason appropriate materials. a cleandesignatedareausingand unnecessary delays.Itshouldbedonein should bedoneassoonpossible,avoiding Cleaning/removing offoreignmaterials Cleaning GMP 2.1 68 and well-ventilatedroom toavoidany Fermentation shouldbe doneinaclean reactions andcontamination oftheproduct. grade andnon-corrodibletoavoidpossible hence itisamustthattheyshouldbefood with theproductforlongperiodsoftime Fermentation containersareindirectcontact Reason room. be carriedoutinacleanandwell-ventilated and non-corrodiblefermentationshould Fermentation containersshouldbefoodgrade Fermentation GMP 4.1 any corrodedpartsofthecontainermaybe safety ofthefinishedproduct.Similarly, Contaminated saltcanaffectthequalityand Reason container. done usingafoodgradeandnon-corrodible be used.Thesaltingprocedureshould Only saltwithpropercertificationshould Mixing GMP 3.1 Section 4 Section 3 Section 2

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN Fermentation Mixing Cleaning Acetes Acetes andSalt andSalt 2. Containers andutensilsusedfor Compliance consumers. may poseasaserioushealththreattothe incorporated intothefi Onlyclean, foodgrade andinertcleaning 2. Cleaning/removing offoreign material 1. Compliance a majorsourceofcontamination. and non-compliantcleaningmaterialscanbe to thequalityofrawmaterials.Unclean . Fermentation rooms shouldbechecked 3. Fermentation shouldbecarriedoutina 2. Fermentation containers shouldbemade 1. Compliance contamination maycauseproductspoilage. forms ofcontaminationthatmayoccur.The Onlysaltwithpropercertifi 1. corrodible. salting shouldbefoodgrade andnon- be usedinprocessing. materials shouldbeuse. should beaccomplishedimmediately. regularly forany possiblecontaminants. clean andwell-ventilated room. salt concentrations. materials thatcantolerate exposure tohigh corrodible. They shouldalsobemadeof from food-grade materialsandbenon- nished product. This product. nished cation should cation Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN available tocontainthefi Clean andfoodgradecontainersshouldbe be usedforanyotherpurposesbesidessieving. be usedinthisprocess.Theclothsshouldnot unnecessary delays.Onlycleanclothsshould Sieving shouldbedonewithoutany 1 GMP 7.1 is properlycookedtopreventspoilage. controlled inordertoensurethatthesauce Time andtemperatureshouldbeproperly Reason vats. be doneusingclean,wellmaintainedcooking monitoring oftimeandtemperature.Itshould Cooking shouldbecarriedoutwithproper 1 GMP 6.1 be observed. proper personnelhygienepracticesshould hand pressingisemployed.Insuchcases, absence ofpressingequipment,manual clean andfi Improvised pressingequipmentshouldbe Extraction GMP 5.1 Section 6 Section 5 Section 7 t fortheirintendeduse.Inthe 1 Extraction 1 st st st st Sieving Cooking Cooking Sieving ltrate. contamination. well maintainedtoavoid any possible Cooking vats shouldbecleanand Proper personnel hygiene practices should 2. Pressing equipmentusedshouldbeclean 1. Compliance of thefi product thatcanaffectthequalityandsafety To preventanypossiblecontaminationofthe Reason . Nodelays should be allowed. 2. Onlycleanandfoodgrade clothsand 1. Compliance of thefi containers mayaffectthequalityandsafety Unclean andnon-foodgradecloths Reason Cookingvats shouldbe clean andmade 2. Cookingtimeandtemperature should be 1. Compliance be observed by theworkers and madeofnon-corrrodible materials containers shouldbe usedinsieving. easily cleaned. of non-corrodible materialsthatcanbe properly observed. nal product. nal nished product. nished

PHILIPPINES PHILIPPINES being usedforthe2 be ensuredthatitisproperlywashedbefore from theoneusedin1 Cloths andcontainersusedshouldbedifferent to containtheproduct. and foodgradecontainersshouldbeavailable any otherpurposethansieving.Clean be used.Theclothsshouldnotusedfor unnecessary delays.Onlycleanclothsshould Sieving shouldbecarriedoutwithoutany 2 GMP 9.1 is usedinthe1 grade cookingvats.Ifthesamevat be doneusingclean,well-maintainedandfood monitoring oftimeandtemperature.Itshould Cooking shouldbecarriedoutwithproper 2 GMP 8.1 70 to theﬁ This isdonetopreventanycontamination Reason be used. materials (bottles,capsandcartons)should Only cleanandundamagedpackaging area intendedandstipulatedforthispurpose. Packing/bottling shouldbedoneinaclean Packing/bottling GMP 10.1 Section 10 Section 9 Section 8

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN nished productandalsotooptimize 2 2 Packing/Bottling nd nd st nd nd and2 Sieving cooking Sieving Cooking nd cooking. nd cooking,itshould st sieving. . Cookingvats shouldbeproperly washed 1. Compliance To preventanycrosscontamination. Reason heat processing. at thisphaseandwillgothroughnofurther is becausetheproductreadyforpackaging observance ofhygieneisveryimportant.This To preventanycross-contamination,utmost Reason . Packing shouldbedoneinaclean2. Onlycleanandundamagedpackaging 1. Compliance Alamang the packagingmaterial’sabilitytokeep Compliance . Theclothsandcontainers usedinthe2 2. Onlycleanandfoodgrade clothsand 1. before useforthe2 designated area. materials shouldbeuse. containers shouldbeused. used inthe1 sieving shouldbedifferent from theones safefromcontamination.

st sieving. nd cooking. nd

consumers safely,retainingitshighquality. To ensurethatthefi Reason protected toavoidanypossibledamage. to theproduct.Theproductmustbewell Distribution conditionshouldbeappropriate Distribution GMP 12.1 and tolengthenitsshelflife. This istopreventtheproductfromdeterioration Reason direct sunlightandintenseheat. Finished productshouldbestoredawayfrom Storage GMP 11.1 Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN Section 12 Section 11 Distribution Storage nal productreachesthe 2. The fi 1. The fi Compliance Regular monitoringofthefi 2. Products shouldbestored 1. Compliance avoiding any delays. appropriate vehicle straight tothebuyer using adelivery van orany available of thebottledshrimpsauceoccur. packed incartonstoensure nobreakages storage area shouldbeconducted. exposure tosunlightandintenseheat. nished products shouldbedelivered nished products shouldbedelivered away from direct direct from away nished product

PHILIPPINES PHILIPPINES in thechillerorfreezerforconsumptionduringleanmonths. or freezer.Duringtheseasonofabundance,fi suitable boxesbeforebeingstoredatroomtemperatureorforlongerstorageperiodsinachiller fi scad Bay. Speciesoffi Smoked fi Product Description Smoked Fish– Product Name Process FlowDiagram 72 shes arepackedintopolyethylenebags.Theythenstyrofoamboxesorother

Ù . Theﬁ Packaging Material

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN Receipt of shor shes arewashed,soakedandcooked inbrinedbeforebeingsmoked.Thesmoked Tinapa Tinapa shes used for , asitislocallycalled,hasalucrativemarketintownsborderingManila Tinapa Storage andDistribution Packing andLabeling Receipt ofFresh Fish include Washing/Cleaning Brine-Cooking Brine-Soaking Smoking Cooling sardines shes arecookedinbulk,smokedandstored , milkfi sh , anchovies Receipt ofSalt , herrings and round Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN 3. Brine-Soaking 2. Washing/Cleaning . ReceiptofRawMaterials 1. Outline ofProcessingSteps pce ffis Durationofbrine-cooking(minutes) Speciesoffi sh Bangus ( Tamban ( Lapad ( Tunso ( Silinyasi, allsizes(young made upofsaltandwaterina1:3ratio. of soakinginbrine.Thebrinesolutionis visceras arenotremovedintheprocess brined intheroundi.e.theirheadsand cooked inbrine. spoilage offi Soaking thefishinbrinecanretard process; hence,icedwaterisused. should bemaintainedthroughoutthe further processed.Lowtemperatures blood, slime,anddirtbeforetheyare The fi Receipt ofsalt c. . Receipt offi b. Receipt ofpackaging materials a. the fi used forthebriningandcookingof Food-grade salt(sodiumchloride)is 5˚C. them atlowtemperaturesnotexceeding processing. Fishesareicedtokeep that theyaresafeandsuitablefor recorded andevaluatedtoensure Every shipmentoffishshouldbe smoked fi and cartons,areusedtopackthe polyethylene bags,styrofoamboxes Packaging materialssuchasfood-grade shes are washedinwatertoremove Sardinella fi Sardinella perforate Chanos chanos shes priortosmoking. Sardinella longiceps sh whileitiswaitingtobe sh priortodistribution. sh Herring mbriata ) 4 to 10 and Sardinella ) 2.5 to 3 Table 1:Duration ofBrine-Cooking ) 2.5 to 3 3to4.5 ) sardines ) 1.3 to 1.5 are 4. Brine-Cooking fi of brine-cookingfordifferentspecies the given timedependsgreatlyonthesizeof of basketsthatcanbeimmersedatany immersed intheboilingbrine.Thenumber then placedinanimmersionbasketand and broughtuptoaboil.Thefi inside acookingvat( 1:9. Afterthebrineisprepared,itplaced in brinesoaking.Thesalttowaterratiois times lessconcentratedthanthebrineused The brineusedinthebrine-cookingisthree depending onthesizeoffi solutions ofbrineforonetotwohours 5min before theyaresoakedinconcentrated 20min Milkfish 4.5cm–8 10cm–14 Sizeoffi The soakingtimesareasshownbelow: shes. carajay Boiling brineincookingvat ontheotherhandaregutted . Table1showstheduration s Timeofsoaking sh Figure 1 carajay , localname) shes. shes are shes

PHILIPPINES PHILIPPINES pce ffis Durationofsmoking(minutes) 5. Smoking Speciesoffi sh 74 Cooked fi Tunso ( Silinyasi, allsizes(young Lapad ( ags(hnscao) 60–360 100 –120 Bangus (Chanoschanos) Tamban (Sardinella longiceps)

Ù different kindsoffi the durationofsmokingtimeusedwith the typeofproductdesired.Table2shows varies accordingtothesizeoffi trays. Thetimetakentosmokethefi cooling, fi out inthedrainingtraysandcooled.After After brine-cooking,thefi

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN Sardinella fi Sardinella perforate sh ondraining trays forcooling shes arearrangedinsmoking Smoking offi Figure 3 Figure 2 mbriata shes. sh Sardinella 60–105 ) ) 45 – 60 shes arelaid Table 2:Duration ofSmoking shes and shes ) 135 – 140 shes 7. Packing and Labeling 6. Cooling Smoked fi with plasticfi are styrofoamboxes/trayswrappedover the morecommonpackagingmaterials on theprocessor’spreference.Someof kinds ofpackagingmaterialsdepending Smoked productsarepackedindifferent before packing. The fi Smoked fi shes arelaidintraysandcooled sh packedonstyrofoam trays with plastic fi sh ontrays forcooling lm, bamboobaskets lined Figure 5 Figure 4 lm 8. Storage and Distribution GMP forSmokedFish( Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN materials shouldberejected immediately. Damaged, dirtyandunsuitable packaging for theirintendeduse. packaging materialsareoffood-gradeandfi processing establishmenttoensurethatthe specifi bags, plasticcontainers)shouldmeetthe Packaging materials(e.g.styrofoam,P.E. ReceiptofPackaging GMP 1A.1 Section 1 trays. shipped tomarketintheoriginalsmoking old newspaper.Smokedfi containers, cardboardcartonslinedwith with bananaleaves,woodenboxes/plastic

cations setbythemanagementon Storage inrefrigerator ReceiptofRawMaterialsandPackaging Materials Figure 6 sh mayalsobe Tinapa t . Packaging materialsshouldbeenclosed in 2. Only clean packaging materialsthatmeet 1. Compliance contamination. product resultingspoilageandmicrobial materials maycontaminatethefinished Damaged, dirtyandinappropriatepackaging Reason ) be appropriatefortheproduct. or freezer.Distributionconditionshould smoked fi at roomtemperatures.Forlongerstorage, Smoked fi a cleancovering upon receipt. into theestablishment. the specifi sh is usually stored and distributed sh isusuallystoredanddistributed sh shouldbeputinarefrigerator cations setare allowed entry Storage infreezer Figure 7

PHILIPPINES PHILIPPINES - Presence ofproper certiﬁ - - Condition of packaging - Supplier/Source - Date received: following informationproperlydocumented: Every batchofsaltreceivedshouldhavethe material uponreceipt. contained inacleanandfood-grade packaging of foreign matter, purity). Saltshouldbe requirements forsalt(microbial load,free that proves thatthesalthasmetsafety establishment shouldhave acertification Every batchofsaltreceived intheprocessing ReceiptofSalt GMP 1B.1 Storage room forpackaging materials 3. Thepackaging materialsare usedfollowing 2. Thestorage area forthepackaging materials 1. Compliance protection totheﬁ materials willnotprovidethenecessary Contaminated anddamagedpackaging Reason contamination. a cleanroomprotectedfromanypossible Packaging materialsshouldbestoredin StorageofPackaging GMP 1A.2 Newspapers are nolongerallowed foruse 3. 76

Ù received, supplier, intendeduse, etc.). identiﬁ should beprovided withshelves foreasy the First-In-First-Out (FIFO) principle. of any otherpossiblecontaminants. for possiblepestinfestationandpresence is always cleanandregularly monitored as packaging material.

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN cation andproper labeling(date Materials nished product. nished cation M B2 StorageofSalt GMP 1B.2 Proper documentationisproperly fi 3. Saltiscontainedincleanandfood-grade 2. Every batchofsaltreceived inthe1. Compliance fi to itwillaffectthequalityandsafetyof smoked fi Salt isamajoringredientforproductionof Reason . Everybatchofsaltshouldbeproperly 3. Thestorage room isregularly cleanedand 2. Saltisproperly stored inaclean,dry, and 1. Compliance safety andqualityofthefi Any contaminationtothesaltmayaffect Reason health hazardstotheconsumers. unwanted chemicalreactionsthatmightcause be food-gradeandinerttosaltavoidany other cleancontainers.Containersshould from itsoriginalpackagingistransferredto the saltintostorageroom.Saltremoved materials shouldberemovedbeforebringing intended forsaltstorage.Dirtyouterpackaging transferred toaclean,dryandspecifi Immediately afterreceipt,saltshouldbe nished product. nished easy traceability. packaging materials. certifi must beaccompaniedwithnecessary with thesetspecifi processing establishmentmustcomply fi labelled andshouldfollow thefi other possiblecontaminations. monitored forpossiblepestinfestationand designated storage room. rst-out principle. rst-out cations. sh. Therefore,anycontamination cations forsaltand nished product. nished led for c area c rst-in- Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN processing steps. which cannotbeimprovedbysucceeding quality deteriorationoftherawmaterial, product. Anydelayscancauseirreversible affect thequalityandsafetyoffi Contaminated waterandcontainersusedcan Reason suitable fortheirintendeduse. ensured thatcontainersusedarecleanand delays shouldbeavoidedanditmust cleaning ofrawmaterials.Anyunnecessary Potable watershouldbeusedforwashingand Washing/Cleaning GMP 2.1 Fishesshouldbecontained incleanand 1. Compliance of theproduct. may affectthequality,safetyandshelflife Contamination fromdirtyiceandcontainers does notexperienceanytemperatureabuse. fish; thereforeitisamustthatthefish Nothing canreversethedeteriorationof Reason attributes setbythemanagement. it shouldmeettherequirementsforsensory fi for processing.Thecoretemperatureofthe clean containershouldbereceivedandused Only freshfi ReceiptofFish GMP 1C.1 sh uponreceiptshouldnotexceed5˚Cand Section 2 in temperatures toabove 5˚C.Thisisto should beproperly icedtoavoid any rise appropriate fi sh, properlyicedandpackedin Washing/Cleaning sh boxes/containers. They nished . Proper documentationshouldbedone 3. . Unnecessarydelays shouldbeavoided 3. Containers shouldbecleanandmadefrom 2. Potable water from approved sources1. Compliance . Sensoryevaluation ofthefi 2. - Sensory evaluation results - Condition of fi - Temperature upon receipt - Species - Fishing Ground - Date caught - Supplier - Date received should include: information thatshouldbedocumented and fi and suitabilityforprocessing. conducted uponreceipt todetermineits maintain itsfreshness. to ensure thattheraw materialswould food-grade materials. future reference. water testingshouldbeproperly kept for should beuseforwashing. Records of period oftimeaspossible. maintained atgoodqualityforaslonga This willinturnensure thatthefi reactions thatmay occurare slowed down. ensure thatany microbial andenzymatic led properly fortraceability. The sh container sh sh should be should sh shes are

PHILIPPINES PHILIPPINES 78 quality. monitored diligentlyto achieve thedesired Smoking timeandtemperatureshouldbe smoking shouldbesafeforitsintendeduse. cleaned andmaintained.Woodusedfor Smoking chambersshouldberegularly Smoking GMP 5.1 desired qualityoftheproduct. salt usedinbrineisimportanttoachievethe observance ofcookingtimeandamount contamination totheproduct.Proper always freshtopreventanypossiblemicrobial It isimportanttokeepthebrinesolution Reason properly observed. and ratioofsaltwaterinbrineshouldbe every batchofﬁ Brine usedshouldberegularlychangedfor Brine-cooking GMP 4.1 contamination. should alwaysbechangedtopreventcross desired qualityoftheproduct.Brinesolution of saltusedinbrineisimportanttoachievethe Proper observanceofsoakingtimeandamount Reason properly observed. and ratioofsaltwaterinbrineshouldbe every batchofﬁ Brine usedshouldberegularlychangedfor Brine-soaking GMP 3.1 Section 4 Section 3 Section 5

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN Brine-Cooking Brine-Soaking Smoking sh being cooked. Cooking time sh beingcooked.Cookingtime sh being soaked. Soaking time sh beingsoaked.Soakingtime Compliance Briningcontainers shouldbecleanand 3. Briningcontainersshouldbemadefrom 2. Brinesolutionshouldbeproperlyprepared, 1. Compliance which canbe detrimentaltohuman health. may impartsubstancesto thefi wood usedinsmoking. Some typeofwood It isnecessarytopayattention tothetypeof temperature andinregulating thesmoke. working properlyinmaintainingtheproper It shouldberegularlymaintainedensureitis cleaned toeliminateanyformofcontaminants. The smokingchambersshouldberegularly Reason Cookingvats shouldbewashed and 3. Cookingvats usedshouldbemadefrom 2. Brinesolutionsshouldbeprepared with 1. well maintained. able totoleratehighsaltconcentrations. food gradematerials,noncorrodibleand contaminants likepest,insectsanddust. water. Brineshouldbeprotectedfrom observing theproperratioofsaltand and stored inacleananddryarea. sanitized before andafterevery operation able totolerate highsaltconcentrations. food grade materials, noncorrodible and any cross contamination. It shouldberegularly changedtoprevent proper observation ofsaltandwater ratio. nished product, . Hardwood shouldbepreferred forusein 1. Compliance product duringstorageand distribution. and underconditions appropriate tothe Finished productsshall be handledproperly Storageand GMP 8.1 Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN in productquality. contamination oftheproductanddeterioration environment isnecessarytoprevent The carefulcontrolofhygieneandthe Reason a cleanandprotectedenvironment. Cooling shouldbecarriedouthygienicallyin Cooling GMP 6.1 condition. therefore itisnecessarytokeepingood product fromanyformofcontamination, intended forenclosingandprotectingthe the fi material canaffectthequalityandsafetyof Any contaminationfromthepackaging Reason be foodgrade,cleanandundamaged. designated area.Packagingmaterialsshould Packing shouldbedonehygienicallyinaclean Packing GMP 7.1 Section 8 Section 7 Section 6 smoking. Hardwood produces mildfl nished product. Packagingmaterialis Storage and Distribution Packing Cooling Distribution avour practices. by temperatureabuseor improperhandling contamination andproduct deterioration Proper handlingwill preventcross Reason . Regular cleaningandmaintenanceofthe 2. . Allworkersmustobservegoodpersonal 3. Coolingtraysare kept cleanandingood 2. . Coolingarea shouldbefree from any fl 1. Compliance . Allworkersmustobservegoodpersonal 3. Onlycleanandundamagedpackaging 2. Thepackingareashouldbecleanand 1. Compliance smoking chambers shouldbeconducted. softwood. and itcontainslessamountsofresin than hygiene practices. dry areawhennotinused. condition. Theyarestoredinacleanand programme shouldbeconducted. insects andotherpests. Regular pestcontrol hygiene practices. materials areused. pests free fromanyfl ies, insectsandother

Ù ies,

PHILIPPINES PHILIPPINES 2. The ﬁ Finishedproductsshouldbestoredin 1. Compliance 80

Ù stored frozen. refrigerated andnotexceeding-18˚Cif - notexceeding5˚Cifstoredchilled/ pests andunderappropriatetemperatures rooms whicharecleanandfreefrom delays. vehicle straighttothebuyeravoidingany using adeliveryvanoranyappropriate

Good Manufacturing Practice (GMP) forSmall andMedium-sized Traditional Fish Products Processing Establishmentin ASEAN nished productsshouldbedelivered . Chilledproducts shouldbetransported in 3. 5. Temperature recorders should be available Temperaturerecordersshouldbeavailable 5. Frozen products shouldbetransported 4. on alldeliveryvehicles. exceeding -18˚Cduringdistribution. in freezer vehicles attemperatures not exceeding 5˚Cduringdistribution. refrigerated vehicles attemperatures not Singapore

Product Name

Fish balls/ﬁ sh cakes

Product Description

Fish balls and fi sh cakes are widely consumed in Singapore as ready to eat snacks as well as ingredients in many local dishes especially that of noodles and vegetable dishes. Fish balls and fi sh cakes come in a variety of shapes and sizes. Traditionally, fi sh balls and fi sh cakes are made from fresh fi sh but inconsistent and insuffi cient supplies of fresh fi sh has led processors in Singapore to favor the use of surimi as the chief raw material. Surimi is fi sh meat that has been minced, leached by washing with water, thoroughly mixed with sugar and polyphosphate and then frozen. The main ingredients in fi sh balls and fi sh cakes are sugar, starch, salt, MSG and cooking oil.

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Ù 81 SINGAPORE Process FlowDiagram 82 (sugar, starch, salt,MSG

and cookingoil) Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN Ingredients Cooling ofcooked products (Frozen surimi,fi and mincedfi Grinding andmixing Cooling afterfrying Loading/Delivery Frying (optional) Metal Detection Product Storage Raw materials (optional) Thawing Forming Cooking Packing Setting sh meat) sh sh fi sh llets Packaging materials . Receipt andstorage ofIngredients 1. . Receipt3. andstorage ofPackaging Receipt andstorage ofRaw Materials 2. 4. Thawing Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN Outline ofProcessingSteps ( of fi Typical ingredientsusedinthemanufacture to packthefi fi density polyethylene(LDPE)films,PP (PS) trays,polypropylene(PP)low- Packaging materialssuchaspolystyrene materials manufacturers. D) butthegradesvarybetweendifferent are nowmarketed(AA,SA,A,B,Cand products. Variousgradesoffrozensurimi to enhancetasteandfl are sometimesusedtogetherwithsurimi (Yellow tailfusilier, spp.). Fishfilletsormincedfishmeat ( eye snapper( Threadfi commonly usedforsurimiproductionare minced fi and fi The rawmaterialsusedformakingfi product. texture, tasteandfl during themixingsteptoenhance temperature. Theingredientsareused ingredients areusuallystoredatroom (based ontheweightofsurimi).These glutamate (MSG)(1%),andwater(40%) sugar (3%),starchmonosodium etc). under hotweather,immersing inwater increases intemperatures (e.g.thawing and shouldnotbesubjected tosudden be thawedundercontrolledconditions Before use,thefrozensurimishould lms, PEandPPbagsarecommonlyused Saurida Pennahia sh ballsandfi sh cakesaresurimiandfi n bream ( bream n sh meat.Thetropicalfi spp.)andgoatfish( , sh ballsand fi Johnius Priacanthus sh cakesaresalt(3-5%), Nemipterus avour ofthefi Caesio erythrogaster avor ofthefi spp.),lizardfish spp.),croaker sh cakes. sh sh fi spp.),big- sh species Upeneus sh balls llets or nished nished ) over thesurfaceofblocks.Theshelves current ofair(e.g.electricfan)evenly on shelvesandthawedbydirectinga The blocksoffrozensurimicanbeplaced Thawing inair(air-conditionedroom) proteins causedbyheat. need notworryaboutdenaturationoffi to thawoutevenlyandtheprocessors slow thawingallowsthefrozensurimi thawed whenrequired.Thismethodof the chillerroomsothatitwillbesemi- The frozensurimicanbeleftovernightin Thawing inchillerroom(0-5˚C) Thawing ofsurimiinchillerroom Thawing ofsurimiinair assisted by electricfan Figure 2 Figure 1

sh 83

SINGAPORE SINGAPORE 5. Grinding & Mixing 84

Ù of thefi can beaddedtoenhancetasteandfl salt, theotheringredientsandicewater on consumerpreferences.Afteradding usually about3-5%byweightdepending fi soluble proteinsandprovidetastetothe added toenhancetheextractionofsalt- loosens themusclefi paste. Theprocessbreaksdownand ingredients intoahomogenoussticky to grindandmixrawmaterials A silentbowlcuttermachineisused before processing. thawed foracertaintime(about2-3hrs) using asurimicutter.Thefrozenis blocks canbecutintopiecesmanuallyor and heat.Whensuffi should bekeptawayfromdirectsunlight nal product.Theamountofsaltaddedis

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN Grinding andmixingusing nished products. nished Silent BowlCutter Figure 3 ciently softened, the softened, ciently bres. Next,saltis avour 6. Forming to producethefi is shapedquicklyinaformingmachine After grindingandmixing,thefi required shapesasquicklypossible. chilled andtoformthepasteinto therefore importanttokeepthepaste shape willthereafterresistchange.Itis results inafi room temperature.Theprocessof“setting” and mixingbeginsto“set”quicklyat conditions, thefi a containerwithwater.Undertropical The productsareformeddirectlyinto Forming offi Forming offi rm translucent product whose rm translucentproductwhose Figure 4 Figure 5 sh pasteaftergrinding sh ballsorfi sh cakes sh sh balls sh s cakes. sh sh paste sh Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN 7. Setting 8. Cooking Setting offi Continuous conveyorcooker (hotwater) a springytexture. sticky fi water andtheshapeareretained.The before cookingsincetheyarebuoyantin balls andfi attained, thesettingprocessbegins.Fish After thefi fi One ofthemainpurposescooking surface oftheproducts. result intheundesirablerougheningof within theproductstovaporise.Thiswill boiling waterislikelytocausethemoisture products arecookedinboilingwater,the are cookedinhotwaterat90°C.Ifthe be takentoensurethattheproducts products. However,specialcaremust sh ballsandfi sh paste will gel to give the product sh pastewillgeltogivetheproduct sh cakesinstainlesssteeltank sh cakes are usually set in water sh cakesareusuallysetinwater nal shapeoftheproductis machine Figure 7 Figure 6 sh cakesistosterilisethe . Coolingofcooked products 9. 10. Frying (For product color) chiller room. air-conditioned roombeforestorageina and fi After cookinginhotwater,thefi operation. carried outeitherbybatchorcontinuous a completelyfriedone.Fryingcouldbe fried orparproduct,ratherthan color. Theusualprocessgivesapartly to givetheproductsurfaceagoldenbrown The fi Cooling inair-conditionedroom sh ballandfi sh cakesareusuallycooledinan Frying offi Figure 8 Figure 9 sh cakesmaybefried sh cakes sh sh balls sh

SINGAPORE SINGAPORE 12. Packing andLabeling 11.frying after Cooling 86 Packing ofraw ﬁ

Ù shelf life. may alsobevacuumpackedtoextend consumption. Fishballsandfi ensure productqualityuntiltimeof prevent dehydrationduringstorageand and marketing.Thepackagingmaterials effi materials. Goodpackagingenhances packed manuallyinsuitablepackaging Fish ballsandfishcakeareusually room. room beforebeingstoredinachiller are usuallycooledinanair-conditioned After frying,thefi

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN cient mechanized handling, distribution cient mechanizedhandling, distribution Frying Machine Figure 10 Figure 11 sh ballsinchilledwater. sh ballsandfi s cakes sh sh cakes sh 4 rdc storage 14. Product Detection 13. Metal 15. Loading/Delivery Refrigerated vehicles usedfordeliveryof Properly packagedfi carried outafterthepackingstep. fi such ahazardiseliminatedfromthe safety hazard.Ametaldetectorwillensure such assilentcutterandmincerisafood chipped) bladesofthecuttingequipment Metal fragmentsfromdamaged(brokenor or containerswithwithoutice. refrigerated vehiclesorininsulatedboxes stalls andrestaurantsarecarriedoutin cakes tosupermarkets,marketstalls,food production. Thedeliveryofthefi distributed within12-24hoursafter The fi chiller roomfor12-24hoursonly. fi consumers desiretheproductsfresh, stacked onrackswithwheels.Aslocal are containedinplastictrays,which before delivery.Thefinishedproducts fi nished product. Metal detection is usually nished product.Metaldetectionisusually nished productsareusuallystoredinthe sh cakesarestoredinthechillerroom sh ballsandfi fi nished products nished Figure 12 nished fi nished sh cakesareusually sh ballsand sh balls/ Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN ingredients. well asdeterioration inthe qualityofthe foreign materials(dust,dirt,sandetc) as as microorganisms, insects, chemicals and contamination by extraneous materialssuch in ahaphazard mannerwillresult in Storage ofingredients in an openarea Reason assigned cleananddryroom. in aneatandtidymannerspecifi Ingredients shallbe stored above thefl Storage GMP 1.2 Ingredient packaging labelsshouldcontain 2. Ingredients inbadlydamagedpackaging 1. Compliance that thecorrect ingredients are used. would helpintheiridentifi dirt, sandetc).Clearlabellingofingredients insects, chemicalsandforeign materials(dust, extraneous materialssuchasmicroorganisms, may leadtocontaminationoftheingredient by desired protection tothestored ingredient and Damaged packaging willnotprovide the Reason receipt andwithproper labels. their packaging intactandundamagedupon glutamate (MSG)andcookingoil)shallhave Ingredients (e.g. sugar, starch, salt,monosodium Receipt GMP 1.1 GMP forFishBallsandCakes Section 1 • • • • the following information: accepted foruseinprocessing. without proper labelingshouldnotbe

Expiry date/Use-by date Country oforigin Name ofmanufacturer or importer Name ofingredient Receipt andStorage ofIngredients cation thus ensuring cation thusensuring cally oor 3. 2. 1. Compliance . Thewater source usedinprocessing andin 1. Compliance and chemicalhazards. contamination oftheproducts by biological unapproved non-potable water may leadto in processing oriceandsteammadefrom The useofunapproved non-potablewater Reason protect themfrom possiblecontamination. water usedshallbehandledandstored soasto shall alsobemadeusingpotablewater. Iceand quality from approved source. Iceandsteam Water usedasaningredient shallbeofpotable Water GMP 1.3 4. labels. dry containers withproper covers and their packaging shouldbestored inclean, Ingredients thathave beenremoved from from away be inplaceforstoringoftheingredients Proper non-wooden shelvingracks should minimal likelihood from contamination. access andharbourage; andc)enable maintenance andcleaning,b)avoid pest and constructedtoa)permitadequate ingredients, whichshouldbedesigned free mustbeprovided forthestorage of A cleananddryroom thatisinsect- beyond theirexpiry/used-by date. schedule. Ingredients shouldnotbeused the factory’s rotation/inventory control First-Out (FIFO) basisoraccording to Ingredients mustbeusedonaFirst-In- obtained from anapproved potablewater the manufacture oficeandsteam mustbe the ﬂ oor.

SINGAPORE SINGAPORE . Regular checksofthewater linesshould 2. 88 Thefreezer andchillerrooms and3. Chilledraw materialsmustbestored or 2. Frozen raw materialsmustbestored or 1. Compliance stored attheappropriate temperatures. the raw materialsare correctly identiﬁ contamination. Proper labelingwillensure that protection totheraw materialsandprevent must bekept intacttoprovide thedesired growth and qualitydeterioration. Packaging or chilledtemperatures toprevent microbial Raw materialsmustbekept atproper frozen Reason with intactpackaging andproper labels. frozen orchilledtemperatures uponreceipt Raw materialsshallbestored attheproper Receiptandstorageof GMP 2.1 Section 2

Ù be carriedouttoensure thatthepipes system. source suchasthepublicwater supply with temperature recorders. transporting vehicles shouldbeequipped exceeding 7˚C. below andhave acore temperature not transported attemperatures of4˚Cor exceeding -12˚C. below andhave acore temperature not transported attemperatures of-18˚Cor

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN Receipt andStorage ofRaw Materials(Surimi,fi fi raw materials llets, minced fi minced llets, sh meat) sh ed and ed . Raw materialsmustbeusedonaFirst- 9. Freezer/chiller mustbekept inawell- 8. Raw materialsmustbestored separately 7. Frozen/chilled raw materialsshould not 6. Freezer/chiller rooms shouldnotbe 5. Frozen/chilled raw materialsmustbe 4. Non-potablewater linesshallbeclearly 3. their expiry oruse-by dates. schedule andshouldnotbeusedbeyond the factory’s rotation/inventory control In-First-Out (FIFO) basisoraccording to freezer chamber. accumulation oficeformationinsidethe maintained sanitaryconditionwithno chiller. from thefi products. proper circulation ofcoldairaround the shelving racks shouldbeavailable toallow freezer/chiller rooms. Proper non-wooden be stored directly onthefloorof capacity. overloaded beyond theirdesignated scheduled tobeuseduponreceipt. immediately uponreceipt unlessthey are kept frozen/chilled inthefreezer/chiller water toavoid cross contamination. identified andseparated from potable no leakages. carry thewater are notrustyandthere are nished products inthefreezer/ sh

Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN Frozen raw materialsshallbeleftto thaw 1. Compliance exposure. quality deterioration duetohigh temperature prevent contamination, microbial growth and frozen raw materialstothaw outevenly and A proper thawing process willallow the Reason proper temperature conditions. carried outinacleanenvironment under Thawing offrozen raw materialsshallbe Thawing GMP 4.1 the product. dirty packaging materialsmay contaminate will notprovide thedesired protection and contamination. Damagedpackaging materials protecting thefinishedproducts from Packaging hasanimportantfunctionin Reason proper conditions. for theirintendeduseandbestored under to containthefi bags andpolystyrene (PS)trays) thatare used polyethylene (PE)andpolypropylene (PP) Packaging materials(e.g. cardboxes, Receiptandstorageof GMP 3.1 . Packaging materialsusedshallbenon-toxic 1. Compliance Section 3 Section 4 semi-thawed usagethenext day. overnight inthechiller room (0-5˚C)for products. they are safeforcontainingthefi and offoodgrade qualitytoensure that Receipt andStorage ofPackaging Materials Thawing packaging materials nished products shallbesafe nished . Frozen goodscanalsobethawed by soaking 4. Non-wooden racks shallbeusedtohold 3. Thawing shallbeconductedby placing 2. . Packaging materialsshallbeusedona 5. Proper shelvingracks shallbeinplacefor 4. Acleananddryroom thatisinsect- 3. Packaging materialsusedshallbeinclean 2. materials should notexceed 5˚C. The core temperature ofthethawed raw not exceeding 20˚C by additionofice. stainless steelorfi tanks madeofnon-corrodible materialse.g. them inwater ofpotablequalityinthaw pits, crevices orcracks. the surfacesofwhichshouldbefree from stainless steelorsomesuitableplastics, The thawing racks shallbemadeof the frozen raw materialsduringthawing. of thefrozen raw materials. air (e.g. electricfan)evenly onthesurfaces racks andassistedby directing acurrent of the frozen raw materialonproper thawing their recommended shelflifeperiod. schedule andshouldnotbeusedbeyond to thefactory’s rotation/inventory control First-In-First-Out (FIFO) basisoraccording from theground. storing ofthepackaging materials, away handled. areas where raw orfoodproducts are room forpackaging materialsaway from contamination by locatingthestorage and c)enableminimallikelihood from b) avoid pestaccessandharbourage; permit adequatemaintenanceandcleaning, should bedesignedandconstructedtoa) packaging materials. Thestorage room free shallbeprovided forthestorage of and hygienic conditions. bre glassatatemperature

SINGAPORE SINGAPORE 5˚C). paste shallbestored inthechiller room (0- is completed.Intheevent ofany delay, the out assoonthegrinding andmixingprocess Forming ofthe ﬁ Formingprocess GMP 6.1 . Thetemperature ofthemixture/paste 2. Grindingandmixingprocess shallbe 1. Compliance may promote microbial growth. temperature alsoposesabiologicalriskasit affecting thequalityofproduct. High heat, whichwillresult inprotein denaturation, The grindingandmixingprocess generates Reason under low temperature conditions. ingredients intoapasteshallbecarriedout Grinding andmixingoftheraw materialsand Grindingandmixing GMP 5.1 90 Externalpackaging materialsofthe 5. Section 5 Section 6

Ù use oficewater asaningredient. should bekept at10˚C orlower by the during thegrindingandmixingprocess carried outinanair-conditionedroom. contamination. the thawing process. Thisistoprevent in contactwiththeraw materialsduring and discarded. They shouldnotremain frozen raw materialsshallberemoved

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN

Forming Grinding andMixing process sh ball/cake shallbecarried . Thawed raw materialsshallbeused 7. Uponcompletionofthethawing process, 6. the products. may becomeasource ofcontamination Dirty and/orpoorlymaintainedequipment Reason maintained. bowl cuttershallbekept cleanandwell mixing process suchasthesilentorvacuum The equipmentusedinthegrindingand Grindingandmixing GMP 5.2 deterioration. to prevent microbial growth andquality The pasteshallbekept chilledatalltimes Reason Thefood-contact surfacesoftheequipment 2. Theequipmentmustbethoroughly1. Compliance until use. immediately orkept inthechillerroom would make themunfi signs ofspoilageorcontamination,which the raw materialsshallbeexamined for smooth andfree from crevices. way. Thefoodcontactsurfacesmustbe should notbecorroded ordamagedinany must bemadeofnon-toxic materialsand of product. before andafterproduction ofeachtype processing day andasappropriate suchas washed andsanitizedattheendofeach equipment t foruse. Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN Thetemperature ofthesettingwater 2. Settingshould becarriedoutinwarm 1. Compliance or chemicalcontamination. prevent itfrom becomingasource ofmicrobial Water usedshouldbeofpotablequalityto mushy-like texture ofthefi temperature range of60-75˚C,resulting ina Disintegration ofgelstructure occurs atthe product isachieved duringthesettingprocess. obtain maximumgelstrength oftheformed Cross-linking offishprotein moleculesto Reason out inwarm potablewater. Setting ofthefi Settingprocess GMP 7.1 shall bekept cleanandwell maintained. The equipmentusedintheformingprocess Formingequipment GMP 6.2 Thepasteshallbestored inachillerroom 2. Forming shallbecarriedoutimmediately 1. Compliance Section 7 should notbeintherange of60-75˚C. surimi) for20-30 minutes. potable water at40˚C(fortropical species immediately. (0-5˚C) ifitisnotscheduledtobeused after thegrindingandmixingprocess. Setting sh balls/cakes shallbecarried nse product. nished 2. The food-contact surfaces of the equipment Thefood-contactsurfacesoftheequipment 2. Theequipmentmustbethoroughly washed 1. Compliance the products. may becomeasource ofcontaminationto Dirty and/orpoorlymaintainedequipment Reason not beused. (iron coatedwithzinc)istoxic andshould with ageandtendtoshatter. Galvanized iron clean anddisinfect.Plastics alsobecomebrittle and abrasion whichmake themdiffi but someare susceptibletocracking, scoring established inthewood. Plasticsmay beused With time, microbial populationsincrease and protected from normalcleaningprocesses. materials intothewood where they may be migration ofmicrobes andsolublefood and willabsorbmoisture. Thispermitsthe of contamination.Wood fi and bacteriaincrevices willbecomeasource crevices. Built-upoftiny particlesoffood should besmoothandfree from pitsand be cleanedanddisinfected.Thesurfaces nature andtheeasewithwhichitcan is stainlesssteel,becauseofitsimpermeable The preferred materialforthesettingtanks Reason and cleanable. non-corrodible materials, whichare durable The settingtanksshallbesetconstructedof Settingtanks GMP 7.2 smooth andfree from crevices. way. Thefoodcontactsurfacesmustbe should notbecorroded ordamagedinany must bemadeofnon-toxic materialand of product. before andafterproduction ofeachtype day andatappropriate instancessuchas and sanitizedattheendofeachprocessing br ae porous are bers cl to cult

SINGAPORE SINGAPORE temperatures. and regaining ability togrow atchilled bacteria are alsoprevented from recovering Bacillus growth ofspore-forming bacteriasuchas the germinationofbacterialspores andthe Rapid coolingofcooked products willprevent Reason out asquicklypossible. Cooling ofthecooked product shallbecarried Coolingtime GMP 9.1 92 Thecooking timeshouldbeadequateto 2. Thetemperature ofthehot water should 1. Compliance product. the totalpopulationofbacteriainﬁ will serve toeliminatepathogensandreduce Cooking atanadequatetemperature and time Reason shape oftheproduct. and timerequired willdependonthesizeand and foranappropriate time. Thetemperature out inhotwater atanadequatetemperature Cooking oftheﬁ Cookingtimeand GMP 8.1 steel orsuitableplastics. Thesurfacesand The settingtanksmustbemadeofstainless Compliance Section 9 Section 8

Ù 80˚C intheﬁ achieve acore temperature ofmore than be atleast90˚C(butnotboiling).

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN and Coolingofcooked products Cooking Clostridium temperature sh balls/cakes shallbecarried nished product. nished species. Heat-injured nished have asmoothﬁ crevices orcracks. Thewelded jointsshould joints ofthecontainers mustbefree from pits, . Thefood-contactsurfacesofthecooking 2. Thecookingmachinemustbethoroughly 1. Compliance contamination totheproducts. machines may becomeasource of Dirty and/orpoorlymaintainedcooking Reason well maintained. The cookingmachineshallbekept cleanand Cookingmachine GMP 8.2 . Cooked products shouldbecooledfrom 2. Coolingofthecooked products shouldbe 1. Compliance crevices. surfaces mustbesmoothandfree from damaged inany way. Thefoodcontact material andshouldnotbecorroded or machine mustbemadeofnon-toxic processing day andasappropriate. washed andsanitizedattheendofeach of spoilagebacteria. germination aswell astoretard thegrowth 4˚C withinanother4hrs toprevent spore 60˚C to21˚C within2hrs andtolessthan by storage inachillerroom (0-5˚C). room (12-15˚C)for less than2hrs followed carried outquicklyinanair-conditioned nish. Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN Burntproduct residues shouldberemoved 2. Frying oilshouldbechangedfrequently 1. Compliance discoloration. product residues intheoilmay causeproduct rancid aftermultipleuse. Inaddition,burnt Frying oilwillbecomeoxidized oiland Reason Frying oilhastobechangedfrequently. Fryingoil GMP 10.1 occurring. cooling prevents cross-contamination from materials andsemi-processed products during Separation ofcooked products from raw Reason materials andsemi-processed products. out inaseparate room orarea from raw Cooling ofcooked products shouldbecarried Coolingarea GMP 9.2 Section 10 from thefryingoil. cloudy. when colourbecomestoodarkand Frying (For product colour) Reason well maintained. The fryingmachineshallbekept cleanand Fryingmachine GMP 10.2 Raw materialsandorsemi-processed 2. Aseparate cleananddryroom1. or Compliance . Thefood-contactsurfacesofthefrying 2. Thefryingmachine mustbethoroughly 1. Compliance products. may becomeasource ofcontaminationthe Dirty and/orpoorlymaintainedfryingmachine room orarea asthecooked product. products shouldnotbekept inthesame cooling. area shouldbedesignatedforproduct crevices. surfaces mustbesmoothandfree from damaged inany way. Thefoodcontact material andshouldnotbecorroded or machine mustbemadeofnon-toxic of product. before andafterproduction ofeachtype processing day andasappropriate suchas washed andsanitizedattheendofeach

SINGAPORE SINGAPORE . Fried product shouldbecooledfrom 60˚C 2. Coolingofthefriedproduct shouldbe 1. Compliance ability togrow atchilledtemperatures. also prevented from recovering andregaining Clostridium of spore-forming bacteriasuchas germination ofbacterialspores andthegrowth Rapid coolingoffriedproduct willprevent the Reason out asquicklypossible. Cooling ofthefriedproduct shallbecarried Coolingtime GMP 11.1 94 deterioration. room toreduce microbial growth andquality temperatures are maintainedinthepacking products toprevent cross contamination.Low room from raw materialsandsemi-processed Packing should becarriedoutinaseparate Reason air-conditioned packingroom. out hygienically inaseparate, cleananddry Packing ofﬁ Packingarea GMP 12.1 Section 12 Section 11

Ù of spoilagebacteria. germination aswell astoretard thegrowth within another4hrs to prevent spore to 21˚C within2 hrs andtolessthan4˚C storage inachillerroom (0-5˚C). (12-15˚C) forlessthan2hrs followed by carried outquicklyinair-conditionedroom

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN species. Heat-injured bacteriaare nished products shallbecarried Packing andLabeling Cooling(Afterfrying) Bacillus and . Raw materialsandorsemi-processed 2. Aseparate cleananddryroom orarea 1. Compliance occurring. cooling prevents cross-contamination from materials andsemi-processed products during Separation offriedproduct from raw Reason and semi-processed products. in aseparate room orarea from raw materials Cooling offriedproducts shallbecarriedout Coolingarea GMP 11.2 . Packing offi 1. Compliance . Temperature5. oftheroom should be New, cleanpackaging materialsshould 4. Staffshouldbeproperly attired withclean 3. Products shouldbepacked onstainless 2. room orarea asthefriedproduct. products shouldnotbekept inthesame cooling. should bedesignatedforfriedproduct’s controlled between 12-15˚C. always beused. products. masks andhandgloves topackthefi uniforms, disposableheadcovers, facial steel tables. contamination andmicrobial growth. delay tominimizeany possibilityofcross- carried outquicklyandwithminimal nished products shouldbe nished nished Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN Chillerrooms should notbeoverloaded 3. Thechillerrooms shouldbeequippedwith 2. Chilledproducts mustbestored at1. Compliance maintain qualityandextend shelflife. temperatures willprevent microbial growth, Proper storage offi Reason at adequatechilledtemperatures. The fi Storage GMP 14.1 possible inclusionofmetalfragments canbe blending process duringproduction. Thus, the metal-to-metal contactduringthecuttingand fragments are normallyproduced through they cancauseinjurytoconsumers. Metal Metal fragments are foodsafetyhazards as Reason through ametaldetector. Every packoffi Metaldetection GMP 13.1 ensure product identityandtraceability. Adequate labellingoffi Reason Packed products shallbeproperly labelled. Labeling GMP 12.2 Section 14 Section 13 beyond theirdesignatedcapacity. temperature recorders. core temperature notexceeding 7˚C. temperatures of4˚Corbelow andhave a nished products shallbestored properly Product Storage Metal Detection nished product shallpass nished products atadequate nishedproduct would . Finishedproducts mustbeusedonaFirst- 7. Chillermustbekept inawell-maintained 6. Finishedproducts mustbestored separately 5. Chilledproducts shouldnotbestored 4. . Aproper recall system orprogram should 2. Every packshouldbeclearlyidentifi 1. Compliance . Themetaldetectormustbeperiodically 2. Asuitable metaldetectorshouldbe 1. Compliance through ametaldetector. or missingpartsbeeliminatedby passing cutting andblendingequipmentfordamage greatly reduced by frequent examination of their expiry oruse-by dates. schedule andshouldnot beusedbeyond the factory’s rotation/inventory control In-First-Out (FIFO) basisoraccording to sanitary condition. processed products inthechiller. from theraw materialsand/or semi- cold airaround theproducts. be available toallow proper circulation of Proper non-wooden shelvingracks should directly onthefl products thatviolatethelaw. be inplacetoremove orcorrect marketed labeled toensure traceability. and marked toshow lotnumberanddate calibrated toensure proper operation hazards. installed toeliminatethemetalfragment oor ofthechillerrooms.

Ù ed

SINGAPORE Section 15 Loading/Delivery

GMP 15.1 Loading and delivery Compliance

Finished products shall be handled properly 1. Products should not be left in the open during loading and delivery. at ambient temperatures for overly long periods during loading/delivery. They Reason should be left in the cold ante-room. Proper handling during loading and delivery 2. All chilled products should be transported will prevent cross contamination and product in refrigerated vehicles. deterioration by temperature abuse or improper handling practices. 3. Temperature recorders should be available on all refrigerated vehicles.

96 Ù Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Thailand

Product Name

Dried Shrimp

Product Description

Dried shrimp is a Thai traditional product that is well known in Thailand and other South East Asian countries as well as more distant countries such as China, India and the United States of America. The preferred raw material for the production of dried shrimp is the marine shrimps belonging to the Penaeidae and Palaemonidae families. Nonetheless, aquaculture shrimps are also being used in the production of dried shrimp due to the shortage of marine shrimp. Many processes are involved in the production of dried shrimp but these processes may vary slightly for each processing establishment. For example, some establishments cook the shrimps before drying them, while some others do not. In cases where the shrimps are cooked before drying, they are ﬁ rst boiled in hot water, or steamed before they are sun dried or dried using a mechanical dryer till their moisture content complies with the requirements of the customer.

Process Flow Diagram

Fresh Shrimps (Raw Material)

Washing

Boiling/Steaming

Drying (Sun drying/ Hot air drying)

De-shelling

Sorting/Sizing

Packing

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Ù 97 THAILAND Outline ofProcessingSteps . Receipt ofFresh Shrimps 1. 98

Ù with properfl fl in acleanandsanitarycondition.The The receivingareashouldbemaintained order tocontrolthequalityofshrimps. keep theshrimpsatlowtemperaturesin clean andcoolcondition.Iceisaddedto traditional processingestablishmentina The freshshrimpsaretransportedtothe oors shouldhaveanimperviousfi

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment inASEAN Receiving offresh shrimp Inspection ofshrimp ooring and sloping. and ooring Figure 2 Figure 1 nish 2. Washing Additional oficetopreserve fresh shrimp are furtherprocessed. water fromapprovedsourcesbeforethey the useofmachinesincleanandpotable Shrimps arewashedmanuallyorwith Machine washing ofshrimps Manual washingofshrimps Figure 4 Figure 3 Figure 5 3. Boiling/Steaming Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN the requirementsofcustomers. added intotheboilingwaterdependingon boiled inwaterorsteamed.Saltmaybe time basedontheirsizes.Theymaybe Shrimps arecookedforvaryingperiodsof Boiling ofshrimpsinbaskets Boiling ofshrimpsinstove Figure 6 Figure 7 4. Drying is tofacilitateeasyremovaloftheshell. shells areseparatedfromthemeat.This The cookedshrimpsaredrieduntiltheir or ovenmaybeusedtodrytheshrimps. event ofrainyweather,thehotairdryer traditional sundrying.However,inthe The preferredmethodofdryingis Drying ofshrimpsoverhotair Sun drying Figure 8 Figure 9

THAILAND THAILAND 100 5. De-shelling shells. with somesmallamountofremnant meat (withoutshells)anddriedshrimps dried shrimpswithshells,shrimp various kindsofdriedshrimpsnamely or withtheaidofequipment.Thereare The shrimpsmaybede-shelledmanually Ù

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional FishProducts Processing Establishment inASEAN Machine de-shelling Manual de-shelling Figure 10 Figure 11 6. Sorting/Sizing establishments. and largerscaletraditionalprocessing Sorting isanecessarystepforbothsmall by handorwiththeaidofamachine. shrimps aresortedaccordingtotheirsizes After theshellsareremoved,dried Machine sorting/sizing Manual sorting/sizing Figure 12 Figure 13

Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN GMP forDriedShrimp control procedures targeted atensuringthat combination ofmanufacturingandquality Good ManufacturingPractice (GMP)isthe 7. Packing Cleantoiletsshouldbeprovided andpresent in sufﬁ dryarea inorder toprevent contamination. Packing shouldbeperformedinacleanand theingredients shouldbewell controlled. shouldbeused.Thequalityandquantityof Allutensilsshouldbecleanandnon- absorbent. stainlesssteelorhardened wood. Ice andwater supplyshould bepotable. cats, birds, insectandothervermin. contamination.Itshouldbefree from dogs, Sanitary andcleaningfacilities 4. Theequipmentusedshouldbemadefrom andkept ingoodrepair toprevent Onlyfresh andwholesomeraw materials Production andprocess controls 3. Food equipment 2. Theestablishmentshouldbewell constructed smoke, dustorotherformsofcontamination. facilities. surrounding area anddesignof aswell asthehygiene ofthe Shouldbefree from objectionableodour, Location ofplantandestablishment 1.

bulk orinsmallerretailpacksbefore food gradepolyethylene(PE)bagsin The driedshrimpsarepackedintoclean Packing inPolyethylene (PE)bag Figure 14 rnil Requirement Principle speciﬁ products are consistentlymanufactured totheir cient numbers. cient their quality. laminated plasticbagsinordertomaintain dried shrimpsarepackedinPEbagsor being storedinachillerorfreezer.The cations andsafeforconsumption. Retail PEpacks Figure 15

101

THAILAND THAILAND 102 the product. potable water willprevent contamination of extraneous foreign materials. Theuseofclean possibility ofcontaminationby removing any The purposeofwashing istominimizethe Reason from approved potablesources. Shrimp shouldbewashed withcleanwater Washing GMP 2.1 involved inspoilage. also slows down theenzymaticreactions Icing shrimpsreduces bacterial growth and Reason transported totheprocessing establishment. proper containers afterharvesting andwhile Shrimp are packed insufficientice Receipt GMP 1.1 Section 2 Section 1 clothing,headcovering andfootwear. necessary, wear suitableprotective degree ofpersonal cleanlinessand,when cleanandshouldbemaintainedingood hygienic physical facilitiesoftheplantshouldbekept condition. Building,equipment,utensilsandother Food handlers shouldmaintainahigh Hygiene ofworkers 6. Sanitationprograms shouldbeadequate. Sanitation program andmaintenance 5. Ù

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional FishProducts Processing Establishment inASEAN Washing Receipt offresh shrimps rnil Requirement Principle . Iceshouldbemadefrom potable water to 2. Shrimpsare icedtokeep thematlow 1. Compliance . Unnecessary delays shouldbeavoided to 3. Containers should becleanandmadefrom 2. Potable water from approved sources1. Compliance prevent contamination. temperatures notexceeding 5˚C. freshness. ensure thattheraw materialsretain their food-grade materials. future reference. water testingshouldbeproperly kept for should beusedforwashing. Records of Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN be cleanandsafe. suitable coating.Allmaterials usedshould materials ifthey are well protected by a of theequipmentmay bemadeofcorrodible contamination canbeprevented. Otherparts Shrimp shellingshallbedoneinanarea where and hygienic manner. De-shelling shouldbecarriedoutinaclean De-shelling GMP 5.1 quality. the product anddeterioration inproduct is necessarytoprevent contaminationof environment duringthedryingprocess The careful control ofhygiene andthe Reason should notbeplaceddirectly onthefl a cleanandprotected environment. Shrimps Drying shouldbecarriedouthygienically in Drying GMP 4.1 drying timeascompared tofresh shrimps. cooked shrimpswillalsorequire ashorter the water contentandtocontrol spoilage. The Shrimps shouldbecooked inorder toreduce Reason cleaned. non corrodible materialsthatcanbeeasily and utensilsshallbeusedmadefrom of time. Theproperly designedequipment water orsteamingforsuffi Washed shrimpsare cooked by boilingin Boiling/Steaming GMP 3.1 Section 3 Section 5 Section 4 Boiling/Steaming De-shelling Drying ciently longperiods oor. Compliance . Thede-shellingarea should befree from 1. Compliance quality. the product anddeterioration inproduct is necessarytoprevent contaminationof environment duringthede-shellingprocess The careful control ofhygiene andthe Reason Allworkers mustobserve goodpersonal 3. Dryingequipmentandutensilsare kept 2. Thedryingarea shouldbefree from any 1. . Water usedisfrom anapproved potable 3. Cookingequipmentandutensilsshould 2. Cookingequipmentandutensilsused 1. Compliance such asdogsandcats. insects aswell asrodents andanimals pest suchascockroaches, fl hygiene practices. clean andingoodcondition. conducted. pest control programmes shouldbe flies, insectsandotherpests. Regular source. dry area. every operation andstored inacleanand be washed andsanitizedbefore andafter and benoncorrodible. should bemadefrom foodgrade materials ies andother

103

THAILAND THAILAND 104 quality. of theproduct anddeterioration inproduct area isnecessaryto prevent contamination of hygiene andtheenvironment inthepacking microbial contamination. Thecareful control other extraneous foreign materials, insectsand product againstmechanical damage, dust,dirt, the qualityofproduct andtoprotect the Packaging materials are designedtopreserve Reason manner. bags orsuitableplasticcontainers inahygienic as possibleintocleanfoodgrade plastic(PE) The driedshrimpsshouldbepacked asquickly GMP 7.1Packing quality. the product anddeterioration inproduct is necessarytoprevent contaminationof environment duringthesorting/sizingprocess The careful control ofhygiene andthe Reason and safe. coating. Allmaterialsusedshouldbeclean materials ifthey are well protected by suitable of theequipmentmay bemadeofcorrodible contamination canbeprevented. Otherparts Shrimp shellingshallbedoneinanarea where and hygienic manner. Sorting/sizing shouldbecarriedoutinaclean Sorting/Sizing GMP 6.1 Allequipment,utensils, containers and 2. Section 7 Section 6 well maintained. materials usedmustbeeasy tocleanand Ù

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional FishProducts Processing Establishment inASEAN Packing Sorting/Sizing . Allworkers mustobserve goodpersonal 3. . Allworkers mustobserve goodpersonal 3. Allequipment,utensils, containers and 2. Thesorting/sizingarea shouldbefree from 1. Compliance . Allworkers mustobserve goodpersonal 4. Allequipment,utensils, containers and 3. Thepackingarea shouldbefree from pests 2. Plastic(PE)bagsorplasticcontainers 1. Compliance hygiene practices. water. suitable handcleaningsoapandclean after usingthetoiletfacilities, witha work, aftereachabsencefrom dutyand hat, washing handspriortocommencing and suitableattire, footwear, hairnet or hygiene practices suchaswearing proper well maintained. materials usedmustbeeasy tocleanand such asdogsandcats. insects aswell asrodents andanimals pest suchascockroaches, ﬂ hygiene practices. condition. materials usedmustbecleanandingood dogs andcats. as well asrodents andanimalssuchas such ascockroaches, ﬂ food grade. used inpackingshouldbecleanandof

ies and other insects ies andotherinsects ies andother Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN suffi During thefermentation,liquefi the hydrolysis orbreaking down ofproteins intotheirconstituentpeptidesandaminoacids. left tofermentinfermentationtanksorjars foratleast12months. Thefermentationinvolves the production offi from many speciesoffi known notonlyinAsiabutalsomany partsoftheworld. Though quality specifi months. Subsequentbatchesare considered aslower grades offi After thefi nitrogen content,saltaminonitrogen, glutamicacid/nitrogen ratio, aroma, andcolor. Thai Food andDrugAdministration (FDA) Act, fi batch offermentationisconsidered topgrade or“Grade Aor1”fi Fish sauceor Product Description Fish sauce– Product Name Process FlowDiagram ciently longperiodoffermentation,thefi rst batchoffi 1st liquefi Nam-pla cations, itisfi Nam-pla, Bottling sh sauce. Thefi ed fi ed shes, freshwater andmarine, anchovies are thebestraw materialsfor asitisknown inThailand,isatraditional fi sh sauceistaken off,theresidue isfermentedinbrineforseveral more sh sauce sh ltered andprepared forretail. Fishsaucederived from thefi Mixing ofFishwithSalt ed fi ed sh isusuallymixed withsaltataratio of2:1or3:1and Put intotanksorjars Natural fermentation sh saucerisestothetopoftanksorjars. Aftera 12-18 months Filtration sh sauceisexamined. Ifitcomplieswithcertain sh sauceisgraded according totheirtotal Natural fermentation Addition ofBrine sh sauce. sh 2-3 months sh sauce. According tothe Filtration shery product thatiswell Residue Nam-pla canbemade

105 rst

THAILAND THAILAND Outline ofProcessingSteps 106 1. Mixing of fi This istopreventcontaminationbywater as jars,vatsorconcretetanksandcovered. is placedintoappropriatecontainerssuch of 2:1or3:1.Next,thefi Fish ismixedwithsaltinafi the processingareainafreshcondition. The rawmaterial(fi Ù

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional FishProducts Processing Establishment inASEAN Mixing offi Receipt ofRaw Fish sh withsalt Receipt ofsalt Figure 2 Figure 1 Figure 3 sh andsalt sh) istransportedto sh and salt mixture sh andsaltmixture sh tosaltratio 2. Natural fermentation The fermentationofthefi outside orinsideabuilding. and insects.Thecontainersmaybeleft largely ontheirsalttolerance.Themost and activityofmicroorganismsdepend the fermentationcontainers.Thegrowth higher concentrationsofsaltremainingin by halophilicbacteriathatcantoleratethe however, thefermentationistakenover bacteria. Inthelaterstagesoffermentation is facilitatedbyagroupofnon-specifi weight), theearlystageoffermentation concentrations ofsalt(>20%by by autolysis.Forproductswithhigh of proteinsintopeptidesandaminoacid pla involvesthehydrolysisorbreakdown Fermentation inearthenjars (12-18 months) Fish sauce Figure 5 Figure 4 sh to form Nam- c

. Filtration andBottling 3. Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN 1. Location and establishment: Personnel6. hygiene Sanitation program5. andmaintenance Sanitary andcleaningfacilities 4. Production andprocess3. controls Equipment 2. Location andestablishment 1. the following: which statestheminimumrequirements for (GMP) thatcomplywiththeThaiFood Act out according toGoodManufacturingPractice The production offi GMP forFishSauce( precipitate, thefi sauce mustbeaclearliquidwithno Thai fi liquid willhaveaspecifi reddish-brown liquidisobtained.This After 12-18monthsoffermentation,a specifi is checkedandifitmeetsthequality 12 months.Afterwhichthefi fermentation usuallylastsbetween8to may enterthefermentationmixture.The serves toinhibitpathogenicbacteriathat of largeamountssalts.Thesaltalso fi common spoilageorganismsfoundin 2. The fl Thesurroundings oftheestablishment 1. shes canbeinhibitedwiththeaddition other contamination. objectionable odours, smoke, dustor must bekept cleanandfree from be kept clean. maintained ingoodrepair andmust easy tocleananddisinfect.They are non-absorbent materials, whichare constructed ofdurable, waterproof, fish isreceived orprocessed are cation, itisreadyforbottling. sh saucestandardstatesthatfi oors in wet working areas where sh saucehastobefi sh saucemustbecarried c aroma.Asthe s sauce sh Nam-pla ltered ltered sh ) . Sanitationandcleaningfacilities 4. Production andprocess controls 3. 2. Equipment Finished product –Fishsauceinbottles . Clean toiletsare provided andin 2. The water supplyshouldbepotable 1. 3. The fi Theratio offi 2. Attention shouldbegiven tomaintain 1. Theseshouldbemadefrom stainless 1. Thehygiene anddesignoffacilities 3. by insectsorfl which iscleantopreventcontamination should beaspeciallydesignatedarea before beingbottled.Theprocessingroom suffi with thequalitystandard. as raw material. according tothesize ofthefi quality. order toattainafi the freshness oftheraw materialsin condition. non-absorbent andkept in ahygienic steel orhardened wood, whichis vermin. from dogs, cats, birds, insectsandother should helpprevent contamination cient numbers. cient nished product shouldcomply ies. Figure 6 sh tosalthasbevaried nal product ofgood sh used sh

107

THAILAND THAILAND 108 the fi be inthecorrect ratio andwell mixed with a cleanarea. Theamountofsaltusedshould Mixing shouldbecarriedouthygienically in Mixingoffi GMP 1.2 Thefreshness ofthefi 1. Compliance substance. harmful tohumanswhoare allergic to this A highhistaminecontentispotentially in thefi there isthedangerofhighhistaminecontent If fi Reason free from decomposition. Fish mustbereceived inafresh conditionand Receiptoffi GMP 1.1 Every person engagedinthehandling or 6. Personnel hygiene 5. Sanitationprogram andmaintenance Section 1 sh isnotfresh orinastate ofdecomposition, the fi at thelandingplacebefore transporting establishment orby adding salttothefi the landingplacetoprocessing by reducing thetransport timefrom a highdegree ofpersonal cleanliness processing procedure shouldmaintain Thebuildingequipment,utensilsand 2. Thesanitationprogram shouldbe 1. Ù

sh.

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional FishProducts Processing Establishment inASEAN in anorderly andhygienic condition. should bekept cleanandmaintained other physical facilitiesoftheplant adequate. sh formedduetobacterialactivity. sh tothe processing establishment. Mixingofﬁ sh can be maintained sh canbemaintained sh andsalt sh sh withsalt sh

process. no spoilageoccurs duringthefermentation be suffi as halophilicbacteriaandmoulds. Saltmust control thegrowth ofmicroorganisms such hygienically toprevent contaminationandhelp Mixing withsaltshouldbecarriedout Reason . Itmay alsobecarriedoutonacleanfl 5. Utensilsandcontainers usedmustbe 4. Utensilsandcontainers used formixing 3. Allworkers mustobserve goodpersonal 2. Mixingshouldbecarriedoutinaclean 1. Compliance . Nojewelry andfi 6. Nosmokingandspitting 5. Nofoodordrinksare tobebrought 4. Wearing suitableprotective clothing. 3. Capsorhatsshouldcover2. hair Washing1. handsbefore andafter should observe thefollowing protocol: particularly inthepackingareas. They and free from corrosion. which cantolerate highdegrees ofsalt constructed from foodgrade materials use. must beproperly sanitizedbefore andafter hygiene practices. from allpests. and properly sanitizedarea whichisfree directly onthefl However, itshouldnever becarriedout which iscovered withacleanplasticsheet. cient andwell mixed toensure that into theworking area properly. work. oor. ngernail polish ngernail oor Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN product contamination unclean bottlesandcapswillalsoresult in contamination ofthefi is necessarytominimizethepossibilityof careful control ofhygiene and sanitation be aclearliquidwithnoprecipitate. the sauce standard statesthatfi fi Filtration isnecessaryinorder toproduce a Reason hygiene amongstworking personnel. used. There shouldbeawareness ofpersonal stored inasanitarymannerbefore andafter equipment andbottlesshouldbeclean dry area withgoodventilation. Thefi be carriedout Filtration andbottlingofthefi FiltrationandBottling GMP 3.1 Thefermentationarea shouldbecleanand 1. Compliance sauce. contamination andspoilageofthefish and environment isnecessarytoprevent 18 months),thecareful control ofhygiene As thefermentationperiodislong(12to Reason in acleanarea. Fermentation shouldbecarriedouthygienically Fermentation GMP 2.1 sh sauceofgoodquality astheThaifi Section 3 Section 2 animals suchasdogsandcats. and otherinsectsaswell asrodents and free from pestssuchascockroaches, fl Filtration andBottling Natural fermentation

hygienically inacleanand sh sauce. Theuseof sh sauceshould sh saucemust lter, ies sh

. Allpersonnel mustcomplywithgood 3. Allfiltration and bottlingutensils,2. 1. The ﬁ Compliance . Thedateoffermentationandthenumber 5. Thecontainers musthave tight-fitting 4. Allutensils, containers andequipmentused 3. Thefermentationcontainers shouldbe 2. personal hygiene practices. cracks orcrevices orany other damage. and well maintainedwithoutany rust, capable oftolerating ahighdegree of salt clean, madeofnon-corrodible materials containers andequipmentusedmustbe as dogsandcats. as vermins andotheranimalpestssuch cockroaches, ﬂ be cleanandfree from pestssuchas fermentation. recorded andlabeledforeachlot of of thefermentationcontainermustbe insects, rain andwater seepage. covers toprevent contaminationfrom damage. any rust,cracks orcrevices orany other degree ofsaltandwell maintainedwithout materials capableoftolerating ahigh must beclean,madeofnon-corrodible after use. washed andsanitizedproperly before and ltration andbottling area should ies andotherinsects aswell

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THAILAND 110 Ù Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Vietnam

Product Name

Fermented tiny shrimp paste – Mam tom

Product Description

Fermented tiny shrimp paste or Mam tom in Vietnamese language is largely produced in the coastal provinces of Vietnam. Its ingredients include tiny shrimps and salt (10-13% by weight). The time required for fermentation may vary between two to six months. Depending on the technology used, the texture of the shrimp-salt mixture may be smooth or very smooth. The mixture will also possess a light and distinct fragrance.

Process Flow Diagram

Receipt of Salt Receipt of Tiny Shrimps

Cleaning

Salting

Ferment and Grind

Ferment, Dry

Packing, Storage and Distribution

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Ù 111 VIETNAM Outline ofProcessingSteps 112 Receipt ofRaw Materials 1. 2. Washing Tiny shrimpsforMamtomproduction . Receipt oftiny shrimps a. ﬁ such assand,grit,seaweed andothersmall sheet. Thisistoallowall foreignmaterials on thecleancementﬂ At theTPE,tinyshrimps arescattered . Receipt ofSalt b. Ù

shes to be removed. This is done manually shes toberemoved.This isdonemanually

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional FishProducts Processing Establishment inASEAN to theTPE. near thelandingsitebefore beingsent Processing Establishment(PPE)ator shrimps have tobesaltedataPre- from away In caseswhere theTPEislocatedfar within three hours oftheircapture. Processing Establishments(TPE) have todespatchedtheTraditional should beused.Thetiny shrimps or driftnetsthatdonotcontainlead captured from theﬂ should onlyusetiny shrimpsthatare paste isproduced, theproducers To ensure thathighqualityshrimp processing ensure thatitishygienic for use in stored inaseparate storage place to consumption. Thesaltisreceived and standard forsaltand beﬁ tom The saltusedfortheproduction of mustcomplywiththenational the locationofcapture, the Figure 1 oor oronplastic oating layer.Cast oating t forhuman Mam Mam

3. Salting and Grinding 4. Fermentation then groundbyagrindingmachine. have beingcleaned.Thesaltedshrimpsare the requiredproportionsaftershrimps PPE beforedelivery,saltisthenaddedin For theshrimpsthatarenotsaltedata clean waterandwashedagain. transferred tothesecondtankcontaining such assandandgrit.Theshrimpsarethen mixed withtheheavierforeignmaterials at thebottomoftankastheymaybe taking carenottoremoveanyshrimps tiny shrimpsareremovedfromthewater removing thefl will sinktothebottomoftank.After heavier materialslikesand,gritandshells lighter materialstofl mixture isstirredcarefullytoallowthe shrimps areputintothetankofwater, are washedin50kg-batches.Afterthetiny removal offoreignmaterials.Theshrimps with waterinatanktoensurethorough The shrimpsarethenwashedtwotimes with orwithoutthehelpofbasketsieves. presence ofpropercovers andlids,or fermentation canoccur outdoorsinthe or plasticbinsfortwoto sixmonths.The in cementtanks,glazed terra-cottajars The groundtinyshrimps arefermented Salting oftinyshrimps oating foreign materials, the oating foreignmaterials,the Figure 2 oat to the surface. The oat tothesurface.The Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN Indoor fermentationinplastic binswith Outdoor fermentationincementtanks up leadingtoashorterfermentationtime so thatthehydrolysisreactionisspeeded This isdonetoincreasethetemperature stirring isreducedtoonceeverytendays. shrimps ceasebloating,thefrequencyof the coversarenotopened.Whentiny afternoon. Intheeventwherethereisrain, to sunandthecoveristhenclosedin stirrer everymorning.Itisthenallowed stir themixturewithawooden/plastic the coverofcontainingvesseland is stirreddaily.Theworkermustopen During fermentation,theshrimppaste of smoothness,colourandtaste. will resultinMamtomofdifferentdegree vary dependingonthelocalpractice.This grinding andthefermentationperiodmay at theTPE.Thetimerequiredfor indoors dependingonthemethodsused with covers Figure 4 Figure 3 lids 5. Packing andStorage room temperature. plastic (polyethylene)bags.Storageisat glass bottles,plasticcansand number ofwaysafterfermentation–in The fi fi and thespecifi Shrimp pastepackedinplasticbottle nal product. nal nished product maybepackedina Stirring theshrimppaste Figure 5 Figure 6 c tasteandcolorofthe

113

VIETNAM VIETNAM 114 . Thecore temperature oftheraw material 4. Lotswithexcessive amountsofforeign 3. Organoleptic qualitiesofraw material 2. Hygieneconditionsofthetransportation 1. each lotofraw material: The following are checked uponreceipt of Compliance processing. for consumptionandsuitableusein the raw materialsare ofhighquality, safe preservation conditionsistoensure that organoleptic qualities, transportation and The purposeofcheckingtheraw material’s Reason to theTPE. preservation temperature duringtransportation conditions, meansofpreservation, and for itsorganoleptic qualities, transportation Each lotoftiny shrimpsshouldbechecked Receiptoftinyshrimps GMP 1.1 GMP forfermentedtinyshrimppaste Section 1 must notexceed 10˚C. and leaves shouldberejected. materials suchassand,grit,dust,wood odours shouldberejected. spoiled, broken ortaintedhave off- (color, smell,structure) -Lotsthatare and preservation means. Ù

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional FishProducts Processing Establishment inASEAN Receipt ofRaw Materials consumption. food safetyregulations andissafeforhuman This istoensure thatthesaltcomplieswith Reason specialized store. it isweighed, recorded anddespatchedtoa If thelotofsaltfulﬁ • Label • Preservation means Hygieneconditionsduring transportation • must bechecked: Upon receipt ofeachlotsalt,thefollowing Receiptofsalt GMP 1.2 3. Thefollowing criteriashouldbe Conditionofthepackage and proper 2. Hygieneconditionsofthetransportation 1. each lotofsalt: The following are checked uponreceipt of Compliance . Saltmustbe usedonaFirst-In-First-Out 4. Foreign matter:withoutgrits, shells, • Percentation ofindissolublesubstances: • Appearance and particlesize:dry, clean, • Taste: Purely salty • • Smell: odourless Color:white, yellowish, pinkish. • observed: labeling. means. by date. should notbebeyond theirexpiry/used rotation/inventory control schedule. Salt (FIFO) basisoraccording totheplant’s materials. pieces ofwood andotherforeign 0.4%. particle sizeof1-1.5mm (Mam tom) ls the speciﬁ the ls ed criteria, ed Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN Mixing withsaltshouldbecarriedoutin 1. Compliance paste. in transforming tiny shrimpsintoshrimp activity ofyeasts andotheruseful bacteria decomposing bacteriatoensure thenormal in arequired concentration caninactivate the such ashalophilicbacteriaandmoulds. Salting help control thegrowth ofmicroorganisms hygienically toprevent contaminationandto Mixing withsaltshouldbecarriedout Reason product. be carefully controlled toattainthedesired a cleanarea. Theamountofsaltusedshould Salting shouldbecarriedouthygienically in Salting GMP 3.1 process. microbial growth duringthewashing Using chilledwater willprevent orreduce contamination oftheproduct by thewater. potable water sources willprevent possible foreign materials. Theuseofapproved contamination by removing allextraneous The purposeofwashing istominimize Reason out from unwanted foreign materials. approved potablewater sources andsorted out hygienically usingchilledwater from Washing ofthetiny shrimpsshouldbecarried Washing GMP 2.1 Section 3 Section 2 is free from allpests. a cleanandproperly sanitizedarea which SaltingandGrinding Washing . Washing utensilsandcontainers mustbe 5. Allworkers mustobserve goodpersonal 4. Thewashing area mustbemaintainedina 3. Thetemperature ofthewater shouldbe 2. Thewater usedmustbefrom anapproved 1. Compliance become contaminatedby dirtyequipment. machine willensure thattheproducts donot Using cleanandwell maintainedgrinding Reason for thepurpose. that are clean,well maintainedandsuitable Grinding shouldbecarriedoutusingequipment Grinding GMP 3.2 Utensilsandcontainers usedmustbe 4. Utensilsandcontainers used formixing 3. Allworkers mustobserve goodpersonal 2. after use. properly washed andsanitizedbefore and and free from corrosion. They shouldbe constructed from foodgrade materials hygiene practices. clean conditionandfree from allpests. or withtheadditionofice. maintained atbelow 5˚Cby refrigeration potable source. free from corrosion. constructed from foodgrade materialsand use. must beproperly sanitizedbefore andafter hygiene practices.

115

VIETNAM VIETNAM 116 tiny shrimppaste. prevent contaminationandspoilageofthe of hygiene andenvironment isnecessaryto about two tosixmonths, thecareful control As thefermentationprocess islongfrom Reason in acleanarea. Fermentation shouldbecarriedouthygienically Fermentation GMP 4.1 Grindingequipmentmustbe constructed 1. Compliance contamination bottles andcapswillalsoresult inproduct the tiny shrimppaste. Theuseofunclean is necessarytoprevent contaminationof the careful control ofhygiene andsanitation As theseprocesses are carriedoutmanually, Reason environment. carried outinaclean,hygienic mannerand Bottling, cappingandlabelingshouldbe Bottling,Cappingand GMP 5.1 Section 4 Section 5 from foodgrade materialsandfree from Ù

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional FishProducts Processing Establishment inASEAN Fermentation Packing andStorage Labeling . Grindingequipmentmustbeproperly 2. . Allutensils, containers and equipmentused 3. Thefermentationcontainers/tanks should 2. Thefermentationarea shouldbecleanand 1. Compliance 4. Thelabelsshouldhave sufficient Thepackingandstorage area shouldbe 3. Allworkers mustobserve goodpersonal 2. Allbottlesandcapsmustbewashed and 1. Compliance sanitized before andafteruse. surfaces corrosion especiallyallfoodcontact damage. any rust,cracks orcrevices orany other degree ofsaltandwell maintainedwithout materials capableoftolerating ahigh must beclean,madeofnon-corrodible and afteruse. be washed andsanitizedproperly before animals suchasdogsandcats. and otherinsectsaswell asrodents and free from pestssuchascockroaches, fl expiry. available), dateofproduction, dateof and address oftheproducer, code (if information suchasproduct name, name cats. as rodents andanimalssuchasdogs cockroaches, fl protected andfree from pestssuchas covers. disposable gloves, facemasksandhair hygiene practices andproperly attired with sanitized properly justbefore use. ies andotherinsectsaswell ies Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN The fi light yellow toadarkbrownish-yellow. - 12months. Dependingonthemethodused,colouroffi single fi Process FlowDiagram together atagiven ratio. Thefi Vietnam. Itstwo mainingredients are marinefi Fish sauceor Product Description Fish sauce– Product Name nal product issoldlocallyfordomesticconsumptionandalsoexported. sh speciestoamixture ofdifferent fi Nuoc mam Nuoc mam Receipt ofSalt isproduced predominantly alongthecoastalandisland provinces of sh usedintheproduction of Nuoc mam sh species. Thismixture islefttofermentfor6 sh andsalt.Thesetwo ingredients are mixed hasitsown distinctive fl Storage AndDistribution Bottling AndLabeling Receipt ofFish Fermentation Extracting Nuoc mam Mixing Salting sh saucemay vary between may vary between a avour andodour.

117

VIETNAM VIETNAM 3. Fermentation 1. Receipt ofRaw Materials Outline ofProcessingSteps 2. Salting 118 stipulated intervals overtheperiod of 12 fi the sunandthenpoured backoverthe inside thejarisextracted, leftexposedto or threedays,theturbid andbloodyfl each jariscarefullyrecorded.Aftertwo bar. Thestartingdateoffermentation set upisthenweigheddownwithawooden the fi A wovenbamboomatisthenplacedover Without stirring: more salt. not reach23-25˚ salinity ofthemixture.Ifdoes salting stage,itisnecessarytocontrolthe into thejarontopoffi to 1.5cmthicklayerofsaltisthenadded to 30cmfromthemouthofjar.A1 into earthenwarejarsleavingagapof20 . Receipt offi a. stirring). Thefi one partsalt(fermentationmethodwith without stirring)ortwopartsfishto to onepartsalt(fermentationmethod well withsaltinaratiooffourpartsfi before mixingwithsalt.Thefi The fi . Receipt ofsalt b. Ù

sh inthe jar.Thisstepisrepeatedat

clean andhygienic foruse. This istoensure thatthesaltremains received andstored inaseparate store. national standard forediblesalts, is The salt,whichisapproved underthe drained andweighed. The fi species andforeign materialsremoved. water andothermiscellaneousfish of raw fi and qualityinspection.Uponreceipt fi Raw Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional FishProducts Processing Establishment inASEAN sh-salt mixtureinthejar.Theentire sh iswashedwithwateranddrained sh isthenplacedinicedwater, sh mustundergo organoleptic sh, thefi sh-salt mixtureisthenfi sh

Be, itisnecessarytoadd sh isrinsedwith sh.Duringthe shismixed lled lled uid sh fi The additionofsaltmustoccurfourto the fi must continueinthefollowingdaysas to stirthemixturecarefully.Thestirring Upon theadditionofsalt,itisimportant • Bubbles develop whenstirringthe • Sour andstinkingodour fl • Fish fi • Fish broken belly • Fish that moresalt(5-10%)isadded: the followingareobserved,itisadvisable fi be stirredonadailybasis.Withintwoto and coveredatnight.Themixturemust may beleftuncoveredduringtheday the salt.Inabsenceofrain,jars the mixturetoensuredissolutionof type offi percentage mayvarydependingonthe weight ofpotablewaterisadded.This two tothreedayafterwhich20-25%by The fi With stirring: set up. under thesunandthenre-placedin wooden barareremoved,washed,dried After eachmonth,thebamboomatsand the fi on thetopofjarandtoensurethat fermented fi to checkonthebloomingstatusof development ofmould-causingbacteria, must beconductedonthejarstoavoid months offermentation.Weeklychecks will beginto materialize. months, thedistinctiveodour offi to exposethefi 30-35%. Thejarsare uncovered daily salt percentageshouldbe approximately should notbefoundfl down tothebottomofjar.Thefi suffi ve timesuntilthefi ve daysupontheadditionofwater,if mixture cient amountofsaltandhavesunk sh arewellsubmergedinsaltwater. shes areleftexposedtothesun. sh-salt mixtureis left tofermentfor oating ontopofmixture torn llet sh used.Arakeisusedtostir sh andtoremovethefoam sh tothesun.After5-6 sh haveabsorbeda oating ontop.The sh sauce sh Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN 4. Extraction Fish saucefermentinginearthenware jars . Preparation ofsaltwater a. extracted. After fermentation,thefi • State of fi Distinct aroma andfl • Colourisdarkbrown orgrey. Thefi • fermentation iscomplete: Parameters todeterminewhenthe ClassC:Pelagic fi • ClassB:Includeotherfi • ClassA: Includefi • sauce: Classifi water. Onepartofsaltisadded tothree Edible saltisusedtoproduce thesalt – – and offodour. colour. extracted liquidisreddish brown in and lizardfi grade fi B fi quality. Fishsaucemadefrom Class as Top grade fi made from Class Afi Mackerels andMudcarps. Fishsauce Fermentation withstirring:Thefi fi Fermentation withoutstirring:The stirred. foam emerges whenthemixture is are completelybroken upandno sh are stillwhole. sh isconsidered Specialand First cation offi sh sauce. sh sh: sh. Figure 1 sh sauce. sh sh usedtomakefi shes suchasgoatfi shes like Anchovies, avor withoutsour sh is considered is sh sh saucecanbe shes of good of shes rst sh sh sh Siphoning fi b. Extracting fi 20˚N. usually containaprotein level of15- from thelasttankinchainwhich grades offi The finishedproduct isthelower jar isconnectedtofi salt water isaddedintothejar. The After theabove procedure, theprepared protein level ofover 35˚N. fi 100 litres/12 hours toobtain top-grade within two tothree days ataspeedof days. Thelastextraction canbedone hours, withinaspanoffourtofi must bedoneataspeedof100 litres/10 extraction andthere-addition ofliquid obtain thetop-grade fi extraction procedure isrepeated to the jarover thefermentedfi removed liquidispoured backinto bamboo matisreplaced andallthe a smallstream intoatank.Thewoven the liquidfrom theearthenware jarin of thejaristhenadjustedtodrain all jar isopened.Thespigotonthebottom suffi After 10-12 months, whenthefi the extraction offi clear andcleansaltwater isusedin to 27˚Béisconsidered satisfactory. This using aBaumemeter. Asalinityof25 salinity ofthewater isthenmeasured to allow allthesalttodissolve. The parts ofwater. Themixture isstirred sh sauce, whichnormally containsa ciently fermented,theearthenware sh saucetothetop ofthejar sh saucethatisextracted Figure 2 sh sauce sh sh sauce. sh ve toseven tanks. s sue The sauce. sh s. The sh.

Ù sh is sh

119 ve ve

VIETNAM VIETNAM 6. BottlingandLabeling 5. Mixing GMP forFishSauce 120 Lotswithexcessive amountsofforeign 3. Organoleptic qualities ofraw material 2. Hygieneconditionsofthetransportation 1. sardine, goatfi each lotofraw material(anchovy, mackerel, The following are checked uponreceipt of Fish: Compliance suitable foruseinprocessing. are ofhighquality, safeforconsumptionand conditions istoensure that theraw materials qualities, transportation andpreservation The purposeofcheckingtheorganoleptic Reason to theTPE. preservation temperature duringtransportation conditions, meansofpreservation, and for itsorganoleptic qualities, transportation Each lotofraw materialsshouldbechecked Receiptoffi GMP 1.1 Section 1 The completedfi fi sauce maybemixedtoobtaincommercial the topgradeandlowergradesoffi Depending oncustomers’requirements, and leaves should berejected. materials suchassand, grit,dust,wood off-odours shouldbe rejected. stale/spoiled, broken ortaintedhave (color, smell,structure) -Lotsthatare and preservation means. Ù

sh saucewithaspeciﬁ

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional FishProducts Processing Establishment inASEAN Receipt ofRaw Materials sh, etc.): sh sauceiscontained c proteinlevel. sh andsalt (Nuoc mam) sh 7. Storage . Saltmustbe usedonaFirst-In-First-Out 4. 3. Thefollowing criteriashouldbe Conditionofthepackaging materialand 2. Hygieneconditionsofthetransportation 1. each lotofsalt: The following are checked uponreceipt of Salt: . Thecore temperature ofthefi 4. temperature. dry andcoolstoreatanoptimal The fishsauceisstoredinaclean, as required. glass orplasticbottles,sealedandlabeled in atank.Thefi by date. should notbebeyond theirexpiry/used rotation/inventory control schedule. Salt (FIFO) basisoraccording totheplant’s Foreign matter:withoutgrits, shells, • Percentation ofindissolublesubstances: • Appearance andparticle size:dry, • Taste: Purely salty • • Smell: Color:white,Odourless yellowish, pinkish. • observed: the presence ofproper labelling. means. exceed 10˚C. materials. pieces ofwood andotherforeign 0.4%. clean, particlesizeof1-1.5mm sh sauceispackedinto sh must not Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN Thefermentationarea shouldbecleanand 1. Compliance odour andfl This stageisessentialincreating thedistinct contamination andspoilageofthefi environment isnecessary toprevent the months), thecareful control ofhygiene and As thefermentationprocess islong(6-12 Reason in acleanarea. Fermentation shouldbecarriedouthygienically Fermentation GMP 3.1 and moulds. microorganisms suchashalophilicbacteria contamination andhelpcontrol thegrowth of should becarriedouthygienically toprevent foreign extraneous materials. Mixingwithsalt The fi Reason attain thedesired product. of saltusedshouldbecarefully controlled to out hygienically inacleanarea. Theamount mixed withsalt.Saltingshouldbecarried The fi Salting GMP 2.1 Section 3 Section 2 animals suchasdogsand cats. and otherinsectsaswell asrodents and free from pestssuchascockroaches, fl shes are washed/rinsed toremove all shes are washed/rinsed before being avour offi Fermentation Salting sh sauce. sh sh sauce. ies . Utensilsandcontainers usedmustbe 5. Utensilsandcontainers usedformixing 4. Allworkers mustobserve goodpersonal 3. Mixingwithsaltshouldbecarriedoutin 2. Fishshouldbewashed/rinsed using 1. Compliance . For fermentationmethodwithoutstirring, 4. Allutensils, containers andequipment used 3. Thefermentationcontainers/tanks should 2. free from corrosion. constructed from foodgrade materialsand use. must beproperly sanitizedbefore andafter hygiene practices. is free from allpests. a cleanandproperly sanitizedarea which by weight ofsaltforthestirringmethod. bamboo matplacingmethodand45-50% used -25%by weight ofsaltforthewoven of saltdependingontheprocessing method potable water andmixed withapercentage 2 intheoutlineofprocessing steps. re-placed inthesetupdescribedstep washed, driedunderthesunandthen and wooden barare removed. They are after eachmonth,thebamboomats damage. any rust,cracks orcrevices orany other degree ofsaltandwell maintainedwithout materials capableoftolerating ahigh must beclean,madeofnon-corrodible and afteruse. be washed andsanitizedproperly before

121

VIETNAM VIETNAM 122 Utensilsandcontainers usedmustbe 6. Utensilsandcontainers used formixing 5. Allworkers mustobserve goodpersonal 4. Saltwater shouldbeprepared inaclean 3. Water usedmustbepotable. 2. Thesaltusedmustcomplywiththe 1. Compliance of thefi water willprevent contaminationandspoilage use ofclean,goodqualitysaltandpotable fi As thesaltwater willbeusedtoextract the Reason water. using clean,goodqualitysaltandpotable Salt water shouldbeprepared hygienically Preparationofsalt GMP 4.1 sh sauce, itshygienic preparation andthe Section 4 free from corrosion. constructed from foodgrade materialsand sanitized before andafteruse. must becleanandproperly washed and hygiene practices. pests. and hygienic area whichisfree from all processing. to ensure thatitishygienic forusein and stored inaseparate storage place human consumption.Thesaltisreceived national standard forsaltandbefi Ù

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional FishProducts Processing Establishment inASEAN sh sauce. sh Extraction water t for t . Allworkers mustobserve goodpersonal 4. Allutensils, containers and equipmentused 3. Thecontainers/tanks usedshouldbe 2. Theextraction area shouldbecleanand 1. Compliance sauce. contamination andspoilageofthefish and environment isnecessarytoprevent a few days, thecareful control ofhygiene As theextraction process takes placeover Reason hygienically inacleanarea. Extraction offi Extractingfi GMP 4.2 hygiene practices. damage. any rust,cracks orcrevices orany other degree ofsaltandwell maintainedwithout materials capableoftolerating ahigh must beclean,madeofnon-corrodible after use. washed andsanitizedproperly before and animals suchasdogsandcats. and otherinsectsaswell asrodents and free from pestssuchascockroaches, fl sh sauceshouldbecarriedout sh sauce sh ies . Themixingarea shouldbecleanand 1. Compliance process. spoilage ofthefi is necessarytoprevent contaminationand The careful control ofhygiene andenvironment Reason The mixingofdifferent grades offi Mixing GMP 5.1 and environment. should bedoneinaclean,hygienic manner Good Manufacturing Practice (GMP) forSmall and Medium-sized Traditional Fish Products Processing Establishment inASEAN Allbottlesand capsmustbewashed and 1. Compliance will alsoresult inproduct contamination sauce. Theuseofuncleanbottlesandcaps necessary toprevent contaminationofthefi the careful control ofhygiene andsanitationis As theseprocesses are carriedoutmanually, Reason a clean,hygienic mannerandenvironment. Bottling andlabelingshouldbecarriedoutin BottlingandLabeling GMP 6.1 Section 6 Section 5 animals suchasdogsandcats. and otherinsectsaswell asrodents and free from pestssuchascockroaches, fl sanitized properly justbefore use. BottlingandLabeling Mixing sh sauceduringthemixing sh sauce sh ies sh

4. Thelabelsshouldhave sufficient Thebottlingandlabelingarea shouldbe 3. Allworkers mustobserve goodpersonal 2. 5. The ﬁ Allworkers mustobserve goodpersonal 4. Allutensils, containers andequipmentused 3. Thecontainers/tanks usedshouldbe 2. expiry. (if available), dateofproduction, dateof name andaddress oftheproducer, code nitrogen andsodium chloridecontent, information suchasproduct name, total cats. as rodents andanimalssuchasdogs cockroaches, ﬂ protected andfree from pestssuchas covers. disposable gloves, face masksandhair hygiene practices andproperly attired with a dryandcoolplace. hygiene practices. damage. any rust,cracks orcrevices orany other degree ofsaltandwell maintainedwithout materials capableoftolerating ahigh must beclean,madeofnon-corrodible after use. washed andsanitizedproperly before and nished product shouldbestored in ies andotherinsects aswell

123

VIETNAM VIETNAM maintain qualityandextend shelflife. Proper storage ofﬁ Reason place. should bestored inahygienic, coolanddry The bottledfishsauce(finishedproduct) Storage GMP 7.1 124 Section 7 Ù

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional FishProducts Processing Establishment inASEAN Storage nished products will help will products nished . Finishedproducts mustbeusedonaFirst- 3. Thestorage area shouldbefree from pests 2. Thestorage area shouldbeclean,dryand 1. Compliance their expiry oruse-by dates. schedule andshouldnotbeusedbeyond the factory’s rotation/inventory control In-First-Out (FIFO) basisoraccording to dogs andcats. as well asrodents andanimalssuchas such ascockroaches, ﬂ well maintained. ies and other insects ies andotherinsects APPENDIX 126 Ù Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN List of Contributors

Brunei Darussalam Indonesia

Mrs Hajah Laila Haji Hamid Dr Simson Masengi Head of Post-Harvest Development and Deputy Director for Small-Medium Quality Assurance Division Processing Enterprise Fisheries Department, Directorate General of Fishery Product Ministry of Industry and Primary Resources, Processing and Marketing, Jalan Menteri Besar, Ministry of Marine Affairs and Fisheries BB3910, Negara Brunei Darussalam Ditjen P2HP, Mina Bahari 2nd Building, Tel: +673 2 2770234/6 10th Floor, Fax: +673 2 2770237 Jl. Medan Merdeka Timur No. 16 Email: laila_hamid@fi sheries.gov.bn Jakarta 10110 Tel: +62 21 3500187 Ms Mariani Haji Sabtu Fax: +62 21 3500187 Senior Fisheries Offi cer E-mail: [email protected] Fisheries Department, Ministry of Industry and Primary Resources, Jalan Menteri Besar, BB3910, Lao PDR Negara Brunei Darussalam Ms Dongdavanh Sibounthong Tel: +673 2 2383412/2383067 Department of Livestock and Fisheries Fax: +673 2 2382069 P.O. Box 811 Vientiane Capital E-mail: mariani.sabtu@fi sheries.gov.bn Lao PDR Tel: +856 21 215 242/243 Fax: +856 21 215141 Cambodia E-mail: [email protected]

Mr Sem Viryak Deputy Director Department of Fisheries Post-harvest Malaysia Technologies and Quality Control Dr Bah Piyan Tan No. 186 Norodom Blvd, Head, Public Health Section Phnom Penh, Department of Fisheries Malaysia, Cambodia Biosecurity Fisheries Division, Tel: +855 11 948088 Level 3, Podium 2, Block 4G2, Fax: +855 23 224871 Wisma Tani, Precinct 4, 62628 Putrajaya, E-mail: [email protected] Malaysia Tel: +6 03 8870 4707 Fax: +6 03 8890 3794 E-mail: [email protected]/pyian_tan@ yahoo.com

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Ù 127 Myanmar Singapore

Mr Tint Wai Mr Norman Kok Head, Inspection and Certiﬁ cation Section Senior Programme Executive Fisheries Inspection and Quality Control Post-Harvest Technology Division Division Agri-Food and Veterinary Authority Department of Fisheries, Myanmar 2 Perahu Road, Singapore 718915 Sinmin Road, Ahlone Township, Tel : +65 6790 7973 Yangon, Myanmar Fax : +65 6861 3196 Tel: +95 1 225 573 E-mail: [email protected] Fax: +95 1 228 628 E-mail: [email protected] / arasf. [email protected] Thailand

Ms Hla Hla Kyu Mrs Niracha Wongchinda Assistant Director, Price Conﬁ rmation Senior Expert on Fisheries Products Section Department of Fisheries, Fish Inspection and Quality Control Division Chulaporn Bldg Department of Fisheries Kaset-Klang, Chatuchak Sinmin Road, Ahlone Township, Bangkok 10900, S Yangon, Myanmar Thailand Tel: +95 1 220631/220597 R Tel: +66 2 940 6526 Fax: +95 1 228258/222139 Fax: +66 2 562 0571 E-mail: [email protected] O E-mail: [email protected]

Varatip Somboonyarithi Philippines Director Fishery Technological Development Division Ms Melannie R. Guerra Department of Fisheries, Supervising Aquaculturist Plodprasop Building, Bureau of Fisheries and Aquatic Resources Kaset-klang, Chatuchak, (BFAR) Bangkok 10900, Thailand PCA Building, Elliptical Road, Tel: +66 2 940 6199 Diliman, Quezon City Fax: +66 29406200 Tel: +63 2 454 58 63 E-mail: [email protected]

NTRIBUT Fax: + E-mail: [email protected]

Ms Norma C. Borja Supervising Aquaculturist CO Bureau of Fisheries and Aquatic Resources (BFAR)

F Fisheries Post-harvest Technology Division PCA Building, Elliptical Road,

O Diliman, Quezon City Tel: +63 2 454 10 83 Fax: + T E-mail: [email protected] S LI

128 Ù Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Vietnam

Mr Nguyen Dinh Thu Director National Agro-Forestry Fisheries Quality Assurance Department (NAFIQAD) Southern Regional Authority 30 Ham Nghi Street, District 1, Ho Chi Minh City Vietnam Tel: +84 8 39151899 Fax: +84 8 39141575 E-mail: dinhthu.naﬁ @mard.gov.vn

Mr Tran The Phong Deputy Director National Agro-Forestry Fisheries Quality Assurance Department Branch I (NAFIQAD Branch I) 39A Le Lai, Ngo Quyen District, Hai Phong City, Vietnam S Tel: +84 313 837124 R Fax: +84 313 837507 E-mail: thephong.naﬁ [email protected]/ O thephongnaﬁ [email protected] T U NTRIB CO F O T S LI

Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN Ù 129 130 Ù Good Manufacturing Practice (GMP) for Small and Medium-sized Traditional Fish Products Processing Establishment in ASEAN