Here we introduce how the frozen fish fillet processing plant uses Marel Food processing company Products and advanced processing solutions for enabling consistent product quality. The demands made on fish processing machines are high and often very specific. Marel is at the forefront of salmon processing
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The share of processed fish products on the market is growing constantly. Jobs that used to be carried out by hand are today performed more and more often by machines. In the meantime there are not only machines for the more basic work such as removing scales and slime but also for highly sensitive processes like filleting, fillet trimming or exact portioning. These systems are particularly worthwhile if they can be combined to form complete processing lines.
The classic ones are the primary processing lines that transform round fish into boneless fillets. What might sound easy often involves several work stages in practice since a cod, for example, has first to be gutted and headed before it can pass through a filleting machine. And even then, the fillets are not quite ready because they still have to be skinned and freed of any remains of the fin bases, bones or impurities. The fact that even these complicated jobs can today be performed by machines shows how efficient processing machines in the fish segment have in the meantime become. They are not only used for gutting, heading, removing scales and slime, filleting or skinning the fish, but can also take the pin bones out of the fillets, trim fillets, sort them according to colour and size and cut them into equal portions. Some machines are even in a position to sort the fish by sex or to separate the more valuable organs such as the liver and roe from the other parts during gutting.
The demands made on fish processing machines are high and often very specific. This can already be seen in the fact that most of them are only suited to processing one single species or similar species that have a comparable body and bone structure and are approximately the same size. It is not possible to process demersal fishes on a processing line for pelagic fishes, and vice versa. Every individual process stage in the chain has to be finely tuned to the particular fish species in order to achieve a perfect result and maximum yield. Even heading a fish, which at a fleeting glance may not seem to be a particularly complicated task, demands considerable know-how if unnecessary losses are to be avoided. Depending on the species, between 10 and 25% of raw fish weight is lost through the heading process. The highest yields are usually achieved when the cut follows the rear edge of the gill flap exactly. This material-saving cut demands relatively high technical skills, however, which makes the heading machine accordingly expensive. Its use is thus particularly worthwhile for more high-value fish species such as salmon or cod. In the case of less expensive mass species, such as a lot of pelagic species, it is not so much a clean cut along an exact contour that is important but rather the speed at which the fishes are headed. When processing these fish species, the cut is thus often made at a right angle to the backbone or diagonally downwards whereby the pectoral and sometimes even the ventral fins are removed at the same time. A straight cut is technically less demanding but often leads to the loss of part of the fillet.
The fact that a processing line will supply high-quality products is today no longer sufficient – it also has to meet all the regulations that are applicable to food companies, it has to fulfil legal hygiene, sanitary and environmental standards, its operation has to be as economical as possible (e.g. as regards water, energy consumption) and it has to be easy to clean and disinfect.
Marel, an acknowledged developer and manufacturer of intelligent processing machines already joined forces years ago with Carnitech, Pols, CP Food Machinery and Geba to form ‘Partners in Processing’. Since then, Stork and Townsend have also joined the group. With offices in more than 30 countries, 3,500 employees and a worldwide sales network the ‘partners’ have become a global player whose machines and plants are to be found in over 60 countries.
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