Seafood Processing Controls

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Questions and Answers

Where can shrimps for frozen product originate from?

Deserts

Deep, cold seas (correct)

Mountainous regions

Shallow, tropical, inshore waters and rivers (correct)

What is essential to consult when preparing a Hazard Analysis Critical Control Point (HACCP) and/or defect action point (DAP) plan?

Section 2

Section 1

Section 5 (correct)

Section 3

What is a common practice for shrimps caught in northern regions?

Cooking and freezing on board

Landing chilled on ice

Raw IQF on board for further processing

All of the above (correct)

What happens to shrimps at onshore plants?

They are precooked, mechanically peeled, cooked, frozen, glazed, and packed Signup and view all the answers

What is a type of treatment that can happen to shrimps on board?

All of the above Signup and view all the answers

Why is it not possible to give details of critical limits, monitoring, record-keeping, and verification for each of the steps?

Because each hazard or defect is unique Signup and view all the answers

What is a type of vessel that can be used for catching shrimps?

Freezer vessel Signup and view all the answers

What is an example of a processing step where hazards and defects can be introduced or controlled?

Any particular step in the processing of shrimps Signup and view all the answers

What type of shrimp species are produced in tropical and subtropical countries?

Penaeus species Signup and view all the answers

What is the primary concern in the production of shrimp products?

Safety considerations Signup and view all the answers

What is the purpose of devising inspection protocols for raw fresh and frozen shrimp reception?

To cover identified quality, HACCP and DAP plan parameters Signup and view all the answers

What is the potential hazard associated with phytotoxins in sea-caught shrimps?

Paralytic shellfish poisoning Signup and view all the answers

What is the primary purpose of controlled thawing in shrimp processing?

To prevent microbiological contamination Signup and view all the answers

Why is it necessary to wash fresh shrimps after reception?

To reduce bacterial contamination Signup and view all the answers

What is the purpose of allocating 'use by' times for processing shrimp?

To ensure product quality Signup and view all the answers

What is the recommended temperature for thawing shrimp?

No higher than 20°C (68°F) Signup and view all the answers

What type of shrimp products may be subject to further added-value processes?

Warmwater shrimp products Signup and view all the answers

Why should unnecessary delays be avoided during chilled storage?

To prevent quality deterioration Signup and view all the answers

What is the purpose of size grading in shrimp processing?

To select shrimps for different quality grades Signup and view all the answers

What is the purpose of monitoring incoming lots of shrimps for sulphites?

To detect sulphites at harvesting Signup and view all the answers

What should be used for thawing shrimp?

Clean seawater or water of potable quality Signup and view all the answers

What is the purpose of performing a sensory evaluation on incoming lots of shrimps?

To ensure product quality and prevent decomposition Signup and view all the answers

What should be used to monitor and record ambient temperatures in frozen storage?

Temperature-monitoring device Signup and view all the answers

What type of equipment is used to wash fresh shrimps after reception?

Low-velocity sprays with chilled clean water Signup and view all the answers

What is the recommended storage temperature for chilled storage?

Less than 4°C (39°F) Signup and view all the answers

Why should the outer and inner packaging be removed prior to defrosting?

To prevent microbiological contamination Signup and view all the answers

What should be used to wash the shrimps after thawing?

Clean chilled water Signup and view all the answers

What should be avoided during frozen storage?

Temperature fluctuations Signup and view all the answers

What is a potential hazard in the cooking process of shrimps?

Microbiological contamination Signup and view all the answers

What is essential for cooked shrimps exiting the cooking cycle?

Separate equipment Signup and view all the answers

What is the purpose of glazing in frozen shrimps?

To protect against dehydration and maintain quality Signup and view all the answers

What is a potential defect in the freezing process of shrimps?

Slow freezing – textural quality and clumping of shrimps Signup and view all the answers

What should be used for cooling cooked shrimps?

Potable water or clean water Signup and view all the answers

What is necessary to ensure in the freezing operation?

Meeting freezing conditions specified Signup and view all the answers

What should be reviewed before each batch of cooking?

Cooking schedule Signup and view all the answers

What is important for peeling of cooked shrimps?

Proper peeling through mechanical or manual means Signup and view all the answers

Why is maintenance and cleaning of cookers important?

To ensure efficient and safe processing Signup and view all the answers

What should be used for cooking shrimps?

Only potable water Signup and view all the answers

What is the purpose of regular inspection in the grading process?

To prevent microbiological growth and product decomposition Signup and view all the answers

What is the purpose of adding sodium metabisulphite to shrimps?

To reduce shell blackening Signup and view all the answers

What is the purpose of using sulphites in the peeling process?

To prevent blackspot formation Signup and view all the answers

What is the potential hazard in the deveining process?

Microbiological contamination Signup and view all the answers

Why is it necessary to wash peeled and deveined shrimps?

To remove shell fragments Signup and view all the answers

What is the purpose of adding sodium polyphosphates to shrimps?

To maintain succulence Signup and view all the answers

Why is it necessary to maintain chill conditions throughout the process?

To prevent microbiological growth Signup and view all the answers

What is the potential defect in the peeling process?

All of the above Signup and view all the answers

What is the purpose of re-icing and storing shrimps in chill prior to further processing?

To prevent microbiological growth Signup and view all the answers

What is the purpose of adding common salt to shrimps?

To improve flavour Signup and view all the answers

What is the primary purpose of glazing shrimps?

To prevent the shrimps from freezing together Signup and view all the answers

What should be declared on packaging and labelling in descending order by weight?

Ingredients and additives Signup and view all the answers

Why is it recommended to perform metal detection after packaging?

To eliminate potential re-contamination prior to packaging Signup and view all the answers

What is the ideal temperature for storing frozen shrimps?

At or below -18 °C Signup and view all the answers

What should be used to transfer frozen products to cold storage?

Insulated containers Signup and view all the answers

What should be implemented to prevent sulphites from being transferred to the packaged food?

Using food grade wrappings and packaging Signup and view all the answers

What should be checked to ensure correct compositional standards?

Product labelling and ingredient declaration Signup and view all the answers

What is the purpose of a systematic stock rotation plan?

To prevent product spoilage Signup and view all the answers

What should be equipped with a calibrated, indicating thermometer?

Freezer storage Signup and view all the answers

What should be done to prevent contamination and inhibit the growth of microorganisms when handling fresh cephalopods?

Handling them with great care and cooling them down to the temperature of melting ice Signup and view all the answers

What is the purpose of metal detection in the processing of shrimps?

To detect contaminants in the product Signup and view all the answers

What should be included in product specifications for accepting sound cephalopods for processing?

Organoleptic characteristics, chemical indicators, microbiological criteria, and parasites Signup and view all the answers

Why is it essential to consult Section 5 when preparing a Hazard Analysis Critical Control Point (HACCP) and/or defect action point (DAP) plan?

To understand the principles of HACCP and DAP analysis Signup and view all the answers

What should be done to cephalopods after reception?

They should be held in chilled condition Signup and view all the answers

What kind of programme should be in place at the processing facility?

A programme for inspecting cephalopods on catching or arrival at the factory Signup and view all the answers

What should personnel inspecting product be trained and experienced with?

The relevant species to recognize any defects and potential hazards Signup and view all the answers

What is an example of a processing step where hazards and defects can be introduced or controlled?

All of the above Signup and view all the answers

Why are fresh cephalopods extremely perishable?

Because they are highly susceptible to microbiological contamination Signup and view all the answers

What is the purpose of Section 17.3 in the Code?

To describe controlled thawing of cephalopods Signup and view all the answers

What should be included in the technical guidance for cephalopod processing?

Product specifications, including organoleptic characteristics, chemical indicators, microbiological criteria, and parasites Signup and view all the answers

What is a potential hazard in canned fish and shellfish products?

All of the above Signup and view all the answers

What is a potential defect in canned fish and shellfish products?

All of the above Signup and view all the answers

Why is it important to limit proliferation and contamination risks during processing?

To prevent botulinum toxin production Signup and view all the answers

What type of contamination can occur in canned fish and shellfish products?

All of the above Signup and view all the answers

What is a potential hazard associated with inadequate heat processing?

Botulinum toxin production Signup and view all the answers

What is a recommended practice for containers used in canned fish and shellfish products?

Using containers made from suitable materials Signup and view all the answers

What is a potential hazard associated with post-process contamination?

Staphylococcus aureus toxin production Signup and view all the answers

Why is it important to inspect live shellfish before canning?

To discard dead or badly damaged animals Signup and view all the answers

What is a potential defect in containers used in canned fish and shellfish products?

Tainting of the product Signup and view all the answers

What is the purpose of referring to the Code of Hygienic Practice for Low and Acidified Low Acid Canned Foods?

To obtain detailed information on canning operations Signup and view all the answers

What is a potential hazard associated with chilled storage of cephalopods?

Microbiological contamination Signup and view all the answers

What should be properly protected from dehydration during frozen storage?

The flesh of the cephalopods Signup and view all the answers

What is a potential defect associated with reception of cephalopods?

Decomposition Signup and view all the answers

Why is it important to control the thawing parameters during thawing of cephalopods?

To prevent the development of pale-pink discoloration Signup and view all the answers

What should be removed during gutting of cephalopods?

All intestinal material and the cephalopod shell and beaks Signup and view all the answers

What should be used to wash whole cephalopods and cephalopod products after gutting?

Clean seawater or potable water Signup and view all the answers

What should be monitored during skinning of cephalopods?

Temperature and time parameters Signup and view all the answers

What should be carried out by trained operators during the mixing and application of additives?

The entire process Signup and view all the answers

What should comply with the requirements of the General Standard for Food Additives?

All additives used in food processing Signup and view all the answers

What should be paid during thawing of cephalopods?

Particular attention to the volume of product being thawed Signup and view all the answers

What is the primary purpose of rapid freezing in cephalopod processing?

To prevent deterioration of the product and reduce shelf-life Signup and view all the answers

What should be considered when developing time/temperature parameters for freezing cephalopods?

The type of freezing equipment, capacity, the size and shape of the product, and production volume Signup and view all the answers

What should be monitored regularly to ensure the completeness of the freezing operation?

The core temperature of the product Signup and view all the answers

What is the purpose of keeping records of freezing and frozen storage operations?

To monitor the effectiveness of the freezing operation Signup and view all the answers

What should be considered when grading and packaging cephalopods?

The potential hazards and defects associated with packaging, labelling and ingredients Signup and view all the answers

What is the purpose of skinning and trimming in cephalopod processing?

To prepare the product for further processing Signup and view all the answers

What should be ensured when using sulphites in the processing of cephalopods?

The sulphites are properly labelled Signup and view all the answers

What is the purpose of applying additives in cephalopod processing?

To enhance the quality of the product Signup and view all the answers

What should be considered when selecting packaging materials for cephalopods?

The packaging material should be clean, suitable for the intended purpose and manufactured from food-grade materials Signup and view all the answers

What is the purpose of grading and packaging operations in cephalopod processing?

To carry out with minimal delay to prevent deterioration of the cephalopod Signup and view all the answers

What should be found to reduce the amount of handling subsequent to precooking?

Means Signup and view all the answers

Why should eviscerated fish be arranged in the belly-down position during precooking?

To allow for drainage of fish oils and juices Signup and view all the answers

What type of oils should be used in precooking fish or shellfish for canning?

Good-quality vegetable oils Signup and view all the answers

Why should precooked fish or shellfish be cooled quickly?

To bring product temperatures into a range limiting proliferation or toxin production Signup and view all the answers

What should be checked in the precooking schedule?

The precooking method Signup and view all the answers

Why should dip solutions be replaced regularly?

To prevent microbiological contamination Signup and view all the answers

What should be taken to avoid in precooking scombrotoxic species?

Temperature abuse Signup and view all the answers

Why should cooking oils be changed frequently?

To prevent the formation of polar compounds Signup and view all the answers

What should be controlled in the precooking schedule?

Time and temperature Signup and view all the answers

Why should water used for precooking be changed frequently?

To prevent contaminants Signup and view all the answers

What is the purpose of creating a flow chart for each process in factory HACCP implementation?

To outline the sequence of operations for a specific process Signup and view all the answers

What is a biological hazard associated with fish and shellfish?

All of the above Signup and view all the answers

What is a primary consideration for containers and covers for canned fish and shellfish?

They should protect the contents from contamination Signup and view all the answers

What is a potential hazard associated with the storage of fish and shellfish?

Microbiological contamination Signup and view all the answers

What is essential for retorts in fish and shellfish canneries?

An adequate supply of energy, vapour, water, and/or air Signup and view all the answers

Why is it important to know the origin and status of the area of origin of molluscan shellfish?

To identify potential hazards Signup and view all the answers

What is a key consideration during the unwrapping and unpacking of fish and shellfish?

Minimizing waiting periods Signup and view all the answers

What is a consideration for the design and working of baskets and handling and loading devices in fish and shellfish canneries?

Preventing excessive mishandling of containers Signup and view all the answers

What is a potential defect associated with the preparation of molluscs and crustaceans?

All of the above Signup and view all the answers

What is a technical guidance for the storage of containers and packaging materials?

Storing them in a clean and hygienic environment Signup and view all the answers

What is the purpose of installing an accurate and clearly visible clock in the retorting room?

To control and monitor the thermal process Signup and view all the answers

What is a potential hazard associated with the precooking of fish and shellfish?

All of the above Signup and view all the answers

What is necessary for instruments used to control and monitor the thermal process in fish and shellfish canneries?

Regular calibration Signup and view all the answers

Why is it important to know the identity of the species and/or origin of fish intended for processing?

To identify potential hazards Signup and view all the answers

What is a key consideration during the handling of empty containers and covers?

Protecting them from dirt, moisture, and temperature fluctuations Signup and view all the answers

What is a potential defect associated with the fish preparation process?

All of the above Signup and view all the answers

What is a consideration for retorts in fish and shellfish canneries?

Their dimensions should be adapted to the production Signup and view all the answers

What is a technical guidance for the preparation of fish and shellfish?

Carrying out an appropriate neutralization Signup and view all the answers

What is the purpose of records concerning the calibration of instruments in fish and shellfish canneries?

To establish and maintain records Signup and view all the answers

What is a key consideration during the storage of raw materials, containers, and packaging materials?

Storing them in a clean and hygienic environment Signup and view all the answers

What is the primary purpose of inspecting containers and covers before filling?

To remove defective containers that may cause trouble during heat processing Signup and view all the answers

Why should fish and shellfish be filled into containers as soon as possible after pre-treatment?

To prevent microbiological contamination Signup and view all the answers

What is the potential hazard associated with incorrect filling or defective containers?

Microbiological contamination Signup and view all the answers

Why should containers be filled with hot fish and shellfish, where appropriate?

To prevent microbiological contamination Signup and view all the answers

What is the importance of regular filling in the processing of canned fish and shellfish?

It affects heat penetration and container integrity Signup and view all the answers

Why should empty containers not be left on the packing tables or in conveyor systems during the cleaning of premises?

To prevent contamination or splashes Signup and view all the answers

What is the purpose of checking mechanical or manual filling of containers?

To ensure compliance with the filling rate and headspace specified in the adopted sterilization schedule Signup and view all the answers

What is the potential defect associated with incorrect filling of containers?

All of the above Signup and view all the answers

Study Notes

Shrimp Processing and Hazard Control

Shrimps can be frozen for further processing in various forms, including whole, head-off, deheaded, raw headless, peeled, peeled and deveined, or cooked.
Shrimps can come from different sources, such as deep-sea fishing, inshore waters, rivers, and aquaculture.
Processing methods vary, including onboard cooking, freezing, and processing at onshore plants.

Reception of Raw Fresh and Frozen Shrimp

Potential hazards: phytotoxins, microbiological contamination, antioxidants, sulphites, pesticides, and fuel oil.
Potential defects: variable batch quality, mixed species, taints, blackspot, softening from head enzymes, and decomposition.
Inspection protocols should be devised to cover identified quality, HACCP, and DAP plan parameters.
Shrimps should be inspected upon receipt to ensure they are well iced or deep frozen and properly documented.

Shrimp Preparation and Processing

Shrimp preparation involves various steps, including cooking, peeling, deveining, washing, and freezing.
Potential hazards and defects vary depending on the processing step.
Technical guidance is provided for each step, including controlled thawing, chilled storage, and addition of ingredients and additives.

Thawing and Chilled Storage

Thawing processes should be undertaken from block frozen or IQF shrimps, depending on the raw material source.
Thawing tanks should be purpose-designed and allow for "counter current" water defrosting.
Clean seawater or water and ice of potable quality should be used for thawing.
Thawing should be achieved as quickly as possible to maintain quality.

Peeling and Deveining

Peeling and deveining processes should be conducted to ensure no carryover of shell fragments.
The vein is the gut, which may appear as a dark line in the upper dorsal region of prawn flesh.
Removal of the vein is by razor, cutting longitudinally along the dorsal region of the shrimp.

Cooking and Cooling

Cooking procedures should be fully defined according to the specification requirements of the final product.
Cooking schedules should be reviewed before each batch, and logging of process parameters should be available.
Cooked shrimps should be cooled as quickly as possible to bring the temperature to a range limiting bacteria proliferation or toxin production.

Freezing and Glazing

Freezing operations vary according to the type of product.
The freezing process should ensure that the specified freezing conditions are met.
Glazing is applied to frozen shrimps to protect against dehydration and maintain quality during storage and distribution.

Weighing, Packaging, and Labelling

All wrappings and packaging materials should be food grade, odourless, and with no risk of substances likely to be harmful to health.
Products should be weighed in packaging with scales appropriately tared and calibrated.
Ingredient lists on packaging and labelling should declare the presence of ingredients in the food product in descending order by weight.

Metal Detection

Products in their final packaging should undergo metal detection using equipment set to the highest sensitivity possible.
Consideration should be given to testing the product prior to packaging.### Cephalopod Processing
Potential hazards: microbiological contamination, chemical contamination, parasites
Potential defects: damaged products, foreign matter
Technical guidance:
- Inspect cephalopods on catching or arrival at the factory
- Only sound product should be accepted for processing
- Product specifications could include:
  - Organoleptic characteristics (appearance, odour, texture)
  - Chemical indicators of decomposition and/or contamination (TVBN, heavy metals)
  - Microbiological criteria
  - Parasites, foreign matter
- Personnel inspecting product should be trained and experienced with the relevant species

Storage of Cephalopods

17.2.1 Chilled storage:
- Potential hazards: microbiological contamination
- Potential defects: decomposition, physical damage
- Technical guidance: Refer to Section 9.1.2
17.2.2 Frozen storage:
- Potential hazards: heavy metals (e.g. cadmium migration from the gut)
- Potential defects: freezer burn
- Technical guidance: Refer to Section 9.1.3

Reception of Cephalopods

Potential hazards: microbiological contamination
Potential defects: decomposition, discoloration
Technical guidance:
- The thawing parameters should be clearly defined and include time and temperature
- Critical limits for thaw time and temperature should be developed
- Particular attention should be paid to the volume of product being thawed in order to control discoloration

Splitting, Gutting, and Washing

Potential hazards: microbiological contamination
Potential defects: presence of gut contents, parasites, shells, ink discolouration, beaks, decomposition
Technical guidance:
- Gutting should remove all intestinal material and the cephalopod shell and beaks, if present
- Cephalopods should be washed in clean seawater or potable water immediately after gutting to remove any remaining material from the tube cavity and to reduce the level of microorganisms present on the product

Skinning, Trimming

Potential hazards: microbiological contamination
Potential defects: presence of objectionable matter, bite damage, skin damage, decomposition
Technical guidance:
- The method of skinning should not contaminate the product nor should it allow the growth of microorganisms
- Care should be taken to prevent waste material from cross-contaminating the product

Application of Additives

Potential hazards: physical contamination, non-approved additives, non-fish allergens
Potential defects: physical contamination, additives exceeding their regulatory limits
Technical guidance:
- The mixing and application of appropriate additives should be carried out by trained operators
- It is essential to monitor the process and product to ensure that regulatory standards are not exceeded and quality parameters met

Grading/Packaging/Labelling

Potential hazards: parasites
Potential defects: freezer burn, decomposition, loss of quality owing to slow freezing
Technical guidance:
- Cephalopods should be frozen as rapidly as possible to prevent deterioration of the product and a resulting reduction in shelf-life caused by microbial growth and chemical reactions
- The time/temperature parameters developed should ensure rapid freezing of product and take into consideration the type of freezing equipment, capacity, the size and shape of the product, and production volume

Processing of Canned Fish, Shellfish and Other Aquatic Invertebrates

This section concerns the processing of heat processed sterilized canned fish and shellfish products that have been packed in hermetically sealed containers and are intended for human consumption
The application of appropriate elements of the prerequisite programme and HACCP principles at these steps will provide the processor with reasonable assurance that the essential quality, composition and labelling provisions of the appropriate Codex standard will be maintained and food safety issues controlled### Canned Fish and Shellfish Containers
Containers should be made of suitable material and constructed to be easily closed and sealed to prevent contamination.
Containers should protect the contents from microorganisms and other substances, and their inner surfaces should not react with the contents.
Outer surfaces should be resistant to corrosion, and containers should be durable enough to withstand mechanical and thermal stresses during canning and distribution.

Storage of Raw Materials and Containers

Fish and shellfish should be stored in clean and hygienic conditions.
Containers and packaging materials should be stored in clean and hygienic conditions to avoid contamination and damage.
During storage, empty containers and covers should be protected from dirt, moisture, and temperature fluctuations to avoid condensation and corrosion.

Unwrapping and Unpacking

Precautions should be taken to limit product contamination and the introduction of foreign matter during unwrapping and unpacking operations.
Waiting periods before further processing should be minimized to avoid microbial proliferation.

Thawing and Precooking

Precooking methods should be designed to bring about the desired effect with minimum delay and handling.
Precooking should be sufficient to avoid excessive release of water during heat processing.
Means should be found to reduce handling subsequent to precooking, wherever practical.
Care should be taken to prevent temperature abuse of scombrotoxic species before precooking.

Fish and Shellfish Preparation

Fish should be gutted, trimmed, and skinned, taking care to carry out an appropriate neutralization.
Particular care should be taken to ensure that shell fragments are removed from shellfish meat.
During preparation, precautions should be taken to limit product contamination and the introduction of foreign matter.

Precooking Schedule and Control

The precooking schedule should be clearly defined and checked.
Fish precooked together in batches should be similar in size and at the same temperature when entering the cooker.
Only good-quality vegetable oils should be used in precooking, and cooking oils should be changed frequently to avoid polar compounds.

Cooling and Smoking

Cooling of precooked fish or shellfish should be done as quickly as possible to bring the product temperature into a range limiting proliferation or toxin production.
Water used for cooling should be potable or clean seawater, and should not be used for more than one batch.

Use of Brine and Other Dips

Solution strength and time of immersion should be carefully controlled to bring about the optimal effect.
Dip solutions should be replaced, and dip tanks and other dipping apparatus should be thoroughly and frequently cleaned.

Packing in Containers

Containers should be inspected before filling to ensure they are clean, undamaged, and without visible flaws.
Empty containers should be cleaned, and defective containers should be removed to prevent contamination or splashes.
Containers should be filled with hot fish and shellfish, or should be filled as soon as possible upon the completion of pre-treatment.
Containers of canned fish and shellfish should be filled as directed in the scheduled process.

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Description

This quiz covers the controls and potential hazards in the processing of shrimps, including on-board and onshore processing. It also provides guidelines for developing control measures and corrective actions.