9810090633

IMPROVED QUALITY CONTROL FOR
THE HANDLING AND PROCESSING OF

FRESH AND FROZEN TUNA
AT SEA AND ON SHORE
ASEAN CANADA FISHERIES POST HARVEST TECHNOLOGY PROJECT

PHASE II
ASEAN-CANADAFISHERIESPOST-HARVEST
TECHNOLOGYPROJECT- PHASEII
The ASEAN-Canada Fisheries Post-Harvest Technology Project - Phase II started in April 1992. The Project's
objectives are to strengthen and upgrade fisheries product quality and fish inspection services within
ASEAN countries; to assist in the development and implementation of improved methods and
technologies in fish processing, preservation and packaging, on the basis of regional collaborative
efforts, to enhance the transfer/adoption of appropriate technologies to the fish processing industries
through training and extension services.
The Project activities are coordinated and administered by the ASEAN Executing Agency (AEA) which is
incorporated in the Marine Fisheries Research Department (MFRD) of the Southeast Asian Fisheries
Development Centre (SEAFDEC). In cooperation with the ASEAN governments, the Project established
regional centres for fish processing technology (RC-FPT, Singapore), fish inspection and quality control
(RC-FIQC, Indonesia), and information preparation and dissemination (RC-IPD, Malaysia) and developed
work programs of national importance and regional interest for all ASEAN countries.
Each ASEAN country except Malaysia conducts two activities on either seafood processing or quality
control in order to develop technical training manuals/materials and assist the RC-IPD in the production
of extension materials based on these Project activities. The technologies developed are then
transferred to the fish processing industries in the region through end-of-activity seminars/demonstrations
and dissemination of information/training materials by government and private sector extension
personnel.
The contribution of the Canadian International Development Agency (CIDA) for providing funds to assist
the development of this work and its publication is gratefully acknowledged.
AUTHORS: Josephine Wiryanti, George F Glynn, and Leonard G Limpus.
LIAISON OFFICE: ASEAN Executing Agency,

ASEAN-Canada Fisheries Post-Harvest Technology Project - Phase II,
Changi Fisheries Complex, 300 Nicoll Drive, Singapore 498989.
Copyright©, 1997 ASEAN Executing Agency, ASEAN-Canada Fisheries Post-Harvest Technology Project -
Phase II. Copyright will be transferred to the Marine Fisheries Research Department, Southeast Asian
Fisheries Development Center1after 31 July, 1997.
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
for com m ercial purposes without the prior written permission of the publisher. However, reproduction
or translation of this publication, in whole or in part, by any method or process, for purely research,
training and non-profit purposes is allowed. The reproduction or translation must include a statement
acknowledging the support and financial contribution of the Canadian International Development
Agency (CIDA) for the development and production of this publication. A letter stating the purpose of
the reproduction or translation must also be sent to the copyright holder.
1 Marine Fisheries Research Department

Southeast Asian Fisheries Development Centre
Changi Fisheries Complex
300 Nicoll Drive, Singapore 498989
ISBN 981-00-9063-3
Foreword
Tuna is one of the leading commodities contributing to the socio-economic development in

ASEAN countries. Fresh and frozen tuna intended for sashimi is destined mainly to Japan and
USA, while other qualities are further processed into a variety of tuna products marketed
throughout the world.
The Directorate General of Fisheries (DGF), Indonesia isvery concerned with the quality, safety
and economic integrity of tuna and tuna products. Since tuna is very delicate fish having a
body temperature higher than the water where it is found, tuna must be handled as quickly
and carefully as possible from the time of catching throughout the handling process.
During the ASEAN-Canada Fisheries Post-Harvest Technology Project - Phase II, the Regional
Centre of Fish Inspection and Quality Control (RC-FIQC), Directorate General of Fisheries,
Indonesia, carried out a pilot project on "Improved Quality Control of Fresh and Frozen Tuna"
(WBS 232). The output of the pilot project is concerned with the improvement of Handling
Practices and the development of a HACCP-based Integrated Quality Management Program
(IQMP). The Manual comprises:
1. Good Handling Practices for the On-Board Handling of Fresh and Frozen Tuna.
2. An Integrated Quality Management Program for Tuna Operations On-Board Fishing
Vessels.
3. Good Manufacturing Practices for the Processing of Tuna by Processing Plants.
4. An Integrated Quality Management Program for Fresh and Frozen Tuna by
Processing Plants.
5. Inspection and Grading of Bigeye and Yellowfin Tuna.
6. Proper Procedures for the Unloading of Fresh Tuna.
The pilot projects also provided a transfer of technology on inspection, grading and quality
control of fresh and frozen tuna to both government inspectors and private personnel in
Indonesia and ASEAN member countries.
This Manual may be used as guideline for Tuna Handling Operators, Tuna Graders and Fish
Inspectors in the application of Good Handling and Manufacturing Practices and for the
HACCP-based Integrated Quality Management Program for Fresh and Frozen Tuna with
particular attention to sashimi quality.
I would like to take the opportunity to express my sincere gratitude to the Canadian
International Development Agency (CIDA), ASEAN Executing Agency (AEA) and the Canadian
Supplies and Services Agency for the support of the ASEAN-Canada Fisheries Post-Harvest
Technology Project - Phase II and this activity.
F.X. Murdjijo,
Director General of Fisheries,
Indonesia.
i
Acknowledgem ent
The Regional Centre for Fish Inspection and Quality Control (RC-FIQC), Directorate General of
Fisheries, Indonesia, would like to acknowledge sincere gratitude to the Canadian
International Development Agency (CIDA), the ASEAN Executing Agency (AEA) and the
Canadian Supplies and Services Agency (CSSA) for the support provided throughout the
implementation of ASEAN-Canada Fisheries Post-Harvest Technology Project - Phase II, and
this activity.
Special appreciation goes to Mr. George F. Glynn, Canadian Specialist on Fresh and Frozen
Tuna Handling and Mr. Haniff Madakia, Fish Technologist, for their generous supervision and
technical assistance in the implementation of pilot project on "Improved Quality of Fresh and
Frozen Tuna" (WBS 232). This Manual on Good Handling and Manufacturing Practices and
the HACCP-based Integrated Quality Management Program (IQMP) for Fresh and Frozen Tuna
intended for sashimi could not have been written without their help.
The RC-FIQC is also indebted to the Indonesian Tuna Processors, namely; P.T. Ratatotok,
Bitung; P.T. Balinusa Windumas, Bali and P.T. Perikanan Samodra Besar, Bali for their favourable
collaboration, without which this Manual would not have been accomplished.
Sincere thanks should also go to all staff from the Sub-Directorate of Fish Inspection and
Quality Control, Directorate General of Fisheries, Indonesia for their technical contributions
during the preparation of the Manual.
The RC-FIQC is also much obliged to the AEA for the editing, formatting and printing of the
Manual.
Dr. Josephine Wiryanti,

Head, Sub-Directorate Fish Inspection and Quality Control, DFG
Indonesia Country Coordinator of the Project.
E-mail: j2103043@rad.net.id
ii
Contents
Section 1 Good Manufacturing Practices for the 1
On-Board Handling and Processing of
Fresh and Frozen Tuna
1.1 Introduction, 2
1.2 Processing Steps, 4
1.3 Method of Catching, 4
1.4 Temperature of Tuna, 5
1.5 Handling, 5
1.6 Clubbing and Killing, 6
1.7 Bleeding, 6
1.8 Gutting and Gilling, 7
1.9 Lowering of Temperature, 8
1.10 Icing of Tuna, 8
1.11 Discharging of Tuna, 9
1.12 On-Board Freezing of Tuna, 9
1.13 Summary of Fish Handling Procedures, 10
Annex 1 Flowcharts for On-board Handling of Fresh and Frozen Tuna, 11
Annex 1.1 Flowchart for the On-board Handling of Fresh Tuna, 12
Annex 1.2 Flowchart for the On-board Handling of Frozen Tuna, 13
Annex 2 Tuna Missile, 14
Annex 3 Diagrams of Proper Handling Procedures and Descriptions, 15
Section 2 An Integrated Quality Management Program (IQMP) for 29

On-Board Handling of Tuna
2.1 Introduction, 30
2.2 Establishment of Control Points or Inspection Points, 30
2.2.1 Process Flowchart for Inspection or Control Points, 32
2.2.2 Potential Critical Control Points, 33
2.2.3 Identification of Control Points, 34
2.3 Fish, 35
2.3.1 Requirements, 35
2.3.2 Defect Deficiency, 36
2.3.3 Monitoring Procedures, 36
2.3.4 Corrective Action, 37
2.3.5 Inspection of Tuna as it is Being Taken On-board, 37
2.3.6 Corrective Action Report, 38
2.3.7 Inspection of Tuna as it is Being Received On-board Vessel, 39
2.3.8 Information to be Supplied by Fishing Vessel, 40
2.4 Ice, 41
2.4.2 Ingredients, 41
2.4.3 Defect Definitions, 41
iii
2.4.4 Monitoring, 41
2.5 Cleaning Agents, Sanitisers, Lubricants, 41
2.5.2 Specifications, 41
2.5.4 Forms for Data Collection and Reporting, 42
2.5.5 Guidelines for Corrective Action, 42
2.5.6 Incoming Chemical Inspection Report, 43
2.5.7 Information to be Supplied by the Fishing Vessel Owner/Operator, 44
2.6 Vessel Design, Production Facilities, 45
2.6.1 Requirements for Vessel Design, 45
2.6.2 Production Facilities, 45
2.7 Operation & Sanitation, 46
2.7.2 Inspection of Vessel, 47
2.7.3 Forms for Inspection, 47
2.7.5 Action Reports, 48
2.8 Process Control, 51
2.8.2 Defects and Deficiencies, 51
2.8.3 Inspection Requirements, 51
2.8.4 Forms for Collection Data, 51
2.9 Fresh Storage Facilities, 51
2.9.4 Fresh Tuna Temperature Recovering Log, 53
2.10 Frozen Storage Facilities, 54
2.10.2 Inspection, 54
2.10.4 Frozen tuna Cold Storage Log, 55
2.11 Final Product, 56
2.11.2 Defect Tolerance, 56
2.11.3 Sampling Plan, 56
2.12 Recall Procedures, 56
iv
2.12.3 G uidelines for C orrective A ction, 57
2.12.4 Shipping Record Report for Fresh/Frozen Tuna
from Fishing Vessels, 58
2.13 Em ployee Q ualifications on Fishing Vessels, 59
2.13.1 Requirem ents, 59
Annex 4 Definitions, 60
Annex 5 Potential C ritical C ontrol Points for the
O n-Board Handling o f Fresh and Frozen Tuna, 61
Section 3 G ood M anufacturing Practices for the 63

On-Shore Handling and Processing o f Tuna
3.1.1 Receiving, 64
3.1.2 G rading o f Tuna, 65
3.1.3 C ooling, 66
3.1.4 Processing o f W hole Fresh Tuna, 66
3.1.5 Processing a nd Packing o f Fresh Tuna Loins, 67
3.1.6 Packing and Shipping o f W hole Fresh Tuna for Exporting, 68
3.1.7 Processing o f Frozen Tuna Loins and Sticks, 69
3.1.7.1 Tuna AKAMI and TORO, 71
3.1.7.2 Proportion o f Akam i a nd Toro, 71
3.1.7.3 Dressing o f Eviscerated Tuna, 72
3.1.8 Processing o f Tuna for D om estic M arket, 73
3.1.9 Summary, 73
3.2 Em ployee Requirem ents, 74
3.2.1 Health, 74
3.2.2 Hand-W ashing, 74
3.2.3 Hand C overing, Disinfection, 74
3.2.4 O uter G arm ents and Head G ear, 74
3.2.5 Smoking and Spitting, 75
3.3 Plant Facility Requirem ents, 75
3.3.1 Building, 75
3.3.2 Floors, 75
3.3.3 Drains, 76
3.3.4 Walls, 76
3.3.5 Ceilings and O verhead Protection, 77
3.3.6 O verhead Lighting, 77
3.3.7 Toilet Facilities, 77
3.3.8 W ater Supply, 78
3.3.9 Floor Tanks for th e Holding and C ooling o f Tuna, 78
3.3.10 O verhead Pipes, 78
3.3.11 Processing, G rading and Packing Tables, 79
3.3.12 Conveyers Used in th e Production o f Loins, 79
3.3.13 Chutes, Containers Trolleys, 79
v
3.3.14 Animals, 79
3.3.15 Rodents and Insects, 80
3.3.16 Trays and Trolleys Used in the Frozen Production, 80
3.3.1 7 Freezing Facilities, 80
3.3.18 Freezing Facility Temperature Recorder, 80
3.3.19 Packing Material for Fresh Tuna Shipping
and Material Used in Shipping, 81
3.3.20 Offal Removal, 81
3.3.21 Room Temperature in Processing Room, 81
3.3.22 Hot Water Supply, 82
3.3.23 Ice, 82
3.3.24 Plant Surroundings, 82
3.3.25 Sewage, 83
3.4 Proper Cleaning Procedures, 83
3.4.1 Clean-up Procedures, 83
Section 4 An Integrated Quality Management Program for the 85

On-Shore Handling and Processing of Fresh and Frozen Tuna
4.1.1 Process Flowchart for Determining Inspection/Control Points, 88
4.1.2 Potential Inspection/Control Points, 89
4.1.3 Identification of Inspection/Control Points, 90
4.2 Fish, 91
4.2.2 Fish Defect Deficiency, 92
4.2.4.1 Corrective Action Report, 94
4.2.4.2 Inspection of Tuna At Receiving Site, 95
4.2.4.3 Raw Product Inspection Report, 96
4.2.4.4 Information to be Supplied by Fish Processing Company, 97
4.3 Other Ingredients, 98
4.3.4 Defect Tolerances, 98
4.3.7 Data Collection and Reporting Forms, 99
4.3.7.1 Incoming Ingredient Inspection Report, 100
4.3.7.2 Information to be Supplied by the Processing Company,
- Monitoring Procedures, 101
4.4 Ice, 102
4.4.1 Ice Requirements, 102
vi
4.4.4 Monitoring, 102
4.5 Cleaning Agents, Sanitisers, Lubricants, 102
4.5.2 Specifications, 103
4.5.5 Forms for Data Collection and Reporting, 103
4.5.5.1 Incoming Chemical Report, 104
4.6 Plant Construction/Production Facilities/Plant Equipment, 105
4.6.1 Building, 105
4.6.2 Floors, 105
4.6.3 Drains, 105
4.6.4 Walls, 105
4.6.5 Ceilings, 105
4.6.6 Overhead Lighting, 105
4.6.7 Overhead Pipes, 106
4.6.8 Toilet Facilities, 106
4.6.9 Water Supply, 106
4.6.10 Floor Tanks, 106
4.6.11 Equipment, 106
4.6.12 Freezing Equipment, 106
4.6.14 Plant Rating Forms, 107
4.7 Operation and Sanitation, 108
4.7.2 Sanitation, 108
4.7.3 Plant Rating Forms, 109
4.8 Process Control, 109
4.8.2 Defects and Deficiencies, 110
4.9 Fresh/Frozen Storage Facilities, 110
4.9.1 Fresh Storage Facility, 110
4.9.1.1 Requirements, 110
4.9.1.2 Inspection Requirements, 111
4.9.1.3 Corrective Action, 111
4.9.1.4 Fresh Tuna Temperature Recording Log, 112
4.9.2 Frozen Storage Facility, 113
4.9.2.1 Requirements, 113
vii
4.9.2.2 Inspection Requirem ents, 113
4.9.2.3 C orrective A ction, 113
4.9.2.4 Frozen Tuna C old Storage Log, 114
4.10 Packaging M aterial, 115
4.10.2 S pecifications, 115
4.10.3 D e fect Definitions, 115
4.10.4 D e fe ct Tolerances, 115
4.10.5 M onitoring Procedures, 115
4.10.6 C orrective A ction, 116
4.10.7 Packing M aterial Inspection Report, 117
4.11 Final Product, 118
4.11.2 D e fect Tolerances, 118
4.11.3 Sam pling Plan, 118
4.11.4 C orrective Action, 118
4.12 Recall Procedures, 119
4.12.1 G eneral Requirem ents for Fresh a n d Frozen Tuna Products, 119
4.12.2 Specifications for th e D ocum entation o f Shipments, 119
4.12.3 M onitoring Procedures, 119
4.12.4 C orrective A ction, 119
4.12.5 Shipm ent Record Form, 120
4.13 Em ployee Q ualifications, 121
Annex 6 Potential C ritical C ontrol Points for Fresh/Frozen Tuna Products. 122
Annex 7 D etailed Plant Inspection a nd Rating Report, 124
Annex 8 Em ployee Hygienic Practices Checklist, 129
Annex 9 D etailed Plant Hygienic Inspection Report, 130
Annex 10 A ction Report, 132
Section 5 G rading o f Bigeye and Yello w fin Tuna 133

5.2 N om enclature, 134
5.3 A Point Score System for G rading o f Tuna, 134
5.3.1 C olour, 134
5.3.2 C ondition, 135
5.3.3 G rading, 135
5.4 C olour Scores for Bigeye Tuna, 135
5.5 C olour Scores for Yellowfin Tuna, 136
5.6 C ondition Scores for Bigeye a nd Yellowfin Tuna, 136
5.7 Q uality G rading Form for the Inspection o f C olour, 138
5.8 Q uality G rading Form for C ondition, 139
5.9 Flow C hart for Tuna G rading; At Sea, On-Shore, 140
viii
Section 6 The Proper Unloading of Fresh Tuna from Fishing Vessels 141
6.1 Procedures in Place At Present in Indonesia, 142
6.1.1 Improvements, 142
6.1.2 Hatch Size and Vessel Design, 143
6.2 Proper Procedures in the Unloading of Fresh Tuna, 143
6.2.1 Temperature, 143
6.2.2 Fish Hole Chart, 144
6.2.3 Temperature Inspection, 144
6.2.4 Equipment, 144
6.2.5 Proper Fish Unloading System, 144
6.2.6 Unloading Requirements, 144
6.2.7 The Age of the Tuna, 145
6.2.8 Insulated Containers, 145
6.2.9 Transportation Procedures, 145
6.2.10 Cleaning of Fish Storage Area, 145
6.2.11 Icing of the Vessel, 145
6.2.12 Fish Hole Chart, 147
6.2.13 Temperature Recording Log Unloading Operation, 148
6.3 Inspection Points, 149
6.3.1 Discharging, 149
6.3.2 Temperature, 149
6.3.3 Unloading System, 149
6.3.4 Transportation, 150
6.3.5 Unloading Sites - Surroundings, 150
6.3.6 Ice, 150
Annex 11 Fish Unloading Systems and Description, 152
Section 7 Bibliography 157
ix
SECTION 1
G O O D M A N U F A C T U R IN G PRACTICES FOR
T H E O N -B O A R D H A N D L IN G A N D PROCESSING OF
TUNA
- 1-
1.1 INTRODUCTION
Tuna is worth a lot of money, To obtain the highest price possible the method of
catching tuna is very important. The demand for fresh tuna is increasing and with it is
also the demand for a consistent quality product.
Good Manufacturing Practices (GMP) guidelines must be followed. GMP procedures are
aimed at prevention of the problems by controlling the quality of the tuna as it is being
caught.
Biology of Tuna
Tuna comes from the family of fishes called SCOMBROIDEA. This family of fishes possess
large amounts of the unbound amino acid, HISTIDINEthrough the flesh. If the tuna is not
handled properly at time of catching, this chemical can be converted, by bacterial
action, to one of several toxic compounds, notably HISTAMINE. If sufficient amounts of
histamine are produces in the muscles, scombroid poisoning may result, which in
humans resembles a severe allergic action. Additional symptoms experienced include
headaches, nausea, vomiting and swelling of the lips. To prevent the build up of this
toxic-by-product, it is very important that the cooling process begin as soon as possible
once the tuna is taking on board the fishing vessel. Histamine production is minimized
at internal temperatures of lower than 7°C.
Tuna are unique among bony fish for their high metabolic rate (resulting in an
extraordinary growth pattern) and in their vascular heat exchange system permitting
them to maintain body temperatures several degrees higher than the ambient
temperature, up to 38°C at time of catching. Most fish cool their muscles by transferring
their metabolic heat to the blood where it cools at the gill surface where blood comes
in close proximity to the water. In tuna however, a countercurrent heat exchange
formed by arteries and veins supplying the red muscles (called retia mirable) acts in a
way that the heated blood leaving the muscles warms the cooled blood entering the
muscle. The retia, therefore, form a thermal barrier retaining metabolic heat in the tissue
and preventing its loss in the gills.
The ability to thermoregulate varies. Large bluefin tuna appears to have a greater
capacity to thermoregulate than smaller fish. Skipjack and yellowfin tuna can maintain
an elevated muscle temperature, but it is only a fixed value above ambient over a wide
rage of temperatures. Large bluefin tuna can maintain a red muscle temperature of
between 26°C and 32°C, while the ambient temperatures varies between 6°C and
30°C respectively, This implies regulation of muscle temperature, which could be
achieved by altering the functional size of the retia and/or by altering the blood flow
through the retia.
It has been noted that when a tuna struggles, it will reduce the cooling of its muscles by
the blood, as it uses all its energy to fight to escape capture. Therefore, it is very
important to let the tuna return to its pre-exercise levels or stop struggling before it is
removed from the hook.
Struggling will also have a dramatic effect on the amount of glycogen (stored
carbohydrate) in the flesh which would be used up by the struggle.
This causes an effect on the amount of Adenosine Triphosphate (ATP) generated in the
- 2 -
flesh after death (from the glycogen). When the concentration of ATP falls to a certain
level, the fish will enter into rigor mortis. Upon resolution of rigor (softening and relaxation
of the muscle tissue), autolytic digestion spoilage will start, resulting in changes in the
freshness of the flesh. The longer it takes the fish to go into and through rigor, the longer
the fish will remain chemically fresh.
The utilisation of glycogen from struggling also effects the ultimate post-mortem
condition of the flesh by the generation of lactic and pyruvic acids as it end-products.
High concentrations of these acids can be built up in the flesh after two minutes of
intense struggling. This acidic condition can lead to a visual deterioration of tuna
causing a rainbow colour if the flesh which may further develop into a serious defect
called "burnt fish". The flesh will turn pale and watery, giving a cooked appearance
(called 'yake' in Japan) greatly reducing its value. Fish in this condition are not suitable
for sashimi.
Struggling will take place upon taking the hook, and if allowed to struggle to death
without immediate cooling, will result in "burnt flesh". The lactic acid will be metabolised
by a live tuna on a hook, so that after two hours the flesh could return to pre-exercise
levels. Care must be taken to stop a re-building of lactic acid as the tuna is being
landed. Bleeding of fish also significantly reduces post-mortem production of lactic
acid.
Other biological and non-biologicaI factors will also contribute to tuna meat quality.
These include feeding/food composition and flesh (fat) composition, parasites, age,
sexual maturation, disease, killing methods, dressing procedures, chilling and storage
procedures, and holding temperatures,
Tuna also contains polyunsaturated fats and oils which are warmed due to the blood in
the system. If oxygen comes in contact with these oils, the fish will become rancid,
producing odours and a poor taste. One cause of rancidity is the failure to properly
bleed oxygen-rich blood from the meat. The GMP procedures will discuss the proper
method for bleeding which must be followed.
Real fresh fish, when cut across will have the bone sticking up. This indicates that fish is
still fresh and rigour mortis has not yet taken place.
For these reasons, fresh tuna especially for sashimi demands special handling and
processing methods including:
gentle catching and landing

proper killing and bleeding
careful dressing
rapid cooling or freezing as appropriate
Rapid cooling and chilling at 0°C throughout the handling process is highly
recommended for raw material intended for sashimi. If the product is to be frozen, it
should be frozen to a core temperature of -60°C within 8 hours or less, followed by
frozen storage at -50°C or lower.
The storage life of chilled tuna (yellowfin) is 10-12 days at 0°C. Frozen tuna will have the
same initial quality as chilled tuna after thawing; however, its market life will only be three
days, after which colour changes and textual changes become noticeable. Thawed
- 3-
tuna also tends to exudate drip accompanied by rapid textural changes. Fresh tuna
should be shipped within seven days of capture, if the product is to enter the fresh
sashimi market.
Quality of tuna will start to decrease as soon as the tuna is caught. The loss of quality in
tuna cannot be stopped, it can only slowed down. With Good Manufacturing Practices,
the more care taken, the better the maintenance of the quality of the tuna for the end
user. Final product grading is determined by the way the tuna is handled aboard the
vessel.
1.2 PROCESSING STEPS
Processing Steps Hazards
Method of Catching Time of Stress
Landing of Tuna on Vessel Area Clean and Safe
Method of Killing System used
Bleeding Proper Removal of Blood
Dressing Removal of Intestines & Gills
Washing Clean and Safe Salt Water
Lowering of Temperature Proper Iced Chilled Sea Water
Storage of Fresh Tuna Protect Skin and Cover with Good Clean Ice
Freezing of Whole Tuna On Board A Core Temperature of -60°C Must be Reached

of Vessel in 8 Hours or Less
1.3 METHODS OF CATCHING
To maintain a food quality product, tuna should be landed as soon as possible after
catching. There are several methods which are used for the catching of tuna.
The longline system isthe most commonly used method for the fishing of sashimi quality
tuna. The proper method when using this system is to tend the lines at all times to ensure
no dead tuna are being landed. Presently, tuna longlines use between 1600 to 3000
hooks. This is considered to many as it can take up to 15 hours to retrieve the lines. It
is recommended that less then 800 hooks be used at any one time, or a number
whereby no dead tuna are found when tending.
Decreasing the amount of hooked time that tuna is in the water will decrease the
amount of dead tuna and increase the amount of higher quality tuna for the end user.
Other hooking methods such as handline, trolling, and the pole and line are also
satisfactory as long as the tuna are landed quickly and killed immediately,
Purse seining may also be used to land sashimi grade tuna. However, with this method
-4-
much care must be taken to ensure that not too many tuna are caught at one given
time. If there are large numbers of tuna caught, it will lead to physical damage and
maximum stress (and acid levels). Tuna which are caught by sein must be allowed to
return to pre-exercise levels before removal. Tuna should be removed from the sein by
gaffing the fish in the head with a hook or by the use of a tuna missile.
Tuna is a very delicate fish and has to be treated as such. The quality of the tuna starts
to decrease as soon as it is on the hook, so what ever can be done from there on will
only slow down the decrease in quality.
Points o f Concern
Tuna must be handled properly even when it is in the water.
Eliminate the amount of stress, by tending the hooks more often.
Decrease the amount of dead tuna by decreasing the amount of time that the tuna
is on the hooks after catching.
1.4 TEMPERATURE OF TUNA
Tuna is a very large fish, and as such it takes time for its heat to be removed. The best
way is to completely surround the fish in a heat removing substance - water/ice slurry.
Ice alone can be used, but ice melting at the surface of the fish may cause "bridges"
in the ice pack, and the ice in the gut may also melt causing little contact and heat
transfer slowing the cooling rate and requiring laborious re-packing.
Also, depending on the species of the tuna, the temperature of the tuna meat could
be 10 to 15°C higher than the water temperature. Additional heat may also be caused
by struggling and, if the fish is not killed properly, the tuna will try to keep the body's
temperature as high as possible after death.
Points o f Concern
Tuna must be cooled as soon as possible after taking on board the vessel.
Tuna must be placed in a cooling tank so as to decrease the core temperature as

quickly as possible.
1.5 HANDLING
One method of taking the tuna on board is by the use of a gaff which is placed very
carefully through the lower jaw. Another method is the use of a Tuna Missile. This is a
multi-jawed griping device which is slid down the line to grip the tuna by the head. It is
said to both clam the tuna and ensure it cannot escape (Annex 2).
When the crew are handling the tuna, they should wear gloves to protect the skin and
the scales of the tuna.
The outer appearance of the tuna will tell the buyers how the tuna has been handled
at time of catching,
- 5-
During handling, if the skin is damaged then the meat will also be damaged. This will
cause the tuna to have a lower grade which in turn can reduce the price. All care must
be taken to ensure proper handling of tuna.
The deck surface must be kept clean and have a proper covering on the surface so as
to protect the tuna from being damaged.
There should also be a proper overhead canopy in place to protect the tuna from the
sun.
NOTE: One very important point to remember especially for the longline fishing vessel
is that there should be enough crew available at all times to handle each tuna as it is
taken on board the vessel. Tuna cannot be left on the deck without being properly
handled; for example, a boat cannot take in all the tuna that are on the long line and
then start the killing and handling operation.
Section 5.9 gives a flowchart for tuna grading at sea.
Points o f Concern
Prevent tuna from being damaged,
Care must be taken to ensure that the skin, scales and outer meat is protected.
1.6 CLUBBING AND KILLING
Tuna is killed by either a sharp blow to the head or a spike inserted into the brain. The
soft spot is found between the two eyes. The brain should be destroyed by placing a
sharp object into the brain and pushing down so as to destroy the nervous system. The
spinal core should also be destroyed by the use of a short metal rod and a tube. Force
the rod through the tube into the brain and down the spinal canal to destroy the spinal
core.
The primary reason for immediate killing is to prevent the tuna from suffering additional
stress and struggling during the bleeding process. The reason for the destruction of
brain and spinal core is to ensure the tuna's central nervous system which regulates
body temperature will not function after death so that the tuna's body temperature will
fall more rapidly in cold storage.
Points o f Concern
Ensure that the tuna is killed properly.
Decrease the chances of struggling.
Decrease the chances of damage.
1.7 BLEEDING
Tuna must be bled as soon as possible after being taken on board. Removal of the hot
blood will allow the tuna to cool much faster, and also reduce acidity. Listed are three
steps that should be taken to properly bleed the tuna.
-6-
STEP #1: Locate the lateral median line behind the pectoral fin and with a clean knife
roughly 2 inches long by ½ inch wide, make a cut no more than 2 inches long behind
the pectoral fin, To cut the blood vessel make a cut 1 to 2 inches deep into the blood
vessel. This cut must be completed on both sides of the fish.
STEP #2: The next step is to cut the blood vessels in the gills, Pull open one side of the
gill cover, and with a clean sharp knife cut through the membrane behind the gill. Cut
upward toward the spine to sever the blood vessel, being careful not to damage the
heart, The heart, even though the tuna is dead, will continue to pump the blood as
long as it is not damaged. This cut must be completed on both sides of the head.
STEP#3: The final step is to cut vertically on both sides of the tail between the third and
fourth dorsal finlet from the tail. Do not remove the tail. During these three steps clean
salt water must be kept running over the tuna to prevent the blood from clotting.
Points o f Concern
Ensure that the proper bleeding is completed with each fish.
Ensure that when cutting the blood vessel in the gill area that the heart is not damaged.
1.8 GUTTING & GILLING (REMOVAL OF EXTERNALORGANS & GILLS)
It is very important that all the internal organs are removed from the tuna as quickly as
possible after bleeding. Fish possess chemically active proteins known as enzymes
which are responsible for the digestion of their food. At death, these enzymes, which
include the digestive enzymes of the stomach and intestines, remains active. If they are
not removed, they will actually breakdown the tissues of the digestive tract and begin
destroying the belly meat, which is very important. The thickest part of the tuna is
around the belly area and this is where the highest yield recovery takes place. It must
be protected.
To remove the internal organs, first make a straight cut 4 inches long in the belly, cutting
towards the anus. You must not cut through the anus. Reach into the cut and pull out
the intestine which is attached to the body wall of the fish. Cut the intestine as close to
the anus as possible.
Next, you must remove the gills from the head, making sure not to damage the head.
Pull open the gill cover and then grab the lower end of gills. Cut gills away from the
head, then pull and remove the gills and gut material.
When this process has been completed, the belly area must be properly cleaned with
proper clean safe sea water. Making sure that all gut remnants and blood is removed.
The area around where the gills have been removed must also be properly washed and
all blood removed. This area is usually scrubbed with a soft nylon brush to ensure that
the blood in the bone area is properly removed. After this process is completed the
outer area of the skin must be washed properly so as to ensure that there are no slime
or foreign material present. The above-mentioned process should be done as quickly
and carefully as possible to ensure that the quality of the tuna is maintained at all times.
Where seawater temperatures are warm, it is recommended that the water be cooled
before it comes in contact with the tuna. One method to do this is to pass the wash
- 7-
water through a 2.5 cm coil of copper pipe approximately 4 m long which has been
placed in an incubated box filled with ice and water. This will help in the initial cooling
of the tuna.
Points o f Concern
Gutting must be done properly.
No fish to be placed in fish hole which is not gutted.
Protect the belly wall by proper washing after gut removal.
1.9 LOWERING THETEMPERATURE
Tuna should be placed in a container of salt water and ice for a period of up to 12
hours or until the core temperature of the tuna is at 0°C. If it is kept for longer than 12
hours, there may be a bleaching effect. The mixture of ice and water should be at least
two parts ice to one part water. This procedure should be used on vessels wherever
possible. Remember that the quicker the body temperature is lowered the better results
you will have in maintaining the quality of the tuna. For vessels that are unable to use
this process due to size, then the tuna must be placed in ice as quickly as possible. If
the tuna is chilled in ice, it may have to be re-packed several times as it chills.
1.10 ICING OF TUNA (STORAGE ON BOARD)
When the proper core temperature has being acquired, the tuna must be removed
from the slush tanks and very quickly and carefully placed in the fish hole. We must
ensure that the skin or the meat are not being damaged when being placed down
through the fish hatch.
The first part of icing a tuna is to properly pack the belly completely with ice. This will
help maintain the proper temperature in the belly wall.
The outer area of the tuna must be covered with a green tuna paper so as to protect
the skin of the tuna from coming in direct contact with the ice. This procedure will help
maintain a good skin surface. Before the paper is placed around the tuna it must be
soaked in clean salt water, not fresh water. Fresh water causes bleaching of the skin.
Salt water help maintain the natural colour of the skin.
Green tuna paper is a special parchment type paper that can be ordered from Japan.
An alternative is to use cheese on muslin cloth.
The main type of ice used in Indonesia is block ice. Due to the very hot climate this is
the only type of ice that is suitable. It will last for a longer period of time. However, block
ice must be properly crushed before it is placed around the tuna. It is very important
that there are no large pieces of ice or sharp edges of ice used in the icing of tuna.
The tuna must be properly covered at all time with a good layer of ice.
There should be a layer of ice 30 centimetres deep under the tuna. The tuna are
placed head to tail ensuring that there is enough room between each fish to properly
ice. Each tuna must be laid flat so as to ensure that the tuna does not bend. If tuna
is allowed to be bent, then this will cause tearing off the meat which in turn will cause
- 8-
downgrading of the quality. There can be two layers of tuna placed in a fish hole
compartment one on top of the other; if more layers, shelving must be used. Between
each layer of tuna, the fish must be covered with at least 30 centimetres of ice. The ice
must be spread evenly over the fish, ensuring that there are no air pockets present. As
the ice melts the water must be able to run clear of the fish. Proper pumping of the fish
hole must be maintained.
Large and small tuna should not be iced together, large tuna should not be placed on
top of small tuna. The more pressure that is placed on the fish the more chances there
is of damage occurring while the fish is in the ice.
The fish hole must be properly insulated to maintain a proper cold temperature. The fish
hatch opening must be well insulated to protect the hole from the outside air
temperature.
Another method of holding tuna is the use of Refrigerated Sea Water. This system can
only be used with vessels that have water tight fish holes and the proper refrigeration
system on board. They must have the proper controls and holding facilities so as to
maintain this system,
When fish are being placed in this system, the tuna must be placed into plastic bags
so as to protect each tuna. The temperature must be maintained at 0°C at all times.
The water must be kept clean and systems must be place to change the water as it
becomes stale.
Once the tuna is properly iced and stored, it must be continuously checked to see that
it is covered by ice at all times. Temperature of the meat should not drop below -2.5°C
in the fresh state as rapid browning of the meat in the outer layers can occur.
Points o f Concern
All tuna must be properly iced.
Regular inspection to ensure that the tuna is completely covered with ice,
Prevent tuna from touching when being iced in the fish hole.
1.11 DISCHARGING OF TUNA
When the time comes to discharge the tuna from the fish hole, all care must be taken
to ensure that the tuna is handled very carefully and quickly,
Before the tuna is removed from the fish hole there should be a proper protected
covering around the fish hole so as to ensure that the skin and flesh cannot be
damaged.
There must be an overhead covering in place aboard the vessel if the tuna are going
to be exposed to the sun for any period of time.
1.12 ON BOARD FREEZINGOF TUNA (FOR SASHIMI AND OTHER MARKETS)
To obtain high quality frozen product, the previously mentioned landing and handling
-9-
on-board procedures apply. Temperature of tuna must be reduced as quickly as
possible.
Air-blast freezing is recommended because low temperature can be obtained relatively

quickly. Tuna in air-blast freezers should be suspended from the head, or aligned head-
first into the air-blast. Tuna laid flat must be protected so that it does not bend. If tuna
is bent during freezing, when it is thawed the meat will become torn causing a decrease
in the quality.
The required core temperature that tuna is to be frozen on board is -60°C. The
refrigeration capacity should be such as to do this within 8 hours or less.
The freezer storage area on board must maintain a constant temperature. The
temperature should be held at -50°C or below. If the temperature is allowed to
fluctuate or rise excessively, the freezer store's atmosphere will hold enough water
vapour to cause a drying effect on the skin of the tuna and create a condition called
freezer burn.
On-board blast freezers and cold storage rooms are required to be equipped with a
monitoring gauge to record the temperature on an hourly basis. This will give
information to show if there is a problem with the temperature in the rooms.
1.13 SUMMARY OF FISH HANDLING PROCEDURES:
1. Remove fish from hook as soon as possible after hooking.

2. Gaff tuna carefully through the lower jaw, or the use of a Tuna Missile is also
recommended.
3. Eliminate struggling by clubbing the fish properly.
4. Handle the fish quickly and carefully at all times.
5. Kill the fish with a spike inserted in the brain as soon as it is on board.
6. Bleed the fish immediately after killing.
7. Wash the fish after bleeding,
8. Gut and gill the fish following bleeding.
9. Wash the fish properly after gutting and gilling.
10. Start chilling as soon as possible.
11. Properly ice the fish in fish hole.
12. Core temperature of fresh tuna must be kept at 0°C.
13. For tuna that is frozen on-board, the core temperature should be at least -60°C.
14. The cold storage area for the tuna frozen on-board should be maintained at -50°C
or below.
-10-
Annex 1
FLOWCHARTS FOR
THE O N -BO AR D H A N D L IN G OF
FRESH A N D FROZEN T U N A
- 11 -
Tuna
Fresh
of
Handling
Board
On
for
Flowchart
1.1
Annex
-12-
Tuna
Frozen
of
Handling
On-Board
for
Flowchart
1.2
Annex
- 13 -
Annex 2
Tuna M issile
-14-
Annex 3
Diagrams of
Proper Handling Procedures and Descriptions
Taken from: Nakamuna, Robert M., et. al.

The Management of Yellowfin Tuna
in the Handline Fishing Industry of Hawaii:
A Fish-Handling Handbook.
University of Hawaii Sea Grant College Program (1987)
UNIHI-SEAGRANT-AR-88-01
Note: To handle tuna head-on, follow steps 1 through 14

as shown in figures 1 to 18.
Note: To head tuna, follow steps 1 through 5

as shown in figures 22 to 24.
-1 5 -
Annex 3
LANDING THE FISH
Run-Fight Time
More runs after hookup mean longer fight time and an increased chance of BTS occurrence.
To reduce this possibility, the number of runs should be minimized and tuna should be landed
as rapidly as possible -- ideally within 6 minutes of hookup.
Gaffing
The best place to gaff a fish is through the lower jaw (Figure 1) because it is strong enough to
support the fish when lifted. Also, a gaff through the jaw makes it easy to position the fish for
stunning. Gaffs should not be made through the body or heart. A gaff through the body
reduces the value of the fish, and an accidental gaff through the heart ruins the chances for
proper bleeding.
Figure 7. Gaff the fish through the lower jaw.
Stunning a n d Killing
Longer struggling time results in increased body temperature, bruising, scale loss, and
muscular contractions. Fish should be stunned and killed as quickly as possible. The best
place to club a fish is on the soft spot. The soft spot, which is whitish in colour, is located on
the mid-dorsal line just above the eyes (Taniguchi, 1977). The brain is located slighted behind
the soft spot.
-1 6 -
• Stunning
Fish should be stunned by clubbing immediately after gaffing or as soon as they are
brought on board. Clubbing can be accomplished with a bat, mallet, or lead-filled steel
pipe (Figure 2).
Figure 2. Stun the fish b y dubbing the soft spot between the eyes.
• Killing
Sometimes stunning only temporary renders the fish unconscious. Fish that appear to be
dead can recover and start to thrash in the fish box. To prevent this, the fish should be
killed immediately after stunning by destroying the brain. Three techniques are described
below. When properly executed, the fish will shudder once, becom e limp, and die.
The first technique involves the use of a sharp probe such as an ice pick or a screwdriver.
These are simple tools which can be used to quickly and easily kill the fish (Figure 3).
Step 1 Place a sharp probe on either side of the soft spot.

Step 2 Pierce the skin, and then push the probe down until the skull is reached.
Step 3 Apply downward pressure on the probe, and then slide it backward in
the direction of the tail until you reach a thin cartilaginous plate at the
base of the ridge. The plate will collapse, and the probe will sink about
1 inch deeper into the brain.
Step 4 Move the probe back and forth to destroy the brain.
Figure 3. Destroy the brain on either side o f the soft

spot using an ice pick o f screwdriver.
- 17-
Another killing techniques involves the use of the Taniguchi tool (Figure 4). Developed in
Japan by Dr. H. Taniguchi (1997) and used mainly on longline fishing vessels, this tool
consists of a short metal tube and a rod. A welding rod or flexible plastic rod may also be
used.
Step 1 Bore a hole into the fish's brain at the soft spot.
Step 2 Force the rod through the tube, into the brain, and down the hollow
core of the spinal canal to destroy the spinal cord.
Figure 4. Insert the metal tube through the brain, followed b y the rod into
the spinal canal to destroy the spinal cord.
A third technique used to kill fish involves the use of a hacksaw and rod (Figure 5). A sharp
knife may be used in place of a hacksaw.
Step 1 Using a hacksaw, cut a wedge from the area over the soft spot to the
base of the eyes.
Step 2 Remove the wedge to expose the brain.
Step 3 Insert the rod through the brain and into the spinal canal to destroy the
spinal cord.
Figure 5. Cut a wedge over the soft spot to expose the brain, and then
pass a rod through the brain into the spinal canal.
-1 8 -
CLEANING THE FISH
Bleeding
Fish should be bled for 5 minutes immediately after killing. Removal of the "hot" blood allows
the fish to cool more rapidly. When heart, which continues to function even after the brain
is destroyed, must be kept intact in order for it to pump the blood out of the fish. Three
methods for proper bleeding are given below,
• Pectoral Cut
To make the pectoral cut, a short, narrow knife roughly 2 inches long by 1/2 inch wide
should be used since the blood vessels (subcutaneous artery) lies no more than 1 inch
below the skin surface of the fish. A sharpened oyster shucker or any other similar-sized
knife is ideal. The knife should be kept extra clean to prevent bacteria - which may
contribute to accelerated spoilage - from being introduced into the fish.
Step 1 Locate a spot the width of three fingers behind the base of the
pectoral fin and about 1/4 inch below the lateral median line which
extends along the side of the fish (Figure 6).
Step 2 To sever the blood vessel, make a 1 to 2 inch cut, 1 inch deep, from
the spot towards the base of the pectoral fin.
Step 3 Make this cut on both sides of the fish.
Step 4 To drain the blood from the fish, position it's head down, on an incline.
Shoot water on the fish to prevent blood c lot.
Figure 6. Bleed fish by cutting behind the pectoral fin.
• Gill Cut
Step 1 Position the fish so that it is lying on its side.

Step 2 Pull open one side of the gill cover, and then insert a knife behind the
gills through the membrane (Figure 7).
Step 3 Cut upwards towards the spine to sever the blood vessels, being careful
not to stab the heart.
Step 4 Make a cut on both sides of the fish.
Step 5 To drain the blood from the fish, position its head down, on an incline.
Shoot water on the fish to prevent blood clotting.
-1 9 -
Figure 7. Bleed fish b y cutting blood vessel a t top o f gills.
• Tail Cut
Step 1 Cut the blood vessel vertically between the third and fourth dorsal finlet
(see appendix) from the tail (Figure 8).
Step 2 Make cuts on both sides of the fish, or remove the tail completely.
Step 3 Drain the blood from the fish. Shoot water on the fish to prevent blood
clotting.
Figure 8. Bleed fish by cutting tail
Gutting and Gilling
Removing the internal organs and gills is another way to cool the fish faster to prevent
spoilage and bacterial growth which can cause BTS. Also, a gutted, gilled fish can be
processed faster and handled less at the market. Female and very large fish should be
handled more quickly - but carefully - since they are prone to a greater incidence of BTS.
Although tuna smaller than 80 pounds rarely develop BTS, those weighing as little as 5 pounds
have been observed with this condition.
The sex of the fish can be determined by the presence of testicles of ovaries. During the
spawning season - from May to October - the male testicles are smooth, elongated, and
noticeably white in appearance; the female ovaries are elongated, rough in texture, and
yellow to orange in colour, and their surface is lined by prominent veins.
-2 0 -
Fish can be gutted and gilled with the head on or off. Both approaches are given below.
• Head-on Approach
Step 1 Make a straight, 4 inch slit in the belly, cutting towards the anus
(Figure 9).
Figure 9. Insert knife 4 inches in front o f the anus, and then cu t

towards it.
Step 2 Reach into the cavity and pull out the intestines attached to the body
wall. Cut the intestine near the anus (Figure 10).
Figure 10. Cut the intestine near the anus
Step 3 Pull one gill away from the body. Then insert a knife at the top of the gill and
slide towards the eye. Make this cut on both sides of the fish (Figure 11).
Figure 11. Insert knife a t the top o f the gill cover and slide it toward the eye.
-2 1 -
Step 4 Pull the gill cover back, reach inside the cavity with a knife, and then
cut the main muscle attaching the gill cover to the head. Make this
cut on both sides of the fish to allow easier access to the gills, which
needs to be removed (Figure 12).
Figure 12. Cut the main muscle attaching the gill cover to the head.
Step 5 Cut the lower end of the gill-to-head attachment and not the entire
connection of the lower body to the underside of the mouth (Figure
13). If you cut the entire connection, unequal pressure exerted by
muscle stiffening will lower the quality of the fish in two ways. First, it will
cause the head to lift up and bend backwards, distorting the shape
and appearance of the fish. Second, this unequal pressure will cause
tearing and gaping of fillets.
Figure 13. Cut lower end o f gill-to-head attachment.
Step 6 Pull one gill cover from the body, and then cut through the membrane
behind the gills. Extend the cut through the kidneys as far back and as
close to the backbone as possible. Bring the cut down each side of
the gill openings. Make this cut on both sides of the fish (Figure 14).
-2 2 -
Figure 14. Cut through the membrane behind the gills.
Step 7 Pull one gill cover away from the body. Insert a knife under the gills,
close to the spinal column, and cut the upper end of the gill-to-head
attachment. Cut on both sides of the fish, and then free gills from the
head.
Figure 15. Cut upper end o f gill-to-head attachment.
Step 8 Pull open gill cover, and then grab the lower end of the gills. Pull and
remove the gills and guts. Remove any remaining attachments (Figure
16).
Figure 16. Remove gills and guts and any remaining attachments.
Step 9 Remove the gonads from the cavity by sliding your hand under them
and tearing the membranes anchoring them to the stomach.
-2 3 -
Step 10 Pop the air bladder.
Step 11 Remove as much of the kidney and coagulated blood as possible
from the backbone. Scrub the area with a stiff wire or nylon brush until
spine becomes white (Figure 17).
Figure 17. Scrub spine through gill openings to remove the

kidney and coagulated blood.
Step 12 Remove as much loose skin and hanging attachments as possible

from the bone within the gill openings.
Step 13 Remove the membranes from inside gill cover (Figure 18).
Figure 18. Trim the membranes lining the gill collar.
Step 14 Rinse fish with chilled water and wash away slime from the outside of
the skin.
Step 15 Remove all fins, and even the tail, if desired (Figures 19 and 20).
-2 4 -
Figure 19. Remove all fins.
Figure 20. Gilled, gutted fish with head on and fins removed.
Step 16 Optional. For easier processing, cut off a portion of the gill cover for better
access to the gills and guts. Either use a saw or bend the gill plate back
until it snaps in half, and then cut along the crease with a knife (Figure 21).
Figure 21. Saw o ff the gill cover or fold it back and cu t along crease.
• Head-off Approach
With the head-off approach, a part or all of the head is sawed off and the gills and guts
are removed with the head. The procedure is as follows.
Step 1 Remove the head by sawing straight down behind the eyes (Figure 22).
Step 2 Alternatively, insert the saw behind the gill cover and saw at an angle towards
the snout. Make this tapered cut on both sides of the fish (Figure 23).
-2 5 -
Figure 22. Saw straight down behind the eyes to remove the head.
Figure 23. Sa w towards snout from behind the gill cover on both
sides o f fish to achieve a tapered cut.
Step 3 For gutting and gilling instructions, follow steps 1, 2 and 6 through 13 in
the head-on approach section.
Step 4 Rinse fish with chilled water and wash away slime from the outside of
the skin.
Step 5 Remove all fins, and even the tail, if desired (Figure 24).
Figure 24. Gilled, gutted fish with head and fins removed.
-2 6 -
External Anatomy o f Yellowfin Tuna
Internal Organs o f Yellowfin Tuna
-2 7 -
- 28 -
S E C T IO N 2
A N IN T E G R A T E D Q U A L IT Y M A N A G E M E N T P R O G R A M
( IQ M P ) FOR
T H E O N - B O A R D H A N D L I N G A N D P R O C E S S IN G O F
TUNA
-2 9 -
2.1 INTRODUCTION
Due to the rising concerns by the different countries o f th e world, there will have to b e
in the very near future requirem ents to have in p la c e an a d e q u a te safety assurance
program for the o n -b o a rd handling o f fresh/frozen tuna. Vessel ow ners/operators will
h a ve to show in writing th e procedures th a t they are using to identify hazards
a ssociated a t e a c h p oint in th e processing ope ra tio n o f th e c a tch in g , handling,
storage o f tuna; w hich points are critica l control points; a n d th e preventive m easures
th e y are taking to assure th a t th e safely o f their p ro d u ct is g ua ra nte ed.
A num ber o f qua lity control systems exist to ensure th e abo ve, th e best known is the
Hazard Analysis a nd C ritical C ontrol Point (HACCP) system. This system, w hile an
international standard, is a narrowly defined food safety system th a t requires a num ber
o f pre-requisite requirem ents a n d does not d e a l with quality or e co n o m ic fraud. A
m o re com prehensive program , w hich incorporates HACCP, its pre-requisite
requirem ents, regulatory requirem ents, a nd m arket requirem ents, is th e Integrated
Q uality M anag em e nt program (IQMP).
The IQMP specifies a num ber o f ge n e ric areas or co n tro l points w here hazards m ay
o c c u r. Each o f these areas m ust b e exam ined to see if there is a control p oint or
critical control p oint in th e process in th a t area. Annex 4 gives th e definitions used in
this m anual to describe "control points" a nd "critica l co n tro l points", e tc.
Vessel owners/operators should c o n d u c t a study o f their ope ra tio n using th e IQMP as

a g u id e , in corporate th e IQMP into their quality control pro g ra m m e a n d subm it this
pro g ra m m e to th e c o m p e te n t authorities for approval.
2.2 ESTABLISHMENT OF CONTROL POINTS OR INSPECTION POINTS
As part of GMP procedures, fishing vessel owners/operators should im p le m e n t planned

procedures for the m onitoring o f their operations a t C ontrol Points or Inspection Points
where problem s are noted. D etection o f problem s a t th e earliest opportunity allows
th e problem s to b e related to th e factors th a t caused th e m and perm its th e m ost
e ffe ctive a p p ro a ch to co rre ct them .
Control or Inspection Points represent the last opportunity b e fo re any other processing
takes p la c e with th e tuna to eva lu a te c o m p lia n c e with requirem ents a n d take
co rre ctive a ctio n where necessary.
For e a c h C ontrol or Inspection Point th e follow ing inform ation m ust b e specified:
1) The requirem ents th a t are being co m p lie d with.

2) The standard th a t is being e m plo yed during inspection.
3) Evaluation o f th e m onitoring procedures.
4) The system for co lle ctio n d a ta a n d record keeping.
5) D escription o f th e corre ctive a c tio n th a t will b e im ple m e n te d
w hen problem s are discovered.
There are 11 areas in the on board handling operation o f tuna th a t are required to b e
e xa m in e d a t control or inspection points to ensure c o m p lia n c e with GMP
requirem ents. They are discussed as th e follow ing sections:
-3 0 -
Fish 2.3
Ice 2.4
C leaning Agents, Sanitisers, Lubricants 2.5
Vessel Design, Production Facilities 2.6
O peration & Sanitation 2.7
Process C ontrol 2.8
Fresh Storage Facilities 2.9
Frozen Storage Facilities 2.10
Final Product 2.11
Recall Procedures 2.12
Em ployee Q ualifications 2.13
In establishing the C ontrol or Inspection Points for th e on-bo ard o pe ra tion o f tuna,
e a ch ow ner m ust understand w h at hazards they are a tte m p tin g to prevent a n d the
location whereby an inspection or control proced ure will provide th e best opportunity
to control th e hazard.
A flow c h a rt a n d ta b le are found in sections 2.2.1 and 2.2.2. They provide an

overview o f where inspection or control points for e a c h item m ay b e established.
Section 2.2.3 is a form for setting up an individual IQMP program .
Annex 5 provides specific inform ation regarding the potentia l critica l control points for
th e on-bo ard handling o f fresh/frozen tuna.
-31 -
Points
Control
or
Inspection
for
Flowchart
Process
2.2.1
2.2.2 Potential Inspectton/Control Points
ITEM HAZARDS CONTROL POINTS
Fish Health & safety risks tainted, Prior to processing, before

d e co m p o se d , unw holesom e tuna c a tch in g
d e a d , n o n -co m p lia n ce
Ice C o nta m ination o f tuna unsafe, Prior to use w hen received,

unclean during use
C leaning Agents C o nta m ination o f tuna with Prior to use, w hen received,
Sanitisers unapproved unsafe chem ica ls during a p p lica tio n
Vessel Design C onta m ination to tuna d u e to Prior to fishing, during fishing

Production poor design o f vessel
Facilities
O peration & C onta m ination to tuna d u e to Prior to c a tch in g , during

Sanitation poo r ope ra tion & sanitation operation, daily inspection
p ra c tic e
Process C ontrol Production o f tuna th a t d o n 't During o pe ra tion -washing,

co m p ly with safety quality, cle aning, coolin g, icing, &/or
wholesom eness &/or fair trad e freezing
requirem ents
Fresh Storage D ecom position or con ta m in a tio n During o pe ra tion o f fish hole
Facilities o f tuna d u e to poor storage
Frozen Storage D ecom position or co n ta m in a tio n During ope ra tio n o f blast

Facilities o f tuna d u e to poor storage freezer/cold storage
Final Product Production o f tuna th a t does not Prior to unloading o f

c o m p ly with safety, quality & fresh/frozen tuna
wholesom eness & fair tra d e
requirem ents
Recall Procedure Unable to tra c e tuna to processor During unloading, shipping
Em ployee Production o f tuna posing health & Prior to start up skilled fishery
Q ualifications safety risk Personnel
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2.2.3
IDENTIFICATION O F CO NTRO L POINTS
T yp e o f O p e r a tio n :____________________________________________________________
C heck o ff those item s which will b e m en tio n e d a t a co n tro lp o in t a n d id e n tify where/w hen th e
p o in t o f tim e th e in spection will occur.
ITEMS POINT O F TIME O F INSPECTION
Fish
Ic e
C le a n in g A g e n ts , S a nitise rs
L u b ric a n ts
V e sse l D e s ig n , P ro d u c tio n
F a c ilitie s
O p e ra tio n & S a n ita tio n

P ro ce ss C o n tro l
Fresh S to ra g e F a c ilitie s
F in a l P ro d u c t
E m p lo y e e Q u a lific a tio n s
Refer to the section in d ica te d fo r com pletion o f those co n tro l po in ts th a t h a ve b e e n c h e c k e d

off.
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2.3 FISH
2.3.1 Requirements
Under GOOD MANUFACTURING PRACTICES the following requirem ents are to be

follow ed by th e fishing vessel ow ner/operator, and crew.
1) No person shall take on board th e fishing vessel any tuna th a t is

d e co m p o se d , ta in te d or unwholesom e.
2) When tuna is taken aboard the vessel it is required to b e ble e d properly.
3) After bleeding, the g u t m aterial m ust be rem oved. No tuna is to b e kept
on boa rd o f fishing vessel w ithout being properly g u tte d a n d w ashed.
4) The gills from all tuna are to b e rem oved properly.
5) Tuna should be p la ce d in an insulated con ta in e r containin g tw o parts
c le a n safe ice and o ne part cle a n safe salt w ater. The tuna should
rem ain in this tank until the co re tem p era ture reaches 0°C.
6) After chilling, tuna intended for the fresh m arket m ust b e p la c e d into the
fish hole. The belly o f th e tuna m ust be packe d co m p le te ly with g o o d
cle an ice. The exterior skin must be com pletely covered with tuna p ap er
to p ro te ct th e outer surface.
7) After chilling, tuna destined for freezing m ust b e p la c e d in blast freezer
either suspended by the head or p la ce d fla t with head first into blast air
flow.
8) Every vessel is required to keep a record o f e a c h day's c a tc h . The
inform ation th a t is required is as follows:
A) The areas th a t w ere fished during the trip.

B) The num ber o f fishing hooks used or lines used e a c h day.
C) The num ber o f live tuna landed e a c h day.
D) The num ber o f d e a d tuna la nded e a ch day.
E) The num ber o f discard tuna for e a c h day.
F) The num ber and kinds of other fish c a u g h t while fishing tuna, for
e a ch day,
G) There m ust be a fish hole ch a rt showing th e list o f e a c h day's
catch, where they are stowed in the hole so as to ensure th a t the
oldest tuna ca n b e kept separate from the fresh tuna.
H) There m ust be a log showing th e m onitoring o f th e tem p era ture
o f the tuna as it is being p la ce d in the fish hole. Also there m ust
b e a log to show th e tem peratures o f th e frozen tuna being
rem oved from th e blast for storage in co ld storage.
Any equipm ent that is used in the processing o f tuna th a t is d a m a g e d or ca n

cause any d a m a g e or co n ta m in a tio n to th e tuna, c a n n o t b e used.
All fish handling equipm ent such as knives, chutes, fish conveyors, fish washers,
ta b le s and utensils, shall b e o f sm ooth, non-absorbent, non-corrodible
m aterials. If w ood is to c o m e in c o n ta c t with th e tuna, it m ust b e free from
cracks and crevices and constructed in such a m anner th a t it c a n b e properly
cle aned .
The c o n ta c t surface o f the fish h a tch m ust b e properly constructed so as it is

of proper size, The co n ta ct surface in the fish hole m ust b e properly insulated.
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Both the fish hole surface and the fish hole hatch m ust b e properly constructed
o f a sm ooth surface, free from cracks and crevices a nd m a d e o f non-
corro dib le m aterial.
Only cle an safe salt w ater is to b e used in th e washing a n d cle a n in g o f tuna.

Fresh w ater is not to b e used d ue to th e fa c t th a t if used, it will cause
bleaching o f th e skin,
A fter th e rem oval o f th e g u t m aterial from th e fish, it is to be discarded

im m ediate ly. It is not to b e le ft around th e tuna d u e to the fa c t th a t it ca n
cause co n ta m in a tio n to th e fish.
Any area a b o a rd th e fishing vessel th a t c a n c o m e in c o n ta c t with th e tuna

m ust be o f a sm ooth surface and kept in a c le a n and sanitary condition.
Fishing vessels must have a proper overhead ca n o p y in p la c e so as to p ro te ct

th e tuna from d ire ct c o n ta c t with th e sun.
2.3.2 D efect Deficiency
A tuna which is taken on board in w hole state is considered d e fe ctive if there

is any tra ce o f fuel oil or other critica l co n ta m in a tio n o f the flesh odour w hich
is indicative o f deco m p osition or taint.
Critical contam ination is the presence of any m aterial or distinct a nd persistent

o d o u r or flavour o f any m aterial w hich has not being derived from fish and
w hich poses a thre at to hum an health.
Tuna which is not bled, cleaned or chilled properly c a n also b e c o m e a d e fe c t

fish.
2.3.3 Monitoring Procedures
The follow ing procedures shall be used in determ ining th e co n d itio n o f the
tuna:
Each tuna is exam ined for co n ta m in a tio n by fuel oil or other critical
co n ta m in a tio n source likely to b e a thre at to hum an health a t tim e of
taking the tuna on-board.
In regards to d e a d tuna th a t are taken on board a t tim e o f ca tch in g ,

these fishes must b e inspected to see th a t there are no con ta m in a tio n
arising from the fish being d e a d . W hen these fish have being dressed
the belly section m ust be inspected to ensure th a t the fish is still fit for
hum an consum ption,
D ead tuna afte r being processed a b o a rd th e vessel m ust b e m arked

and separated so as when produ ct is landed, it c a n b e reinspected by
the receiving plant.
2.3.4 Corrective Action
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W hen there is a problem with th e tuna there should b e a co rre ctive a ctio n
report filled o u t describing th e problem a nd w hat a c tio n has be e n taken. An
exam ple o f a C orrective A ction reporting form is found in 2.3.6.
The fishing vessel will identify th e position responsible for taking corrective
action and the position responsible for ensuring th a t th e co rre ctive a c tio n was
carried out. If th e vessel ow ner wants to use its own form s it m ust provide an
exam ple o f th e form s th a t will b e used to record the co rre ctive a ctio n .
For e a c h instance o f n o n -co m p lia n ce the fishing vessel m ust have a record
o f the corrective action th a t took p lace and th a t th e records m ust provide the
follow ing inform ation:
■ A description o f th e n o n -co m p lia n ce item

■ The d a te th e n o n -co m p lia n ce item hap p e n e d
■ The d a te th e corre ctive a ctio n took p la ce
■ W hat corre ctive a ctio n was taken
■ The o u tco m e
■ The signature o f th e person responsible
2.3.5 Inspection o f Tuna As it is Being Taken On board
During the ca tch in g and taking on board o f tuna a n inspection o f th e overall

a p p e a ra n c e should b e done. Section 2.3.7 contains an exam ple o f an
inspection o f landing report and Section 2.3.8 is th e inform ation to b e supplied
by th e fishing vessel.
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2.3.6
CORRECTIVE AC TIO N REPORT
D a te : A re a A ffe c te d :
D e s c rip tio n o f th e P ro b le m w ith th e T un a:
S h o w A c tio n W h ic h H as B e in g T aken to C o rre c t th e P ro b le m :
D a te P ro b le m S o lv e d :
C u rre n t S ta tu s :_______
V e sse l O w n e r :_______
In s p e c to r :___________
This report m ust b e filled o u t when there is a p ro b le m th a t is a ffe c tin g th e q u a lity o f the tuna.
This report m ust b e ke p t to show whether there was a p ro b le m a n d w hat was d o n e to c o rre c t
th e problem .
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2.3.7
INSPECTION O F TUNA AS IT IS BEING

RECEIVED O N -BO AR D VESSEL
D a te : N a m e o f V e sse l:
A re a F ish e d : T yp e o f F ish in g G e a r:
S p e c ie s :
O u te r A p p e a r a n c e o f F is h :
A ny O d o u rs :
Fish L iv e :
Fish D e a d :
C o n d itio n o f B e lly o f F is h :
T e m p e ra tu re o f th e F is h :
A n y N o tic e a b le C o n ta m in a tio n :
Fish P a s s :
Fish F a il:
A n y C o m m e n ts to th e C o n d itio n W h ic h is N o t L iste d o n th is S h e e t:
In s p e c te d By:
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2.3.8
INFORM ATION TO BE SUPPLIED

BY FISHING VESSEL
Type o f Fishing O p e ra tio n :
R e q u ire m e n ts
W e w ill m e e t g o o d m a n u fa c tu rin g p ra c tic e s fo r th e o n b o a rd h a n d lin g o f tu n a as
o u tlin e d in this m a n u a l.
Or
W e w ill p ro v id e o u r o w n c o m p a n y re q u ire m e n ts th a t w ill m e e t o r e x c e e d th o se
s u p p lie d in th e GMP. ________
D e fe c t D e finitio ns a n d D e fe c t T olerances
W e will utilise th e d e fe c t d e fin itio n s a n d d e fe c t to le ra n c e s as d e s c rib e d b y fisheries fo r
th e h a n d lin g o f w h o le dressed tu n a w h ic h is b e in g p re s e n te d in this d o c u m e n t.
Or
W e w ill p ro v id e o u r ow n c o m p a n y d e fe c t d e fin itio n s a n d to le ra n c e s th a t m e e t o r
e x c e e d th o s e s u p p lie d b y th e GMP. ________
M o n ito rin g P rocedures

W e w ill im p le m e n t th e le ve l o f m o n ito rin g as s p e c ifie d in this d o c u m e n t. ________
Or
W e will p ro vid e o u r ow n c o m p a n y m o n ito rin g p ro c e d u re s th a t m e e t o r e x c e e d th o se
s u p p lie d b y in th e G M P. ________
Form s fo r d a ta c o lle c tio n a n d in s p e c tio n re p o rtin g

W e w ill u tilize c o rre c tiv e a c tio n sh e e t a n d th e raw in s p e c tio n fo rm s u p p lie d in this
m a n u a l.
Or
W e will p ro vid e our ow n c o m p a n y reports fo r c o rre c tiv e a c tio n a n d th e raw in s p e c tio n
reports th a t m e e t o r e x c e e d th o se s u p p lie d b y in this d o c u m e n t. ________
If th e fis h in g vessel is g o in g to su p p ly its ow n re p o rt fo rm s fo r a n y o f th e a b o v e

m e n tio n e d re p o rtin g fo rm s it m ust p re se n t a c o p y o f th e fo rm s th a t it w ill b e using to
th e a p p ro p ria te a u th o ritie s.
N a m e o f vessel o w n e r/o p e ra to r:__________________________________________
D a te :_____________________________
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2.4 ICE
2.4.1 Requirements
Only b e th a t is m a d e from cle a n safe w ater c a n b e used for th e chilling and

icing o f tu n a a b o a rd a fishing vessel.
O nly properly crushed ice should b e used when icing th e tuna. W herever
possible b lo ck ice should b e crushed in a proper crushing m a ch in e before
pla cin g a b o a rd th e vessel.
2.4.2 Ingredients
The only additive perm itted in w ater for m aking ice is chlorine. The a m o u n t o f
chlorine w hen tested in w ater should not excee d 10 parts per m illion (ppm ).
2.4.3 D efect Definitions
Ice w hich is not cle a n or safe is not perm itted to b e used in th e chilling o f or
th e icing o f tuna.
Ice w hich has c o m e in c o n ta c t with co n ta m in a tio n c a n not b e used in th e

produ ction o f tuna.
Ice which has a sharp edges or large pieces o f ic e should not b e used in the
icing o f tuna.
It is not p erm itted to reuse ice th a t has already being used for previous
p ro d u ctio n . Ice w hich has being transported to th e fishing vessel in an
unsanitary truck or in unclean containers is not a c c e p ta b le .
2.4.4 Monitoring
The fishing vessel will describe how it ensures th a t th e ic e w hich th e y use will b e
only ice th a t is approved and uncontam inated. The fishing vessel will describe
how it ensures th a t th e ice is stored in a proper p ro te cte d insulated fish hole
free from any safety risks w hereby the ice c a n cause d a m a g e to th e tuna.
2.5 CLEANING AGENTS. SANITISERS, LUBRICANTS
2.5.1 Requirements
O nly cle aning agents, sanitisers, lubricants w hich have bee n a p p ro ve d for
food grade ca n be used in th e cle aning o f th e equ ipm ent, fish hole and any
area th a t th e tuna will c o m e in co n ta c t, during th e o pe ra tion o f fishing.
It is th e responsibility o f th e ow ner/operator o f th e fishing vessel to ensure th a t

the com pou nds m e e t the requirem ents.
2.5.2 Specifications
The fishing vessel m ust m aintain a list o f all cle aning agents, sanitisers,
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lubricants, and any other chem ica ls th a t are to b e used in th e on-board
operation. The list must include the specifications for e a ch c h e m ica l used and
w hat and where they are used.
The fishing vessel ow ner/operator is required to provide th e proper procedures

fo r ensuring th a t only a pp ro ved ch e m ica ls are used in th e cle a n in g o f the
vessel.
2.5.4 Forms for Data C ollection & Reporting
The fishing vessel must c o m p le te form s showing th a t incom ing ch e m ica ls are
approved. Examples o f the form s to b e used are found in Sections 2 .5 .6 and
2.5.7.
2.5.5 Guidelines for Corrective Action
The fishing vessel m ust show w h at a ctio n is taken to rem ove unapproved
chem ica ls from the vessel.
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2.5.6
IN C O M IN G CH EM IC AL
INSPECTION REPORT
D ate:
Type o f C h e m ic a l: S upplier:
W h a t it is to Be Used For:
Brand N a m e :
M a n u fa c tu re r:
Yes No
Has th e c h e m ic a l b e in g a p p ro v e d ?
A re th e c o n ta in e rs safe?
A re th e c h e m ic a ls p ro te c te d fro m
c o n ta m in a tio n ?
D o th e c h e m ic a ls m e e t th e c o m p a n y
s p e c ific a tio n s a n d re q u ire m e n ts?
If th e re is a p ro b le m , th e n list th e a c tio n th a t w ill b e ta k e n to e lim in a te a n y p ro b le m s:
This in sp e ctio n re p o rt is to b e c o m p le te d fo r e a c h c h e m ic a l w h ich is to b e u s e d in th e

o n b o a rd h a n d lin g fo r tuna.
This fo rm w hen c o m p le te d is to b e s ig n e d a n d k e p t o n file fo r fu tu re re fe re n c e .
In s p e c te d by:
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2.5.7
INFORM ATION TO BE SUPPLIED BY THE

FISHING VESSEL OWNER/OPERATOR
Type o f Fishing V e s s e l:______________________________________________________
The O w n e r/O p e ra to r o f th e fishing vessel a g re e s th a t th e re q u ire m e n ts as s p e c ifie d in

this d o c u m e n t re g a rd in g th e use o f c le a n in g age nts, sanitisers & lu b ric a n ts w ill b e m e t.
Item s Used:
The fis h in g vessel w ill ke e p a list o f a ll c h e m ic a ls used o n -b o a rd th e vessel fo r th e

m a in te n a n c e o f e q u ip m e n t a n d fish facilities. This list will show all th e in fo rm a tio n w h ic h
has b e in g id e n tifie d in this re p o rt a n d w ill h a v e a v a ila b le fo r in s p e c tio n o n request.
M onitoring Procedures:
The fis h in g vessel w ill show w h a t p ro c e d u re s it w ill im p le m e n t to ensu re th a t o n ly

a p p ro v e d c h e m ic a ls a re used in th e p rocess fo r th e o n -b o a rd h a n d lin g e q u ip m e n t
w h ic h is used fo r th e tu n a o p e ra tio n .
N a m e o f C o m p a n y O ffic ia l:
D a te :
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2.6 VESSEL DESIGN, PRODUCTION FACILITIES
2.6.1 Requirements for Vessel Design
The requirem ents th a t a fishing vessel m ust m e e t to b e a b le to fish for

fresh/frozen tuna.
The de ck area used for the handling o f tuna must b e constructe d o f a sm ooth
surface, free from cracks and crevices a nd m a d e o f non -co rrodible m aterial.
The de ck area m ust not have any areas th a t c a n cause co n ta m in a tio n to the
tuna.
M aterials w hich are used w hen tuna is being p la c e d on th e d e c k area m ust

b e kept cle a n a n d safe. Any m aterials w hich c a n cause d a m a g e or
co n ta m in a tio n to th e tuna are not perm itted to b e used.
The fish hole h a tch m ust b e constructed in th e proper m anner. The h atch
should have a proper opening w hich is properly constructed o f a sm ooth
surface free from cracks a nd crevices and non-corrodible m aterial. A h atch
w hich is m a d e o f w ood m ust b e p ro te cte d with a sm ooth covering so as to
protect the skin and flesh o f the tuna w hen either being p la c e d in th e hole, or
being rem oved from the hole.
The fish hole itself, must be constructed o f a sm ooth surface, free from cracks
and crevices, a nd m a d e o f non-corrodible m aterial. The fish hole m ust also
be well insulated to protect the tuna from the heat. If th e insulation is to c o m e
in d ire ct c o n ta c t with th e fish, then it is to b e m a d e o f only proper app ro ved
insulation. This insulation c a n n o t have any ch e m ica ls w hich c a n cause
co n ta m in a tio n or harm to hum an beings.
Fishing vessels w hich have a REFRIGERATED SEA WATER SYSTEM on board: are
required to have fish holes th a t are co m p le te ly w atertight. They are required
to have the proper system to control the tem perature of the w ater a n d th e fish.
The te m p e ra tu re o f th e fish m ust b e m aintained a t 0°C a t all tim es.
Fishing vessel which have a FREEZING ON-BOARD SYSTEM: are required to have
a proper freezing system a b o a rd to ensure th a t th e co re te m p e ra tu re o f the
tuna is low ered to a te m p e ra tu re o f -6 0 °C within 8 hours or less, a n d th a t the
co ld storage room air tem p era ture c a n b e m aintained a t -50°C or below .
Fishing vessels w hich store th e tuna in ice in th e fish hole are required to have
proper insulation and a pum ping system in a p la ce , so as to ensure th a t the
fish hole is being properly p u m p e d a t all tim es.
The fish hole must be constructed in a m anner whereby there is no risk th a t any
BILGE WATER ca n co m e into the fish hole. If this w ere to hap pen, it c a n cause
the tuna to b e c o m e co n ta m in a te d .
There must be in p la ce a cano py to p ro te ct the tuna from d ire c t c o n ta c t with

the sun.
2.6.2 Production Facilities
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All vessels for fishing of tuna are required to have on board a properly insulated
c o n ta in e r for the coolin g process. This co n ta in e r is to b e constructed o f a
sm ooth surface, free from cracks a nd crevices a nd m a d e o f non-corrodible
m aterials.
All fish handling equipm ent such as chutes, fish conveyors, fish washers, tables
and utensils for processing, shall be o f sm ooth, non-absorbent, non-corrodible
m aterials. No e q u ip m e n t c a n b e constructed w hereby it c a n cause
co n ta m in a tio n to the tuna.
Any vessel m ust identify w hat a c tio n is to b e taken if there is a problem

w hereby it c a n cause th e follow ing results:
A) If there is a d e ficie n cy w hich ca n result in the production being not o f

a c c e p ta b le quality.
B) If there is a th re a t to th e health and safety o f th e consum er.
C) If there is a problem w hich prevents proper sanitation a b o a rd th e vessel.
D) If th e problem c a n cause th e tuna to b e c o m e tainted, d e co m p o se d or
unw holesom e.
E) If the problem inhibits the general sanitation o f th e vessel.
The fishing vessel's ow ners/operators m ust identify if any o f th e above-

m en tio n e d problem s exist, a nd identify who will take th e corre ctive action.
W hat system is to b e used, and w ho is responsible for taking this a ctio n . The
vessel m ust ensure th a t if there is a problem , w hich c a n cause any
d e fic ie n c ie s o f a critica l nature to th e tuna m ust b e willing to provide the
proper a ctio n to p ro te ct th e tuna.
The fishing vessel's ow ner/operator m ust identify th e person responsible for

taking the corrective a ctio n a nd ensure th a t th e corre ctive a ctio n has been
carried out.
The vessel m ust show a record th a t has bee n taken showing w hat has
h a p p e n e d . The record should show for e a c h instance o f n o n -co m p lia n ce ,
th e follow ing inform ation is recorded:
■ A description o f th e n o n -co m p lia n ce item .

■ The d a te th e n o n -co m p lia n ce item occurred.
■ The d a te th e corre ctive a ctio n was taken.
■ W hat a ctio n was taken a nd w hat was th e o u tco m e .
■ The signature o f the person responsible.
2.7 OPERATION & SANITATION
2.7.1 Requirements
The ow ner o f the fishing vessel for the ca tch in g , processing a nd holding o f
tuna is required to ensure that there is no co n ta m in a tio n present on board the
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vessel.
The ow ner m ust ensure th a t th e fishing vessel m eets th e regulations th a t are

required by the authorities having jurisdiction.
The fishing vessel's ow ners/operators m ust provide assurance th a t the

fisherm en w ho c o m e in c o n ta c t with th e tuna d o not directly or indirectly
c o n ta m in a te th e fish, The vessel owners m ust have a training program in
p lace for th e fisherm en to show w hat ca n a nd will hap pen w hen th e y d o not
follow th e requirem ents for th e proper handling o f th e tuna.
The fisherm en should report any m e d ica l conditions w hich m a y present a

h e a lth a n d safety risk to th e production o f th e tuna. This w ould also include
b e in g a carrier o f a disease w hich c a n likely b e transm itted through fo o d or
while having in fe cte d wounds.
2.7.2 Inspection o f Vessel
The owner is required before e a c h trip co m m e n ce s to ensure th a t th e proper

cleaning and sanitation is co m p le te ly a b o a rd his vessel. They are required to
c o m p le te a form showing a t th e co m m e n cin g o f e a c h trip th a t their vessel
m eets th e requirem ents. They m ust show the critica l control points in the
operations and w hat a ctio n will b e taken for any deficie n cie s th a t c a n occur.
2.7.3 Forms for Inspection
It is re co m m e n d e d th a t th e owners either a c c e p t the form s listed in this

m a n u a l or show to the authorities w hat typ e o f form s they intend to use. A
c o p y o f th e form s should b e given to th e authorities.
The Action Reports 2.7.5 A, vessel fault inspection report is used to record the
inform ation and results o f the sanitation inspection and to in d ica te w here there
is corrective action needed; and the Inspection Report 2.7.5B is used to cover
th e overall ope ra tion for th e processing e q u ip m e n t for tuna and also the
storage areas.
The vessel must identify w hat a ctio n is to b e im plem ented for, deficie n cie s o f
a critical nature, serious nature, m ajor & m inor nature. If deficie n cie s are o f a
critical nature, the vessel will not b e a b le to o p e ra te till th e critica l deficiencies
are co rre cte d .
-4 7 -
2.7.5 Action Reports
A : VESSEL FAULT INSPECTION REPORT
Vessel N a m e : D a te o f In sp e ctio n :
CATEGORY OF DEFICIENCY
LIST DEFICIENCY ACTION BY
CRI SER MAJ MIN
CRI: m eans th a t it is c ritic a l a n d a c tio n m ust b e ta k e n im m e d ia te ly .

SER: m eans th a t it is serious a n d a c tio n m ust b e ta ken as soon as possible.
MAJ: m eans th a t it is m a jo r n a tu re a n d c a n b e c o rre c te d w ith in th e d a y.
MIN: m eans th a t it is m in o r n a tu re a n d c a n b e c o rre c te d w ith in se ve ra l days.
NOTE:
N o vessel sh o u ld o p e ra te w h e re th e re a re o n e o r m o re c ritic a l d e fic ie n c ie s o r fiv e o r
m o re serious d e fic ie n c ie s w h ic h ha v e b e e n id e n tifie d .
DEFICIENCY: m e a n s a n y im p e rfe ctio n s o r in a d e q u a c y in p hysical fa c ilitie s , e q u ip m e n t

w h ic h c a n c a u s e d a m a g e to th e tu n a .
-4 8 -
B: DETAILED VESSEL INSPECTION REPORT
Vessel N a m e : D a te:
Type o f Fishing G e a r:
Fresh Tuna O p e ra tio n :
Frozen Tuna O p e ra tio n :
OPERATION
REQUIREMENTS DATE FOR
ITEM DEFICIENCY SCORE CORRECTIONS
CRI SER MAJ MIN
E m p lo y e e H e a lth
A. N o know n ca rrie r
B. N o c o m m u n ic a b le o f sores
C. N o o p e n w o u n d s o r sores
H a n d W ash F a cilitie s
A. P roper w a shin g o f h a n d s
B. P roper d is in fe c tio n g lo ve s
W ashing o f E q u ip m e n t
A. P roperly w a sh e d a n d c le a n e d
b e fo re a n d a fte r using
B. P roperly sanitized
Ic e
A. M a d e o f w a te r fro m a p p ro v e d
s o u rc e fre e fro m fo re ig n
m a tte r, n o c o n ta m in a tio n
B. P roperly sto re d in c le a n fish

h o le
-4 9 -
OPERATION
REQUIREMENTS DATE FOR
ITEM DEFICIENCY SCORE CORRECTION
CRI SER MAJ MIN
O ffa l R e m o v a l
A. R e m o ve d im m e d ia te ly
B. E q u ip m e n t ke p t c le a n
C. P roper m e th o d o f disposal
U tensil C le a n in g
A. C le a n in g a n d sanitized d u rin g
p ro ce ssin g
B. C le a n e d a n d d is in fe c te d a fte r
w ork
C. D ried a n d sto re d in sanita ry

m anner
G e n e ra l c le a n in g a n d
m a in te n a n c e
A. F acilities a n d e q u ip m e n t in
g o o d re p a ir
B. F acilities a n d e q u ip p e d ke p t
c le a n
Fish H o le S to ra g e
A. P roperly c le a n e d a n d sanitized
B. P roper te m p e ra tu re o f ic e
C. P roper p ro te c tio n o f rise in

ro o m te m p e ra tu re
C o ld S to ra g e A re a
P roper te m p e ra tu re d e v ic e to
re c o rd th e te m p e ra tu re o n a
c o n tin u o u s basis
Frozen Tuna
P roperly p ro te c te d fro m rise in
te m p e ra tu re
If during in spection it is fo u n d th a t there are n o d e fe cts fo r a n item , then you are to re c o rd
th a t it is OK in the are m a rke d D ate fo r Corrections.
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2.8 PROCESS CONTROL
2.8.1 Requirements
Tuna is to b e properly w ashed during and a fte r being processed. It is very

im portant th a t all m easures are taken to rem ove all blood, g u t rem nants and
any foreign m aterial from th e tuna.
During washing only fresh safe sea w ater is to b e used in th e washing o f the
tuna. Tuna is to be handled as quickly and as carefully as possible a fte r being
taken o n-bo ard th e vessel.
Tuna is to b e properly co o le d in slush ice, w hich is m a d e up o f tw o parts ice

and one p a rt w ater. After properly coolin g o f tuna, the fish are to b e p la ce d
properly in th e fish hole in ice, or in th e blast freezer for freezing.
During the process there must be regular tem p era ture checks d o n e to ensure
th a t th e co re tem p era ture o f th e fresh tuna is m aintained a t 0 °C .
In the process o f freezing tuna, the core tem perature is to b e low ered to -6 0 °C
within 8 hours or less.
2.8.2 Defects & Deficiencies
The im proper or in a d e q u a te washing o f tuna will b e considered a process

control d eficiency.
The im proper cooling o f tuna is considered a process control d e ficie n cy. The
im proper icing o f the tuna is considered a process control d e ficie n cy a nd the
im proper freezing o f the tuna is also considered a process d eficiency.
2.8.3 Inspection Requirements
On a regular or continuous basis, the vessel's designated inspector is required

to inspect the tuna during th e handling ope ra tion to ensure th a t th e washing,
coolin g, icing a n d /o r freezing is carried out in a proper a nd safe m anner.
2.8.4 Forms for C ollection Data
The vessel owner is required to provide exam ples o f the inspection form s they
intend to use in recording activities d ire cte d tow ards process control.
The vessel m ust identify w hat a ctio n is to b e taken when they identified
defects, deviations, or deficiencies in th e process control.
2.9 FRESH STORAGE FACILITIES
2.9.1 Requirements
The follow ing are the requirem ents for th e proper storing o f fresh tuna in fish
-5 1 -
storage area:
A) The fish hole m ust b e free from any conta m in a tio n .

B) The fish hole m ust b e properly insulated.
C) The ic e for icing th e tuna m ust b e cle a n a nd safe.
D) The ic e m ust co n ta in a g o o d low co o lin g tem perature.
E) Only fish a nd fish products are to b e stored in th e fish hole.
F) In regard to tuna stored in Refrigerated Sea W ater only cle a n safe sea
w ater with th e proper te m p e ra tu re and controls to be used.
G) The co re tem p era ture o f th e tuna m ust b e m aintained a t 0°C .
2.9.2 Inspection Requirements
The fishing vessel m ust keep a record o f th e tem peratures o f th e tuna as they
are being p la ce d either in th e ic e or th e refrigerated sea w ater a fte r cooling.
The fishing vessel must also ensure th a t th e tuna in ic e is always covered a t all
tim es to ensure th a t th e tem p era ture does not rise.
The fishing vessel must have in p lace a corre ctive a ctio n plan so as to prevent
the tem perature from rising in tuna. If this occurs, it m ust show w hat a ctio n will
b e taken a nd by w hom .
A corre ctive a ctio n report should co n ta in th e follow ing inform ation:
A) A description o f th e problem with th e tem perature.

B) The d a te th a t th e problem was first notice d.
C) The d a te th e corre ctive a ctio n was taken and w hat was d o n e to co rre ct
th e problem .
D) The signature o f the person responsible.
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2.9.4
FRESH TUNA TEMPERATURE

RECOVERING LOG
DATE TIME STORED IN ICE TEMPERATURE
Vessel N a m e :
Start D ate o f Trip :
Finish D ate o f Trip :
C o m pa ny O ffic ia l:
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2.10 FROZEN STORAGE FACILITIES
2.10.1 Requirements
Blast freezers for the on-board freezing of tuna are required to have th e proper
equipm ent to freeze the core tem perature o f th e tuna to -6 0 °C within 8 hours
or less.
Rooms used for the storage o f th e frozen tuna are required to m aintain an air
te m p e ra tu re o f -5 0 °C or below .
Room s fo r th e freezing & storage o f th e frozen tuna are required to have a

proper tem p era ture recorder showing th e m ovem ent in th e tem perature.
When tuna is being rem oved from either th e blast freezer or th e c o ld storage
th e frozen fish shall be p ro te cte d to m inim ise th e rise in th e tem perature.
2.10.2 Inspection
The vessel is required to keep a log which shows the tem peratures o f th e frozen
tuna.
The tem perature recorder m ust b e ch e cke d on a continuous basis to ensure

th a t th e proper tem peratures are being m aintained.
The vessel owner must show w hat action will be taken when there is a rise in the
te m p e ra tu re o f th e co ld storage.
The vessel ow ner m ust also show w hat a ctio n will b e taken w hen there is to o
m uch d elay in freezing th e tuna to its proper core.
The fishing vessel will b e required to identify th e person responsible for taking
corrective a ctio n and m ust show w hat proced ure was used. The inform ation
should show th e follow ing items:
A) A description o f th e problem with th e tem perature.

B) The d a te th e problem h a p p e n e d on.
C) The d a te the corrective a ctio n was taken a nd w hat was d o n e to solve the
problem .
D) The signature o f th e person responsible.
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2.10.4
FROZEN TUNA
C O LD STORAGE LO G
DATE TIME BLAST FREEZER C O LD STORAGE TEMPERATURE
N o o f Fish Tem p
V e sse l N a m e :
S ta rt D a te o f Trip:
Finish D a te o f Trip :
C o m p a n y O f f ic ia l:
-5 5 -
2.11 FINAL PRODUCT
2.11.1 Requirements
No vessel shall a tte m p t to unload any tuna th a t is ta in te d , d e co m p o se d , or

unw holesom e or otherwise fails to m e e t th e requirem ents laid dow n by th e
authorities having jurisdiction.
No vessel shall a tte m p t to unload any frozen tuna th a t was before freezing
tainted, d e co m p o se d , unw holesom e. Frozen tuna whose co re tem p era ture
is not a t -60°C , should b e specially m arked.
Fresh tuna being discharged from th e fishing hole m ust show th e a g e o f the
tuna so as to distinguished w h at m arket th e p ro d u ct is destined for.
Fresh tuna with a core te m p e ra tu re a b o ve 0°C m ust rem ain in ic e as to such

tim e as th e te m p e ra tu re o f 0 °C is atta ined .
2.11.2 D efect Tolerance
Sam e as in Section 2.11.1.
2.11.3 Sampling Plan
The sam pling will b e d o n e by th e receiving processing plant.
The fishing vessel m ust show w hat a ctio n is to b e taken to rem ove any
u n a c c e p ta b le tuna, w ho will take th e a ctio n , w h at system will b e used to
record th e a c tio n a nd w hat is being d o n e with th e u n a c c e p ta b le tuna. The
inform ation on the form which is required to be com ple te d by th e vessel ow ner
should have th e follow ing item s listed:
A) A description showing why th e tuna was rejected.

B) The num ber o f fish w hich w ere u n a cce p ta b le .
C) The d a te o f unloading.
D) W hat a c tio n was taken to rem ove th e u n a c c e p ta b le product.
E) W here did th e u n a cc e p ta b le p ro d u ct b e disposed.
2.12 RECALL PROCEDURES
2.12.1 Requirements
All tu n a w hether they b e fresh/frozen being rem oved from th e fishing vessel
m ust have the following inform ation to a c c o m p a n y th e fish to th e processing
plant.
■ The d a te th e fish w ere landed

■ The nam e o f th e vessel
■ The p ro d u ct form th e w hether fresh/frozen
■ The num ber o f fish
-5 6 -
■ The na m e o f th e fish
■ The a g e o f th e fish w hether it is old or new
■ The n a m e o f the carrier if it is to b e transported via truck to the
processing p lant
■ The na m e o f th e buyer
■ The address o f th e buyer
An exam ple o f this form appears in Section 2.12.4
The fishing vessel m ust have in p la c e a proced ure so as to identify th e tuna

w h ich it is shipping to their first destination. It m ust show th a t th e fish c a m e
from their vessel.
The fishing vessel m ust show w hat a ctio n it will take if there is required a recall
o f their product. They m ust have in writing a system w hereby if there is a ctio n
n ee ded a fte r th e tuna has been rem oved from th e vessel a n d shipped they
c a n properly execu te this a ctio n . They m ust have on th e form th e follow ing
inform ation:
■ Description o f th e problem
■ The num ber o f fish
■ The d a te n o tice d
■ The d a te it is co rre cte d
■ The outcom e when the corrective action was taken a n d signature o f the
person responsible for taking th e a ctio n
-5 7 -
2.12.4
SHIPPING RECO RD REPORT FOR

FRESH/FROZEN TUNA
FROM FISHING VESSELS
D a te :
N am e o f Vessel:
Type o f Fishing G ear Used:
Product D e scrip tio n :
Fresh:
Frozen:
N am e o f Fish :
Total N um ber o f Fish :
The A ge o f th e O ld Fish:
The N um ber o f th e O ld Fish:
The N am e o f th e C a rrie r:
The N am e o f th e Buyer:
Address o f th e Buyer:
Vessel O fficials S ignature:
-5 8 -
2.13 EMPLOYEE QUALIFICATIONS ON FISHING VESSELS
2.13.1 Requirements
There should b e in p la c e a program w here by th e fishery p e o p le on-bo ard

e a c h vessel should b e trained in the proper handling o f fresh/frozen tuna.
In th e o n -b o a rd handling o f tuna it is ve ry im portant th a t both the

ow ner/operator plus the fisherm en understand th e proper m ethods w hich are
required to b e used.
They m ust understand th a t w h at ever they d o in th e c a tch in g , handling,

processing, icing a n d /o r freezing o f th e tuna will d eterm ine w h at th e quality is
a nd this inturn will determ ine th e price.
The GOOD MANUFACTURING PRACTICES guidelines shows th e proper

procedures for th e o n-bo ard handling o f tuna.
Annex 3 shows th e step-by-step m ethods with diagram s as to th e proper

handling o f tuna.
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Annex 4
D e fin itio n s
C ontrol or
Inspection Point: A point in tim e a t which there is an opportunity to e valuate c o m p lia n ce
with specific requirem ents and, if necessary, to c o rre ct defects,
deviations or deficiencies th a t m ay b e found relating to quality, a nd /or
fair tra d e practices, a n d /o r regulations in fo rce.
C ritical C ontrol Point: A point a t w hich if preventive m easures are not taken, will expose a
custom er to una cceptable risks related to safety or unwholesom eness.
D ecom posed: W ith respect to tuna, m eans th a t th e tuna has an offensive or

objection able odour, colour, flavour, texture or substance associated
with spoilage.
D e fe c t: An im perfection or in a d e q u a cy in tuna, or products.
D e fic ie n c y : An im perfection or inadequacy in facilities, e q u ip m e n t or environm ent.
D e v ia tio n : An im perfection or in a d e q u a cy in a process, or procedure.
Hazard : Anything in th e handling o f tuna th a t m ight co n ta m in a te fo o d and

m ake it unsafe for consumers, or th a t m islead consum ers, m aking one
liable to e co n o m ic fraud.
Poisonous or
Harm ful Substances: Includes b a cteria o f pub lic health significance, natural toxins, all
regulated pesticides, non-perm itted additives and other contam inants.
Tainted : Tuna th a t is rancid or has an a bn orm al odour or flavour.
U nw holesom e: Tuna which, either in th e m e a t or on th e surface, contains b a cte ria o f

pub lic health significance, or toxins harm ful or offensive to m an.
-6 0 -
Annex 5
POTENTIAL CRITICAL CONTROL POINTS FOR

THE ON-BOARD HANDLING OF
FRESH/FROZEN TUNA
NO ITEM HAZARD POTENTIAL CRITICAL

CONTROL POINTS
1 INPUT MATERIALS
Fish (Tuna) Taint Prior to processing

D ecom position,
unwholesom eness
D ead, n o n -co m p lia n ce with
regulations
Ice Not o f fo o d g ra d e Prior to use

Unsuitable, unclean A p plication area
N o n-co m p lia nce with regulations
C leaning Agents Not a p p ro ve d for use In fo o d Prior to use

Sanitisers, operations or on fo o d c o n ta c t
Lubricants surfaces
M isapplication A p plication area
2 Production N o n-co m p lia nce with regulations Prior to fishing

C onditions for th e proper handling
Vessel Design
Production Facilities
O peration & N o n-co m p lia nce with regulations Prior to, during
Sanitation processing
Process C ontrol N o n-co m p lia nce with regulations During processing
Fresh & Frozen N o n-co m p lia nce with regulations During tim e tuna is
Storage Facilities either In ic e or in co ld
storage
3 PRODUCTS
Final Product Taint During processing

Required D ecom position, a fte r last process
C haracteristics unwholesom eness prior to unloading
D efects &/or n o n -co m p lia n ce & a fte r freezing
Recall Procedures Unable to tra c e p ro d u ct to the During unloading

custom er to w hom tuna was & shipping
sold
-6 1 -
4 PERSONNEL
Health & Hygiene Fishermen suffering from or Prior to fishing

carrying a c o m m u n ica b le
disease
Fishermen with an in fe cte d or
op e n c u t
Q uality Not properly trained in the Prior to processing

M anag em e nt proper procedures for the
handling o f tuna
-6 2 -
S E C T I O N 3
G O O D M A N U F A C T U R IN G P R A C T IC E S F O R
T H E O N -S H O R E H A N D L IN G A N D P R O C E S S IN G O F
T U N A
- 6 3 -
3.1 INTRODUCTION
Tuna is a very d e lic a te fish, w hich dem ands th a t th e quality o f th e p ro d u ct b e

protected a t all times. We m ust view the workm anship m ethods o f handling tuna and
ensure th a t every m eth od o f handling is to p ro te ct th e tuna a t all tim es.
In this section, G ood M anufacturing Practices (GMP) will b e outlined to show th e proper
m ethods w hich should b e a d a p te d to m aintain a g o o d quality p ro d u ct for th e end
user. GMP procedures are a im e d a t th e prevention o f problem s by controlling and
m aintaining th e quality o f the tuna a t all tim es. W hen w e receive th e p ro d u ct a t the
u n lo a d in g site w e c a n n o t im prove th e quality o f th e p rodu ct, w e c a n only try to
m aintain th e existing quality.
The biology and GMP for handling tuna on boa rd is given in Section 1.
To prevent deterioration in th e quality o f tuna, th e te m p e ra tu re o f th e tuna m ust be

m a in ta in e d a t 0°C a t all tim es during c a tch in g , storage on vessel, unloading,
processing and shipping. Histamine production is controlled by m inim izing th e internal
te m p e ra tu re o f th e tuna to below 7°C a t all tim es.
The GMP procedures in this section will a tte m p t to establish a set o f guidelines to help
th e processor in th e production o f tuna products.
This ch a p te r is set up into a series o f guidelines. They are listed as follows:
a) Processing Procedures for th e Proper Receiving, G rading, 3.1

Processing Holding, Packing o f Fresh W hole Tuna;
Frozen Tuna Loins; Frozen Tuna Sticks; and
Proper Packing Procedures.
b) Em ployee Requirem ents 3.2
c) Plant Facility Requirem ents 3.3
d) Proper C leaning Procedures 3.4
In exam ining processing procedures (a), we will take a step-by-step a p p ro a ch used

in th e processing o f tuna.
Receiving 3.1.1
G rading 3.1.2
C ooling 3.1.3
Processing o f W hole Fresh Tuna 3.1.4
Processing and Packing o f Fresh Tuna Loins 3.1.5
Packing a nd Shipping o f W hole Fresh Tuna 3.1.6
Processing o f Frozen Tuna Loins 3.1.7
Processing o f Tuna for D om estic M arket 3.1.8
Sum m ary 3.1.9
The processing procedures list the factors w hich c a n a ffe c t th e processing operation,
a n d th e m ethods o f correcting these problem s.
3.1.1 Receiving
During receiving it is very im portant to have th e tuna delivered to th e receiving
-6 4 -
a re a in a prope r insulated container, w hich is m a d e u p o f slush ic e a n d salt
w ater. Tuna is to b e properly han dle d in a safe a n d prope r m anner. The
te m p e ra tu re o f th e tuna is very im portant a n d there should b e a form th a t
shows th e re corded te m p e ra tu re th a t has be e n in spected a t tim e o f
discharge.
S ection 4.2.3 shows th e typ e o f form s w hich is required to b e c o m p le te d a t

p o in t o f discharge. These form s will also show if there is a problem w ith th e
te m p e ra tu re o f th e tuna. If there is any problem s a t tim e o f discharge, then
w hen th e p ro d u ct arrives to th e receiving area it c a n b e co rre cte d .
Points o f C oncern
No tuna is to b e taken into th e receiving area th a t has b e c o m e d e co m p o se d ,

unw holesom e a n d /o r co n ta m in a te d .
No tuna w hich has not be e n properly g u tte d is perm itted.
No tuna is to b e a c c e p te d a t th e receiving area w hich has be e n transported

by th e m eans o f a n o p e n truck.
No tuna is to b e p la c e d on th e floor o f th e receiving area. Tuna w hich is

p laced on th e floor will b e c o m e c o n ta m in a te d very easily. It is u n a c c e p ta b le
to have a p ro d u ct th a t is being processed for hum an consum ption handled
in this m anner. There are to o m any ways for the floor to b e c o n ta m in a te d , a n d
in turn cause co n ta m in a tio n to th e product.
3.1.2 G rading o f Tuna
The grading o f tuna is d o n e a t this stage for colour, co n d itio n a n d size. Tuna
m ust b e p la c e d on a proper grading ta b le w hen being inspected for these
procedures.
Section 5 details th e system th a t is used for th e grading o f Bigeye a n d Yellow

Fin Tuna for co lo u r and co n d itio n and th e form s w hich should b e c o m p le te d
when inspection o f tuna Is being carried out.
During quality inspection for colour a nd cond ition , th e tuna should b e m arked
as to w hat m arket it is intended for by pla cin g a ta g with th e proper m arkings
on them .
Points o f C oncern
Tuna are not to be p lace d on floor, for fear o f co n ta m in a tio n a n d d a m a g e to

th e outer area o f th e fish.
Tuna are not to b e d ra g g e d on floor area for fe a r o f d a m a g e .
Tables fo r th e Inspection a nd processing o f tuna are to b e constructe d o f a

sm ooth surface w hich is free from cracks a n d crevices. The ta b le should be
constructed o f a p p ro ve d m aterials.
-6 5 -
During inspection all atte m p ts m ust b e taken to prevent th e co n ta m in a tio n o f
th e tuna from foreign m aterial.
All utensils used during th e inspection pro ce d u re m ust b e cle a n a n d safe.
3.1.3 Cooling
Tuna m ust b e kept c o o l a t all tim es to ensure th a t there is no rise in th e co re

te m p e ra tu re o f th e tuna.
Tuna Is not to b e le ft exposed for a long period o f tim e.
Tuna should only be rem oved from th e slush tanks as they are g o in g to b e
processed.
The co re tem p era ture o f th e tuna should b e a t 0°C a t all tim es.
Tuna for dom estic markets must be m aintained a t a proper co re tem perature.
The air tem p era ture in th e processing a re a should b e m a intained a t 18°C or

less.
Points o f C oncern
Tuna w hich has a high te m p e ra tu re is not p e rm itte d to b e exported.
Tuna Is n o t to b e rem oved from slush tanks until tim e o f packing for shipping.
Tem perature before being rem oved from th e tanks m ust b e a t 0°C.
If tem perature o f tuna rises a b o ve 7°C th a n th e m e a t is being exposed to th e

process o f increasing chances o f histamine. The only w ay th a t this co m p o u n d
c a n b e co ntrolled is by elim inating th e ch a n ce s o f a rise in th e tem perature.
3.1.4 Processing o f W hole Fresh Tuna
Tuna is to b e p la c e d on tables w hereby th e process o f rem oving th e fins is

carried out. All fins should b e rem oved properly a t this sta g e in production.
The belly ca vity is inspected for w orkm anship to ensure th a t there are no g u t
rem nants le ft in th e belly w all o f th e tuna.
The a re a around th e he a d w here th e gills have be e n rem oved m ust b e

in sp e cte d to ensure th a t it is properly cle a n e d . If there are any d e a d blood
present it m ust b e rem oved im m ediately. The section o f visible b o n e around
the head section must, if not already during c a tc h in g being c le a n e d properly,
b e co m p le te d a t this tim e.
The inner belly lining m ust b e properly trim m ed. Any pieces o f th e m em b ran e
w h ich a re hanging or loose m ust b e rem oved properly. W hen th e tu n a has
bee n inspected for workm anship, if th e tuna a re to b e held fo r any period o f
tim e b e fo re being p a cke d a n d shipped, th e y m ust b e p la c e d in properly
constructe d slush tanks, w hich have c le a n a n d safe slush ic e a n d salt w ater.
-6 6 -
If the tem perature o f the wash w ater is high, it is re co m m e n d e d th a t th e w ater
b e co o le d before com ing in c o n ta c t with the tuna. O ne m eth od is to pass the
w ash w a te r through a co il o f c o p p e r p ip e w hich has be e n p la c e d in a
ice /w ate r slurry.
Points o f C oncern
No tuna w hich is d e co m p o se d , ta in te d or unw holesom e shall b e processed.
No tuna is to b e inspected or processed on th e floor surface o f th e processing

area. The reason for this is to prevent contam in ation.
No tuna is to b e d ra g g e d across th e floor. Tuna is a very d e lic a te fish. It is very

easy to d a m a g e the skin surface o f th e tuna. If th e scales are d a m a g e d a nd
th e skin is torn, th e co n d itio n o f th e tuna will b e a ffe c te d by this m e th o d o f
h a n d lin g tuna. The outer m e a t w hen th e tuna is being d ra g g e d will also b e
d a m a g e d causing a decrease in the usable m eat. R em em ber th a t th e buyer
is only paying for th e a m o u n t o f p ro d u ct th a t he c a n use.
No tu n a is to b e exposed to th e h e a t for a long period o f tim e. If th e

tem perature o f th e m e a t o f th e tuna is p erm itted to rise it will c re a te a quality
problem ,
No tuna should b e p la ce d in im properly designed slush tanks.
No blood is perm itted to rem ain in th e tuna. This will cause rancid ity to form in
th e m e a t o f th e tuna, causing health a nd quality problem s.
If these measures are followed, tuna will be protected from co n ta m in a tio n a nd

d a m a g e to th e scales, skin, a n d outer m eat.
3.1.5 Processing and Packing o f Fresh Tuna Loins
Tuna w hich is being d ire cte d for processing as fresh tuna loins m ust b e
processed im m ediate ly prior to shipping.
Tuna loins m ust be processed and inspected for any d e fe cts as quickly a n d as
carefully as possible. All d e fe cts m ust b e rem oved a t tim e o f processing.
Tuna loins m ust b e covered im m ediate ly in a proper a p p ro ve d poly sheet

Im m ediately a fte r being inspected.
Tuna bins are to b e packed in a proper shipping box whic h m ust co n ta in either
frozen gel-packs or dry ice.
Tuna bins should only b e p ro d u ce d in a specially designed te m p e ra tu re

controlled room . The air te m p e ra tu re should not excee d 18°C .
Points o f C oncern
No tuna bins th a t is unsafe, decom posed, or unw holesom e is p erm itted to b e

packe d or shipped.
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Tuna loins m ust m aintain a te m p e ra tu re o f 0°C .
No fresh tuna loins destined for sashimi are p erm itted to b e processed from
tuna th a t does not m e e t th e colour a nd co n d itio n score o f 40 a n d higher.
No tuna loins are to b e transported in an unrefrigerated truck.
3.1.6 Packing and Shipping o f W hole Fresh Tuna for Exporting
Tuna m ust have a co re te m p e ra tu re o f 0°C before it is p la c e d into ca rto n for

shipping.
Tuna is to b e rem oved from th e slush tanks just prior to packing.
The outer surface m ust b e w iped cle a n with a sponge a n d cle a n safe salt
water.
The belly section m ust b e w iped cle a n from any w ater or foreign m aterial.
The belly wall m ust be packed with frozen g el packs to help in m aintaining the
co re tem p era ture o f th e tuna.
The outer skin surface must be covered with green tuna p a p e r w hich has been
previously soaked in salt water. This will prevent th e skin o f th e tuna from losing
its m oisture; and also, w here there are m ore than o n e tuna in a ca rto n , it will
p ro te ct e a c h tuna from th e other.
The tuna a fte r being properly co ve re d is to b e p la c e d gently into th e carton.

The ca rto n m ust co n ta in tw o sheets o f 10 m il poly w hich is large enough to
co m p le te ly co ve r th e tuna.
Before closing the plastic you m ust p la c e frozen g el packs around th e tuna to
help m aintain the proper tem p era ture. If dry ice is used, it m ust b e p la c e d in
the container so as not to cause freezer burn to th e skin surface and th e outer
m eat.
The ca rto n m ust be constructed o f w ater tig h t m aterial and have strength to
w ithstand packages stacked on to p o f e a c h other w ithout being crushed.
The ca rto n m ust also b e constructed o f m aterial th a t prevents th e transfer o f

te m p e ra tu re . It m ust b e designed for c o ld retention a n d b e insulated from
external tem peratures.
Transporting o f fresh tuna p a cke d for air shipm ent. The truck m ust co n ta in a
chill unit so as to m aintain th e air tem p era ture a t 0°C during transportation to
th e airport.
Points o f C oncern
Tuna which is decom posed or unwholesom e is not perm itted to b e pa cke d for
export.
-6 8 -
Tuna, a t no tim e is to be rem oved from the slush tanks a nd p la c e d on th e floor
prior to or during th e processing operation.
Tuna th a t is im properly chilled shall not b e p a cke d for shipping.
No tu n a is to b e shipped unless e a c h co n ta in e r contains either frozen gel

packs a n d /o r dry ice.
No tuna is to b e p la c e d into ca rto n w ithout proper prote ctio n o f th e skin.
No tuna is to b e packed without the belly section containin g a proper a m o u n t

o f frozen g e l packs.
No c a rto n to b e used w hich does not reach th e requirem ents m entioned

above.
No tuna to b e transported to th e airport in n o n -co o la n t trucks.
3.1.7 Processing o f Frozen Tuna Loins and Sticks
Tuna which is destined for frozen production must b e processed as quickly and
as carefully as possible as soon as it is received. Sections 3.1.7.1 a n d 3.1.7.2
show parts o f tuna loins a nd section 3.1.7.3, th e dressing o f eviscerated tuna.
Fresh Tuna w hich is destined for frozen loin p rodu ction m ust b e properly
handled. The tuna must be transferred to th e loin produ ction area in a proper
m anner. The fish m ust b e m oved into the produ ction area by m eans o f
containers or trolley.
All c a re m ust b e taken to ensure th a t during th e produ ction process th a t no

tuna com es in c o n ta c t with any contam in ation,
Frozen loins a nd sticks m ust b e processed in a proper cle a n a n d safe

environm ent. The produ ction facilities m ust b e properly constructe d so as to
p ro d u ce th e best quality p ro d u ct with th e utm ost o f care. The workm anship
o f th e p ro d u ct m ust b e controlled a t all tim es.
Tem perature m ust be reduced as quickly as possible a fte r th e p rodu ction has
been co m p le te d .
Air-blast freezing is re co m m e n d e d because low tem peratures c a n be

obtained very quickly. The blast freezer should b e a b le to re d u ce th e product's
co re tem p era ture to -60°C within 6 hours. After th e p ro d u ct is properly frozen
it must be stored in the cold storage. The tem perature o f the co ld storage m ust
b e m aintained a t -50°C or lower.
Both th e blast freezer and th e co ld storage should have a recorder to

continuously record th e tem peratures.
During th e processing o f tuna there are to b e no chem ica ls a d d e d to enrich

the c o lour o f the bins or sticks, unless they have be e n previously a p p ro ve d for
hum an consum ption by th e c o m p e te n t authority having jurisdiction. A
-6 9 -
description o f the chem icals should a c c o m p a n y th e frozen p rodu ction w hich
contains th e additives.
A fter freezing and during th e rem oval o f outer skin, only th e a m o u n t o f

pro d u ctio n w hich c a n b e properly handled is to b e rem oved from th e co ld
storage.
During th e rem oval o f th e skin a n d defects, all c a re m ust b e taken to ensure

th a t th e p ro d u ct does not c o m e in c o n ta c t with any contam in ation.
Before the product is placed into the carton, it is required to b e p la c e d through

a m eta l d e te c to r to ensure th a t there is no m etals present in th e m eat.
Each tuna b in is to be p la ce d into a sleeve a n d th e sleeve properly sealed to

ensure th a t th e frozen loin or sticks are p ro te cte d from contam in ation.
During th e tim e th a t th e frozen p ro d u ct is o u t o f th e co ld storage for final

processing, all ca re m ust b e taken to m inim ize th e c h a n c e o f rise in
tem perature.
Points o f C oncern
No tuna which is tainted, decom posed, and unwholesom e shall b e processed.
No tuna is to b e p la c e d on th e floor before processing com m e nces.
No tuna is to b e rem oved from th e slush tanks until ready for processing.
No tuna is to b e d ra g g e d across the p rodu ction floor.
No p ro d u ct is to be rem oved from th e blast freezer until proper co re

tem p era ture has been reached.
All products are to be properly co ve re d with plastic sleeves a n d p la c e d into a

proper shipping carton.
No frozen product is to be transported from the processing plant by op e n truck.
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3.1.7.1: Tuna AKAMI a nd TORO
Source: Narasaki
3.1.7.2: Proportion o f A ka m ia nd Toro
Source: Williams: Queensland Fishing Industry Training Council
From INFOFISH Technical Handbook 1, Handling and Processing of Tuna for Sashimi.
- 71 -
3.1.7.3 Dressing o f Eviscerated Tuna
Place the fish on a cle a n cu ttin g -b o a rd on one side with th e head

to your left.
• Hold th e p e cto ra l fin a nd raise it slightly. Insert knife ne a t the

base o f pectoral fin and cu t down tow ards th e dorsal line, and
m ove th e knife gently follow ing th e line o f th e operculum .
• C ut just behind the isthmus to th e base o f th e p e cto ra l fin also

follow ing th e line o f th e ope rcu lum to c o m p le te th e cut.
Som etim es, th e pelvic fins are rem oved a t this stage by
cu ttin g from th e isthmus.
• Turn th e fish o n to th e other side, and re p e a t th e a b o ve steps,

followed by chopping the backbone by holding th e head and
using a heavy knife or hacksaw until th e hea d is cut.
• The fully dressed tuna is then quarter filleted by inserting a sharp

knife through th e b a ck until reaches th e backb one, and
cu ttin g along th e dorsal line as shown in th e follow ing
diagram s.
• The four quarter-fillets are then carefully sliced into thinner fillets,
or directly c u t into blocks o f 300-400 m m in length for th e
wholesale market. Upon proper chilling condition, these blocks
c a n b e stored up to o n e week.
Filleting o f
Dressed Tuna fo r Sashim i
Source: Narasaki, 1986
From INFOFISH Technical Handbook 1, Handling and Processing of Tuna for Sashimi.
- 72 -
3.1.8 Processing o f Tuna for Dom estic Market
No tuna w hich is ta in te d , d e co m p o se d or unw holesom e shall b e processed

for th e d om estic m arket.
Tuna m ust b e properly chilled before being shipped.
Tuna is to b e properly stored in slush ice a nd salt w ater prior to shipping.
Tuna is to b e properly transported to th e m arket.
Points o f C oncern
No tuna for th e dom estic m arket is to b e le ft on th e processing floor.
Tuna which is im properly gutted or is not g u tte d is not perm itted to b e shipped
to th e m arket.
No tuna for the dom estic m arket is to b e le ft in th e o p e n air with no covering,
No tuna is to b e shipped to th e m arket in op e n trucks.
No tuna is to b e shipped w ithout being properly iced.
3.1.9 Summary
The m ain p oint to rem em ber is th e w ay in w hich tuna is to b e handled a t all

tim e.
Tuna is g ra d e d by both th e colour a nd co n d itio n o f th e w hole fish.
The freshness a nd colour are th e m ain factors th a t are considered in

determ ining th e p rice w hich is to b e paid for tuna. The next fa c to r is
d e te rm in e d by th e Yield Recovery o f th e m eat. This is d e term ined by the
c o n d itio n o f th e outer surface. By looking a t th e scales a n d skin they
determ ine how m uch o f th e outer m e a t will b e used.
W hen w e sell a w hole tuna, w e sell th e w hole fish w hich includes th e scales,
and skin as well as th e m eat. The end user will only pay for w h at usable m e a t
he will recover from the tuna. For every tim e th a t a tuna is d ra g g e d , pulled, or
slides across a floor there is not only d a m a g e to th e loss o f scales or torn skin,
but also d a m a g e to th e outer m e a t area, both in co n ta m in a tio n a nd in loss
o f unable product.
Tuna must be handled very carefully a t all tim es, it is not to b e d ra g g e d across
a processing floor. The floor is not to b e used as part o f th e processing
operation.
W e m ust im prove th e workm anship o f th e tuna wherever a nd w henever

possible. If w e show th e buyers th a t w e are im proving our work m ethods and
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decreasing any d a m a g e to the tuna then we c a n b e in a position to d e m a n d
m ore return on th e end product.
3.2 EMPLOYEE REQUIREMENTS
3.2.1 Health
No e m plo yee w ho is known to b e suffering from any c o m m u n ica b le disease

is perm itted to work with tuna.
No e m plo yee w ho is a known carrier o f any disease is perm itted to work with
tuna.
No e m p lo y e e who has in fe cte d w ound or o p e n cuts on their b o d y shall be

e m plo yed in th e d ire ct handling o f tuna.
REASON: A person w ho is suffering from a c o m m u n ica b le disease or w ho is a

carrier c a n in fe ct th e tuna p ro d u ct with b a cte ria c a p a b le o f causing fo o d
poisoning. A person w ho has o p e n cuts or in fe cte d wounds m ust n o t b e
e m p loyed in the working area d u e to th e fa c t th a t there is d a n g e r o f infecting
th e tuna p ro d u ct with fo o d poisoning organism s.
3.2.2 Hand-Washing
Each em ployee who is involved in th e processing o f tuna products m ust wash

th e ir hands with w arm w ater a n d liquid or pow ered soap im m ediate ly afte r
e a c h a bse nce from their work area.
REASON: In order to m aintain satisfactory sanitary conditions in th e processing

area e a ch person is required to wash their hands. Unless th e em ployees wash
th e ir hands properly a fte r e a c h tim e they return to th e work station then the
contam ination o f the product, work station, a n d utensils th a t they are using will
b e c o m e in fected.
3.2.3 Hand Covering, Disinfecting
All ha n d coverings used by th e em ployees in th e handling o f tuna, m ust be

kept cle a n and disinfected on a continuous basis.
REASON: Large num bers o f b a cte ria a c c u m u la te on pro te ctive hand

coverings. Unless they are frequently cle a n e d a n d disinfected, they b e co m e
a serious source o f co n ta m in a tio n to th e product.
3.2.4 Outer Garm ents and Head G ear
3.2.4.1 All em ployees e n g a g e d in th e p rodu ction o f tuna are required to

wear coveralls, smocks, or coats, and h e a d g e a r w hich is app ro ved
by th e c o m p e te n t authority having jurisdiction.
REASON: Unless the clothing o f the em ployees handling th e p ro d u ct

is c le a n , there is d a n g e r th a t co n ta m in a tio n will o c c u r on the
product. H eadgear is also necessary to p ro te ct th e p ro d u ct from
-7 4 -
contam in ation.
3.2.4.2 P rotective outer garm ents worn by em ployees in th e tuna

processing operations is to b e kept cle a n a t all tim es.
REASON: Unless th e p rotective clo thing worn by th e em ployees is

kept clean a t all tim es there is th e d a n g e r o f co n ta m in a tio n to the
products.
3.2.5 Smoking and Spitting
No person is perm itted to smoke or spit in any working area w hich is designa ted
for processing.
REASON: Smoking is o b je ctio n a b le because o f th e d a n g e r o f co n ta m in a tio n

to th e tuna products with ash, cig a re tte buts a nd m atches. Spitting is
o b je ctio n a b le to pub lic health.
3.3 PLANT FACILITY REQUIREMENTS
3.3.1 Building
The building m ust b e properly constructed in a c c o rd a n c e with the

requirem ents o f th e c o m p e te n t authorities having jurisdiction.
The building should b e properly enclosed with th e proper construction o f the

fa c ility m eeting all requirem ents for th e processing o f fresh/frozen tuna
products. Listed are th e requirem ents w hich should b e follow ed in the
processing facility.
REASON: The area o f a processing building for the production o pe ra tion o f tuna
p ro d u cts m ust b e properly enclosed so as to prevent co n ta m in a tio n from
occurring to th e produ ct.
The tu n a m ust b e p ro te cte d a t all tim es from conta m in a tio n . As we have

discussed previously in this report, tuna if not handled properly a t all tim es ca n
b e c o m e co n ta m in a te d very easily,
The area w hen properly enclosed with th e proper air te m p e ra tu re will ensure
th a t the tuna will not be exposed to excessive he a t a n d also will b e p ro te cte d
from th e co n ta m in a tio n o f th e outer air itself.
3.3.2 Floors
Floors are to be constructed o f a durable m aterial w hich is properly sloped so

as to ensure th a t th e d ra in a g e occurs.
The floors m ust b e m aintained in g o o d repair a t all tim es. It is im possible to

prevent hair line cracks on th e floor. A ction is to b e taken w hen such cracks
are large enough to cause difficu lty in cleaning.
Floors must b e properly sloped so as to ensure th e rapid disposal o f w aste a nd
-7 5 -
are easy to clean.
Floors in processing area are to b e kept c le a n a t all tim es, and a t th e end o f
produ ction they m ust b e properly sanitized.
REASON: If floors are not constructed o f proper a p p ro ve d m aterial a n d is not

sloped properly, then there c a n b e problem s with th e sanitation o f this area.
If there are cracks or crevices in th e floor area it c a n cause a build up o f
bacteria. If there is an inadequate sloping o f th e floor it will prevent th e proper
rem oval o f liquid and solid w aste from th e processing area.
3.3.3 Drains
All drains are to be property constructed. They are to b e sm ooth a nd properly

sloped to ensure th e rem oval o f w aste from th e processing area.
All drains which are co n n e c te d to a sewer line m ust have a ch e ck backw ater
valve installed to prevent a backflow .
All drains must be constructed d e e p enough so as to prevent overflow ing onto

th e processing floor. If this occurs it c a n cre a te an unsanitary condition.
All drains which exit th e processing a nd produ ction areas are to b e e q u ip p e d

with a m eta l fla p or covering to prevent e n tra n ce to rodents a nd or anim als.
Drains are to be cleaned a t all tim es to prevent a build up o f stale w ater. There
should b e a g o o d flow o f w ater running thro ugho ut th e drains.
REASONS: If th e drains are not p la ce d properly in th e floors, there will b e a

problem with th e sanitary co n d itio n o f th e plant,
3.3.4 Walls
The su rfa ce o f th e walls in all processing areas m ust b e constructed o f a

sm ooth surface. If th e surface is not sm ooth it is very hard to keep cle an.
Walls m ust b e constructed o f a w aterproof m aterial to prevent a build up o f

b a cte ria a n d debris.
Walls should b e o f a light co lo u r so as to b e a b le to d e te c t dirt. The light

colour also gives th e establishm ent a bright a n d sanitary a p p e a ra n ce .
W here walls are constructed o f sheeting m aterials, all joints m ust b e m a d e

w ater tig h t by th e use o f a suitable jointing co m p o u n d .
Walls where they are joined to th e floor m ust b e e q u ip p e d with a proper w ater
tight curb. This curb is installed to prevent any build up o f b a cte ria w hich ca n
cause co n ta m in a tio n to th e tuna products.
REASON: If walls are not properly constructe d a nd kept cle a n and

waterproofed then there will be a problem with the building up o f b a cte ria and
debris.
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3.3.5 Ceilings and O verhead Protection
Processing area w hich have ceilings a nd or overhead p ro te ctio n m ust b e

constructed o f materials which are free from cracks, crevices and o p e n joints.
There should b e no exposed area where by dust or debris m ay c o lle c t and

subsequently fall or b e flow n on th e product.
REASON: The work area a n d p ro d u ct m ust b e p ro te cte d from falling debris

w hich co u ld b e a source o f co n ta m in a tio n to th e tuna products.
3.3.6 O verhead Lighting
All overhead lighting must b e placed into th e ceiling w hereby there c a n n o t be

any build up o f dust a n d debris.
All lighting bulbs a nd lighting tubes m ust b e constructed o f non-shattered

m aterial.
REASON: The produ ction area a nd p ro d u ct m ust b e p ro te cte d from falling

debris, dust a nd broken lighting. If this happens, it w ould b e a source o f
co n ta m in a tio n to th e tuna products.
3.3.7 Toilet Facilities
There should b e th e proper types and num ber o f to ile t facilities to

a c c o m m o d a te th e num ber o f em ployees.
The follow ing num bers are suggested as a g u id e for th e num ber o f to ile t
facilities:
1 to 9 Em ployees 1 Toilet
10 to 24 Em ployees 2 Toilets
for every 30 em ployees over 100 an extra to ile t is required.
Toilet areas should b e ventilated to th e outside.
All to ile t room s m ust b e constructed o f a sm ooth surface, w ashable, light-

co lo u re d a nd th e floors m ust b e constructed o f a p p ro ve d m aterials. There
m ust b e w herever possible a floor drain in th e facilities.
There should be a fo o t d ip which covers the area larger than th e d oo r opening

as you leave th e wash room facilities.
The d oo r to th e washroom area m ust b e self closing.
There is required an a u to m a tic wash basin e q u ip p e d with a fo o t p a d d le with

th e p ro p e r liquid or pow ered soap a tta c h e d . There is also n e e d e d an
a u to m a tic air hand dryer to b e in p la c e rather th a n th e use o f p a p e r towels.
-7 7 -
REASONS: The presence in food products o f organisms associated with sew age
or hum an disease or infection is highly o b je ctio n a b le . Poor sanitary practices
m ay con trib u te to outbreaks o f gastro-intestinal disease a nd other infections
a m o n g workers.
3.3.8 W ater Supply
An a de quate supply o f safe, sanitary w ater th a t has a coliform b a cte ria co u n t

o f less than tw o per hundred m illilitre.
OR
A water supply which has been approved by the c o m p e te n t authorities having

jurisdiction.
W ater used in the ope ra tion o f fresh tuna m ust b e either pure a nd safe salt
water o f fresh water approved with salt a d d e d to m a tch th e equivalent o f salt
w ater.
REASON: We m ust ensure th a t th e w ater supply will not b e a source o f

co n ta m in a tio n to th e tuna products.
There m ust b e no cross-connection with th e w ater w hich is used in the

processing and the water which is used for th e co o lin g o f freezing equipm ent.
Only approved water is to b e used throughout th e w hole process, even in the
wash dow n system or the drain system.
3.3.9 Floor Tanks for the Holding and Cooling o f Tuna
All th e floor tanks for th e holding a n d coolin g o f tuna m ust b e constructed o f

a non-corrodible m aterial.
The construction o f these tanks shall b e so constructe d th a t th e surfaces are

sm ooth, free from th e cracks a n d crevices a n d c a n b e properly drained and
cle a n e d .
These tanks must have installed into them a proper non-corrodible ram p w hich
is constructed o f a sm ooth surface, free from cracks a nd crevices and c a n be
properly cle a n e d .
All floors tanks must be between 30 to 50 c m a b o ve th e surface o f th e floor to

p ro te ct any co n ta m in a te d w ater from training from th e floor surface into the
tanks.
REASON: All floor tanks if not constructed with th e proper m aterials, with the
su rfa ce area being sm ooth a nd free from cracks a n d crevices will cause
d a m a g e to the outer surface o f th e tuna, causing areas for co n ta m in a tio n to
set into th e m eat.
3.3.10 O verhead Pipes
There are to b e no overhead pipes in any areas o f th e processing facility,
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Pipes even if they are covered to prevent rust or condensation from falling are
not p erm itted in th e processing areas.
REASON: The work area and product must b e p ro te cte d from any falling debris
a n d dust w hich co u ld b e a source o f co n ta m in a tio n to th e products.
3.3.11 Processing, G rading and Packing Tables
All ta b le surfaces used in th e ope ra tion for th e processing, grading and

pa ckin g o f fresh tuna m ust b e m a d e o f non-corrodible m aterial such as
stainless steel, salt w ater resistant alum inium alloys, fibreglass reinforced, a nd
plastic sheets w hich is m a d e o f a pp ro ved m aterial.
Any o f these m aterials w hich are used in th e process m ust b e m a d e o f a

sm ooth surface free from cracks a n d crevices. W ood is not to c o m e in
c o n ta c t with th e product.
REASONS: If there are m aterials w hich are not corrosion resistant, non-sm ooth
a n d n o t fre e from cracks a n d crevices used in th e produ ction o f tuna then
there is a g o o d c h a n c e th a t co n ta m in a tio n o f th e p ro d u ct will occur.
3.3.12 Conveyors Used in the Production o f Loins
C o nveyor belts th a t c o m e in c o n ta c t with tuna loin p rodu ction m ust b e

e q u ip p e d with a spray washer a nd where p ra ctica l a scraper.
REASON: Because tuna com es in c o n ta c t with conveyor belts during

p ro d u ctio n , it leaves large num bers o f b a cte ria on th e surface o f th e belt.
Unless the belt is equipped with a g o o d w a ter spray, b a cte ria will a c c u m u la te
a nd th e tuna m e a t will c o m e in co n ta c t, b e co m in g heavily co n ta m in a te d .
3.3.13 Chutes, Containers, Trolleys
All chutes, containers and trolleys are to be m a d e o f a non-corrodible m aterial,

o th e r th a n w ood, and shall b e free from cracks, crevices a n d m a d e o f a
sm ooth surface.
W ood or galvanized m eta l is not perm itted to b e used.
REASON: W ood and galvanized m etal are not a c c e p ta b le d u e to th e fa c t th a t

there is to o great a risk o f contam ination. If the chutes, containers, a n d trolleys
a re n o t m a d e o f proper m aterials such as stainless steel, saltw ater-resistant
alum inium , or reinforced fibreglass, and are sm ooth a nd free from cracks and
crevices then there is a high risk o f co n ta m in a tio n to th e products.
3.3.14 Animals
Dogs, cats, a nd other anim als are not allow ed in or around processing
establishm ent.
REASON: Dogs, cats, and other anim als are potentia l carriers o f diseases and,
w hen present in a fo o d establishm ent, are co n ta m in a tio n hazards to the
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establishm ent a nd to th e tuna products,
3.3.15 Rodents and Insects
A proper rodent and insect control program m ust b e in p la c e with all areas o f
th e processing facility. W here pesticides are being used only trained p e o p le
w ith th e proper e q u ip m e n t should b e used in this m anner th a t prevents the
co n ta m in a tio n o f the products.
All openings w here these rodents and insects c a n gain access to th e pla n t
m ust b e p ro te cte d by th e proper m ethods.
Only pesticides which have been approved for use around fo o d are perm itted
to b e used. These pesticides are only to b e used a fte r app ro val by the
c o m p e te n t authorities having jurisdiction.
REASONS: Rodents a nd insects are potentia l pub lic health hazards. Rodents
carry diseases which ca n b e transm itted to m an by contam ination o f fo o d with
rodent excreta and urine. The co m m o n house fly has long been known as a
ca rrie r o f diseases caused by m icro-organism s. Any typ e o f insect is
objectionable. There is also a d a n g e r o f co n ta m in a tio n to th e tuna products
with rodent hairs or droppings and insect fragm ents.
3.3.16 Trays and Trolleys Used in the Frozen Production
All trays a nd trolleys used in th e p rodu ction o f tuna loins or sticks destined for
freezing must b e m ade o f non-corrodible materials, other than w ood, and shall
b e free from cracks and crevices.
Trays and trolley which co m e in c o n ta c t with th e tuna m e a t m ust b e m a d e o f

either stainless steel, or saltwater-resistant alum inium alloys. The fra m e m ust be
m a d e o f a sm ooth surface, free from cracks a n d crevices, a n d b e easily
cle a n e d .
REASONS: Only corrosion-resistant m aterial is p erm itted in th e handling o f tuna

p ro d u c t destined for freezing. The use o f any other m aterial c a n cause
co n ta m in a tio n to th e product.
3.3.17 Freezing Facilities
Freezing facilities for processed tuna loins a nd sticks shall b e c a p a b le o f

reducing th e tem p era ture a t th e ce n tre o f th e fish to -60°C within 6 hours.
REASON: It is very im portant to have th e p ro d u ct frozen as quickly as possible.

If the tuna m e a t is exposed to a slow freezing it will cre a te quality problem s to
th e m eat.
The slow rem oval o f th e w arm te m p e ra tu re from th e m e a t will cause the

ce n tre o f th e m e a t to b e soft a nd cruddy. This in turn will cause a decrease
in th e quality o f th e product.
3.3.18 Freezing Facility Tem perature Recorder
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All freezing facilities are required to have a recorder in p la c e to continuously
m onitor th e room tem perature.
REASON: There must be a system to record th e te m p e ra tu re o f th e room so as

to determ ine if there is a problem with th e freezing o f th e p rodu ct. If there are
c h a n g e s in th e te m p e ra tu re w hereby it rises a nd falls it c a n cre a te m oisture
loss and freezer burn to th e p rodu ct. This will cause a d ecrea se in qua lity and
a loss in yield.
3.3.19 Packing Material for Fresh Tuna Shipping and Material Used in Shipping
All cartons used in the shipping o f fresh tuna must be constructed from a strong
ca rd b o a rd m aterial.
The ca rto n m ust b e w aterproof to prevent w ater d a m a g e a n d w eaken the

carton.
The ca rto n m ust b e m a d e w atertight. This is d o n e by ensuring th a t th e tuna

a re w ip e d cle a n a n d th a t there are tw o sheets o f 10 m il (very heavy) plastic
covering th e tuna.
The c a rto n m ust have co ld retention c a p a b ility a nd insulation from external

tem perature factors. This is very im portant in th e quality control fa c to r for the
shipping o f tuna.
Frozen g el packs or dry ice m ust b e a va ila b le for th e packing o f fresh tuna.
Tuna paper m ust be available for covering th e skin to p ro te ct it from d a m a g e

in shipping.
REASON: Tuna ca rto n m ust b e constructed in such a m anner th a t during

shipping th e cartons are a b le to b e stacked on to p o f e a c h other w ithout
b eing crushed. Im proper cartons will cre a te problem s to th e quality o f the
tuna.
3.3.20 O ffal Removal
Bins or containers in w hich o ffa l is stored shall b e w atertight, constructe d o f

either m etal or other m aterial approved by the authorities and, w ere necessary
to preven t co n ta m in a tio n o f th e processing p la n t or any fish therein, b e
e q u ip p e d with w ell-fitted covers.
REASON: If o ffa l to other refuse while being on site a t th e processing fa cility is

n o t properly stored it will cre a te a safety problem , It will a ttra c t insects, birds
and rodents. Therefore it is very im portant to have th e proper co n ta in e r or bin
w hich is properly co ve re d a t all tim es,
3.3.21 Temperature in Processing Tuna
The room tem p era ture in th e processing areas should b e con tro lle d a t 18°C
or less.
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REASON: The lower th a t the air tem perature c a n b e kept during th e processing
o f fresh tuna th e better it will b e in helping m aintain th e m e a t te m p e ra tu re o f
th e tuna. R em em ber th a t if th e m e a t te m p e ra tu re rises a b o ve 7°C, it will
c re a te quality problem s.
3.3.22 Hot W ater Supply
Hot w a te r shall b e provided and m aintained a t a m inim um te m p e ra tu re o f

43 °C in sufficient quantity for th e fresh a n d frozen tuna processing facilities.
REASON: Hot water is necessary for efficient hand washing. It also greatly assists
in th e washing o f e q u ip m e n t a fte r processing is co m p le te d . The a ctio n o f
detergents used in th e cle aning o f th e e q u ip m e n t is ch e m ica l in nature and
the speed o f reaction increases with the rise in th e w ater tem perature. W ithout
th e use o f hot w ater there will b e a serious c h a n c e th a t th e p ro d u ct will
be co m e contam inated, d u e to poor washing o f hands a n d poor cle aning o f
equipm ent.
3.3.23 Ice
O nly c le a n ic e w hich is m a d e from a source o f w ater w hich has been

a p p ro ve d by th e co m p e te n t authorities having jurisdiction m ay b e used in a
fresh tuna a n d /o r a frozen tuna operation.
Where block foe is being used, a ll sawdust a n d other debris m ust b e rem oved
by washing with approved water under pressure. Ice, a t tim e o f use, m ust not
have a coliform b a cte ria MPN co u n t o f m ore th a n 2 per 100 millilitres.
C ontainers used for the handling a nd storage o f ic e shall b e constructed o f

non-corrodible m aterial a nd all such containers m ust b e well m aintained and
kept cle a n a t all tim es.
Processing facilities which receive their b e from a n outside source m ust ensure
th a t th e ic e w hich they are receiving m eets th e requirem ents th a t are
discussed in these regulations.
When receiving b e from outside sources, only ic e w hich is transported in either

c le a n a nd safe closed trucks e q u ip p e d with a coolin g unit or insulated
containers are to b e used.
No ice which is contam inated is perm itted to b e used in the processing o f tuna.
No b e which is transported in unsafe or unclean trucks or containers are to be

a c c e p te d by th e processing plants. Ice being transported in this m anner will
b e c o m e co n ta m in a te d and cause co n ta m in a tio n to th e products.
3.3.24 Plant Surroundings
The area a nd b e a ch surroundings w hich are in d ire ct c o n ta c t with the

processing facility shall b e kept cle a n and safe a t ail tim es.
REASON: The a ccu m u la tio n o f refuse in th e area a n d b e a ch surroundings
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around the processing facility m ay give rise to o b je ctio n a b le odours, w hich will
a ttra c t insects and rodents and thus b e co m e a sanitation problem .
3.3.25 Sewage
Sew age, including liquid w aste from fish processing operations, shall be
disposed o f in such a m anner th a t the waste is inaccessible to flies a n d the
w a te r supply for th e establishm ent will not b e c o m e c o n ta m in a te d . Any
disposal system w hich c a n c o n ta m in a te th e w aste supply, then th a t w ater
supply will not b e approved.
REASON: Sewage is characterized by the presence o f vast num bers o f b a cte ria
o f pub lic health significance. Unless sew age is e ffe ctive ly rem oved, working
surfaces will b e c o m e co n ta m in a te d . Any disposal system w hich ca n
c o n ta m in a te th e w ater supply, then th a t w ater supply will not b e app ro ved.
3.4 PROPER CLEANING PROCEDURES
3.4.1 C lean-up Procedures
EVERY QUALITY ASSURANCE PROGRAM SHOULD INCLUDE A COMPREHENSIVE

WRITTEN CLEANING AND DISINFECTION PROGRAM FOR ITS OPERATION. THIS
PROGRAM SHOULD ENSURE THAT ALL FISH HANDLING AREAS ARE ADEQUATELY
CLEANED AND DISINFECTED.
The sp e cifics o f th e cle aning program will vary a cco rd in g to individual

circum stances and th e program should b e designed to m e e t th e needs o f
e a ch operation. Each cle aning step m ay b e custom ised to provide th e best
possible results. W here app ro priate, program s should b e draw n up in
consultation with relevant specialist.
O nce the cleaning and disinfection program has been designed it is im portant
th a t it b e recorded. The written program will serve as a reference d o cu m e n t
for th e training and daily function o f personnel e n g a g e d in cle a n in g and
disinfection. W here written cle aning program s are used, they should specify:
areas, item s o f e q u ip m e n t a nd utensils to b e cle a n e d ;

responsibility for particular task;
m eth od a nd freq uency o f cle aning; and
m onitoring arrangem ents.
It will also serve as a reference for m a n a g e m e n t and the a g e n cy having

jurisdiction against w hich th e daily cle a n -u p c a n b e m easured. The written
program should specify the cleaning and disinfection to b e perform ed in every
food-han dling area. A separate program m ay b e cre a te d for different
processing areas or lines, as required. Cleaning schedules should b e prepared
to cover every item o f equipm ent and all areas o f the fa cto ry including toilets,
cloakroom s, and dining and rest areas,
C lean ing c a n b e carried o u t by th e separate or co m b in e d use o f physical

m ethods, such as scrubbing or turbulent flow, a nd ch e m ic a l m ethods using
detergents, alkalis or acids. A typ ica l cle aning and disinfection process m ay
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involve as m any as six separate steps:
1 PRE-CLEANING
Preparation o f area and equipm ent for cleaning. Involve steps such as
rem oval o f all p ro d u ct from area, p ro te ctio n o f sensitive com pon ents
a n d pa cka g in g m aterials from w ater, rem oval by hand or squeegee
o f fish scraps, e tc .
2 PRE-RINSE
A rinsing with w ater to rem ove rem aining large pieces o f loose soil or
gross debris from surfaces.
3 CLEANING
Treatment o f surfaces w ith a n a p p ro p ria te d e te rg e n t to rem ove soil or

to loose soil and bacteria film a n d hold th e m in solution or suspension.
4 RINSE
A rinsing with water to rem ove loosened soil a n d residues o f detergen t.
5 DISINFECTION
Where necessary, application o f chem icals and/or heat to destroy m ost

m icroorganism s on surface.
6 POST-RINSE
A fin a l rinse with w ater to rem ove disinfectant. This step is not
a p p lic a b le or re co m m e n d e d in all situations.
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S E C T IO N 4
A N IN T E G R A T E D Q U A L IT Y M A N A G E M E N T P R O G R A M
(IQ M P ) F O R
T H E O N -S H O R E H A N D L IN G A N D P R O C E S S IN G O F
FR E S H A N D F R O Z E N T U N A
- 8 5 -
4 .1 IN TR O D U C TIO N
D u e t o th e ris in g c o n c e rn s b y th e c o u n trie s o f th e w o rld t o e a t s a fe fo o d , re q u ire m e n ts

a r e b e in g e s ta b lis h e d in fo o d p ro c e s s in g in d u s trie s t o s h o w t h a t th e y h a v e in p la c e a n
a d e q u a te f o o d s a fe ty p r o g r a m fo r t h e c o n tr o l o f th e ir p r o d u c ts in te n d e d fo r h u m a n
c o n s u m p tio n . P la n t o p e ra to rs w ill h a v e t o s h o w in w ritin g t h e p r o c e d u r e s t h a t th e y a r e
u s in g t o id e n tify h a z a rd s a s s o c ia te d w ith t h e h a n d lin g , p ro c e s s in g a n d d is tr ib u tio n o f
tu n a a n d th o s e p re v e n tiv e m e a s u re s b e in g ta k e n t o e n s u re th e s a fe ty o f th e p r o d u c ts
is g u a r a n te e d , s u c h a s m o n ito rin g a t c r itic a l c o n tr o l p o in ts a n d a p p ly in g a p re v e n tiv e
a c t io n p la n if a n y o f t h e c r itic a l p o in ts a r e o u t o f c o n tr o l.
A n u m b e r o f q u a lity c o n tr o l s y s te m s e x is t t o e n s u re t h e a b o v e , t h e b e s t k n o w n is th e
H a z a rd A n a ly s is a n d C r itic a l C o n tr o l P o in t (H A C C P ) s y s te m . T his s y s te m , w h ile a n
in te rn a tio n a l s ta n d a rd , is a n a rro w ly d e fin e d fo o d s a fe ty s y s te m t h a t re q u ire s a n u m b e r
o f p r e - r e q u is ite re q u ir e m e n ts a n d d o e s n o t d e a l w ith q u a lity o r e c o n o m ic fr a u d . A
m o re c o m p r e h e n s iv e p ro g ra m , w h ic h in c o r p o r a te s HACCP, its p r e - r e q u is ite
r e q u ir e m e n ts , r e g u la to r y r e q u ir e m e n ts a n d m a r k e t re q u ir e m e n ts is t h e In te g r a te d
Q u a lity M a n a g e m e n t P ro g ra m (IQ M P ).
T h e IQ M P s p e c ifie s a n u m b e r o f g e n e r ic a r e a s /c o n tr o l p o in ts o r p o in ts o f in s p e c tio n .
E a c h o f th e s e a r e a s m u s t b e e x a m in e d t o s e e if th e r e is a c o n tr o l p o in t o r c r itic a l
c o n tr o l p o in t in th e p ro c e s s in th a t a r e a . A n n e x 4 g iv e s d e fin itio n s u s e d in th is m a n u a l
t o d e s c r ib e " c o n tr o l p o in ts " a n d " c r itic a l c o n tr o l p o in ts " , e tc .
P la n t o w n e rs /o p e ra to rs s h o u ld c o n d u c t a s tu d y o f th e ir o p e r a tio n u s in g th e IQ M P a s a
g u id e , in c o r p o r a te t h e IQ M P in to th e ir q u a lity c o n tr o l p r o g r a m m e a n d s u b m it th is
p r o g r a m m e t o th e c o m p e t e n t a u th o r itie s fo r a p p r o v a l.
A s p a r t o f G M P P ro c e d u re s , e a c h Fish P la n t O w n e r /O p e r a to r w ill b e re q u ir e d t o
im p le m e n t p la n n e d p ro c e d u re s fo r th e m o n ito rin g o f th e ir o p e r a tio n s a t C o n tr o l P o in ts
o r In s p e c tio n P o in ts w h e re p r o b le m s a r e n o te d . D e te c tio n o f p r o b le m s a t t h e e a rlie s t
o p p o r tu n ity a llo w s th e p r o b le m s t o b e r e la te d t o th e fa c to r s t h a t c a u s e d th e m a n d
p e rm its th e m o s t e ffe c tiv e a p p r o a c h t o c o r r e c t th e m .
E a c h C o n tr o l P o in t o r In s p e c tio n P o in t r e p re s e n t a n o p p o r tu n ity , b e fo r e a n y o th e r
p ro c e s s in g ta k e s p la c e w ith th e tu n a , t o e v a lu a te c o m p lia n c e w ith re q u ire m e n ts a n d
ta k e c o r r e c tiv e a c tio n w h e re n e c e s s a ry .
F o r e a c h c o n tr o l o r in s p e c tio n p o in t th e fo llo w in g in fo r m a tio n m u s t b e s p e c ifie d :
1. T h e re q u ire m e n ts t h a t a r e b e in g c o m p lie d w ith .

2. T h e s ta n d a r d t h a t is b e in g e m p lo y e d d u r in g in s p e c tio n .
3. E v a lu a tio n o f th e m o n ito r in g p r o c e d u r e s .
4. T h e s y s te m fo r c o lle c tin g d a t a a n d r e c o r d k e e p in g .
5. D e s c rip tio n o f th e c o r r e c tiv e a c tio n t h a t w ill b e im p le m e n te d w h e n p r o b le m s
a r e d is c o v e r e d .
T h e re a r e 1 2 a re a s in th e p ro c e s s in g o p e r a tio n fo r t h e h a n d lin g o f tu n a o n -s h o re t h a t
n e e d to b e e x a m in e d a t c o n tr o l o r in s p e c tio n p o in ts t o e n s u re c o m p lia n c e w ith G M P
re q u ire m e n ts .
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F ish 4 .2
O th e r In g re d ie n ts 4 .3
Ic e 4 .4
C le a n in g A g e n ts , S a n itis e rs , L u b ric a n ts 4 .5
P la n t D e s ig n , P ro d u c tio n F a c ilitie s 4 .6
O p e r a tio n A n d S a n ita tio n 4 .7
P ro c e s s C o n tr o l 4 .8
F re s h /fro z e n S to ra g e F a c ilitie s 4 .9
P a c k a g in g M a te r ia l 4 .1 0
F in a l P ro d u c t 4 .1 1
R e c a ll P ro c e d u re s 4 .1 2
E m p lo y e e Q u a lific a tio n s 4 .1 3
In e s ta b lis h in g t h e C o n tr o l o r In s p e c tio n P o in ts fo r th e p r o c e s s in g o f tu n a , e a c h
p r o c e s s o r m u s t u n d e r s ta n d w h a t h a z a rd s th e y a r e a tte m p tin g t o p r e v e n t a n d th e
lo c a tio n fo r in s p e c tio n w h ic h w ill p r o v id e t h e b e s t o p p o r tu n ity t o c o n tr o l th e h a z a rd .
A f lo w c h a r t a n d ta b le a r e fo u n d in s e c tio n s 4 .1 .1 a n d 4 .1 .2 . T h e y p r o v id e a n o v e rv ie w
o f w h e re in s p e c tio n o r c o n tr o l p o in ts fo r e a c h ite m .
A n n e x 6 p ro v id e s th e s p e c ific in fo rm a tio n r e g a r d in g p o te n tia l C r itic a l C o n tr o l P o in ts fo r

th e p ro c e s s in g o f fre s h /fro z e n tu n a .
-8 7 -
Points
Inspection/Control
Determining
for
Flowchart
Process
4.1.1
4 .1 .2 P o te n tia l In s p e c tio n /C o n tro l P o in ts
Ite m s H a z a rd s C o n tro l P o in ts
F ish H e a lth a n d S a fe ty Risks P rio r t o P ro c e s s

T a in te d , D e c o m p o s e d B e fo re R e c e iv in g
U n w h o le s o m e T u n a
D e a d , N o n - c o m p lia n c e
O th e r In g re d ie n ts C o n ta m in a tio n o f T u n a P rio r t o U se
W ith U n a p p r o v e d , U n s a fe W h e n R e c e iv e d
C o m p o u n d s /n o t M e e tin g S p e c ific a tio n s
Ic e C o n ta m in a tio n o f T u n a P rio r t o U se
U n s a fe , U n c le a n W h e n R e c e iv e d
D u rin g U se
C le a n in g A g e n ts , C o n ta m in a tio n t o T u n a P rio r t o U se
S a n itis e rs W ith U n a p p r o v e d /u n s a fe C h e m ic a ls W h e n R e c e iv e d
D u rin g A p p lic a tio n
P la n t D e s ig n / C o n ta m in a tio n t o T u n a D u e t o P o o r P rio r t o S ta rt U p /
P ro d u c tio n D e s ig n o f E q u ip m e n t/b u ild in g D u rin g O p e r a tio n
E q u ip m e n t
O p e r a tio n a n d C o n ta m in a tio n t o T u n a P rio r t o U se

S a n ita tio n D u e t o P o o r O p e r a tio n A n d S a n ita tio n D u rin g In s p e c tio n
P r a c tic e O p e r a tio n /d a ily
P ro c e s s P r o d u c tio n o f T u n a T h a t D o n 't C o m p ly D u rin g O p e r a tio n

C o n tr o l w ith S a fe ty , Q u a lity W h o le s o m e n e s s W a s h in g
a n d /o r F a ir T ra d e R e q u ire m e n ts C le a n in g
C o o lin g /ic in g
P a c k in g
F re s h a n d F ro z e n D e c o m p o s itio n O r C o n ta m in a tio n o f T u n a D u rin g O p e r a tio n o f

S to ra g e F a c ilitie s D u e t o P o o r S to ra g e C o o lin g /fr e e z in g
P a c k a g in g M a te ria l U se o f U n a p p ro v e d D a m a g e d , U n c le a n P rio r t o U se
C a rto n s Im m e d ia te ly B e fo re
U se
F in a l P ro d u c t P r o d u c tio n o f T u n a T h a t D o e s N o t C o m p ly P rio r t o P a c k in g o f
W ith S a fe ty , Q u a lity A n d W h o le s o m e n e s s F re s h /fro z e n T u n a
A n d F a ir T ra d e R e q u ire m e n ts
R e c a ll P ro c e d u re s U n a b le t o T ra c e T u n a t o B u y e r/c u s to m e r D u rin g P a c k in g
P rio r t o S h ip p in g
E m p lo y e e P ro d u c tio n o f T u n a P o s in g H e a lth A n d P rio r t o S ta rt U p

Q u a lific a tio n S a fe ty Risks S k ille d T ra in e d
P e rs o n n e l
-8 9 -
4 .1 .3
ID E N T IF IC A T IO N O F
IN S P E C T IO N /C O N T R O L P O IN T S
T y p e o f O p e r a t i o n : ____________________________________________________________________________
C h e c k o f f th o s e ite m s w h ic h w ill b e m e n tio n e d a t a c o n tr o l p o in t a n d id e n tify w h e re /w h e n th e

p o in t o f tim e o f in s p e c tio n w ill o c c u r .
Ite m s P o in t o f T im e o f In s p e c t i o n
F is h :
O th e r
I n g r e d ie n t s :
Ic e :
C le a n in g A g e n t s ,
S a n itis e r , L u b r ic a n t s :
P la n t D e s ig n /
P r o d u c t io n F a c ilit ie s :
O p e r a t io n a n d S a n it a t io n :
P r o c e s s C o n t r o l:
F r e s h /fr o z e n
S t o r a g e F a c ilit ie s :
P a c k a g in g M a t e r ia l:
F in a l P r o d u c t :
E m p lo y e e
Q u a lif ic a t io n s :
R e fe r t o th e s e c tio n in d ic a te d fo r c o m p le tio n o f th o s e c o n tr o l p o in ts t h a t h a v e b e e n c h e c k e d
o ff.
-9 0 -
4 .2 FISH
4 .2 .1 R e q u ire m e n ts :
U n d e r G O O D M ANUFACTURING PRACTICES th e fo llo w in g r e q u ir e m e n ts a r e t o b e

fo llo w e d b y th e p ro c e s s in g p la n t:
1. N o tu n a w h ic h is d e c o m p o s e d , ta in te d o r u n w h o le s o m e is p e r m itte d t o
b e r e c e iv e d o r p ro c e s s e d fo r e x p o rt, o r p ro c e s s e d fo r d o m e s tic m a rk e t.
2. T u n a is t o b e b le d p r o p e r ly a t tim e o f r e c e iv in g fo r fu r th e r p r o d u c tio n .
3. N o tu n a w h ic h is im p r o p e r ly g u tte d is a c c e p t a b le .
4. N o u n g u tte d tu n a is p e r m itte d t o b e r e c e iv e d a t p ro c e s s in g p la n t.
5. T u n a m u s t h a v e a ll g ills r e m o v e d b e fo r e d e liv e ry .
6. T u n a is t o h a v e a te m p e r a tu r e o f 0 ° C a t t im e o f r e c e iv in g .
7. T u n a is o n ly t o b e d e liv e r e d t o p ro c e s s in g p la n t in p r o p e r in s u la te d
c o n ta in e rs , w h ic h h a s b e e n p ro p e rly c le a n e d a n d is fre e fr o m c r a c k s a n d
c r e v ic e s a n d is n o t c o n ta m in a te d .
8. N o tu n a is p e r m itte d t o b e p la c e d o n th e p ro c e s s in g flo o r , th is w ill c a u s e

c o n ta m in a tio n t o th e p r o d u c t.
9. T u n a is n o t p e r m itte d t o b e e x p o s e d t o th e a ir fo r a lo n g p e r io d o f tim e .
T u n a if n o t b e in g p a c k a g e d im m e d ia te ly a fte r r e c e iv in g m u s t b e p la c e d
in to s lu s h ic e in a p r o p e r a p p r o v e d h o ld in g ta n k .
1 0 .T u n a fo r p ro c e s s in g fo r fre s h /fro z e n lo in s m u s t b e p ro c e s s e d im m e d ia te ly
a fte r r e m o v a l fr o m ta n k s .
11. T u n a is n o t t o b e d r a g g e d o r p u lle d a c ro s s th e p ro c e s s in g flo o r a t a n y

tim e .
D u rin g th e r e c e iv in g o f tu n a a t th e p ro c e s s in g p la n t th e fo llo w in g in fo r m a tio n

is re q u ir e d t o b e c o m p le te d b y th e p ro c e s s o r:
A. T h e n a m e o f th e v e s s e l w h ic h th e fis h c a m e fr o m .
B. T h e q u a n tity o f tu n a r e c e iv e d .
C. T h e q u a lity o f th e tu n a a s in s p e c te d w h e n r e c e iv e d . E a c h fis h t o b e
g r a d e d a n d th e in fo r m a tio n r e c o r d e d .
D. E n s u re t h a t th e r e is a d is c h a r g e c h a r t s h o w in g th e a g e o f th e tu n a .
E. A te m p e r a tu r e lo g s h o w in g th e te m p e r a tu r e o f th e tu n a a t tim e o f
d is c h a r g e .
A n y e q u ip m e n t w h ic h is u s e d in th e p ro c e s s fo r th e h o ld in g o f tu n a t h a t is
d a m a g e d o r c a n c a u s e d a m a g e o r c o n ta m in a tio n o f th e tu n a c a n n o t b e
used.
-9 1 -
A ll fis h h a n d lin g e q u ip m e n t s u c h a s ta b le s , c h u te s , c o n ta in e r s a n d u te n s ils ,
s h a ll b e o f a s m o o th s u r fa c e , n o n - a b s o r b e n t, n o n - c o r r o d ib le m a te ria ls .
A ll fis h h o ld in g ta n k s m u s t b e o f a s m o o th s u r fa c e , fr e e fr o m c ra c k s a n d
c r e v ic e s s o a s t o p r e v e n t c o n ta m in a tio n t o th e tu n a .
A ll a re a s w h ic h in th e p ro c e s s in g p la n t a r e u s e d fo r th e p r o d u c tio n o f tu n a a r e
to be c le a n and s a fe . No a re a s a re to be used w h ic h can cause
c o n ta m in a tio n t o o c c u r in th e tu n a .
4 .2 .2 Fish D e fe c t D e fic ie n c y :
A tu n a w h ic h is re c e iv e d a t th e p ro c e s s in g p la n t is c o n s id e re d d e fe c tiv e if th e r e
is a n y tr a c e o f fu e l o il o r o th e r c r itic a l c o n ta m in a tio n o f th e fle s h o d o u r w h ic h
is in d ic a tiv e o f d e c o m p o s itio n o r ta in t.
T u n a w h ic h is n o t b le d , c le a n e d o r c h ille d p r o p e r ly c a n a ls o b e c o m e a d e f e c t
fis h .
T h e re a r e th re e a re a s w h e re b y a tu n a s h o u ld b e in s p e c te d t o s e e if th e p r o p e r
b le e d in g p ro c e s s h a s b e e n c o m p le te d . T h e th r e e a r e a s a r e a s fo llo w s :
(A) T h e a rte rie s b e h in d th e p e c to r a l fin ,

(B) T h e a rte rie s w h ic h s u p p ly th e g ills w ith b lo o d .
(C ) T h e ta il s e c tio n b e tw e e n th e th ir d a n d fo u r th d o rs a l fin le t fr o m t h e ta il.
C ritic a l c o n ta m in a tio n is th e p re s e n c e o f a n y m a te r ia l o r d is tin c t a n d p e rs is te n t

o d o u r o r fla v o u r o f a n y m a te r ia l w h ic h h a s n o t b e e n d e r iv e d fr o m fis h a n d
w h ic h p o s e s a th r e a t t o h u m a n h e a lth .
4 .2 .3 M o n ito rin g P ro c e d u re s :
T h e fo llo w in g p ro c e d u re s s h a ll b e u s e d in d e te rm in in g th e c o n d itio n o f t h e tu n a .
E ach fis h is e x a m in e d fo r c o n ta m in a tio n by fu e l o il or o th e r c r itic a l

c o n ta m in a tio n s o u r c e lik e ly t o b e a th r e a t t o h u m a n h e a lth .
A t t im e o f r e c e iv in g th e tu n a a t t h e p ro c e s s in g p la n t it m u s t b e in s p e c te d fo r
fle s h c o lo u r, fre s h n e s s , a n d c o n d itio n . This p r o c e s s is c o m p le te d b y re m o v in g
a p ie c e o f m e a t fro m th e t a il s e c tio n b e tw e e n t h e fifth a n d s ix th c a u d e l fin le t.
A ll to ts o f ra w fis h w h ic h is la n d e d a t a fis h p ro c e s s in g p la n t m u s t b e in s p e c te d
a t t h e id e n tifie d c r itic a l p o in ts o f in s p e c tio n t o e n s u re t h a t th e y a r e d e r iv e d
fr o m ra w m a te r ia l w h ic h m e a n s t h e m in im u m r e g u la to r y r e q u ire m e n ts .
4 .2 .4 C o rre c tiv e A c tio n s :
T h e p ro c e s s o r w ill id e n tify th e p o s itio n re s p o n s ib le fo r ta k in g c o r r e c tiv e a c tio n

a n d th e p o s itio n re s p o n s ib le fo r e n s u rin g t h a t t h e c o r r e c tiv e a c tio n w a s c a r r ie d
o u t. If th e p ro c e s s o r w a n ts t o u s e th e ir o w n fo rm s th e y m u s t s u p p ly a n e x a m p le
o f t h e ty p e o f fo r m th e y in te n d t o u s e t o r e c o r d c o r r e c tiv e a c tio n .
-9 2 -
F o r e a c h in s ta n c e o f n o n - c o m p lia n c e th e p ro c e s s o r m u s t h a v e a r e c o r d o f th e
c o r r e c t iv e a c t io n t h a t to o k p la c e a n d t h a t th e r e c o r d s m u s t p r o v id e th e
fo llo w in g in fo r m a tio n :
■ A d e s c r ip tio n o f t h e n o n - c o m p lia n c e ite m

■ T h e d a t e t h e n o n - c o m p lia n c e ite m h a p p e n e d
■ -The d a t e th e c o r r e c tiv e a c tio n to o k p la c e
■ W h a t c o r r e c tiv e a c t io n w a s ta k e n
■ T h e o u tc o m e
■ T h e s ig n a tu r e o f t h e p e rs o n re s p o n s ib le
T h e fo llo w in g fo r m s a r e t o b e c o m p le t e d b y t h e c o m p a n y :
-9 3 -
4.2.4.1
CORRECTIVE AC TIO N REPORT
D a te : A re a A ffe c te d :
D e s c rip tio n o f The P ro b le m W ith The Tuna:
S h o w W h a t A c tio n H as B e e n Taken to C o rre c t P ro b le m :
D a te P ro b le m S o lv e d :
C u rre n t S ta tu s :
C om pany N am e:
In s p e c to r :
This re port m ust b e fille d o u t when there is a p ro b le m th a t is a ffe c tin g th e q u a lity o f th e tuna.
This re p o rt is to b e k e p t o n file as a re c o rd to show th a t th e co rre ctive a c tio n was taken.
-9 4 -
4.2.4.2
INSPECTION O F TUNA AT
RECEIVING SITE
D a te :
N a m e o f S h ip p e r:
N a m e o f P ro c e s s in g C o m p a n y :
S p e c ie s :
O u te r A p p e a r a n c e o f Fish:
C o lo u r o f M e a t:
F reshness o f M e a t:
T e m p e ra tu re o f Fish:
C o n d itio n o f In n e r B e lly W a ll:
A n y N o tic e a b le C o n ta m in a tio n :
A n y O th e r C o m m e n ts to The C o n d itio n O r H a n d lin g o f The Fish:
In s p e c te d b y :
-95-
4 .2 .4 .3
RAW PRODUCT
IN S P E C TIO N REPORT
D a te : V e s s e l/A r e a :
S p e c ie s : T e m p e r a t u r e o f fis h : °C
SAM PLES
DEFECTS 1 2 3 4 5 6 7 8 9 10
R a w F is h
D e c o m p o s e d o d o u rs
( a m m o n ia , s o u r,
v e g e t a b le , f a e c a l,
p u tr id )
T a in t o d o u r s ( r a n c id
o il, a b n o r m a l o d o u r
a s s o c ia t e d w ith fe e d )
B r o k e n /p e r fo r a te d
b e lly w a lls
C r it ic a l
C o n ta m in a t io n
P a s s o r F a il
Lo t P a s s e s Lo t F a ils
- 96-
4 .2 .4 .4
IN F O R M A T IO N T O BE SUPPLIED BY
FISH P R O C E S S IN G C O M P A N Y
T y p e o f F ish P r o c e s s in g O p e r a t io n : __________________________________________________
R e q u ire m e n ts :
W e w ill m e e t th e r e q u ir e m e n ts a s s p e c if ie d b y t h e G M P fo r t h e p r o c e s s in g a n d
h a n d lin g o f tu n a .
OR
W e w ill p r o v id e o u r o w n c o m p a n y r e q u ir e m e n ts t h a t w ill m e e t o r e x c e e d th o s e
s u p p lie d in t h e G M P . _______
D EFEC T D E FIN ITIO N S a n d D E FEC T TO LER AN C ES :

W e w ill u tiliz e t h e d e f e c t d e fin itio n s a n d d e f e c t t o le r a n c e s a s d e s c r ib e d f o r th e
h a n d lin g o f tu n a w h ic h is b e in g p r e s e n te d in th is d o c u m e n t .
OR
W e w ill p r o v id e o u r o w n c o m p a n y d e f e c t d e fin itio n s a n d t o le r a n c e t h a t m e e t
o r e x c e e d th o s e s u p p lie d in th is d o c u m e n t . _______
M O N IT O R IN G PR O C ED U R ES:
W e w ill im p le m e n t t h e le v e l o f m o n ito r in g a s s p e c if ie d in th is d o c u m e n t . _______
OR
W e w ill p r o v id e o u r o w n c o m p a n y m o n ito r in g p r o c e d u r e s t h a t m e e t o r e x c e e d
th o s e s u p p lie d b y t h e d o c u m e n t _______
F O R M S F O R D A T A C O L L E C T IO N , IN S P E C TIO N a n d R A W P R O D U C T :
W e w ill u tiliz e t h e fo r m s s u p p lie d in th is r e p o r t fo r C o r r e c tiv e A c tio n , In s p e c tio n
R e p o r tin g a n d R a w P r o d u c t.
OR
W e w ill p r o v id e o u r o w n c o m p a n y r e p o r ts fo r C o r r e c tiv e A c tio n , In s p e c tio n
R e p o r tin g a n d R a w P r o d u c t t h a t m e e ts o r e x c e e d s th o s e s u p p lie d b y th is
d o c u m e n t. _______
If th e p r o c e s s o r is g o in g t o s u p p ly th e ir o w n fo rm s , t h e y m u s t p r o d u c e a c o p y o f
th e ty p e o f fo r m s t h e y w ill u s e in th is r e p o r t t o th e a u th o r itie s h a v in g ju r is d ic tio n .
N A M E O F C O M P A N Y :_________________________________________________________
D A T E :___________________________________________
-9 7 -
4 .3 OTHER INGREDIENTS
N o c o m p a n y s h a ll a t t e m p t t o u s e a n y in g r e d ie n ts a d d e d t o tu n a p r o d u c ts
u n le s s th e y m e e t th e r e q u ir e m e n ts o f th e c o m p e t e n t a u th o r itie s h a v in g
ju r is d ic tio n a n d b e a c c e p t a b le fo r th e m a n u fa c tu r in g o f fo o d .
4 .3 .2 In g re d ie n ts :
T h e tu n a p ro c e s s in g c o m p a n y m u s t k e e p a lis t o f t h e in g r e d ie n ts w h ic h is
a d d e d t o th e tu n a p r o d u c ts d u r in g th e p r o c e s s in g p r o c e d u r e . T h e lis t m u s t
c o n ta in th e fo llo w in g in fo r m a tio n :
■ T h e a m o u n t o f In g re d ie n ts t o b e u s e d
■ W h e n in th e p ro c e s s th e in g r e d ie n ts is a d d e d
■ T h e c o n c e n tr a tio n o f in g re d ie n ts
■ A n y s p e c ia l a p p lic a tio n p r o c e d u r e s
■ T h e m a n u fa c tu r e r 's d e s c r ip tio n o f th e in g re d ie n ts
T h e lis t m u s t b e a v a ila b le t o t h e c o m p e t e n t a u th o r itie s u p o n re q u e s t.
4 .3 .3 D e fe c t D e fin itio n s :
T h e fis h p ro c e s s o r is o n ly t o u s e th o s e in g r e d ie n ts t h a t m e e t th e r e q u ire m e n ts
o f th e a u th o r itie s h a v in g ju ris d ic tio n . T h e y m u s t e n s u re t h a t th e s e in g re d ie n ts
a r e a p p r o v e d fo r u s e in tu n a p ro d u c ts . This in fo r m a tio n m u s t b e a c q u ir e d fr o m
th e m a n u fa c tu re r. This in fo r m a tio n is t o b e m a d e a v a ila b le t o th e a u th o ritie s .
4 .3 .4 D e fe c t T o le ra n c e s :
T h e re is z e ro (0) to le r a n c e fo r in g re d ie n ts o r a d d itiv e s w h ic h d o e s n o t r e a c h th e
re q u ire m e n ts .
NOTE: A re q u e s t m a d e b y a n y tu n a p ro c e s s o r fo r th e u s e o f in g r e d ie n ts w h ic h
is n o t p e rm itte d b y th e lo c a l a u th o ritie s b u t p e r m itte d b y t h e im p o r tin g c o u n tr y
m u s t b e a c c o m p a n ie d w ith t h e fo llo w in g d o c u m e n ta tio n :
The p ro c e s s o r m u s t o b ta in th e p r o p e r d o c u m e n ta tio n fr o m th e
c o m p e t e n t a u th o r itie s o f th e im p o r tin g c o u n tr y , s ta tin g t h a t th e
in g re d ie n ts o r a d d itiv e s is o f fo o d g r a d e a n d a c c e p t a b le fo r u s e in t h a t
c o u n try .
A ll p ro d u c ts c o n ta in in g in g re d ie n ts n o t p e r m itte d fo r u s e in t h e c o u n tr y
o f o r ig in m u s t c a r r y th e s ta te m e n t "FO R EXPORT O N LY ". This m u s t b e
c le a r ly p r in te d o n th e c a r to n s fo r p r o p e r v ie w in g . T h e firs t s h ip m e n t fo r
th e y e a r c o n ta in in g n o n - a p p r o v e d in g r e d ie n ts m u s t b e a c c o m p a n ie d
b y a CERTIFICATE fr o m th e c o m p e t e n t a u th o rity .
4 .3 .5 M o n ito rin g P ro c e d u re s :
T h e tu n a p ro c e s s in g c o m p a n y m u s t p r o v id e a m o n ito r in g s y s te m t h a t e n s u re s
-9 8 -
t h a t a ll tu n a p r o d u c ts c o n ta in in g in g re d ie n ts n o t p e r m itte d in th e c o u n tr y o f
o rig in a r e n o t s o ld in t h a t c o u n try .
T h a t th e p e r m itte d in g r e d ie n ts a r e o n ly u s e d s o le ly fo r th e ir in te n d e d u s e a n d
th e in g re d ie n ts a d d e d c o n fo r m to th e re q u ire m e n ts o f th e c o m p e te n t a u th o r ity
a n d m a n u fa c tu r e r 's s p e c ific a tio n s .
A ll in g r e d ie n ts m u s t b e p r o p e r ly s to re d a n d in s p e c te d fo r c o n ta m in a tio n a n d
p la c e d in a s e c u r e d a r e a w h e r e b y th e in g r e d ie n ts c a n n o t b e m ix e d w ith
a n o th e r p r o d u c t.
4 .3 .6 C o rre c tiv e A c tio n s
T h e c o m p a n y w ill id e n tify th e p e rs o n w h o is re s p o n s ib le fo r ta k in g t h e c o r r e c tiv e

a c tio n a n d e n s u re t h a t th e c o r r e c tiv e a c tio n is b e in g c a r r ie d o u t.
T h e c o m p a n y m u s t s u p p ly fo rm s t o a n in s p e c to r u p o n r e q u e s t t h e r e c o r d o f
th e c o r r e c tiv e a c tio n ta k e n . T h e fo r m m u s t c o n ta in th e fo llo w in g in fo r m a tio n :
■ A d e s c r ip tio n o f th e n o n - c o m p lia n c e in g r e d ie n t
■ T h e id e n tific a tio n o f in fo r m a tio n
■ T h e d a t e th e n o n - c o m p lia n c e in g r e d ie n t w a s id e n tifie d
■ T h e d a t e th e c o r r e c tiv e a c tio n w a s ta k e n
■ W h a t c o r r e c tiv e a c tio n w a s ta k e n
■ W h a t w a s th e o u tc o m e
■ T h e s ig n a tu r e o f th e p e rs o n re s p o n s ib le
4 .3 .7 D a ta C o lle c tio n A n d R e p o rtin g F o rm s :
T h e c o m p a n y m a y u s e th e a t t a c h e d d a t a r e p o r tin g fo rm s o r m u s t p r o v id e
e x a m p le s o f th e ty p e o f fo rm s it in te n d s t o use in r e c o r d in g in c o m in g
in g r e d ie n ts in s p e c tio n t o e n s u re t h a t th e m a te r ia l is a p p r o v e d a n d is n o t
c o n ta m in a te d . T h e c o m p a n y m u s t s u p p ly a c o p y o f th e in te n d e d fo rm s t h a t
a re to b e u s e d .
-9 9 -
4.3.7.1
IN C O M IN G IN G R E D IE N T
D a te :
T y p e o f In g r e d ie n t:
S u p p lie r:
B ra n d N a m e :
M a n u fa c tu r e r :
L o t# : C ode#:
Yes No
H a s T h e In g r e d ie n ts B e e n A p p r o v e d ?
In g r e d ie n t C o n ta in e r s S o u n d ?
A r e T h e In g r e d ie n ts U n c o n ta m in a te d ?
W h a t A c tio n N e e d s t o B e T a k e n :
In s p e c te d By:
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4.3.7.2
INFORMATION TO BE SUPPLIED
BY THE PROCESSING COMPANY
M onitoring Procedures
Type o f O p e ra tio n :_______________________________________________
W e w ill im p le m e n t th e fo llo w in g m o n ito rin g p ro c e d u re s to ensure th a t o n ly

a p p ro v e d a n d u n c o n ta m in a te d in g re d ie n ts a re used in th e pro ce ssin g o f tu n a
p ro d u cts.
List The Procedures That Will Be Used:
C om pany N am e :
C o m p a n y O ffic ia l:
D a te :
-1 0 1 -
4 .4 IC E
O n ly ic e w h ic h is m a d e fr o m c le a n a n d s a fe w a te r is p e r m itte d t o b e u s e d in
th e p ro c e s s in g o f tu n a .
O n ly p r o p e r ly c r u s h e d ic e is t o b e u s e d in th e s lu s h in g a n d ic in g o f tu n a . Ic e
is t o b e p r o p e r ly s to re d in c le a n a n d s a fe c o n ta in e rs .
4 .4 .2 In g re d ie n ts :
W h e re th e r e is b lo c k ic e b e in g u s e d , a ll s a w d u s t a n d o th e r d e b ris m u s t b e
re m o v e d b y w a s h in g w ith a p p r o v e d w a te r u n d e r p re s s u re . Ic e , a t tim e o f u s e ,
m u s t h a v e a c o lifo rm b a c te r ia M P N c o u n t o f n o m o r e th a n 2 p e r 1 0 0 m illilitre s
a n d b e a p p r o v e d b y th e c o m p e t e n t a u th o r itie s h a v in g ju ris d ic tio n .
4 .4 .3 D e fe c t D e fin itio n s :
N o ic e w h ic h is c o n ta m in a te d is t o b e u s e d in th e p r o d u c tio n o f tu n a .
N o ic e w h ic h is tr a n s p o r te d in u n c le a n tru c k s o r c o n ta in e r s is p e r m itte d t o b e
used.
D irty o r u s e d ic e is n o t p e r m itte d t o b e u s e d in th e p ro c e s s in g o f tu n a .
No ic e is p e r m itte d to be tr a n s p o r te d in open tru c k s , This c a n cause

c o n ta m in a tio n t o th e ic e a n d in tu rn w ill c a u s e c o n ta m in a tio n t o th e tu n a
p ro d u c ts .
4 .4 .4 M o n ito rin g
T h e p ro c e s s in g c o m p a n y w ill d e s c r ib e h o w it e n s u re s t h a t th e ic e th e y u s e w ill
b e o n ly ic e th a t h a s b e e n a p p r o v e d a n d u n c o n ta m in a te d . T h e p ro c e s s o r w ill
d e s c r ib e h o w it e n s u re s t h a t th e ic e is s to re d in p r o p e r in s u la te d c o n ta in e r s o r
in a p ro p e r c le a n a n d s a fe b e h o u s e . W h e re ic e is b e in g tr u c k e d t o th e p la n t
fro m o u ts id e s o u rc e , th e p ro c e s s o r m u s t d e s c r ib e h o w it e n s u re s t h a t th e ic e
th e y a r e r e c e iv in g is fr e e a n d s a fe fr o m a n y c o n ta m in a tio n . This in fo r m a tio n
in re g a rd s t o ic e m ust b e re c o rd e d and p re s e n te d to th e c o m p e te n t
a u th o r itie s o n re q u e s t.
4 .5 C L E A N IN G AGENTS, SANITISERS, LUBRICANTS
4 .5 .1 R e q u ire m e n ts
O n ly c le a n in g a g e n ts , s a n itis e rs , lu b r ic a n ts , p e s tic id e s th a t have been

a p p r o v e d b y th e c o m p e te n t a u th o r itie s a r e p e r m itte d t o b e u s e d in th e tu n a
p ro c e s s in g o p e ra tio n s .
T h e p ro c e s s in g c o m p a n y is re s p o n s ib le t o e n s u re t h a t th e c o m p o u n d s u s e d
m e e t a ll re q u ire m e n ts .
-1 0 2 -
4 .5 .2 S p e c ific a tio n s
T h e p ro c e s s in g c o m p a n y m u s t m a in ta in a list o f a ll c le a n in g a g e n ts , s a n itis e rs ,
lu b r ic a n ts , p e s tic id e s and any o th e r c h e m ic a ls th a t a re used in th e
m a in te n a n c e o f e q u ip m e n t a n d p la n t fa c ilitie s , a n d p r o d u c e p r o o f o f th e
a p p r o v a l o f th o s e c h e m ic a ls . T h e list m u s t s h o w w h e re e a c h c h e m ic a l is t o b e
u s e d in th e p la n t, w h e n it is t o b e u s e d , a n d a n y s p e c ia l m a n u fa c tu r in g
in s tru c tio n s r e g a r d in g o f h o w it t o b e u s e d .
4 .5 .3 M o n ito rin g P ro c e d u re s
T h e p r o c e s s o r w ill s h o w w h a t p r o c e d u r e s th e y w ill im p le m e n t t o e n s u re t h a t
o n ly a p p ro v e d c h e m ic a ls a re used in th e p ro c e s s fo r th e p r o d u c tio n
e q u ip m e n t w h ic h is u s e d in th e tu n a o p e r a tio n .
4 .5 .4 C o rre c tiv e A c tio n
T h e c o m p a n y w ill id e n tify w h o is re s p o n s ib le fo r ta k in g th e c o r r e c tiv e a c tio n

and lis t w h a t a c tio n h a s b e e n ta k e n . T h e fo r m m u s t s h o w th e fo llo w in g
in fo r m a tio n :
■ A d e s c r ip tio n o f th e n o n - c o m p lia n c e ite m

■ T h e lo t # o r id e n tific a tio n o f in fo r m a tio n
■ T h e d a t e th e n o n - c o m p lia n c e ite m w a s id e n tifie d
■ W h a t m e th o d o f c o r r e c tiv e a c tio n w a s ta k e n
■ T h e o u tc o m e
4 .5 .5 F o rm s fo r D a ta C o lle c tio n a n d R e p o rtin g
T h e p ro c e s s o r is r e q u ire d t o p r o v id e s a m p le s o f th e ty p e o f fo rm s it in te n d e d
t o u s e in re c o rd in g th e re s u lts o f th e in c o m in g c h e m ic a ls . A c o p y o f t h e ty p e
o f fo r m w h ic h s h o u ld b e u s e d is g iv e n in 4 .5 .5 .1 .
-1 0 3 -
4 .5 .5 .1
IN C O M IN G C H E M IC A L REPORT
D a te :
T y p e o f C h e m ic a l:
S u p p lie r:
W h a t is T h e C h e m ic a l U se d F o r in T he P ro c e s s in g A re a :
B ra n d N a m e :
M a n u fa c tu re r:
Yes No
H a s T h e C h e m ic a l B e in g A p p ro v e d ?
A re T he C o n ta in e rs S a fe ?
A re T h e C h e m ic a ls P ro te c te d
F ro m C o n ta m in a tio n ?
D o T he C h e m ic a ls M e e t T he C o m p a n y
S p e c ific a tio n s A n d R e q u ire m e n ts ?
If T h e re is A P ro b le m T hen List T he P ro b le m A n d The A c tio n T h a t W ill B e T a k e n to E lim in a te

T h e P ro b le m :
This in s p e c tio n r e p o r t is to b e c o m p le te d fo r e a c h c h e m ic a l w h ic h is to b e u s e d in th e
p ro c e s s in g p la n t. This fo rm w h e n c o m p le te d is to b e s ig n e d a n d k e p t o n file f o r fu tu re
re fe re n c e .
In s p e c te d b y : ________________________________________________________
- 104-
4 .6 PLANT C O N S TR U C TIO N /P R O D UCTIO N FACILITIES/PLANT EQUIPMENT
T h e re q u ire m e n ts th a t a p ro c e s s in g p la n t m u s t m e e t to b e a b le t o p ro c e s s fre s h /fro z e n

tu n a p r o d u c ts a r e a s lis te d b e lo w :
4 .6 .1 B u ild in g
The b u ild in g m ust be p r o p e r ly c o n s tr u c te d in a c c o rd a n c e w ith th e

r e q u ir e m e n ts la id d o w n in th e G M P fo r p ro c e s s in g p la n ts .
4 .6 .2 F lo o rs
F lo o rs a r e t o b e p r o p e r ly c o n s tr u c te d o f a d u r a b le s u r fa c e m a te r ia l w h ic h is
p r o p e r ly s lo p e d s o a s t o e n s u re t h a t th e p r o p e r d r a in a g e o c c u r s ,
T h e re a r e to b e n o c ra c k s o r c re v ic e s w h e r e b y th e y b e c o m e la r g e e n o u g h t o
h a v e im p r o p e r c le a n in g w h ic h w ill c a u s e th e b u ild u p o f b a c te r ia .
4 .6 .3 D ra in s
A ll d ra in s a r e t o b e p ro p e rly c o n s tr u c te d . T h e y a r e t o b e s m o o th a n d p r o p e r ly
s lo p e d t o e n s u re p r o p e r r e m o v a l o f w a s te fr o m th e p ro c e s s in g a r e a .
A ll d r a in s w h ic h a r e c o n n e c te d t o a s e w e r lin e a r e t o h a v e a p r o p e r c h e c k
b a c k w a te r v a lv e in s ta lle d t o p r e v e n t a b a c k flo w .
D ra in s w h ic h a r e e x p o s e d t o t h e o u ts id e m u s t b e e q u ip p e d w ith a m e ta l fla p
o r c o v e r in g t o p r e v e n t e n tr a n c e t o ro d e n ts a n d o r a n im a ls .
D ra in s a r e t o b e c o n s tr u c te d d e e p e n o u g h s o a s t o p r e v e n t a n o v e r flo w o n to
th e p r o d u c tio n flo o r w h ic h c a n c a u s e b a c te r ia l p ro b le m s .
4 .6 .4 W a lls
T h e s u rfa c e o f w a lls in a ll p r o d u c tio n a r e a s m u s t b e c o n s tr u c te d o f a s m o o th

s u r fa c e , w ith w a te r p r o o f m a te r ia l t o p r e v e n t a b u ild u p o f b a c te r ia .
W a lls s h o u ld b e o f a lig h t c o lo u r s o a s t o b e a b le t o d e t e c t d irt. L ig h t c o lo u r

a ls o g iv e s th e e s ta b lis h m e n t a b r ig h t a n d s a n ita ry a p p e a r a n c e .
W a lls w h ic h a r e c o n s tru c te d o f s h e e tin g m a te ria l, w h e re it m e e ts th e flo o r th e r e

m u s t b e a p ro p e r w a te r tig h t c u r b in s ta lle d to p re v e n t a n y b u ild u p o f b a c te r ia .
A ls o w a lls c o n s tr u c te d w ith s h e e tin g , m u s t h a v e th e jo in ts m a d e w a te r t ig h t b y
th e u s e o f s u ita b le jo in tin g m a te r ia l t o p r o te c t th e b u ild o f b a c te r ia .
4 .6 .5 C e ilin g s
A ll c e ilin g s a r e t o b e c o n s tr u c te d o f m a te r ia ls fr e e fr o m c ra c k s , c r e v ic e s a n d
o p e n jo in ts .
4 .6 .6 O v e rh e a d L ig h tin g
-1 0 5 -
A ll o v e rh e a d lig h tin g m u s t b e p la c e d u p in to t h e c e ilin g t o p r e v e n t a n y b u ild
up o f dust an d d e b ris . A ll b u lb s a n d lig h tin g m ust b e c o n s tr u c te d of
s h a tte r p r o o f m a te r ia l t o p r e v e n t c o n ta m in a tio n o f fo r e ig n m a te r ia l in to th e
tu n a .
4 .6 .7 O v e rh e a d P ip e s
T h e re a r e t o b e n o o v e r h e a d p ip e s in a n y a r e a o f th e p r o d u c tio n fo r th e
p ro c e s s in g o f fis h .
4 .6 .8 T o ile t F a c ilitie s
A s t o t h e r e g u la tio n s fo r th e n u m b e r o f to ile t fa c ilitie s t o a c c o m m o d a t e th e

n u m b e r o f e m p lo y e e s , th is is in th e G M P R e q u ire m e n ts fo r th e p ro c e s s in g p la n t
re g u la tio n s .
A ll t o ile t ro o m s s h o u ld b e c o n s tr u c te d o f a s m o o th s u r fa c e , w a s h a b le , lig h t-
c o lo u r e d a n d th e flo o rs m u s t b e c o n s tr u c te d o f a p p r o v e d m a te ria ls . T h e re
s h o u ld b e w h e re v e r p o s s ib le a flo o r d r a in in t h e fa c ilitie s .
A ll d o o rs t o th e w a s h ro o m s s h o u ld b e s e lf-c lo s in g .
A ll to ile t fa c ilitie s m u s t b e p r o p e r ly v e n te d t o th e o u ts id e a ir.
4 .6 .9 W a te r S u p p ly
A n a d e q u a te s u p p ly o f s a fe , s a n ita ry w a te r t h a t h a s a c o lifo r m b a c te r ia c o u n t
o f le s s th a n tw o p e r h u n d r e d m illilitre .
OR
A w a te r s u p p ly w h ic h h a s b e e n a p p r o v e d b y th e c o m p e te n t a u th o r itie s h a v in g
ju r is d ic tio n .
4 .6 .1 0 F lo o r T anks
A ll flo o rs ta n k s fo r th e c o o lin g and h o ld in g o f tu n a m ust b e p r o p e r ly

c o n s tr u c te d o f a n o n -c o rro d ib le m a te ria l. T h e c o n s tr u c tio n o f th e s e ta n k s s h a ll
be s o c o n s tr u c te d th a t th e s u rfa c e s a r e s m o o th , fr e e fr o m c ra c k s a n d
c r e v ic e s , a n d c a n b e p r o p e r ly d r a in e d . A ll flo o r ta n k t o p s e c tio n m u s t b e a t
le a s t 3 0 c m u p fr o m th e flo o r s u rfa c e .
4 .6 .1 1 E q u ip m e n t
T h e e q u ip m e n t u s e d fo r th e p ro c e s s in g o f tu n a m ust b e m a d e o f non-
c o r r o d ib le m a te ria l s u c h a s s ta in le s s s te e l, s a lt w a te r re s is ta n t a lu m in iu m a llo y s ,
fib re g la s s r e in fo r c e d , a n d o r p la s tic w h ic h is o f a p p r o v e d m a te ria ls . Any o f
th e s e m a te r ia ls m u s t b e m a d e o f a s m o o th s u r fa c e , fr e e fr o m c r a c k s a n d
c r e v ic e s .
4 .6 .1 2 F re e z in g E q u ip m e n t
A ll fre e z in g e q u ip m e n t m u s t b e a b le t o fr e e z e th e tu n a t o a c o r e te m p e r a tu r e
o f -6 0 °C a s q u ic k ly a s p o s s ib le . C o ld s to r a g e fa c ilitie s m u s t b e a b le to
-1 0 6 -
m a in ta in a n a ir te m p e r a tu r e o f -5 0 ° C o r b e lo w . B o th th e b la s t fr e e z e r a n d th e
c o ld s to r a g e m u s t h a v e a c o n tin u o u s te m p e r a tu r e r e c o r d e r t o m o n ito r th e
c h a n g e in th e te m p e r a tu r e s .
4 .6 .1 3 G u id e lin e s F o r C o rre c tiv e A c tio n :
T h e c o m p a n y m u s t id e n tify w h a t a c tio n w ill b e im p le m e n te d fo r d e fic ie n c ie s

o f a c r itic a l n a tu r e -- a c o n d itio n o r p r a c tic e w h ic h :
(A) re s u lts in th e p r o d u c tio n o f a p r o d u c t t h a t is u n w h o le s o m e ,

(B) p re s e n ts a th r e a t t o th e h e a lth a n d s a fe ty o f th e c o n s u m e r , o r
(C ) is n o t in a c c o r d a n c e w ith re g u la tio n s .
C R ITIC A L D E F IC IE N C IE S M U S T B E C O R R E C T E D IM M E D IA T E LY
D e fic ie n c ie s o f a s e rio u s n a tu r e -- a c o n d itio n o r p r a c t ic e w h ic h :
(A) p re v e n ts p r o p e r s a n ita tio n , a n d /o r

(B) m ay re s u lt in th e p r o d u c t io n o f a ta in te d , decom posed or
u n w h o le s o m e p r o d u c t, b u t w h ic h is n o t c o n s id e r e d t o b e a c r itic a l
d e fic ie n c y .
D e fic ie n c ie s o f a m a jo r /m in o r n a tu re : c o n d itio n s o r p r a c tic e s w h ic h :
(A) m a y in h ib it g e n e r a l s a n ita tio n , a n d /o r

(B) m a y re s u lt in th e d e te r io r a tio n o f p r o d u c t q u a lity , b u t w h ic h is n o t
c o n s id e r e d t o b e a s e rio u s o r c r itic a l d e fic ie n c y .
T h e c o m p a n y m u s t a ls o id e n tify w h o w ill ta k e th e a c tio n , w h a t s y s te m w ill b e

u s e d t o r e c o r d th e a c tio n a n d w h o w ill v e rify t h a t th e a c tio n w a s ta k e n .
No p la n t is p e r m itte d to o p e r a te w h e re th e r e a re one o r m o r e c r itic a l

d e fic ie n c ie s o r fiv e o r m o r e s e rio u s d e fic ie n c ie s a r e id e n tifie d .
4 .6 .1 4 P la n t R a tin g F o rm s
T h e c o m p a n y m u s t id e n tify th e fo rm s th e y in te n d t o u s e to r e c o r d th e ir
in s p e c tio n o f c o n s tr u c tio n /e q u ip m e n t. It is r e c o m m e n d e d t h a t th e p la n ts u s e
t h e d e ta ile d p la n t ra tin g r e p o r t fo r m w h ic h is p r o v id e d in A n n e x 7 in th is
s e c tio n .
T h e A c tio n R e p o rt: This r e p o r t fo r m (A n n e x 1 0 ) is u s e d t o s u m m a riz e th e re s u lts

o f a fu ll s c a le c o n s tr u c tio n /e q u ip m e n t in s p e c tio n a n d t o in d ic a te a d a t e fo r
th e c o r r e c tiv e a c tio n . This fo r m is a ls o used in th e w e e k ly
c o n s tr u c tio n /e q u ip m e n t in s p e c tio n d ir e c te d a t c r itic a l c o n tr o l p o in ts .
T h e D e ta ile d P la n t In s p e c tio n a n d R a tin g R e p o rt: This r e p o r t is u s e d in a ll fis h

p ro c e s s in g o p e r a tio n s t o r e c o r d th e in d iv id u a l c o n s tr u c tio n a n d e q u ip m e n t
ite m s . T his fo r m is u s e d in th e in s p e c tio n a n d ra tin g th e s e rio u s n e s s o f th e
d e fic ie n c ie s .
4 .6 .1 5 G u id e lin e s F o r C o rre c tiv e A c tio n :
-1 0 7 -
T h e c o m p a n y m u s t id e n tify e a c h in s ta n c e o f n o n - c o m p lia n c e a n d h a v e a
r e c o r d o f th e c o r r e c tiv e a c tio n t h a t to o k p la c e . T h e r e c o r d m u s t s h o w th e
fo llo w in g in fo r m a tio n :
■ A d e s c r ip tio n o f t h e n o n - c o m p lia n c e ite m

■ T h e id e n tific a tio n o f th e in fo r m a tio n
■ T h e d a t e th e n o n - c o m p lia n c e ite m w a s id e n tifie d
■ W h a t ty p e o f c o r r e c tiv e a c tio n w a s ta k e n
■ T h e fin a l o u tc o m e
4 .7 O PERATIO N A N D SANITATION
N o p e rs o n w h o is a c a r r ie r o f a n y d is e a s e o r h a s a n in fe c te d w o u n d o r o p e n
c u t is p e r m itte d t o b e in c o n t a c t w ith th e p ro c e s s in g o f tu n a p ro d u c ts .
N O TE: The p ro c e s s o r o f tu n a is re q u ir e d to e n s u re t h a t th e r e is n o
c o n ta m in a tio n p re s e n t in th e ir p la n t.
T h e o w n e r m u s t e n s u re t h a t th e p la n t m e e ts th e re q u ire m e n ts o f t h e o ffic ia l
a g e n c ie s h a v in g ju ris d ic tio n .
T h e c o m p a n y m u s t p r o v id e a s s u ra n c e t h a t th e e m p lo y e e s w h o c o m e in
c o n t a c t w ith th e tu n a p r o d u c ts d o n o t d ir e c tly o r in d ir e c tly c o n ta m in a te th e
f o o d w ith p a th o g e n ic m ic ro o rg a n is m s .
T h e c o m p a n y m u s t ta k e s te p s t o tr a in th e ir e m p lo y e e s in th e p r e c a u tio n s
n e c e s s a ry t o p r e v e n t c o n ta m in a tio n t o th e tu n a p r o d u c ts .
A ll c o m p a n ie s w h ic h a r e p ro c e s s in g tu n a p r o d u c ts m u s t h a v e a p o lic y in
p la c e w h e re b y th e e m p lo y e e s a r e re q u ir e d t o r e p o r t a n y m e d ic a l c o n d itio n s
w h ic h m a y p re s e n t a h e a lth a n d s a fe ty risk in th e p r o d u c tio n p ro c e s s . This
w o u ld a ls o in c lu d e b e in g a c a rrie r o f a d is e a s e lik e ly t o b e tr a n s m itte d th r o u g h
fo o d w h ile b e in g a f flic te d w ith in fe c te d w o u n d s , s k in in fe c tio n s o r d ia r r h e a .
A ll c o m p a n ie s s h o u ld have on a r e g u la r b a s is a t le a s t o n c e a w eek a
E m p lo y e e H y g ie n ic P ra c tic e re p o rt s h o w in g th e w o rk h a b its o f th e e m p lo y e e s .
A n n e x 8 in th is s e c tio n h a s a fo r m fo r th e E m p lo y e e H y g ie n ic P ra c tic e s
C h e c k lis t.
4 .7 .2 S a n ita tio n :
T h e c o m p a n y m u s t e n s u re t h a t th e p r o p e r s a n ita tio n o f th e p la n t is b e in g
c a r r ie d o u t d u rin g c le a n - u p a n d a ls o d u r in g th e r e g u la r p r o d u c tio n . T h e
a b s o lu te c le a n lin e s s o f p e rs o n n e l, e q u ip m e n t a n d p re m is e s is v e ry im p o r ta n t
a t a ll s ta g e s o f th e p r o d u c tio n o f tu n a .
T u n a m u s t b e p r o te c te d fro m c o n ta m in a tio n b y p a th o g e n ic m ic r o - o r g a n is m s
w h ic h c a n c a u s e d is e a s e in p e o p le .
Tuna m ust be p r o te c te d fr o m s p o ila g e o rg a n is m s w h ic h can cause
-1 0 8 -
d e te r io r a tio n in th e q u a lity o f th e tu n a .
G o o d s ta n d a r d s o f c le a n lin e s s b o th w ith th e e m p lo y e e s a n d t h e m e th o d o f
c le a n in g a n d p r o p e r s a n ita tio n w ill m in im iz e th e risk o f r o d e n t a n d in s e c t
in fe s ta tio n .
T h e m o s t im p o r ta n t o b je c tiv e o f c le a n in g is t o m in im iz e th e risk o f C R O S S -
C O N T A M IN A T IO N b e tw e e n tu n a . W a s te tu n a m a te r ia l le ft o n e q u ip m e n t,
g lo v e s a n d s u rfa c e s c a n a c t a s a p r im a r y s o u r c e o f c o n ta m in a tio n s in c e it
s e rv e s t o h a r b o u r la r g e p o p u la tio n s o f c o n ta m in a tin g m ic r o - o r g a n is m s .
4 .7 .3 P la n t R a tin g F o rm s :
W e r e c o m m e n d th e D e ta ile d P la n t H y g ie n e in s p e c tio n R e p o rt fo r m a n d th e
A c tio n R e p o rt fo r m fo r o p e r a tio n a n d s a n ita tio n re c o rd fo rm s w h ic h a r e
a tta c h e d in th is M a n u a l a s A n n e x 9 a n d 1 0 re s p e c tiv e ly , a s a g u id e t o
d e te r m in e c r itic a l p o in ts in o p e r a tio n a n d s a n ita tio n .
4 .7 .4 C o rre c tiv e A c tio n :
T h e c o m p a n y fo r e a c h c o r r e c tiv e a c tio n t h a t ta k e s p la c e fo r e a c h n o n -
c o m p lia n c e m u s t r e c o r d th e fo llo w in g in fo r m a tio n :
■ A d e s c r ip tio n o f th e n o n - c o m p lia n c e ite m

■ T h e a r e a o f th e n o n - c o m p lia n c e
■ T h e d a t e th e n o n - c o m p lia n c e w a s id e n tifie d
■ W h a t m e th o d o f c o r r e c tiv e a c tio n w a s ta k e n
■ W h a t w a s t h e fin a l o u tc o m e
4 .8 PROCESS C O N T R O L
T u n a is t o b e p ro p e rly w a s h e d d u rin g a n d a fte r p ro c e s s in g . It is v e ry im p o r ta n t

th a t a ll o ld b lo o d a r o u n d th e g ills a r e r e m o v e d a n d w a s h e d p r o p e r ly a n d th e
b e lly w a ll is p r o p e r ly w a s h e d d u r in g th e p ro c e s s in g p ro c e s s b e fo r e p a c k in g .
A ls o b e fo r e p a c k in g th e o u te r sk in m u s t a ls o b e p r o p e r ly w a s h e d .
D u rin g t h e p r o d u c tio n p ro c e s s th e te m p e r a tu r e o f th e fis h m u s t b e p r o p e r ly

c o n tr o lle d .
D u rin g th e p r o d u c tio n o f lo in s th e a r e a fo r p ro c e s s in g m ust b e p r o p e r ly

c o n tr o lle d s o a s t o e n s u re n o c o n ta m in a tio n w ill o c c u r w ith th e tu n a lo in s . T h e
a re a m u s t b e k e p t c le a n a t a ll tim e s t o p r e v e n t c r o s s - c o n ta m in a tio n b y
im p r o p e r c le a n in g d u r in g p r o d u c tio n .
D u rin g th e p r o d u c tio n o f fro z e n tu n a p r o d u c ts th e p r o p e r c o n tr o ls a r e t o b e in

p la c e t o e n s u re t h a t th e tu n a is fro z e n a s q u ic k ly a s p o s s ib le .
D u rin g th e re m o v a l o f th e skin a n d th e trim m in g o f t h e tu n a lo in s a fte r fre e z in g ,
-1 0 9 -
th e a m o u n t o f tim e th a t th e fro z e n p r o d u c t in o u t o f th e c o ld s to r a g e m u s t b e
c o n tr o lle d t o e n s u re th e m in im u m ris e in te m p e r a tu r e .
4 .8 .2 D e fe c ts a n d D e fic ie n c ie s :
T h e im p r o p e r h a n d lin g o r d r a g g in g o f tu n a is c o n s id e r e d a d e f e c t c o n tr o l
d e fic ie n c y .
The d a m a g e to th e o u te r s u r fa c e o f th e sk in a n d o u te r m e a t b y p o o r
p r o c e s s in g and h a n d lin g p ro c e d u re s is c o n s id e r e d a d e fe c t c o n tr o l
d e fic ie n c y .
4 .8 .3 In s p e c tio n R e q u ire m e n ts :
O n a c o n tin u o u s b a s ic th e r e is re q u ir e d d u r in g th e p a c k in g o f th e fre s h tu n a
t o m o n ito r th e te m p e ra tu re s o f th e fis h . This is d o n e v e ry e a s ily b y p la c in g th e
te m p e r a tu r e p r o b e in th e c u t w h ic h h a s b e e n a lr e a d y m a d e fo r b le e d in g
b e h in d th e p e c to r a l fin le t.
4 .8 .4 C o rre c tiv e A c tio n :
T h e c o m p a n y w ill id e n tify th e p e rs o n w h o is re s p o n s ib le fo r ta k in g th e c o r r e c tiv e

a c tio n , e n s u rin g t h a t th e c o r r e c tiv e a c tio n w a s c a r r ie d o u t. The c o m p a n y
m u s t p r o v id e a c o p y o f th e fo rm s th e y in te n d t o u s e w h ic h m u s t c o n ta in th e
fo llo w in g in fo r m a tio n .
■ A d e s c r ip tio n o f th e n o n - c o m p lia n c e ite m s

■ T h e s e c tio n o f n o n - c o m p lia n c e
■ T h e d a t e t h a t th e n o n - c o m p lia n c e ite m w a s id e n tifie d
■ W h a t ty p e o f c o r r e c tiv e a c tio n w a s n e e d e d
■ W h a t w a s th e fin a l o u tc o m e
■ T h e s ig n a tu r e o f th e p e rs o n re s p o n s ib le fo r c a r r y in g o u t th e c o r r e c tiv e
a c tio n .
4 .9 FRESH/FROZEN STORAGE FACILITIES
4 .9 .1 F re sh S to ra g e F a c ility
4 .9 .1 .1 R e q u ire m e n ts :
T h e fo llo w in g a r e th e re q u ire m e n ts fo r th e p ro p e r s to ra g e o f fre s h tu n a :
(A) A ll tu n a a r e to b e s to re d w h e n in th e p ro c e s s in g p la n t a w a itin g
p ro c e s s in g in e ith e r in s u la te d c o n ta in e r s o r in s lu s h b in s .
(B) E ith e r th e c o n ta in e rs o r th e ta n k s a r e t o b e p r o p e r ly c o n s tr u c te d
o f n o n - c o r r o d ib le m a te r ia l. T h e s u r fa c e is t o b e s m o o th a n d
fr e e fr o m c r a c k s a n d c r e v ic e s .
(C ) T h e ic e fo r ic in g th e tu n a m u s t b e m a d e fr o m c le a n a n d s a fe
w a te r.
(D ) T h e w a te r u s e d in th e c o o lin g p ro c e s s m u s t b e e ith e r c le a n a n d
s a fe s a lt w a te r o r c le a n a n d s a fe fre s h w a te r w h ic h is c o n v e r te d
t o th e s a m e s tre n g th a s s a lt w a te r.
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(E) T h e c o r e te m p e r a tu r e o f th e fre s h tu n a m u s t b e m a in ta in e d a t
0 °C .
4 .9 .1 .2 In s p e c tio n R e q u ire m e n ts :
T h e p la n t is r e q u ir e d t o in s p e c t th e tu n a b e fo r e p a c k in g fo r s h ip p in g
t o e n s u re t h a t th e te m p e r a tu r e is m a in ta in e d a t 0 ° C .
4 .9 .1 .3 C o rre c tiv e A c tio n :
T h e p r o c e s s in g c o m p a n y m u s t h a v e in p la c e a c o r r e c tiv e a c tio n s o
a s t o p re v e n t a n y in c re a s e in th e fre s h tu n a d u r in g p ro c e s s in g b e fo r e
s h ip p in g . T h e c o r r e c tiv e a c tio n fo r m s h o u ld c o n ta in th e fo llo w in g
in fo r m a tio n :
■ A d e s c r ip tio n o f th e p r o b le m w ith te m p e r a tu r e
■ T h e d a t e t h a t th e p r o b le m w a s d e t e c t e d
■ T h e d a t e t h a t th e c o r r e c tiv e a c tio n w a s ta k e n a n d w h a t w a s
d o n e t o c o r r e c t th e p r o b le m .
■ T h e s ig n a tu re o f th e p e rs o n re s p o n s ib le fo r th e c o r r e c tiv e a c tio n
b e in g ta k e n .
-1 1 1 -
4.9.1.4
FRESH TUNA TEMPERATURE

RECO RDING LO G
DATE TIME STORED IN ICE TEMPERATURE
C om pany N am e :
D a te :
C o m p a n y O ffic ia l :
-1 1 2 -
4 .9 .2 F ro z e n S to ra g e F a c ility
4 .9 .2 .1 R e q u ire m e n ts :
T h e fo llo w in g a r e t h e r e q u ir e m e n ts fo r th e h a n d lin g o f fro z e n tu n a :
(A) T h e c o r e te m p e r a tu r e o f th e tu n a m u s t b e lo w e r e d t o - 6 0 ° C a s
q u ic k ly a s p o s s ib le .
(B) T h e c o ld s to r a g e te m p e r a tu r e is t o b e m a in ta in e d a t - 5 0 ° C o r
lo w e r a t a ll tim e s ,
(C ) W h e n th e fro z e n tu n a is b e in g r e m o v e d fr o m e ith e r t h e b la s t o r
th e c o ld s to r a g e it m u s t b e p r o te c te d t o m in im iz e a ris e in th e
te m p e r a tu r e .
4 .9 .2 .2 In s p e c tio n R e q u ire m e n ts :
The p ro c e s s o r is r e q u ir e d to have a c o n tin u o u s te m p e r a tu r e

r e c o r d in g d e v ic e in s ta lle d in a ll fre e z e r ro o m s s o a s t o e n s u re t h a t if
th e r e is a p ro b le m w ith th e te m p e ra tu re s it is r e c o r d e d a n d c o r r e c tiv e
a c tio n c a n b e ta k e n .
4 .9 .2 .3 C o rre c tiv e A c tio n :
T h e c o m p a n y m u s t s h o w w h a t c o r r e c tiv e a c tio n is t o b e ta k e n . T h e y
m ust have a p e rs o n w ho is re s p o n s ib le fo r e n s u rin g t h a t th e
c o r r e c tiv e a c tio n is c a rrie d o u t a n d th e y a r e re q u ir e d t o h a v e a fo r m
c o m p le te d w ith th e fo llo w in g in fo r m a tio n :
■ A d e s c r ip tio n o f th e p r o b le m w ith th e c o ld s to r a g e .
■ T h e d a t e t h e p r o b le m h a p p e n e d .
■ T h e d a te th e c o r r e c tiv e a c tio n w a s ta k e n a n d a d e s c r ip tio n o f
w h a t w a s d o n e t o c o r r e c t th e p r o b le m .
■ T h e s ig n a tu r e o f th e p e rs o n re s p o n s ib le .
-1 1 3 -
4.9.2.4
FROZEN TUNA
COLD STORAGE LOG
DATE TIME BLASTFREEZER COLD STORAGE TEMPERATURE
N o o f Fish Tem p.
C om p any N am e :
D a te :
COMPANY OFFICIAL :
-1 1 4 -
4 .1 0 P A C K A G IN G MATERIAL
4 .1 0 .1 R e q u ire m e n ts
N o p e rs o n s h a ll e x p o r t a n y p r o d u c t u n le s s it is p a c k e d p r o p e r ly in a c le a n s a fe
c a r to n w h ic h is fr e e fr o m a n y c o n ta m in a tio n .
A ll c a rto n s fo r th e s h ip p in g o f e ith e r fre s h /fro z e n tu n a m u s t b e n e w , c le a n , a n d

s o u n d . W h e n p a c k in g fro z e n tu n a lo in s e a c h lo in m u s t b e p la c e d in to a p r o p e r
p la s tic s le e v e , This s le e v e is th e n s e a le d s o a s t o p r e v e n t c o n ta m in a tio n a n d
d e h y d r a tio n t o th e p r o d u c t.
A ll c a rto n s fo r th e s h ip p in g o f fre s h w h o le tu n a m u s t b e c o n s tr u c te d a s fo llo w s :
- C a r to n m u s t b e c o n s tr u c te d fr o m a s tro n g m a te r ia l. This m a te r ia l m u s t b e
c o n s tr u c te d in s u c h a m a n n e r t h a t d u rin g tr a n s p o r ta tio n th e y w ill n o t c ru s h
w h e n s ta c k e d o n t o p o f e a c h o th e r.
- C a rto n s m u s t b e w a te r p r o o f to p r e v e n t le a k a g e .
- C a rto n s m u s t b e c o n s tr u c te d o f a m a te r ia l t h a t w ill m in im is e te m p e r a tu r e
flu c tu a tio n s t o its c o n te n ts .
4 .1 0 .2 S p e c ific a tio n s
T h e c o m p a n y is o n ly p e r m itte d t o u s e p a c k a g in g m a te r ia l t h a t h a s b e e n
a p p r o v e d b y th e c o m p e t e n t a u th o r itie s h a v in g ju r is d ic tio n . T h e p a c k a g in g
m a te r ia ls m u s t b e o f fo o d g r a d e . This m e a n s t h a t th e r e is n o c h a n c e fo r
c o n ta m in a tio n to th e tu n a p ro d u c ts fro m th e m a te ria ls u s e d in th e c o n s tr u c tio n
o f t h e p a c k a g in g m a te r ia l. T h e c o m p a n y is re s p o n s ib le fo r p r o v in g t h a t th e
p a c k a g in g m a te ria l u s e d m e e ts th o s e re q u ire m e n ts . T h e c o m p a n y m u s t h a v e
fro m th e m a n u fa c tu r e r a d o c u m e n t s ta tin g th a t th e p a c k a g in g m a te r ia l m e e ts
th e re q u ire m e n ts a n d is a c c e p t a b le fo r th e p a c k a g in g o f tu n a p r o d u c ts .
4 .1 0 .3 D e fe c t D e fin itio n s
A ll p a c k a g in g m a te r ia l t h a t is n o t a p p r o v e d fo r fo o d c o n t a c t , n o t n e w , n o t
c le a n o r s o u n d , o r o th e rw is e fa ils t o m e e t th e s p e c ifie d r e q u ir e m e n ts o f th is
s e c tio n s h a ll b e c o n s id e r e d d e fe c tiv e ,
4 .1 0 .4 D e fe c t T o le ra n c e s
T h e d e f e c t to le r a n c e fo r p a c k a g in g m a te r ia l is n il.
4 .1 0 .5 M o n ito rin g P ro c e d u re s
T h e c o m p a n y w ill d e s c rib e th e m o n ito r in g p r o c e d u r e s u s e d t o e n s u re t h a t o n ly

a p p r o v e d , c le a n , s o u n d a n d u n d a m a g e d p a c k a g in g m a te r ia l a r e u s e d fo r
tu n a p r o d u c ts .
-1 1 5 -
4 .1 0 .6 C o rre c tiv e A c tio n
T h e c o m p a n y w ill id e n tify a p e rs o n re s p o n s ib le fo r ta k in g th e c o r r e c tiv e a c tio n

a n d e n s u re t h a t th e c o r r e c tiv e a c tio n is c a r r ie d o u t. T h e c o m p a n y m u s t a ls o
s u p p ly a fo rm th a t w ill b e u s e d t o r e c o r d th e c o r r e c tiv e a c tio n t h a t to o k p la c e ,
it m u s t s h o w th e fo llo w in g in fo r m a tio n :
■ A d e s c r ip tio n o f th e n o n - c o m p lia n c e m a te r ia l
■ T h e a m o u n t o f m a te r ia l in v o lv e d
■ T h e d a t e t h a t th e n o n - c o m p lia n c e ite m w a s id e n tifie d
■ The in fo r m a tio n s h o w in g w h a t w as d o n e w ith th e n o n - c o m p lia n c e
m a te r ia l.
■ T h e fin a l o u tc o m e
■ T h e s ig n a tu r e o f th e p e rs o n re s p o n s ib le fo r e n s u rin g t h a t th e c o r r e c tiv e
a c t io n w a s ta k e n . This in fo rm a tio n is to b e m a d e a v a ila b le t o a n in s p e c to r
u p o n re q u e s t.
-1 1 6 -
4 .1 0 .7
P A C K A G IN G M ATER IAL IN S P E C TIO N REPORT
D a te :
P a c k a g in g M a te r ia l T y p e :
S u p p lie r :
YES NO
A re t h e c o n ta in e r s o r p a c k a g in g m a te r ia l c le a n ?
A r e t h e c o n ta in e r s o r p a c k a g in g m a te r ia l n e w ?
A r e t h e c o n ta in e r s o r p a c k a g in g m a te r ia l
undam aged?
D o t h e c o n ta in e r s o r p a c k a g in g m e e t t h e
s p e c ific a tio n s ?
A c tio n :
C o m p a n y In s p e c to r
-1 1 7 -
4 .1 1 FINAL PR O D U C T
4 .1 1 .1 R e q u ire m e n ts
N o c o m p a n y s h a ll im p o rt, e x p o r t o r p ro c e s s fo r e x p o r t o r a t t e m p t t o im p o r t, o r
e x p o rt o r p ro c e s s a n y tu n a w h ic h is ta in te d , d e c o m p o s e d , o r u n w h o le s o m e o r
o th e rw is e fa ils t o m e e t th e r e q u ir e m e n ts o r re g u la tio n s w h ic h a r e la id d o w n b y
th e c o m p e t e n t a u th o r itie s h a v in g ju ris d ic tio n .
A ll tu n a p ro d u c ts p r o d u c e d b y th e p ro c e s s in g c o m p a n y m u s t b e fr e e fr o m a n y
c o n ta m in a tio n and m ust b e p ro c e s s e d in a c c o r d a n c e w ith th e G M P o r
R EG ULATIO NS is s u e d b y th e c o m p e t e n t a u th o r itie s h a v in g ju r is d ic tio n .
4 .1 1 .2 D e fe c t T o le ra n c e
S a m e a s m e n tio n e d a b o v e .
4 .1 1 .3 S a m p lin g P la n
B e fo re th e s h ip p in g o f th e p r o d u c t, th e p ro c e s s o r m u s t e n s u re t h a t a ll
re q u ire m e n ts fo r th e p ro c e s s in g o f fre s h a n d fro z e n tu n a p r o d u c ts h a v e b e e n
m e t. N o p r o d u c t w h ic h d o e s n o t m e e t th e fo llo w in g s ta n d a r d s a r e p e r m itte d
t o b e s h ip p e d .
T u n a m u s t b e a c c e p t a b le fo r h u m a n c o n s u m p tio n .
T h e p ro p e r c o r e te m p e r a tu r e s o f fre s h /fro z e n tu n a m u s t b e a c c o r d in g t o w h a t
is re q u ire d in th e G M P R e q u ire m e n ts a n d r e g u la tio n s is s u e d b y th e c o m p e te n t
a u th o ritie s .
F re s h tu n a , th e fis h m u s t b e p r o p e r ly ic e d , c o v e r e d a n d p r o p e r ly p a c k a g e d
a c c o r d in g t o th e re q u ire m e n ts in th is r e p o rt, th e r e g u la tio n s in fo r c e a n d G M P
p ro c e d u re s .
T h e c o m p a n y m u s t id e n tify w h a t a c tio n is to b e ta k e n to re m o v e u n a c c e p ta b le
fin a l p r o d u c t. T h e y m u s t s h o w w h o is re s p o n s ib le fo r ta k in g th e a c tio n a n d w h a t
s y s te m w ill b e u s e d t o r e c o r d th e a c tio n .
T h e c o m p a n y m u s t s u p p ly a n e x a m p le o f th e ty p e o f fo r m w h ic h it w ill u s e in
r e c o r d in g th e c o r r e c tiv e a c tio n . This fo r m m u s t c o n ta in th e fo llo w in g
in fo r m a tio n :
■ A d e s c r ip tio n o f th e u n a c c e p t a b le fin a l p r o d u c t
■ T h e q u a n tify o f th e P ro d u c t
■ T h e d a t e t h a t th e n o n - c o m p lia n c e w a s id e n tifie d
■ T h e d a t e it w a s c o r r e c te d
■ W h a t a c tio n w a s ta k e n t o c o r r e c t th e u n a c c e p t a b le p r o d u c t
■ W h e re is th e p r o d u c t n o w
■ T h e s ig n a tu re o f th e p e rs o n re s p o n s ib le fo r ta k in g th e c o r r e c tiv e a c tio n .
-1 1 8 -
4 .1 2 RECALL PROCEDURES
4 .1 2 .1 G e n e ra l R e q u ire m e n ts fo r F re sh a n d F ro z e n T u n a P ro d u c ts
E v e ry c a r to n a n d c a s e in w h ic h tu n a is p a c k e d a t a p ro c e s s in g p la n t s h a ll b e
le g ib ly m a r k e d o n o n e e n d in s u c h a m a n n e r t h a t th e fo llo w in g in fo r m a tio n is
s e e n p ro p e rly :
■ T h e n a m e o f th e fis h p ro c e s s o r
■ T h e d a y , m o n th , a n d y e a r
■ T h e ty p e o f p r o d u c t, e x a m p le : F re sh T u n a
This in fo r m a tio n m u s t b e v is ib le s o a s it c a n b e r e a d b y t h e a u th o ritie s .
4 .1 2 .2 S p e c ific a tio n s fo r th e D o c u m e n ta tio n o f S h ip m e n ts
A ll fis h p ro c e s s in g c o m p a n ie s m u s t h a v e in p la c e a r e c a ll p r o c e d u r e , t h a t if
th e r e is a p r o b le m d e te c te d a fte r th e p r o d u c t h a s b e e n s h ip p e d t o th e
d is tr ib u tio n s ite , it c a n b e r e m o v e d fr o m th e m a r k e t in a q u ic k a n d e ffe c tiv e
m a n n e r. This re q u ire s th e fis h p ro c e s s in g p la n t t o h a v e th e p r o p e r u p - to - d a te
p r o c e d u r e s fo r a ll s h ip m e n ts . T h e fo llo w in g in fo r m a tio n m u s t b e k e p t in th e
s h ip p in g r e c o r d d o c u m e n t:
■ T h e d a te o f th e s h ip m e n t
■ T h e d e s c rip tio n o f th e p r o d u c t
■ T h e to t n u m b e r
■ T h e to t s ize
■ T h e c o d e m a rk in g s
■ T h e s h ip p e r
■ T h e c a rrie r
■ T h e c o n s ig n e e
■ T h e d e s tin a tio n
4 .1 2 .3 M o n ito rin g P ro c e d u re s
T h e c o m p a n y w ill d e s c r ib e th e p r o c e d u r e s it u s e s t o e n s u re t h a t a ll s h ip m e n ts
a r e r e c o r d e d a n d m a y b e t r a c e d t o th e ir firs t s h ip p in g d e s tin a tio n :
Th e c o m p a n y w ill id e n tify th e p e rs o n re s p o n s ib le fo r ta k in g th e c o r r e c tiv e a c tio n

a n d w ill e n s u re t h a t th e c o r r e c tiv e a c tio n is c a r r ie d o u t. T h e c o m p a n y w ill
p r o v id e a fo r m t h a t w ill s h o w th e fo llo w in g in fo r m a tio n :
■ A d e s c r ip tio n o f th e n o n - c o m p lia n c e p r o d u c t
■ T h e lo t n u m b e r
■ T h e d a t e t h a t th e n o n - c o m p lia n c e w a s d e t e c t e d
■ T h e d a t e t h a t th e c o r r e c tiv e a c tio n w a s im p le m e n te d
■ W h a t c o r r e c tiv e a c tio n w a s ta k e n to r e c a ll th e p r o d u c t
■ W h a t w a s th e fin a l o u tc o m e
■ T h e s ig n a tu r e o f th e p e rs o n re s p o n s ib le fo r ta k in g th e c o r r e c tiv e a c tio n .
-1 1 9 -
4 .1 2 .5
SH IPM EN T
R EC O R D FO RM
D a te :
P r o d u c t D e s c r ip tio n :
L o t S iz e :
L o t# :
C odes:
S h ip p e r:
C a r r ie r :
C o n s ig n e e :
D e s tin a tio n :
If S h ip p e d b y A ir T h e W a y Bill N u m b e r :
E x p e c te d T im e o f A rriv a l:
C o m p a n y O ff ic ia l:
This in fo rm a tio n s h o u ld b e c o m p le te d w ith e a c h s h ip m e n t a n d k e p t o n file.
-1 2 0 -
4 .1 3 EMPLOYEE Q U ALIFIC ATIO N S
4 .1 3 .1 R e q u ire m e n ts :
T h e p la n t e m p lo y e e s a r e t o be p r o p e r ly tr a in e d in th e p r o p e r p e rs o n a l
h y g ie n ic p r a c tic e s w h ic h a f f e c t th e q u a lify o f tu n a . T h e s e h y g ie n ic p r a c tic e s
a r e a s fo llo w s :
E m p lo y e e h e a lth , e m p lo y e e a p p e a r a n c e , s m o k in g , s p ittin g , h a n d w a s h in g ,
h a n d d is in fe c tio n , p r o p e r u s e o f f o o t d ip s , h e a d g e a r , o u te r g a r m e n ts , a n d
th e p ro p e r p ro c e d u r e w h e n re tu rn in g t o w o rk s ta tio n a fte r c o m in g fr o m to ile t
a re a .
The com pany a g re e s to m eet th e re q u ir e m e n ts of th e GOOD

M A N U F A C T U R IN G PRACTICES fo r th e p ro c e s s in g p la n t a n d a s s u re t h a t th e
p e rs o n n e l w h ic h w o rk in tu n a p ro c e s s in g w ill b e tr a in e d in th e p e rs o n a l
h y g ie n ic p r a c tic e s .
-1 2 1 -
A nnex 6
POTENTIAL C R ITIC A L C O N T R O L POINTS

FO R FRESH/FROZEN TUNA PRODUCTS
ITEM HAZARD POTENTIAL C R ITIC AL

C O N T R O L POINTS
1) INPUT MATERIALS
F ish T a in t P rio r t o P ro c e s s in g
D e c o m p o s itio n
U n w h o le s o m e n e s s
N o n - c o m p lia n c e w ith R e g u la tio n s
O th e r In g re d ie n ts N o t fo o d g r a d e P rio r t o u s e
U n s u ita b le
N o n - c o m p lia n c e w ith R e g u la tio n s
U n c le a n M is a p p lic a tio n A p p lic a tio n A re a
P a c k in g M a te r ia l N o t a p p r o v e d fo r fo o d c o n t a c t P rio r t o U se
U s e d , U n c le a n , U n s o u n d P a c k in g A re a
Ic e N o t a p p r o v e d fo r fo o d P rio r t o U se
C le a n in g A g e n ts , N o t a p p r o v e d fo r u s e in fo o d p la n ts o r o n P rio r t o U se
S a n itis e rs , L u b ric a n ts fo o d c o n t a c t s u rfa c e s
M is a p p lic a tio n A p p lic a tio n A re a
2 ) P R O D U C T IO N C O N D IT IO N S
C o n s tr u c tin g N o n - c o m p lia n c e w ith R e g u la tio n s P rio r t o P ro c e s s in g

M a in te n a n c e o f
P ro d u c tio n F a c ilitie s
a n d P ro c e s s in g
E q u ip m e n t
O p e r a tio n a n d N o n - c o m p lia n c e w ith R e g u la tio n s P rio r to , d u rin g

S a n ita tio n P ro c e s s in g
P ro c e s s C o n tro ls N o n - C o m p lia n c e w ith R e g u la tio n s D u rin g P ro c e s s in g
S to ra g e N o n - c o m p lia n c e w ith R e g u la tio n s D u rin g tim e p r o d u c ts

a r e in s to r a g e
3 ) PR O D U C TS
R e q u ire d T a in t D u rin g p ro c e s s in g
C h a r a c te r is tic s D e c o m p o s itio n a) A t/a fte r la s t
U n w h o le s o m e n e s s p ro c e s s s te p
D e fe c ts a n d /o r n o n - c o m p lia n c e w ith p rio r t o p a c k in g
g r a d e d e s ig n a tio n s b) A fte r fre e z in g
- 122-
R e q u ire d M is la b e lin g D u rin g p ro c e s s in g ,
C h a r a c te r is tic s U n d e rw e ig h t a) A t/a fte r p a c k in g
b) A fte r fre e z in g
R e c a ll P ro c e d u re s In a b ility t o t r a c e p r o d u c ts t o th e P a c k in g a r e a fo r
c u s to m e r s t o w h o m th e y w e re s o ld p r o d u c t c o d in g
4 ) PERSO NNEL
H y g ie n e a n d H e a lth E m p lo y e e (s ) s u ffe rin g fr o m /c a r r y in g P rio r t o P ro c e s s in g

c o m m u n ic a b le d is e a s e . E m p lo y e e (s )
w ith in fe c te d w o u n d s o p e n le s io n s
Q u a lity R e s p o n s ib ility fo r q u a lity m a n a g e m e n t n o t P rio r t o P ro c e s s in g

M anagem ent c le a r ly id e n tifie d
-1 2 3 -
A nnex 7
DETAILED PLANT IN SPEC TIO N

A N D R ATIN G REPORT
(p a g e 1)
P LAN T N A M E O P E R . TYPE(S) DATE O F INSP. TYPE O F INSP.
C O N S T R U C T IO N A N D E Q U IP M E N T R EQ U IR E M E N TS
D EFIC IEN CY SCORE NA S D EFIC IEN CY DESCRIPTION/

C C O M M EN TS
O
Ite m /S u b -lte m M A/ s C R
l e R E DATES FOR C O R R EC TIO N
1 FLOORS - WET W O R KIN G AREA
a ) im p e rv io u s fin is h
b ) g o o d re p a ir
c ) p ro p e r s lo p e (1 :4 8 0 )
d ) p ro p e r flo o r/w a ll jo in t
2 FLOORS - DRY W O RKING AREA
a ) p ro p e rly c o n s tru c te d
b ) in g o o d re p a ir
3 DRAINS
a ) s u ffic ie n t c a p a c ity
b ) s m o o th a n d im p e rv io u s
c ) p ro p e rly tr a p p e d a n d c o v e re d
d ) ro d e n t p ro o f
e ) e q u ip p e d w ith c h e c k v a lv e
w h e re
n e c e s s a ry
4 WALLS - WET O R DRY AREAS
a ) s m o o th , c ra c k -fre e s u rfa c e
b ) lig h t-c o lo u re d
c ) w a te rp ro o f
d ) w a s h a b le w ith n o o b s tru c tio n

b e lo w 1 .5 m
e ) w in d o w sills s lo p e d in w a rd
-1 2 4 -
DETAILED PLANT INSPECTION
AND RATING REPORT
(page 2)
PLANT NAME OPER. TYPE(S) DATE OF INSP. TYPE OF INSP.
CONSTRUCTION AND EQUIPMENT REQUIREMENTS
DEFICIENCY NA S DEFICIENCY
SCORE C DESCRIPTION/
O COMMENTS
Item/Sub-ltem MA/ S C R
l e R E DATES FOR CORRECTION
5 CEILINGS
a) smooth, crack-free surface
b) light coloured
c) washable
d) acceptable height
e) free of ledges, pipes, etc.

over work surface
6 LIGHTING
a) acceptable light levels

(min. 20 ft candles)
b) protective covers provided if

necessary
c) designed to facilitate cleaning
7 VENTILATION
a) provides for odour, smoke,

steam removal
b) prevent condensation
8 WATER SUPPLY
a) safe sanitary water from

approved source
b) adequate volume and

pressure
9 HOT WATER SUPPLY
a) available in sufficient quantity
b) minimum of 43°C
-1 2 5 -
AND RATING REPORT
(page 3)
O COMMENTS
10 HANDWASHING FACILITIES
a) adequate no. of fixtures
b) equipped with hot and cold

running water
c) soap, towels, waste

receptacles provided
d) facilities visible from work

areas
11 HAND COVERING DIPS
a) facilities provided
b) conveniently located
12 TOILET FACILITIES
a) adequate no. of fixtures
b) adequately ventilated
c) properly constructed (floors,

walls, ceiling anteroom)
d) drain provided
e) toilet room doors of

approved type
13 OFFAL CONTAINERS
a) approved construction of
container and facilities
b) provided with fitted lids
-126-
AND RATING REPORT
(page 4)
O COMMENTS
14 BOXES. CARTS, BINS FOR HOLDING FISH PRIOR TO

PROCESSING
a) If wood, treated to prevent

moisture from entering wood
b) in good repair
c) provided for drainage
15 a) product contact surfaces of

approved material
b) joints smooth and watertight
16 TABLE CONSTRUCTION/DESIGN
a) constructed to facilitate
cleaning of table and area
beneath
b) stands for workers of approved

material
17 FRAMES AND LEGS
a) of approved material
b) properly maintained
18 PRODUCT CONVEYORS
a) equipped with water spray,

scraper, etc.
19 FISH FLUMES
b) properly constructed
-1 2 7 -
AND RATING REPORT
(page 5)
Item/Sub-ltem DEFICIENCY NA S DEFICIENCY

O COMMENTS
MA/ S C R
20 CUTTING BOARD, CRACKING BLOCKS AND MALLETS,

ROLLER DEVICES
b) In good repair, crack-free
c) roller devices equipped with

Spray washers
21 RECEPTACLES, TRAYS, TANKS VATS AND UTENSILS
b) surfaces smooth, crack-free,

In good repair
c) provided for drainage, where

required
22 WIRE MESH UTENSILS
a) not permitted
23 ENAMELS UTENSILS
a) not permitted
24 FREEZING FACILITIES - CONTACT FREEZERS
a) adequate
25 FREEZING FACILITIES - BLAST FREEZERS
a) adequate
26 FROZEN STORAGE
a) rooms maintained at proper

temperature
b) rooms equipped with

approved thermometer
-1 2 8 -
A nnex 8
EM PLOYEE
H Y G IE N IC PR AC TIC ES C H EC KLIST
P la n t D a te :
In s p e c to r :
R EQ U IR ED P R A C TIC E S N U CO M M ENTS
E m p lo y e e A p p e a r a n c e
S m o k in g
S p ittin g
H a n d w a s h in g /D ip p in g
U s in g F o o t D ip s
H eadgear
O u te r G a r m e n ts
H a n d C o v e r in g
T o ile t A re a s
S = S a tis fa c to r y
N = N e e d s Im p r o v e m e n t
U = U n s a tis fa c to r y
C o m m e n ts /A c tio n T a k e n
-1 2 9 -
A nnex 9
DETAILED PLANT H Y G IE N IC
C om pany N am e :
D a te :
OPERATION REQUIREMENTS
DEFICIENCY SCORE
DATE OF
CRI SER MAJ MIN CORRECTION
ITEM
A. N o know n c a rrie r
B. N o c o m m u n ic a b le d is e a s e o r
sore
C . N o o p e n w o u n d s o r sores
H a n d W ash F a cilitie s
A. P rope r w a s h in g o f h a n d s
B. P ro p e r d is in fe c tio n o f g lo v e s
W ashing o f Eq u ip m e n t
A. P roperly w a s h e d a n d c le a n
b e fo re a n d a fte r using
B. P rope rly s a n itiz e d
Ic e
A. M a d e o f w a te r fro m a p p ro v e d
s o u rc e fre e fro m fo re ig n
m a tte r, n o c o n ta m in a tio n
B. P rope rly s to re d in c o o lin g tanks
O ffa l R e m o v a l
A. R e m o v e d im m e d ia te ly
B. E q u ip m e n t k e p t c le a n
C . P rope r m e th o d o f d is p o s a l
U tensil C le a n in g
A. C le a n e d a n d s a n itiz e d d u rin g
p ro c e s s in g
-1 3 0 -
OPERATION REQUIREMENTS
DEFICIENCY SCORE
DATE OF
ITEM CRI SER MAJ MIN CORRECTION
B. C le a n e d a n d d is in fe c te d a fte r
w o rk
C . D rie d a n d s to re d in s a n ita ry
m anner
G e n e ra l c le a n in g a n d
m a in te n a n c e
A. F a c ilitie s a n d e q u ip m e n t in
g o o d re p a ir
B. F a c ilitie s a n d e q u ip m e n t k e p t
c le a n
C h ill Tanks
A. P roperly c le a n e d a n d s a n itiz e d
B. P rope r te m p e ra tu re o f ic e
C . P rope r p ro te c tio n a g a in s t a rise

in ro o m te m p e ra tu re
C o ld S torag e A re a
A. P rope r te m p e ra tu re d e v ic e to
re c o rd th e te m p e ra tu re o n a
c o n tin u o u s basis
B. Frozen Tuna p ro p e rly p ro te c te d

fro m rise in te m p e ra tu re
T oilet F a cilitie s
P rope rly c le a n e d a n d s a n itiz e d
O u te r P lant S u rroun ding s

C le a n a n d Tidy
If d u r in g in s p e c tio n it is fo u n d th a t th e r e a r e n o d e fe c ts fo r a n ite m , th e n y o u a r e to
re c o r d th a t it is O K in th e a r e a m a rk e d D a te fo r C o rre c tio n s .
-1 3 1 -
A n n e x 10
A C T IO N REPORT
P la n t N a m e :
T y p e o f O p e r a tio n :
ITEM AC TIO N
NO. DEFICIENCY BY
S ig n a tu re
D a te
-1 3 2 -
SECTION 5
GRADING OF
BIGEYE A N D YELLOWFIN TU N A
- 133-
5.1 INTRODUCTION
There is a need of establish the proper standards for the grading of tuna.
Tuna must be graded before it is shipped to the end user. By using the system which
has been adapted by the countries which process tuna, we will attem pt to set up a set
of guidelines for the proper quality grading standards for bigeye and yellow fin tuna.
There are separate standards for the colour of bigeye and yellowfin tuna. In regards
to the condition of both types of fish there is only one set of standards.
5.2 NOMENCLATURE
ABRASIONS Scratching of the skin
BLEACHING Whitening of the skin surface
DISTORTION Improper shape
GLOSSY The m eat is shining
INGRESO Entering
OPAQUE Cannot see through
STAINING Skin or flesh is discoloured
TRANSLUCENT Shining throughout
TRANSPARENT Very clear
5.3 A POINT SCORE SYSTEM FOR GRADING TUNA
5.3.1 Colour
The natural colour of tuna is affected by many factors. The most important one
being the freshness, fat content, and time of exposure to the air. Freshly cut
surface of tuna m eat are dark, and becom e bright red as the tissues take up
oxygen. It is important to remember this factor when grading, you must wait 30
minutes after the notches are cut.
To inspect colour, remove the tuna from the ice and cut off from the fifth and
sixth caudal finlet. Cut a notch about 3 to 4 cm in from this cut.
Remove the piece of meat, and wait 30 minutes before comparing with the
descriptions in Sections 5.4 and 5.5.
Inspection is done for colour to determine whether it is for sashimi, loins,

canning, and or other markets, depending on the buyer.
- 134-
5.3.2 Condition
Condition has two aspects: carcass and flesh condition. Carcass condition is
assessed in terms of dam age of the exterior dam age to the skin; for example
rips, cuts and tears. Flesh condition is done by assessing the m eat at the tail
cut to see if there is gaping, parasites and disease, and also along the exterior
surface of the carcass dam age which can be felt with the fingers. Bruising is
one example.
The table presented in Section 5.6 is for assessing and scoring carcass
condition. It is also important that the characteristics described in the table can
occur in various combinations, and therefore a judgement must be made. For
example, you can have a tuna which has a good fat content but is not very
fresh. This tuna may be considered the same as a tuna that is very fresh but
has a very little or no fat.
5.3.3 Grading
A flowchart for sizing and tuna grading at sea and on shore is given in Section
5.9.
5.4 COLOUR SCORES FOR BIGEYE TUNA
5.4.1 Very Good (Score 50)
i) Meat is transparent, glossy.

ii) Colours are bright.
iii) Large amounts of fat present, penetrating into the inner muscles layers.
5.4.2 Good (Score 40)
i) Meat is a little translucent, and less glossy.

ii) Colours are less bright.
iii) Large amounts of fat present, penetrating into the inner muscle layers,
note some carcasses are too fat,
5.4.3 Medium (Score 30)
i) Meat is translucent, and has lost its gloss.

ii) Colours are a little dull.
iii) Fat is present, but with little or no penetration to the inner muscles.
iv) Meat colour may appear a little brownish.
5.4.4 Poor (Score 20)
i) The m eat is almost opaque.

ii) The colour of the m eat is distinctively brownish, and dull.
iii) There is no visible fat in the outer layers, the m eat is the same colour
throughout.
-1 3 5 -
5.4.5 Very Poor (Score 10)
i) The m eat is opaque.

ii) The colour of the m eat is brown, whitish or grey.
iii) Little or no fat visible in the outer layers.
5.5 COLOUR SCORES FOR THEYELLOWFIN TUNA
i) Meat is transparent, glossy.

ii) Colours are bright.
iii) Fat is clearly visible.
i) Meat is a little translucent, and less glossy.

ii) Colours are less bright.
iii) Fat just visible in outer layers.
i) Meat is translucent, and has lost its gloss.

ii) Colours are a little dull, a little brownish.
iii) No fat visible in outer layers.
i) The m eat is almost opaque, no gloss.

ii) Colours distinctively brownish and dull.
i) The m eat is opaque.

ii) The colour is brown, whitish, or grey.
5.6 CONDITION SCORES FOR YELLOWFIN AND BIGEYE TUNA
i) No apparent defects/dam age (no rips, tears, cuts and abrasions).

ii) Scales intact.
iii) Fish looks as though it has just been lifted from the water, natural body
colours bright.
iv) Flesh a t notch very firm, springs back quickly on pressing lightly with
fingertips. No soft spots present on carcass surface.
i) Slight defects/dam age, there are a few minor rips, tears, cuts,
-1 3 6 -
abrasions.
ii) Some scales loss.
iii) Body colours are a little dull.
iv) Flesh at notch, springs back slowly on pressing lightly with fingertips. One
or two very small soft spots present on carcass surface.
i) Noticeable defects/dam age, a maximum of two rips, tears, cuts,

abrasions which could affect the m eat yield.
ii) Small patches of scales lost.
iii) Body colours dull/dark.
iv) Flesh at notch less firm, does not spring back fully on pressing lightly with
the finger tips several small spots present on carcass surface.
i) More than two rips, tears, cuts or abrasions which could affect meat
yield.
ii) Large patches of scales lost.
iii) Body colours dark.
iv) Bleaching, red staining very apparent.
v) Flesh at notch soft, does not spring back at all on pressing lightly with
fingertips. Large soft areas on carcass surface.
i) Severe body dam age, distortion.

ii) Severe scale loss.
iii) Body colours dark.
iv) Severe bleaching, staining.
v) Flesh at notch very soft, falling apart. Carcass surface breaking up.
vi) Meat has evidence of parasites or disease.
-137 -
5.7
QUALITY GRADING FORM

FOR THE INSPECTION OF COLOUR
Name of Vessel:
Date Landed:
Description Very Good Good Medium Poor Very Poor

Flesh Colour
Transparency Flesh
Fat Content
Freshness
COMMENTS
SIGNATURE
POSITION
-138 -
5.8
QUALITY GRADING FORM

FOR THE INSPECTION OF CONDITION
Name of Vessel:
Date Landed:
Description Very Good Good Medium Poor Very Poor

Scales
Skin Surface
Body Colour
Texture
Bleaching
Staining
COMMENTS
SIGNATURE
POSITION
-1 3 9 -
5.9 Flowchart for Tuna Grading
1. AT SEA
-140-
S E C T IO N 6
T H E PRO PER U N L O A D I N G O F
FRESH T U N A F R O M F IS H IN G VESSELS
- 141-
6.1 PROCEDURE IN PLACE AT PRESENT IN INDONESIA
6.1.1 Improvements
There is at present a need to improve the method of handling for the unloading
process.
The systems which are presently in use in different areas are as follows:
SYSTEM 1
The tuna in this type of operation is unloaded by the procedure of using people
to unload the fishing vessel.
All tuna is handled by the use of human labour. Every tuna is man-handled.
From the tim e it is removed from the ice till the tim e it is placed into the
processing plant it must be handled by the use of human intervention. This, in
actual fact means, that this process requires that a tuna must be handled at
a minimum of SIX times before it is placed into the processing plant. If this
m ethod of handling is to be continued it will create many problems with the
QUALITY of tuna. We must remember that for every time that we handle a tuna,
we are decreasing the value of the fish. It is estimated that for every tim e a
tuna is handled, the percentage of Grade A tuna is decreased by 3 to 5
percentage points,
SYSTEM 2
In this method of unloading, there is in place aboard the fishing vessel, a fish
hoist that will remove the tuna from the fish hole and place on the deck of the
vessel. The tuna is then removed from the deck by the means of human
intervention up a chute and onto either a trolley or into the back of a truck. Also
with this type of system, there are some facilities, whereby the tuna is
transported to the processing plant by the means of fibreglass chutes. Even
though there is a decrease in handling by the method of the use of chutes,
considerable handling and a decrease in the overall quality of the tuna is still
present.
In System 2 there is a method of handling of tuna at unloading which must be

addressed: the method of placing tuna in the back of an open truck, and
transporting the tuna to a processing plant. There must be a more effective
means to handle tuna. This system of handling must discontinue, if we are
going to maintain the quality of the tuna.
SYSTEM 3
In this method of unloading, there is a boom truck available to decrease the

am ount of handling. With this system in place, it eliminates the am ount of
handling which is placed on the tuna. When the product is removed from the
be, there is a rope or sling placed around the tail, which inturn is placed onto
the hook of the cable from the boom truck. The tuna is removed from the
vessel and placed into the slush container. This system is very effective
because it eliminates excessive handling.
-142 -
6 .1 .2 H a tc h Size A n d Vessel D esign
FISH HOLE SIZE: There is a concern in regards to the size of the hatch for the
removal of the tuna from the fish hole.
During our travels to the unloading and processing facilities, it was noticed that
the fish hole opening was very small. This, when the unloading process was in
operation, raised concerns to the quality of the tuna.
Many vessels have at present, a very small opening for the loading and
unloading of tuna. Due to the size of the fish hole opening, there is a problem
with the am ount of dam age that occurs with the outer surface of the tuna,
There is not sufficient area so as to protect the tuna, When the overall
inspection of the whole tuna is com pleted, the outer surface is also taken into
consideration.
In the inspection procedure, if the skin and outer surface is dam aged, then it
will and do affect the overall quality grading of the tuna. Tuna is graded by
colour and appearance. The outer surface will tell the buyer what way we are
handling our tuna. If there is dam age to the skin and outer m eat it affects the
yield that the end user will recover. If the skin is dam aged, then the outer meat
is also dam aged, which in turn causes a decrease in the recovery of usable
meat. When this happens, it is a determining factor in what price is to be paid
to both the processor and the fishing vessel.
We must all remember that the price of tuna is always determined by the
quality of the m eat and the method in which the tuna is handled. When the
buyer is viewing the whole tuna, he is looking at what the appearance of the
outer surface is like. He determines his price only on what usable product he
can deliver to the end user. Usable product is determined by the colour and
texture of the meat.
6.2 PROPER PROCEDURES FOR THE UNLOADING OF FRESH TUNA
In order to dem and a higher price for our tuna, we must ensure the end user that we
are doing everything possible to maintain the highest quality and excellent
workmanship of our product. In the proper unloading system we will attem pt to show
the end user that we are controlling the way in which we will handle our tuna at time
of discharging. The system which is required to be established is listed in the following
text of this report.
6.2.1 Temperature
The first requirement is to have an inspection carried out on the temperature of

the tuna before it is removed from the fishing vessel. The first fish to be
inspected for the proper temperature is the last fish which has been processed
at sea.
The proper equipment which is required to inspect the core temperature of the
tuna is by using an Electronic Temperature Gauge which has a probe attached
that can reach the core of the tuna.
-143-
To check the temperature, place the probe into the cut which has been
previously made behind the pectoral fin for bleeding, If the core temperature
of the tuna is not at 0°C, the fish should remain aboard the vessel or if needed
to be removed, it must be placed into slush ice and water until the proper
temperature is reached.
6.2.2 Fish Hole Chart
Before the discharge is to com m ence, the unloading personnel must have
from the fishing vessel a fish hole chart which should show where each day's
fishing is properly stored. It is very important to know where the oldest fish is on
board the vessel. The buyer will want to know the age of the tuna so as to
determine what market to ship the fish to. The type of chart which should be
used by the vessel owner is attached in Section 6.2.12.
6.2.3 Temperature Inspection
During discharging of the tuna, there must be random checks recorded to

ensure that all the tuna have a core temperature of CPC. The am ount of tuna
to be inspected is 20%. So for every 10 tuna, we must check TWO tuna for
temperature. Attached in Section 6.2.13 is a form showing the type of
Temperature Log which should be used.
6.2.4 Equipment
Before the unloading begins, there should be in place a required number of

insulated containers to handle the unloading of the tuna. These containers
must be properly cleaned and free from contamination. There must be a
proper mixture of two parts ice and one part clean and safe salt water.
6.2.5 Proper Fish Unloading System
The system which is needed, is to have a permanent fish unloading system in

place a t the unloading sites. With the proper system there would be a
considerable decrease in the handling of tuna. The handling would decrease
by 80%. This would help to maintain the quality of the tuna by improving the
workmanship procedure. With this system it would be required that the tuna
would be handled when it is removed from the ice in the fish hole, control the
fish as it is being hoisted up through the fish hatch, and when it is being placed
into the slush container. The diagrams attached as Annex 11 shows the proper
design of equipment for the unloading of tuna.
6.2.6 Unloading Requirements
Some requirements that are needed when the discharge is to begin. The fish
hatch must be properly covered around each side so as to ensure that no
damage can happen to tuna as it is being removed from the fish hole. There
should be clean salt water to clean off the old ice from the surface of the tuna
as it is being removed from the fish hole. All old ice in the belly section must
also be removed from the tuna as it is being discharged.
-144-
6.2.7 The Age of the Tuna
During the unloading process, the oldest tuna must be kept separate from the
other tuna. When the old tuna is being discharged, the containers which they
are placed in should be marked and kept separately.
6.2.8 Insulated Containers
With the use of insulated containers which have the proper slush ice and water,
the tuna can be properly stored and moved to the processing plant for further
processing. The use of containers at unloading sites, helps with the handling
and maintains the temperature of the fish. The containers should not be over
filled. The least am ount of pressure that can be put on the tuna, the better it
is for the fish in the bottom of the container. After the container is filled it should
be properly covered and removed to the processing plant if it is close by.
6.2.9 Transportation Procedures
For tuna which has to be transported by truck to a processing plant, the

required system that must be used is in a proper clean insulated truck which is
equipped with a cooling unit so as to control the temperature during
transportation. Tuna must not be transported loose in any type of truck, the
quality of the tuna must be cared for at all times.
Open trucks are not permitted to be used in the transportation of tuna from the
fishing vessel to the processing plant. With the use of this method the quality of
the tuna and workmanship would be decreased.
6.2.10 Cleaning of Fish Storage Area
Immediately after the tuna has been removed from the fish hole, all ice must
be removed.
The fish hole must be properly cleaned and sanitized, All care must be taken
to ensure that the fish hole is free from any contamination and any discarded
materials.
Only clean safe water is to be used in the cleaning process of the fish hole.
After the fish hole has been properly cleaned and sanitized and before new ice
is placed in the hole, the fish hole must be properly rinsed so as to ensure that
the sanitized solution is properly removed.
6.2.11 Icing of the Vessel
Only ice which is m ade from properly approved water is permitted to be used
aboard the vessel.
Ice should be properly crushed so as to ensure that there are no sharp edges
or large pieces of ice which could create a problem in the icing of tuna.
-145-
The proper method of transportation of ice to the fishing vessel is as follows:
A) Truck which is used for the purpose of transporting of ice to the vessel
must be properly cleaned and sanitized and rinsed before any ice is
placed in it.
B) Ice, while being transported to the vessel must be covered properly to

protect from contamination.
-146-
6.2.12
FISH HOLE CHART
N a m e o f V e s s e l:_________________________________________________________
D ate Started F ishing:_____________________________________________________
D ate S to p p e d F ish in g:____________________________________________________
D ay 1 Day 2 Day 3 Day 4 Day 5 Day 6
Each d a y there m ust b e a re c o rd show ing how m a n y tuna were p la c e d in the

fish h o le a n d where th e y are lo ca te d . The fishing vessel m ust p re se n t the
lo ca tio n o f e a ch day's fishing where the tuna is p la c e d in the fish hole.
Signature o f Vessel Owner:
-147-
6.2.13
TEMPERATURE RECORDING LOG

UNLOADING OPERATION
N a m e o f Vessel: _______________________ D a te L a n d e d :_____
Time Start D is c h a rg in g :___________ Time Finished D ischarging:
Time T em pe ratu re No. O f Days C o m m e n ts

In Ice
Signature o f Inspector:
This docum ent should accom pany the shipm ent to the processing plant. If there are any
problem s with any p a rt o f the shipm ent o f tuna in regards to the tem perature, the problem
tuna should be m arked & held in insulated container a t processing p la n t fo r further inspection.
-148 -
6.3 CONTROL POINTS
6.3.1 Discharging
In the method of discharging there are areas which can becom e critical if
effective planning is not carried out.
1) Tuna must be handled quickly and carefully at all times.
2) Protect the tuna during discharge that it will not be dam aged.
3) Tuna is not to be dragged or hauled either across the deck or up a chute.
4) Tuna must be protected from the heat of the sun.
Decrease the number of times tuna is handled from the time it is removed from
the fish hole till the tim e it gets to the processing plant.
All tuna whether it is for the sashimi, fresh loins, canning, freezing, or for local
markets, must be treated as a food item and must be handled in accordance
with Good Handling and Manufacturing Practices.
6.3.2 Temperature
There must be regular checks carried out during the unloading process to
ensure that the fish are properly chilled. If there are fish that have high
temperatures, these fish will have qualify problems if not corrected.
1) Know where the problem can occur and have a plan in place to prevent
it from happening.
2) Have proper canopy in place to protect the tuna from direct contact with
the sun.
3) Proper slush tanks be prepared before start of discharging.
4) Decrease the amount of time that the tuna is out of the ice.
5) Tuna must be kept in proper containers that contain slush ice and salt
water.
6.3.3 Unloading System
There must be a proper unloading system in place so as to maintain the quality

of the tuna when it is being removed from the vessel. It is very important to
decrease the am ount of handling that occurs during discharge.
Tuna cannot be man-handled.
Proper protection must be in place around fish hole opening to protect the
outer surface of the Tuna. The workmanship of the tuna will affect the quality of
the fish.
-149-
Tuna should be lifted out of the vessel by the head.
All tuna must be treated in the same manner.
When removing tuna from the ice in the fish hole you cannot walk on the fish.
6.3.4 Transportation
The proper system for the transporting of tuna must be followed. Tuna can be
dam aged very easily if it is not handled properly.
No tuna is to be transported in an open truck.
No tuna is to be transported without proper protection.
All tuna is to be iced properly before transporting to the processing plant.
Properly cleaned and safe insulated containers must be used to transport tuna.
Trolleys should not be used, unless there is protection in place so as the tuna
cannot be dam aged.
Only trucks that have a proper cooling system in place should be used for the
transporting of tuna to the processing plant. The truck box must be constructed
of a clean and safe material whereby there is no means of contamination
happening to the product.
6.3.5 Unloading Sites - Surroundings
The area around and the unloading site shall be kept clean at all times. If there
is an accum ulation of refuse in the area it will create objectionable odours,
which in turn will attract insect and rodents which in turn will cause a sanitation
problem.
No dam aged or discarded containers are permitted around or on the

unloading site.
Proper washing facilities must be in place. No dogs, cats and other animals are
permitted around the site.
No containers which are used for offal shall be used for the handling of tuna.
A rodent and insect control program must be in place so as to ensure that the
site does not becom e a public health hazard.
6.3.6 Ice
Ice must be handled in such a manner that it cannot com e in contact with
items which can cause contamination to the tuna. Ice must be m ade from
approved water supply so as to ensure that the ice will not be a source of
product contamination.
- 150-
Only clean safe ice is to be used in the slush containers.
Used ice is not permitted.
Ice for use in the unloading system must be protected from contamination.
Ice which has com e in contact with dirty containers is not permitted.
-151-
A nnex 11
FISH UNLOADING SYSTEMS

& DESCRIPTION
The Fish Handling System shown in D ia g ra m A1 shows th e m e th o d for u n lo a d in g

fro m sm all fishing vessels. It shows th e m e th o d o f g ra d in g , cu llin g a n d boxing.
D ia g ra m A2 shows th e s a m e system with a tu n a s u s p e n d e d fro m th e hook.
-1 5 2 -
Diagram A1 Fishing Handling System
- 153 -
Diagram A2
- 154
-
S E C T IO N 7
B IB L IO G R A P H Y
-155-
7.0 BIBLIOGRAPHY
Handbook of C om pliance
Departm ent of Fisheries and Oceans
Ottawa, C anada
Quality M anagem ent Program Submission Guide (1990)

Departm ent of Fisheries and Oceans
Ottawa, C anada
Sanitation & Hygiene Employee Handbook

Institute of Fisheries and Marine Technology
St. John's, Newfoundland, C anada
Nakamura, Robert M. et. al.

The M anagem ent of Yellowfin Tuna In the Handline Fishing Industry of Hawaii:
A Fish-handling Handbook
University of Hawaii Sea Grant College Program (1987)
UNIHI-SEAGRANT-AR-88-01
Putro, Sumpenlo
Handling and Processing of Tuna for Sashimi
INFOFISH Technical Handbook 1:
INFOFISH, Malaysia 1990
Williams, S. E.
Marketing Tuna in Japan.
Queensland Fishing Industry Training C om m ittee, Australia, 1986
Guide to G ood Manufacturing Practices (GMP)

Departm ent o f Fisheries and Oceans
Ottawa, C anada
Proper Unloading Procedures Guide

Institute of Fisheries and Marine Technology
St. John's Newfoundland, C anada
Hoar, W. S. and Randall D. J. Ed

Fish Physiology Vol IV: The Nervous System, Circulation and Respiration,
A ca d e m ic Press 1970
-156-

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IMPROVED QUALITY CONTROL FOR

THE HANDLING AND PROCESSING OF

ASEAN CANADA FISHERIES POST HARVEST TECHNOLOGY PROJECT

AUTHORS: Josephine Wiryanti, George F Glynn, and Leonard G Limpus.

LIAISON OFFICE: ASEAN Executing Agency,

1 Marine Fisheries Research Department

Tuna is one of the leading commodities contributing to the socio-economic development in

Dr. Josephine Wiryanti,

Section 2 An Integrated Quality Management Program (IQMP) for 29

Section 3 G ood M anufacturing Practices for the 63

Section 4 An Integrated Quality Management Program for the 85

Section 5 G rading o f Bigeye and Yello w fin Tuna 133

Section 7 Bibliography 157

gentle catching and landing

1.2 PROCESSING STEPS

Processing Steps Hazards

Method of Catching Time of Stress

Landing of Tuna on Vessel Area Clean and Safe

Method of Killing System used

Bleeding Proper Removal of Blood

Dressing Removal of Intestines & Gills

Washing Clean and Safe Salt Water

Lowering of Temperature Proper Iced Chilled Sea Water

Freezing of Whole Tuna On Board A Core Temperature of -60°C Must be Reached

1.3 METHODS OF CATCHING

Tuna must be handled properly even when it is in the water.

Eliminate the amount of stress, by tending the hooks more often.

1.4 TEMPERATURE OF TUNA

Tuna must be placed in a cooling tank so as to decrease the core temperature as

Section 5.9 gives a flowchart for tuna grading at sea.

Prevent tuna from being damaged,

1.6 CLUBBING AND KILLING

Ensure that the tuna is killed properly.

Decrease the chances of struggling.

Decrease the chances of damage.

Ensure that the proper bleeding is completed with each fish.

1.8 GUTTING & GILLING (REMOVAL OF EXTERNALORGANS & GILLS)

Gutting must be done properly.

No fish to be placed in fish hole which is not gutted.

Protect the belly wall by proper washing after gut removal.

1.9 LOWERING THETEMPERATURE

1.10 ICING OF TUNA (STORAGE ON BOARD)

All tuna must be properly iced.

1.11 DISCHARGING OF TUNA

1.12 ON BOARD FREEZINGOF TUNA (FOR SASHIMI AND OTHER MARKETS)

Air-blast freezing is recommended because low temperature can be obtained relatively

1.13 SUMMARY OF FISH HANDLING PROCEDURES:

1. Remove fish from hook as soon as possible after hooking.

Taken from: Nakamuna, Robert M., et. al.

Note: To handle tuna head-on, follow steps 1 through 14

Note: To head tuna, follow steps 1 through 5

LANDING THE FISH

Figure 7. Gaff the fish through the lower jaw.

Step 1 Place a sharp probe on either side of the soft spot.

Figure 3. Destroy the brain on either side o f the soft

Figure 6. Bleed fish by cutting behind the pectoral fin.

Step 1 Position the fish so that it is lying on its side.

Figure 8. Bleed fish by cutting tail

Gutting and Gilling

Figure 9. Insert knife 4 inches in front o f the anus, and then cu t