With some tuna stocks in danger, and the price of fish increasing across the board, processors are looking for ways to cut costs and make filling more efficient.
Such factors and increasing demand for high yield systems has prompted filling equipment specialist FMC FoodTech to revamp its tuna processing line.
It has added two new processes — Tuna CAL and Thaw CAL — to its existing range of tuna filling kit. Both use mathematical modeling software, with the former claimed to optimize the tuna precooking process and the latter said to improve defrosting.
“This mathematical model is able to predict the ideal temperature profile to improve yield, reduce precooking time, and reduce energy costs without overcooking the product,†explained Dr. Jun Weng, a researcher at FMC’s Process Systems Division in
“It is very easy to use because it features a database of settings for every conceivable species of tuna. The customer simply selects the species and size, and Tuna CAL automatically predicts the best cooking profile.â€
Its software is said to improve the cooking and cooling process by using ‘perfect heat transfer’. “Temperature profile is predicted in accordance to the initial temperature of the fish and its physical variables,†enthused Weng.
“Tuna
The new processes make up part of a fully automated filling line offered by FMC that includes precooking, cooling, filling, brining-oiling, closing and sterilizing equipment.
According to Dino Bertani, tuna product line manager at FMC FoodTech’s Italian subsidiary, the system ensures high quality finished products packed in various shaped containers in formats such as cans, glass jars and pouches.
“Price increases for raw materials have forced tuna processors to search for the highest yield filling systems that also guarantee quality,†he said.
“We have optimized our tuna processing line by scrutinizing each step of the process and making each step more efficient. FMC’s Vacuum Pre Cooker-Cooler combined with the Tuna Cal process control system represents the optimization of the tuna cooking technologies.â€
FMC’s 3266 tuna filler has been updated with a mechanism which allows two cans to be filled at the same time. As such, it now has an output of 300 units per minute, and fills cans in round, oval and club formats keeping consistent fill weight accuracy.
The company’s portfolio of filling machines also includes the 3466 model, which is particularly suited to filling larger cans for the food service industry.
The recently launched 3366 tuna filler comes in a chamber less version, and has been specifically developed for tuna in brine.
Fish fillers also have the option of selecting the TwinTec filling and closing machine: a two-in-one filling seaming/unit made entirely from non-corrosive material and stainless steel. Both filling and seaming stations are positioned on a single stainless steel, sanitary bottom plate with large drainage channels.
Oiling and brining of the product is synchronized with the seaming unit, which removes trapped air from the product and helps ensure constant net weight.
â€The oiling system is set to each specific can size. It creates a vacuum to remove excess air, and then fills oil into a fixed headspace for each can,†said Bart Roels, sales area manager at FMC in
After oiling, cans move to sterilization, which benefits from the Steam Water Spray (SWS) process. “It is an efficient, fast and homogenous sterilization process with air overpressure,†continued Roels.
“Direct steam injection ensure fast and uniform cooking and an even temperature distribution.â€
Sterile cooling then takes place over a plate heat exchanger that FMC claims saves water, water treatment chemicals and energy. “The whole line has been designed with efficiency in mind,†explained Weng. “This continues to the sterilization process.â€
More information from FMC Technologies
Italia, Via Mantova 63/A,
960. Web: www.fmcfoodtech.com or