PM FME‐ Detailed Project Report of Fish Processing Unit

2.3. RAW MATERIAL DESCRIPTION:

Indian rivers are the primary source of food for the irrigation scheme, drinking water and fish.
There is a list of freshwater fish present in Indian rivers, with Rohu, Katla, Mahseer, Magur and
Vaam being some of India's most common names for freshwater fish.

Here in this project we have taken Rohu fish for processing which would be the whole raw
material.

3. PROCESS FLOW CHART

The processing of fish can be categorized in the following steps:

 Handling of freshwater fish before Processing:

 The fish capture approach has an effect on the consistency of the raw material and its
suitability for further processing.
 Producers should keep in mind that not all fish can be transported alive. As a result,
fish should be sorted immediately after fishing, with only those in excellent shape,
stable, and undamaged destined for sale as live fish.
 The conditioning mechanism lowers discomfort and inhibits digestion while also
removing food remnants from the alimentary ducts and lowering oxygen demand.
Fish are not fed during the conditioning period, which slows digestion and reduces
ammonia and carbon dioxide excretion.
 Raw material is graded during the pre-processing stage based on its suitability for
different processing methods. The species of fish, the manufacturing processes, and
the desired finished product all influence how the fish (raw material) is handled
during processing.

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 PM FME‐ Detailed Project Report of Fish Processing Unit

 Preliminary Processing of freshwater Fish: Preliminary processing of freshwater fish

usually consists of the following steps or unit processes: evisceration, de-heading, scaling,
cutting of fins and belly flaps, slicing of whole fish into steaks, filleting, skinning, grinding
of skinned fillets
 Stunning of fish: Electric current is the fastest way to stunning newly captured fish or
fish shipped live to a manufacturing facility. The fish are first put in a water tank, and
then an electric current is transmitted through the water to shock or kill the fish. When
mechanical or ceremonial factors demand the removal of blood from the tissue before
further processing, live fish are often slaughtered by cutting the aorta and bleeding to
death.

 Grading: The rating of the fish by species and scale is the first step in the processing
chain. Sorting by organisms, freshness, and physical damage are still manual
operations, but rating fish by scale can be achieved quickly and efficiently with
mechanical equipment.

 Removal of Slime: Slime builds up on the surface of dying fish's skin as a protection
mechanism against unhealthy environments. Eel, trout, and other freshwater animals
can be cleaned of slime by soaking them in a 2 percent baking soda solution and then
washing them in a cylindrical circular washer.

 Scaling: Many freshwater organisms are scaled on a regular basis, which is a time-
consuming process when performed manually. According to some sources, manual
scaling of larger species takes about half the time it takes to produce heads and gutted
fish without fins. The scales are removed from the body of the fish by moving tools
from the tail fin to the head.

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 PM FME‐ Detailed Project Report of Fish Processing Unit

 Washing: The aim of washing is to clean the fish and remove any bacteria that has
collected. The kinetic energy of the water stream, the ratio of fish volume to water
volume, and the water temperature all influence the efficacy of the washing process.

 De-heading: Larger fish take more effort to de-head, and automatic heading devices
are required. De-heading machines use disc, contoured, cylindrical blades, band saws,
or guillotine cutters as cutting elements. The location of the cutting factor is adjusted
by a machine operator based on the size of the fish. As a result, the amount of meat
lost during the de-heading process is determined not only by the method of head cut,
but also by the operator's expertise and ability.

 Gutting: Gutting is used to extract the areas of the fish that are most likely to degrade
product consistency, as well as the gonads and, in some cases, the swim bladder.
Freshwater fish evisceration is a time-consuming process that is normally done by
hand. Gutting involves chopping off the abdomen (the fish may or may not be de-
headed), scraping internal organs, and, if desired, washing the peritoneum, kidney
tissue, and blood from the body cavity. The fish were sliced longitudinally from the
anal opening to the anal opening, with great care taken to prevent cutting the gall
bladder.

 Cutting Fins: When handling larger fish, manually chopping away the fins with a
knife, special mechanized scissors, or spinning disc knives is a labor-intensive and
strenuous process. During the processing of de-headed whole fish and fish steaks, this
procedure is most often performed after gutting.

 Slicing of whole fish into steak: A traditional fish processing technique is to slice de-
headed whole fish into steaks with a cut perpendicular to the animal's backbone. This
processing technique is common in retail markets and the canning industry due to its
high technical performance as compared to filleting and automated cutting into parts.

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 PM FME‐ Detailed Project Report of Fish Processing Unit

 Filleting: In the retail market, a fillet, which is a piece of meat made up of the dorsal
and abdominal muscles, has long been a popular fish food. Filleting performance is
determined by the type of fish, its sex, age, and nutritional status. Manual filleting is
time-consuming and heavily reliant on the employees' abilities.

 Skinning: Manual fillet skinning is time-consuming and difficult; a sharp knife and a
flat metal or plastic board are needed. The fillet is put skin-down on the sheet, the
meat is held in the left hand, and the knife is drawn between the skin and the meat.

 Meat bone separation: Minced meat is often made from less valuable fish species
after de-heading, cleaning their body cavities, and removing kidney tissue. Meat is
removed from bones, clothing, and scales using separators, which are automatic
machines.

 Storage:
 Canning- A wide variety of fish and shellfish suitable for canning. Sardine, mackerel,
salmon, sardines, and shellfish such as lobster, clams, oysters, mussels, crab, and
other shellfish are ideal for canning. When it comes to canning, the consistency of the
raw materials is crucial. Canning should only be done for fresh seafood. Since heat
processing is uniform in relation to a defined amount of microbial spore population,
an excess will result in microorganism destruction failure. As a result, it's important to
keep the bacterial load in the fish as minimal as possible before canning. This can be
accomplished by using very fresh seafood, dressing it properly, thoroughly cleaning it
in potable water, and keeping it iced.

 Freezing- To eliminate bacterial activities, in order to prevent undesirable enzymatic

and microbiological processes, de-heading, gutting, washing and chilling should be
carried out immediately on dead fish. In order to preserve shelf life, processing
techniques should be implemented when fish is not sold fresh. Freezing, smoking,
heat treatment may be used in these (sterilization, pasteurization, etc.).

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 PM FME‐ Detailed Project Report of Fish Processing Unit

Raw material Procurement

Handling of Fish
(Capturing, Transporting & Conditioning)

Preliminary Processing of Freshwater Fish

(Stunning, Grading, Slime Removal, Scaling, Washing, De-heading,
Gutting, Cutting Fins, Slicing, Filleting, Skining & Meat Bone
Seperation)

Storage
(Canning/Freezing)

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 PM FME‐ Detailed Project Report of Fish Processing Unit

4. ECONOMICS OF THE PROJECT

4.1. BASIS & PRESUMPTIONS

1. Production Capacity of Processed Fish is 50 kg per hr. First year, Capacity has been taken @
60%.

2. Working shift of 8 hours per day has been considered.

3. Raw Material stock is for 7 days and Finished goods Closing Stock has been taken for 7 days.

4. Credit period to Sundry Debtors has been given for 14 days.

5. Credit period by the Sundry Creditors has been provided for 7 days.

6. Depreciation and Income tax has been taken as per the Income tax Act, 1961.

7. Interest on working Capital Loan and Term loan has been taken at 11%.

8. Salary and wages rates are taken as per the Current Market Scenario.

9. Power Consumption has been taken at 20 KW.

10. Increase in sales and raw material costing has been taken @ 5% on a yearly basis.

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 PM FME‐ Detailed Project Report of Fish Processing Unit

4.4. MACHINERY & EQUIPMENTS

Machine Name Description Machine Image.

Fish stunning This system is designed for the fast and
machine painless stunning (electroanesthesia) of
fish (up to 50 kg/cycle) prior to
slaughter.

Grading Machine When the fish are harvested, either for

stocking as juveniles or for selling as
food fish, they are first sorted by
species, then size-graded if possible.

Drum washing A front-loading washer's drum rotates

with a horizontal along a longitudinal axis. The water in
rotation axis the drum is just partly filled, and the
clothes are tumbled into the water by
the revolving drum.

Vertical This kitchen method is designed to

cylindrical scaler quickly and efficiently strip the scales
from the skin of a whole fish that will
be cleaned and grilled. Scaling a fish
would not be an issue because filleting
it removes the skin and scales as well.

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 PM FME‐ Detailed Project Report of Fish Processing Unit

Combination The purpose of this project is to design

washer conveyor a device to clean fish solids and plaque.

De- heading De-heading machine is used for

machine accurately and efficiently removes the
head and tail of the fish.

Gutting machine Gutting machines reduce the amount

of waste by basically gutting all forms
of fish with extremely high accuracy,
leading to a decline in the cost of
processing. The guts are sucked out
with the aid of a vacuum when the
fish is gutted and sliced.
Rotating disc A manual fish processing knife,
knives mechanized scissors or a rotating disc
knife can cut away fins from
the fish's body.

Filleting A fish-cutting machine for cutting

machine with fillets from the backbone of fish.
conveyor

Skinning Cod, sleeve-egg, catfish, carp, grouper,

machine with pike, salmon, tilapia, and snapper are
stationery knife among the fish that can be skinned by
the fish skinning system. Fish meat,

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 PM FME‐ Detailed Project Report of Fish Processing Unit

skinned fish fillets, and skinned fish

fillets can all be used to produce
delectable dishes.

Meat separator This system is used to pick fish meat

from fish bones, flesh, and tendon in
order to capture and harvest fish meat.
The selected fish meat or fish meat
paste is pure enough to make fish balls,
fish noodles, fish gelatin, and fish
dumplings, among other things.

Material These Equipments are used for

handling and material handling. Other equipments
other like water pumps, weighing machine,
Equipments etc are also used.

Machine Unit Rate Price

Fish stunning machine 1 130000 130000
Grading Machine 1 100000 100000
Drum washing with a horizontal rotation axis 1 240000 240000
Vertical cylindrical scaler 1 75000 75000
Combination washer conveyor 1 115000 115000
De- heading machine 1 380000 380000
Gutting machine 1 450000 450000
Filleting machine with conveyor 1 65000 65000
Skinning machine with stationery knife 1 135000 135000
Meat separator 1 750000 750000

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