Continuous Sardine Cooker: Control, Efficiency, and Quality
The process of cooking sardines and other pelagic fish requires precise and meticulous control to ensure the quality of the final product. Respecting the raw material and production efficiency is crucial in this stage of canned sardine production.
In this article, we delve into the sardine cooking process and how Gaictech’s continuous sardine cooker offers the necessary features and advantages to optimize the production of canned sardines and other pelagic fish.
Contents
Sardine Cooking Process
Before the cooking process, the fish undergoes a preliminary preparation process. Upon arrival at the factory, the sardines are sorted, descaled, cut, and eviscerated. Depending on each producer’s needs and objectives, they may be subjected to a brining process to adjust their flavor and liquid retention.
Once prepared, the sardines are packed in cans that are then placed upside down on plastic racks. This arrangement is crucial to ensure that the liquids and fats exuded during cooking are drained out of the cans, resulting in a drier and better-tasting fish.
Once mounted on the racks, the cans are introduced into the continuous cooker. The racks are transported through the cooker by chains that move in a zigzag pattern, either horizontally or vertically, depending on the type of container and the production volume. Cooking is carried out with direct steam in an automatically controlled chamber. Cooking times and temperatures are adjusted according to the size of the fish and the required specifications.
In some cases, after cooking, the sardines may go through a drying module where hot air is blown in to reduce the product’s moisture. However, Gaictech recommends avoiding this step as it can accelerate the oxidation of the fish and excessively dehydrate it, negatively impacting the quality of the final product. Additionally, this step can cause skin detachment issues if post-cooker conditions are not optimal.
Finally, the racks with the cooked cans are removed from the cooker to proceed with the final stages of the fish canning process.
Features of the Gaictech Continuous Sardine Cooker
The Gaictech continuous sardine cooker is tailored to meet client-specific needs, adapting to the desired can format and production volume. It is built using stainless steel AISI 316-304, a material that ensures strength, longevity, and full compliance with FDA food industry standards.
Here are some of its main technical features:
- Temperature control. The cooker measures the temperature using either a circular or electronic recorder, following standard regulations. Additionally, it features a digital display of the cooking chamber temperature.
- Cooking times. There is the possibility to vary the cooking times, which are monitored through a digital display.
- Controlled cooking. The control of cooking with direct steam can be fully automated thanks to an isoproportional valve.
- Internal movement. The chains can move in a horizontal or vertical zigzag pattern, depending on the type of production and packaging.
- Grill washing system. Options are available for hot air drying and continuous washing of the cooking grills.
- Safety and traceability. The cooker is equipped with mechanical and electronic safety systems against power surges in the conveyor chains. Additionally, it allows for the export of cooking data to a PC to facilitate traceability.
Benefits of the Gaictech Continuous Sardine Cooker
Final Product Quality
The design allows cans to be positioned upside down during cooking, ensuring continuous drainage of liquids and fats. This results in drier fish with better flavor and optimal texture.
Efficiency and Utilization of By-products
The equipment is designed to optimize factory space usage and reduce steam consumption, ensuring an efficient process. Its modular design also enables the automation of processes such as loading and unloading grills, thereby improving overall productivity.
Additionally, it features a system for recovering exuded fats, which not only helps to reduce waste but also allows for the utilization of useful by-products. The fats are channeled to a recovery point where they can be reused in other processes, such as the production of flours or cosmetic products.
Adaptability
The cooker is versatile, allowing it to work with different types of containers and production volumes. Additional options, such as the drying module or the continuous washing system, offer the flexibility to adapt to the specific requirements of each producer.
Conclusion
The sardine cooking process for canning requires a precise and specialized cooker to ensure a high-quality final product. The control of temperature and cooking times is crucial to guarantee that the fish reaches the end of the process in optimal condition.
Therefore, at Gaictech, we work to design and manufacture efficient, precise machinery tailored to your cannery’s needs. If you need more information or expert advice, feel free to reach out to us.
Leaders in design and manufacturing of technically efficient, customised, quality, and easy-to-maintain solutions for the canning industry.
Call us at +34 986 44 29 04 or write to info@gaictech.com.
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