Presentations and Markets for Small Pelagic Fish

Small pelagic fish account for over 25% of global marine catches. Species such as sardines, herring, anchovy, mackerel, and jack mackerel are in high demand, either for direct human consumption or for producing fishmeal and fish oil, which are used in sectors like aquaculture, cosmetics, or the food industry.

As a global product, presentation options vary depending on the market and packaging format. From the classic whole sardine to more elaborate options like butterflied sardines (opened and deboned), skinless sardines, or sardine fillets, a wide range of options is available.

Therefore, at Gaictech, we work to offer machinery tailored to each market and the final product presentation desired. In this article, we present some of our solutions and recommendations for the sector.

Raw Material Condition: Freezing and Thawing

Sardines can arrive at the factory either fresh or frozen. In the latter case, a defrosting machine is needed for processing. As sardines are a seasonal fish, many manufacturers freeze them during the fishing season to enable year-round processing, which is vital for the profitability of a factory.

For businesses that work with frozen products, at Gaictech we provide equipment utilizing the two most common freezing methods:

• Individual quick freezing (IQF): the sardine is individually frozen, which simplifies its handling. At our company, we manufacture brine-based IQF freezers that ensure rapid and uniform freezing. This method guarantees greater flexibility in handling the final product.
• Block freezing: sardines are grouped into blocks to facilitate stowage and transport to distant destinations.

In countries where it is not possible to receive a constant supply of fresh product throughout the year, it is common to purchase frozen products and thaw them for processing. This is where Gaictech’s continuous sardine defroster comes into play. This equipment is designed to thaw large volumes of small pelagic fish uniformly, continuously, and with savings in water and space.

Fish Processing: Common Processes and Exceptions

Regardless of the product’s final presentation, there are several common steps in the processing of pelagic fish, such as size grading, cutting, and evisceration.

However, there are other optional processes that may depend on the context or the market for which the final product is intended:

• De-scaling

  This is an optional process depending on the species of sardine and how it was caught and transported. Some species have fewer scales that are removed during initial handling, while others require a de-scaling machine, such as those we offer at Gaictech.

  Our de-scaling machine operates continuously, using a rotating drum and an internal helical screw for the safe fish conveyance, coupled with a water system to evacuate the scales.

• Cutting and Evisceration

  After grading and de-scaling (if applicable), the sardine undergoes head, tail, and gut cutting. Some customers, like those from the Spanish market, prefer to keep the tail.

  At Gaictech, we manufacturesardine cutting and gutting machines that accommodate a wide range of fish sizes without requiring complex adjustments.

• Sardine Belly Cutting

  This is an exclusive machine from Gaictech, unique in the market, designed for sardine species that require this additional cut. It automates a traditionally manual and labor-intensive process, resulting in considerable labor savings. It can process up to 300 fish per minute and integrates with any existing cutting and gutting machine.

• Brining

  An optional process where sardines are submerged in brine for a specified time (5 to 15 minutes, depending on the size) to achieve a specific salt tone and retain water in the flesh. This improves the product’s flavor and avoids excessive dehydration during cooking, which can enhance economic yield by requiring less covering oil.

  At Gaictech, we recommend installing the briner machine after the cutting and gutting processes for better salt absorption and to prevent salt loss when washing the pieces. This ensures uniform flavor.

Packaging: Container Formats and Lines

In general, the packaging line format depends on the type of can or container to be used: rectangular, oval, round, etc.

Manual packaging allows greater flexibility for working with different sizes of fish and achieving a better appearance of the product in the can, especially in the typical rectangular formats of European markets, such as the Spanish market.

Automatic packers are usually efficient only for very specific sizes and species, making them less versatile.

In Europe, value-added products such as butterflied sardines (open-body, deboned), skinless sardines, and sardine fillets have become popular. These presentations require lines with work tables and closed circuits that allow operators to prepare the product with greater attention to detail. In other markets, simpler and faster packaging is preferred, so automatic lines tend to be more efficient.

After packaging and subsequent cooking, there is the option to present the fish with a covering liquid. Oil is usually one of the most common, although sauces like tomato are also in demand. For this purpose, at Gaictech, we offer the possibility of installing an oil or sauce dispenser on the line. This equipment is designed to avoid wasting resources by recovering the excess liquid for reuse.

After sterilization of the containers, the final packaging is done, where the type of container determines the end of the line:

• For rectangular cans, cardboard packaging can be chosen.
• For oval and round formats, the cans are labeled.
• If the can is already lithographed (with printed artwork), no packaging or labeling is usually applied.

Conclusions: Technology and Adaptability

In conclusion, processing small pelagic fish, particularly sardines, requires a blend of appropriate technology and adaptation to market preferences. Each decision, from managing frozen or fresh raw materials to selecting the cut, brining method, and packaging type, significantly impacts the final product’s quality and profitability.

Thanks to specific solutions developed at Gaictech —including continuous defrosters, exclusive cutters, and optimized packaging systems— it is possible to ensure efficient processes, high-value products, and a flexible response to global demands.