Raw Material Processing in Sardine Lines: Efficiency, Yield, and Safety from the first step

In the canning industry, the quality of the final product is the result of a series of coordinated tasks and processes starting with the reception of raw materials. It all begins in the initial stages of the process. How the raw material is received, thawed, sorted, and prepared directly impacts product yield, production continuity, and food safety.

In the case of pelagic fish processing, such as sardines, at Gaictech, we design complete machinery lines with a clear objective: to ensure a continuous flow, maximize fish utilization, and maintain absolute temperature control throughout the process.

Our expertise in the initial phase of the line allows us to develop solutions tailored to the actual needs of each plant: automation, mechanical precision, and in-depth product knowledge.

Reception and Thawing: Industrial Flexibility

Sardines can arrive at the factory in two main formats: fresh when the plant is near fishing grounds, or frozen, either in blocks or IQF (Individually Quick Frozen). This second option is crucial for ensuring that production does not rely solely on the fishing season and remains active year-round.

To meet this need, Gaictech integrates a continuous sardine thawer into its lines, a piece of equipment designed for efficiency, uniformity, and space-saving. Its transport system, the bubbling system applied to the water, and temperature control provide homogeneous thawing, whether the fish comes in blocks or IQF.

Compared to other methods, water thawing offers clear advantages: a more uniform and gentler treatment of the product and a continuous in-feed and out-feed system, reducing the need for personnel. The result is a raw material ready to move to the next phase without disrupting the plant’s rhythm.

The Importance of Sorting to Optimize Yield

Once thawed, sardines must undergo a size sorting process. This step is crucial to ensure the efficiency of subsequent operations, especially in cutting and packaging.

Ideally, customers would purchase pre-sorted sardines at the source, but this rarely happens. Sardine suppliers typically do not perform this operation upon unloading the fish from the boat; instead, they freeze the fish and send it directly to customers. Therefore, a canning factory must incorporate this sorting operation within its production process, whether dealing with fresh or thawed sardines.

Gaictech’s sardine classifier uses divergent rollers to separate the fish into 3 to 5 different sizes, adjusting both the inclination and the opening according to the processed species. This adjustment capability allows adaptation to different species of pelagic fish.

Accurate sorting is not a trivial matter. When fish enter the cutter unevenly, the machine makes the incision at the same spot, which can lead to unnecessary loss of usable meat. On the other hand, proper sorting helps improve yield and standardize the quality of the final product.

Controlled Descaling to Ensure Final Presentation

The descaling process is not always necessary. It depends on the species and the method of capture, since in some cases, such as with suction pumping, much of the scales are already removed by friction before reaching the plant.

When this operation is indeed necessary, Gaictech offers a sardine descaler designed to work gently and accurately. The equipment features an internal helix that safely advances the fish and allows precise control of the processing time, preventing skin damage. Additionally, it integrates a water system to effectively remove scales during the process.

This is a delicate phase where the balance between cleanliness and product handling is crucial to not compromise the final presentation.

Cutting and Evisceration: Automation and Precision

If there is a stage where Gaictech has developed a distinctive specialization within the sardine line, it is in the cutting and eviscerating process. The goal here is twofold: to maximize automation and ensure complete cleaning of the fish’s body.

The sardine cutter-eviscerator removes the head, gut, and, optionally, the tail, depending on the requirements of each market. Evisceration is performed using a vacuum system with suction discs, followed by a water jet to ensure cleanliness of the abdominal cavity. In some species, it’s even necessary to install a double suction station to ensure no viscera remain in the abdominal cavity.

This system enables highly effective and homogeneous cleaning, which is crucial for both product quality and overall line performance.

Moreover, Gaictech enhances this phase with a significant innovation: a mechanical vibrating feeder that automatically positions the fish in the machine. Thanks to this development, the necessary labor at this stage can be reduced from six operators to just one or two, who then take on a supervisory and occasional correction role.

This improvement optimizes human resources, increases process regularity, and reduces manual handling of the product, contributing to hygiene and preventing errors.

Sardine gutting machine: a specific solution for targeted markets

Among the range of equipment from Gaictech, there is also an optional solution for certain species: the sardine gutting machine.

This equipment is specifically designed for markets like Latin America, where larger Pacific species are processed with a more pronounced abdominal area. Its function is to remove excess bones or cartilage in that area, which is characteristic of some species, to enhance both the appearance and culinary quality of the product.

The system operates with circular blades and is transported by toothed belts, capable of processing between 300 to 350 fish per minute. Additionally, it easily integrates with any head cutter on the market, facilitating its implementation in existing lines.

Post-Cut brining: Gaictech’s recommendation

Brining is one of the most critical phases in the treatment of raw materials, due to its organoleptic impact and its influence on the economic yield of the preserved product.

At Gaictech, we advocate that this process should be carried out after cutting and evisceration since the exposed flesh absorbs the salt more evenly and deeply. This difference in process order has a direct effect on the final product quality.

Our briner advances the fish submerged in brine via a conveyor, with an adjustable immersion time ranging from 5 to 20 minutes, depending on the size of the sardine. Salt not only imparts flavor but also helps retain water in the muscle during cooking. This prevents excessive dehydration, helps adjust the final weight in the can, and reduces the need for covering oil.

Control and Plant Design

Throughout the entire processing of raw materials, there’s one element that allows no margin for error: temperature. In sardine lines, it’s crucial to keep the fish below 10°C throughout the entire process.

This control is essential to prevent the development of histamine, a toxic compound whose presence would require production to be discarded. Therefore, Gaictech advises our clients on the overall line design, including room climate control and the incorporation of cold water or ice systems at strategic points.

In many cases, processing rooms are maintained at around 15°C, creating an environment suitable for food safety and facilitating the work of the operators.

Gaictech: the Technological Partner for the Canning Industry

The handling of raw materials is where much of the line’s efficiency, fish yield, and process stability are determined. For this reason, having the appropriate technology in these initial stages provides a fundamental competitive advantage.

At Gaictech, we design solutions to ensure each sardine enters the line in optimal condition and moves through the process with precision, continuity, and control. From reception to completion, we take care of designing and optimizing the layout of the line with three clear objectives: to produce better, maximize yield, and work safely.