Tuna Line Raw Material Processing: Machinery for Reception and Initial Stages

In the canned food industry, profitability doesn’t begin with canning. It starts much earlier: at the reception, classification, and cutting of the tuna. These early stages determine the actual yield of the raw material, the stability of the process, and the overall efficiency of the plant.

In this context, Gaictech stands as a global leader in designing and manufacturing complete machinery lines for tuna processing, with a clear specialization in the initial phases of the production process. Our approach combines precision engineering, productivity control, thermal processing, industrial ergonomics, and automation, making us the leading technology partner for the tuna industry.

Reception and Classification: Precision from the Start

The process begins with the arrival of whole, brine-frozen tuna at the factory, typically maintained between -15 and -18°C (depending on the vessel and onboard freezing facility), directly from the fishing ships. Proper management of this phase is critical to ensuring a continuous and stable flow in the plant.

Product unloading

Unloading the tuna is logically the first step after the fish arrives at the plant. Gaictech’s solutions enable the simultaneous unloading of up to 20 tons of fish into specially designed reception hoppers. This volume can be integrated into the production line in just 30 minutes to ensure production continuity and prevent bottlenecks.

Species separation

When tuna arrives directly from the vessel, it typically contains mixed species, with one predominant, and others or accompanying fauna present in smaller quantities. Therefore, an initial manual pre-classification at a station prior to the classification of the predominant species is necessary to remove non-predominant and minority species from the line, ensuring each species follows its optimal treatment process.

In this initial tuna classification process, one of Gaictech’s significant technological differentiators is its tuna grading system:

• Vibrating pre-system to avoid fish overlap.
• Divergent “V”-shaped belts that progressively open.
• Precise classification by shape or size.

At Gaictech, we advocate for grading by shape as it allows for large productions (up to 50 tons/hour) with high precision, more than sufficient to ensure uniformity in subsequent cooking processes. This precision is crucial. Grouping homogeneous pieces facilitates achieving the optimal cooking temperature simultaneously. Without adequate classification, losses occur through overcooking or raw pieces, directly impacting overall production yield.

Tuna Cutting Lines: Precision and Ergonomics

The fish performance heavily depends on the cutting precision and uniformity in a repetitive series of tuna sizes. This is where Gaictech engineering makes a difference. For every project, we tailor the line according to the size of the raw material and the production volume.

Gaictech tuna cutting lines incorporate a specific number of saws depending on the size of the tuna and the number of cuts required to achieve an optimal size for cooking, ranging from 1 to 6 cuts.

For large caliber pieces, “V” belts are used to ensure a homogeneous longitudinal cut of each piece, a task that is extremely difficult to perform manually by one person due to the morphology and weight of the tuna.

Additionally, Gaictech understands that efficiency depends not only on the machine but also on the operator. Therefore, the cutting lines are designed to:

• Respect the 20 kg manual handling limit.
• Reduce accidents and workplace injuries by minimizing human intervention.
• Optimize working heights.
• Avoid awkward movements.

Additionally, by establishing specialization through stations in different work areas where each operator consistently performs the same function mechanically, greater productivity is achieved. A comfortable worker is a more productive worker. And a more stable plant.

Preparation for Cooking: Comprehensive Thermal Control

The initial thermal treatment is one of the most sensitive points in tuna processing, both from a sanitary and productive perspective. Rigorous temperature maintenance is essential to prevent the formation of histamine, one of the main quality indicators in the tuna industry.

Monitoring with probes, especially in the central spine of the fish, ensures that the thermal treatment evenly reaches the entire product.

Before entering the cutting line, tuna must undergo a controlled thawing process. This thawing can be done in chambers with controlled temperature and humidity to ensure uniform thawing throughout the product. However, there is also a trend in some companies not to thaw the tuna before the cooking process, which can lead to yield losses if the cooking process begins without adequate thawing.

Alternatively, some producers choose to conduct thawing directly within the cooker, allowing for more precise temperature control and saving handling time. Gaictech’s vacuum tuna cooker offers this option, which, although this additional phase extends the cycle within the cooker, ensures:

• Total thermal uniformity.
• Greater process control.
• Homogeneous flow to the next phase.

Gaictech: your Technological Partner for Maximizing Performance

The market positions Gaictech as a leader in raw material processing, particularly in tasks like receiving, sorting, cutting, and cleaning fish.

It is precisely at these stages that the real profitability of the business is defined.

With a presence in more than 50 countries, Gaictech tailors its solutions to the specific requirements of each region, product type, and packaging format.

In the tuna industry, every kilo counts. Every degree of temperature matters. Every cut impacts the final yield.

Therefore, choosing the right technology in the early phases of the process is not just a technical decision; it is a strategic one.

Gaictech, as a leader in manufacturing complete lines for tuna processing, designs comprehensive solutions that ensure efficiency, food safety, and maximum profitability from the reception of raw materials to the final packaging.