5. Processing Equipment

Producedby:FisheriesandAquacultureDepartment

Title:Planningandengineeringdata.2.FishCanning... Moredetails

5.PROCESSINGEQUIPMENT

5.1GeneralCanningEquipment5.2EquipmentforCanningTuna5.3EquipmentforCanningSardines5.4EquipmentforCanningFishPasteProducts

Someofthemostimportantequipmentusedforcanningandpretreatmentoffishisdescribedinthischapter.Theitemsselectedarechosen,moretogiveanimpressionoftheprocessingprinciples,ratherthantorecommendparticularequipment.

5.1GeneralCanningEquipment

5.1.1Retorts

Asbrieflydescribedpreviouslyretortsareusedtosterilizethecontentsofthecans.

Horizontalretorts,whicharecommunwithinthefishcanningindustry,havethefollowinggeneralfeatures:

Themajorcomponentsofsuchretortsaretheretortshell(body),cratesandvariouscontrollers.

Thecapacityoftheretortis.optionalanddependsontheoutputofthecannery,howeverasaguidearetortwhichholds1400cans(850ml)perbatchwouldsuitmostmediumsizedbatchoperations.Inthiscasetheretortwouldbeapproximately4000mmlongandhaveadiameterof1200mm.Thesizeofeachcratewouldbe800mmx700mmx700mm.

Approximatesteamconsumptionwouldbe400kgperbatchwhilewaterconsumptionduringcoolingwouldbeapproximately10000lperbatch.Consumptionofelectricitywouldbeapproximately5kWhperhourforcirculationpumpetc.

Stainlesssteellsmainlyusedintheconstructionofretorts.

Normallytheretortcanbeoperatedbyoneperson,whoinmanycasesisinchargeofabatchofretorts.

5.1.2Seamingmachines

Thereareseveralautomaticseamingmachinesspeciallydesignedforclosingfilledsquare,ovalandroundaluminiumortinplatecans.CharacteristicsofacommonmachineareshowninFigure22.

Automaticmachinesarefittedwithcanendandcanbodyfeedingdevicesandalsowithequipmentforautomaticcodemarkingofcanends.

Inadditiontheymayalsobelinkedwiththefollowingdevices:

Automaticfillingdevice

Thedeviceisdesignedforfillingofoil,tomatosauceandotherliquidsaucesintocans.Itispneumaticallyoperatedandfillspreciselymeasuredquantitiesintoeachcan.

Lidplungerandcontrolclosingdevice

Thedeviceismountedontheclosingmachineandisparticularlyusefulforoverpackedcans.Itpressestheliddownonthecan,andifthelidisnotlyingonthecan,theseamingoperationisautomaticallystopped.

Automaticseamingmachinescanoperateatspeedsof35004000cansperhour.Diatetersofcansthatmaybeseamedrangefromapproximately50to195mm.Theheightofthecansmayrangefrom15to120mm.Multiplecodemarkingsareavailable.

Approximatelengthoftheseamingmachinewillbe2000mmwhilewidthwillbe2000mm.

Figure22Automaticseamingmachine

Approximateconsumptionofelectricityis3035kWhper8hours.

Themachinecanbeoperatedbytwoworkers.

5.1.3Canwashinganddryingmachine

Canwashinganddryingmachinesareusedtocleancansaftersterilizationinordertoremoveresidualoilsthatmayhaveadheredtothecansurfacesduringfillingandretorting.

Thesemachinesarefrequentlyfittedwithavariablespeeddrivetoregulatethespeedoftheconveyorbelt.

Approximatedimensionsofthesemachinesare3600mm(length),1500mm(height)and1600mm(width).

Thedrivemotorswillconsumeapproximately6070kWhper8hourswhenfullyused.Ifsteambatteryisusedforheatingitwillconsumeapproximately200kgsteamperhour.Ifthemachineisheatedbyelectricityitwillconsumeapproximately100kWhper8hours.

Allpartsaremadefromstainlesssteel.

Themachineisautomatic,butmaybefedbyoneortwoworkers.SeeFigure23.

5.1.4Cartoningmachine

Cartoningmachinesareusedforpackingcansintoindividualcartons.Themaincharacteristicsofanairoperatedcartoningmachinesaregivenbelow.

Figure23Canwashinganddryingmachine

Theymaybeequippedwitharotatinginfeedtable.Thecartonsareseparatedandopenedbyuseofvacuumandthemachineisequippedwithapumpforthispurpose.Themachinehastwoelectricmotorseachof0.25hp.

ThecapacityofthemachineshowninFigure24isupto65cansperminute

Table14Dimensionsofcansthatmaybeoperatedbythecartoningmachine,showninFigure24

Length: 85180mm

Width: 50100mm

Height: 1240mm

Lengthofthemachineis2400mmandwidthis800mm

Themotorswillconsumeapproximately35kWhper8hours.Consumptionofcompressedairis160200litresperminute.

Themachinemaybefullyautomaticoritmaybefedbyoneortwoworkers.

Thereareonthemarketothertypesofcartoningmachineswithcapacity120ormorecansperminute.

5.2EquipmentforCanningTuna

5.2.1Racks

Racksareusedintheprecookingprocess.Basketswithtunaareplacedontheracksbeforetheyareloadedintothecooker.

Themaincharacteristicsofracksusedfortunaaregiveninthefollowing:

Theracksareequippedwithtwofixedandtwoswivelwheels.Theholdingcapacityofeachrackisdeterminedbytherequirementsofproduction.

CARTONINGMACHINE:A:FeedingconveyorforproductB:CardboardboxesstackandextractionC:InfeedattachmentforproductD:ClosingstationforboxesE:Dischargeoffinishedcardboardboxes

Figure24Automaticcartoningmachine

Approximatedimensionsofarackare760mm,width838mmandheight1400mmwheel.ThematerialusedinconstructioniseithergalvanizedorblackironTwoworkersareusedtofillthebasketsandloadthecooker.

5.2.2Basketsforcookingtuna

Basketsfilledwithtunaareplacedinracksandloadedintothecooker.

Themaincharacteristicsofbasketsoftenusedforprecookingtunaaregivenbelow:

Theholdingcapacityofeachbasketisapproximately1516kgfish.Dimensionsofthebasketsusedfortheracksdescribedaboveare810mmx380mmx100mmandthenetweightofeachbasketis4kg.Galvanizedwireisoftenused.toconstructthesebaskets.Twoworkmencanfillthebasketsandloadthecooker.

5.2.3Highspeedtunafiller

Ahighspeedtunafillerisafullyautomaticmachinedesignedtocutandfillprecookedtunameatintoroundand/orovalcans.

Themaincomponentsarethefeedingunit,thecuttingunitandthefillingunit.

Themachinefillstunatabletsrangingfrom100gto1kg.MassspeedsareshowninTable15.

Lengthofthemachineis3600mm,widthis1700mmandheightis1250mm.

Table15Summaryofoperatingparametersforautomaticfillingofroundandovaltunacans

Candescription Candimensions Fishtabletdiameter Fillingspeed

Diameter(mm)

Height(mm)

Minimum(mm)

Maximum(mm) (c.p.m.)

Standardround 60to90 24to45 54 82 upto150

Largeround 80to110 48to106 75 93 upto70

Oval 65x105 20to40 56 92 upto100

Allcontactpartsaremadefromstainlesssteel.

Onlyonepersonisrequiredtofeedtunaloinsintothemachine.

5.2.4Exhaustbox

Exhaustboxesareusedforheatingcanstoensurethatwhensealedandcooledavacuumisproducedinthecontainer.

Themaincharacteristicsforatypicalexhaustboxesusedfortunaaregiveninthefollowing:

Theyareequippedwithcanfeedinganddischargebeltsandelectricmotor.

Thecapacityoftheexhaustboxshouldbeapproximately10tonsper8hourswithanexhaustingtimevaryingbetween110minutesinsteamopentotheatmosphere.Lengthoftheboxis3600mmandwidthis600mm.Themotorwillconsumeapproximately25kWhper8hours.Consumptionofsteamis7080kgperhour.Materialusedinconstructionismainlystainlesssteel.Themachinecanbeoperatedbyoneormoreworker,dependingonthedegreeofautomationusedattheinfeedandexiststations.

5.3EquipmentforCanningSardines

5.3.1Gradingmachines

Themachineisdesignedtoautomaticallygradesardinesintovarioussizes.

Themaincharacteristicsofatypicalgradingmachineforsardinesaregivenbelow:

ThemachineshownnFigure25ispoweredbya1.0hpmotor.Ifgreatersegregationisdemandedthanisachievableinasinglegradingoperation,themachinecanbeequippedwithadoublesetofgradingrollers,thesecondmountedunderneaththefirst.Inthismanneradoublegradingofthefishwillbeachieved.Thecapacityofthemachineis15002000kgperhour,whengradingsardinesofasizerangingfrom20to100fishesperkg.Theapproximatedimensionsofthemachinearelength2700mm,width1100mm,andheight700mm.

Figure25Gradingmachineforsardines

Themotorwillrequireapproximately56kWhper8hours.Aluminiumalloyismainlyusedintheconstructionofthemachine.

5.3.2Briningunit

Themaincharacteristicsofanautomaticbriningunit.usedforsardinesaredescribedbelowandshowninFigure26.

Themaincomponentsareadrummadeofperforatedplate,whichisconnectedtoavariablespeeddriveanda1.0hpmotor.Thecapacityofabriningunitvariesfrom1000to5000kgperhouranthespeedofthedrivecontrolsthebriningtimefrombetween1and15minutes.Theapproximatedimensionsarelength4000mm,width1550mmandheight1700mm.Themotorwillrequireapproximately56kWhper8hours.Themachineismanufacturedfromstainlesssteel.

5.3.3Nobbingmachine

AnobbingmachineasdescribedpreviouslyandillustratedinFigure27isusedforheadcutting,nobbing(whichmeanspullingthevisceraoutofthebelly),cleaningandtailcuttingand/orfixedbodycutting.

Thecharacteristicsofanobbingmachineusedforsardinesandherringaregivenbelow.

Themaincomponentsofthemachinearethefeedingunit,fishmagazine,headcuttingunit,nobbingunit,cleaningunitandcuttingunitforthetails.Thecapacityofthemachinedescribedis400550fishesperminutedependingonfishlength,whichmayvaryfrom110to260mm.Approximatedimensionsarelength2700mm,width2200mmandheight1600mm.Powerconsumptionisapproximately20kWhper8hoursandwaterconsumptionisapproximately12litresperminute.

Figure26Briningunit

Figure27Cuttingandnobbingmachine

MaterialsusedinconstructionarestainlesssteelandaluminiumalloyThemachineshownmaybeoperatedbyonesupervisor.

5.3.4Continuousflashcooker

Theflashcookerisusedforprecookinganddryingofsardinesbeforeexhaustingandclosingthecans.

ThemaincomponentsofthecookershowninFigure28aretheautomaticchargeanddischargesection,thesteamchamber,thedrainingsectionandthedryingsection.Twochainscarryapproximately800cratesinwhichthecansareplaced.

Chainspeedandtherebycookingtimeisvariable.Differenttypesofcanscanbecookedwithoutadjustmentstothecooker.Upto12500clubcansperhourcanbeprocessed.

Approximatedimensionsarelength15500mm,width1600mmandheight3900mm.

Thecookerwillrequireapproximately5060kWhper8hoursifitisusedfullywhiledependingonloadsteamconsumptionisapproximately500kgperhour.

Thecookerismainlyconstructedfromstainlesssteel.

Beingfullyautomaticoneoperatorisrequiredtosupervisethemachine.

5.3.5Smokingkiln

Thesmokingkilnisalsousedfordrying,precookingandsmokingsardines.Themaincomponentsofakilnarethedryingunit,thesmokingchamber,thefans,theheatexchangerandtwomotors,a4hpmotorforthefansanda1.5hpmotorforthechains.

ThecapacityoftheautomatickilnshowninFigure29is60008000kgper8hours.

Approximatedimensionsarelength11650mm,width2200mmandheight2170mm.

Thekilnrequiresapproximately3040kWhper8hoursandconsumptionofoilisapproximately5litresperhour.

Materialusedinconstructionismainlyblackiron.Beingfullyautomaticthekilnisoperatedbyoneworker.

5.4EquipmentforCanningFishPasteProducts5.4.1Meatseparator

Fishmeatseparatorsareusedtorecovermeatfromsplitandwashedfish.

Themaincomponentsofaseparatorarenormallyarotatingperforateddrum/cylinder,mountedhorizontally,andarubberbelt.Theperforateddrumandtherubberbeltrotatesinthesamedirection,andthefishissqueezedinbetweentherubberbeltandthedrum.Theseparatorisequippedwitha5hpmotor.

Thecapacityis10tonswashedandsplitfishper8hours,withanapproximateyieldof7tonsmincedfishand3tonsoffal.

Approximatedimensionsofatypicalseparatorare1060mmx1127mmx1050mm.

Thediameteroftheholesindrumare21/23mm.

Themotorwillrequireapproximately30kWhper8hours.

Allcontactpartsaremadefromstainlesssteel.

Themachineisoperatedbyoneworker.

Figure28Flashcooker

Figure29Smokingkiln

5.4.2Bowlchopper/mincer

Theingredients(fish,salt,milkstarch,etc.)mustbemixedandfinelyminced.Themincerbowlrotates,andtheingredientshavetopassunderverticalhighspeedcuttingknives.

Themaincomponentsofthemachinearethebowl,theminceranda50100hpmotor.

Mincer/cuttercapacitiesvaryfromapproximately25litrestoseveralhundredlitres.Thebowlcapacityisapproximately325litres.

Approximatedimensionsofthechopper/mincerare(2200mmx1800mmx1350mm)

Themotorwillconsumefromapproximately300to600kWhper8hours.

Allcontactpartsaremadefromstainlesssteel.

Themachineisoperatedbyoneworker.

5.4.3Pumpsformincedmaterials

Themixtureoffishandingredientsisemptiedfromthebowlmincerintoacontainerwithabuiltinscrewandpumpatitsbase.Fromthiscontainerthemasscanbepumped,eithertotheballformer,orthefishcakeformer.Thefishballsandcakesareextendedthroughstainlesssteelpipes.

Themaincomponentsarethecontainer,thepumpwitha2hpmotorandthepipes.

Approximatecapacityis4050litresperminute,withvariablespeed.

Thedimensionsare1550mmx1100mm.

Themotorwillrequireapproximately12kWhper8hours.

Allcontactpartsaremadefromstainlesssteel.

Oneoperatorisrequired.

5.4.4Cookingequipmentforfishballs

Thecookerforfishballsmayvaryinsizehoweveranexampleofacookerwitha2000kg/hcapacityisgivenbelow.

Themaincomponentsofthemachinearenormallyaballformerandcookingchamber.Approximatedimensionsarelength6000mm,width1250mmandheight400mm.Forthesizequotedsteamconsumptionisapproximately500700litresperhour.Thecookerismadefromstainlesssteelanditisusuallyoperatedautomatically.

5.4.5Fryerforfishcakes

Asthecakeshavetobefriedonbothsides,theyhaveeithertobeturnedmanuallyotherwisethemachinecandothis

automatically.

AdescriptionofanelectricalfryerforfishcakesisgivenbelowandshowninFigure30.

Themaincomponentsofthemachinearenormallythecakeformer,abeltandaheatingelement.Capacityis650kgfriedcakesperhour(13000cakesx50gpercake).Approximatedimensionsarelength6000mm,width1500mmandheight1500mm.Thefryerdescribedrequires900to1000kWhper8hourswhenitisusedtofullcapacity.Themachinemaybeoperatedbyoneworker.

Figure30Fryingmachinewithfishcakeformer