Mechanized Processing and Value Addition for Fish Products

From Catch to Cuisine: Enhancing Fish Quality and Sustainability

This technology is a fish processing and preservation method involving the use of equipment such as solar tent dryers and smoking kilns. It addresses the challenge of fish's high perishability by improving shelf-life and enhancing taste and nutritional value. Solar dryers offer a low-cost alternative to refrigeration, and smoking kilns utilize smoke to kill microorganisms while drying the fish. These methods enable the production of various value-added fish products, providing economic opportunities, reducing post-harvest losses, and contributing to food quality and market appeal.

This technology is TAAT1 validated.

8•7

Scaling readiness: idea maturity 8/9; level of use 7/9

Adults 18 and over: Positive high

The poor: Positive low

Under 18: Positive low

Women: Positive high

Climate adaptability: Moderately adaptable

Farmer climate change readiness: Significant improvement

Biodiversity: No impact on biodiversity

Carbon footprint: A bit less carbon released

Environmental health: Greatly improves environmental health

Soil quality: Does not affect soil health and fertility

Water use: Same amount of water used

Problem

Fish processing and preservation technologies play a vital role in addressing several issues in the industry:

Post-Harvest Losses: Freshly caught fish are highly perishable, and without proper processing and preservation, significant post-harvest losses occur due to bacterial activity and oxidation.
Temperature Sensitivity: High ambient temperatures in many regions accelerate the spoilage of fish, making it crucial to act quickly in processing and preserving the catch.
Complex Equipment Dependency: While mechanized equipment like electric scalers, cutters, and solar dryers can enhance processing efficiency, their availability and maintenance might pose challenges, particularly in resource-constrained areas.
Energy Consumption: Traditional smoking kilns may consume significant energy and time, making it necessary to explore energy-efficient alternatives for smoke control and hygiene.
Skill and Job Opportunities: Transitioning to mechanized processing may require training and skill development for workers in the industry. However, this also presents an opportunity to create jobs in processing, particularly when meeting sanitation standards.
Processing Time Variability: The time required for processing different sizes of fish can vary, which needs to be considered in the production process to ensure uniform product quality.
Alternative Fuel Sources: The dependence on charcoal for smoking kilns raises concerns about deforestation and sustainability, prompting exploration of alternative fuel sources for generating heat and smoke.

Solution

Fish processing and preservation technologies extend the shelf life of highly perishable fish, reducing post-harvest losses.
These methods improve the palatability, taste, and nutritional value of fish products, enhancing their market acceptance.
Solar tent dryers and smoking kilns are cost-effective and widely used, eliminating the need for refrigeration during transport and storage.
Value-added products like fish powder, fillets, and sausages are manufactured, contributing to food quality and market appeal.
Mechanized equipment, such as electric scalers and deboning machines, streamline fish processing, reducing manual labor and increasing efficiency.
Improved smoking kiln designs reduce energy consumption, processing time, and enhance smoke control and hygiene.
Solar dryers provide a low-cost alternative for fish drying, using readily available materials and reducing dependency on complex equipment.
These technologies are adaptable to different fish sizes, providing flexibility in processing a variety of fish species.
Fish processed using these methods maintain high quality, with smoke acting as a natural antimicrobial agent.
These technologies not only preserve fish but also offer employment opportunities and meet sanitation requirements, benefiting local communities.

Key points to design your project

The Mechanized Processing and Value Addition for Fish Products technology addresses efficiency and value addition in fish processing, while also promoting sustainability. It contributes to food security and environmental conservation, aligning with key Sustainable Development Goals such as Zero Hunger, Gender Equality, and Climate Action.

To establish a fish processing and value-added operation requires, follow these steps:

A business plan and mobilization of funds for investment in equipment and premises,
Training staff on the safe and hygienic processing,
Regular and adequate supply of fish to operate the facility at planned capacity,
Access to reliable and affordable utilities and fuel,
Contracted marketing of finished products to minimize storage and maintain cash flow.

The primary expense of mechanized fish processing equipment varies depending on the type and size of the machinery required. Consider the cost of equipment installation, transportation, and any associated import duties and taxes, with the technology available in countries like Democratic Republic of the Congo, Burundi, Ethiopia, Kenya, Rwanda, Tanzania, Uganda, Benin, Ghana, Côte d’Ivoire, Mali, Nigeria, Senegal, Togo, Angola, Madagascar, Malawi, Mozambique, Zambia, Zimbabwe.

Collaborate with agricultural development institutes and fisheries management organizations to facilitate the adoption and implementation of mechanized processing and value addition technology. Additionally, consider integrating complementary practices such as improved fish storage facilities and efficient transportation methods.

1500 USD

Handheld electric fish scaler

1,000 USD

Filleting equipment

2,500 USD

Equipment for skinning and deboning 10 to 20 fish/minute

2,000 USD

A greenhouse-style solar dryer 15 m × 8 m with capacity of 850 kg fish per batch

IP

Patent granted

Countries with a green colour: Tested & adopted
Countries with a bright green colour: Adopted
Countries with a yellow colour: Tested
Countries with a blue colour: Testing ongoing

Countries where the technology is being tested or has been tested and adopted
Country	Testing ongoing	Tested	Adopted
Angola	–No ongoing testing	Tested	Adopted
Benin	–No ongoing testing	Tested	Adopted
Burundi	–No ongoing testing	Tested	Adopted
Côte d’Ivoire	–No ongoing testing	Tested	Adopted
Democratic Republic of the Congo	–No ongoing testing	Tested	Adopted
Ethiopia	–No ongoing testing	Tested	Adopted
Ghana	–No ongoing testing	Tested	Adopted
Kenya	–No ongoing testing	Tested	Adopted
Madagascar	–No ongoing testing	Tested	Adopted
Malawi	–No ongoing testing	Tested	Adopted
Mali	–No ongoing testing	Tested	Adopted
Mozambique	–No ongoing testing	Tested	Adopted
Nigeria	–No ongoing testing	Tested	Adopted
Rwanda	–No ongoing testing	Tested	Adopted
Senegal	–No ongoing testing	Tested	Adopted
Tanzania	–No ongoing testing	Tested	Adopted
Togo	–No ongoing testing	Tested	Adopted
Uganda	–No ongoing testing	Tested	Adopted
Zambia	–No ongoing testing	Tested	Adopted
Zimbabwe	–No ongoing testing	Tested	Adopted

This technology can be used in the colored agro-ecological zones. Any zones shown in white are not suitable for this technology.

Agro-ecological zones where this technology can be used
AEZ	Subtropic - warm	Subtropic - cool	Tropic - warm	Tropic - cool
Arid
Semiarid
Subhumid
Humid

Source: HarvestChoice/IFPRI 2009

The United Nations Sustainable Development Goals that are applicable to this technology.

Goal 2: zero hunger

Goal 3: good health and well-being

Goal 5: gender equality

Goal 12: responsible production and consumption

Preparation: Start by removing scales and gut contents from whole fresh fish. For catfish without scales, use pliers to pull skin away from flesh and bones.
Sanitization: Ensure all tools and surfaces used for processing are regularly sanitized with clean water and disinfectant to maintain hygiene.
Staff Hygiene: Staff hygiene is critical for food safety. Ensure workers use gloves, hairnets, and overalls to maintain cleanliness during processing.
Cutting and Deboning: After cleaning, the fish can be cut into fillets, skinned, and deboned as needed.
Drying: For drying, consider using solar tent dryers. Sunlight heats the air inside the tent, gently desiccating the fish. A motorized fan can accelerate convection and air circulation for efficient drying.
Positioning Tents: Position the tents facing the prevailing wind to improve air movement. Well-constructed units are rainproof and can even be operated in bad weather.
Smoking (Optional): If desired, smoking fish can add flavor and provide short-term preservation. The optimal smoking temperature ranges from 45°C to 70°C. Smoking for one to two hours provides an appetizing taste, but you can extend it for four to six hours for complete drying.