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This Manual belongs to Uwezo Fish Shop. No part of this Manual may be reproduced or transited in any form or by any means, electronic or mechanical, including photocopying, microfilming and recording, or by any information storage and retrieval system, without the permission in writing from Uwezo Fish Shop.

OPERATIONAL MANUAL FOR FISH

A project implemented by Funded by

Standard Operating Manual Page 1 of 35 CONTROLLED COPY

Uwezo Fish Shop P.O. Box ……………. Kilifi, Kenya.

STANDARD OPERATING MANUAL FOR FISH

Document No: UFS/SOP/01

Revision 1 QUALITY ASSURANCE Date : 01/08/2015

TABLE OF CONTENTS

Page

1. Scope 2

2. Introduction 3

3. Food Safety Policy 4

4. Shop Layout 5

5. Operational Plan 6

6. Sanitation Standard Operating Procedures 7

7. Cleaning Procedures 10

8. Personnel 13

9. Processing of Fin Fish (All sizes) 14

12. Waste Management 23

13. Pest Control 24

14. Record Keeping 25

15. Use and Maintenance of Equipments 26

16. Legal Requirements 26

17. Definitions 27

18. Checklists 28

10. Processing of Octopus 21

11. Processing of Prawns 22






SCOPE/ OVERVIEW

The complete Operational Manual includes appropriate prerequisite programs such as Good Manufacturing Practices (GMP) and Sanitation Standard Operating Procedures (SSOP), which are essential for assuring that safe fish and fishery products are produced.

This manual elaborates the best practices for the shop for hazard prevention and identification, evaluation and control of hazards to ensure food safety. The manual will be aimed to define best practices and procedures during fish post-harvest, temporary preservation and transport from landing site to the shop, reception, processing, preservation and selling at the shop.

The people at Uwezo fish shop are dedicated to providing consistently high quality and safe seafood products. For this reason we have written this manual as a guide for our customer and workers. We are dedicated to working closely with our workers, suppliers and customers to achieve our goal of exceeding the standards for hygiene, sanitation and hazard control in our fish shop that produces seafood products. The document is availed to all employees for reading in order to instill proper understanding of our Food safety Policy.






INTRODUCTION: Kilifi County hosts 5,085 families totally dependent on fisheries for their livelihood. Many peo-ple are also increasingly getting involved in the fisheries value chain and the number of families that will directly and indirectly depend on the same will continue to grow in the near future. Mama Karanga refers to female small scale fishery actors, traditional fish mongers and proces-sors, well-known for their characteristic fried fish sold in the street markets of coastal Kenya. Their fish is mostly used at household level. According to surveys conducted by Cast (CAST NGO is an Italian Non Governmental Organi-zation, which has been working in Kilifi County since 2007) in the concluded project dubbed “Wavuvi project - Supporting small scale fisheries in Kilifi District”, Mama Karanga are faced with daily structural and gender-based challenges. These challenges include the following: 1. Difficulty in access to fresh fish due to their total dependence on the fishermen and the

competition from bigger traders;

2. Low representation and decision-making power inside the Beach Management Units (BMU)

3. Poor quality and low value processed products due to inappropriate equipment and lack of relevant skills

4. Household food insecurity due to low and uncertain income: 25.9% of women are head of family with average of 7 dependents in the family.

As a response to the above and associated problems in Kilifi County, Cast has started up a new project named “Mama Karanga - Women of small scale fisheries for food sovereignty”. The intervention is aimed at spreading food safety practices in order to reduce Post-Harvest Losses (PHL) in small scale fisheries; to improve raw and processed sea food quality and its added value and, to diversify the final products sold into local markets.






UWEZO FISH SHOP

FOOD SAFETY POLICY

Uwezo Fish shop is committed to providing safe and wholesome marine prod-

ucts. We shall Endeavour to provide adequate resources and personnel necessary in the implementation and sustenance Good Manufacturing Practices (GMP)

and Good hygiene practices (GHP) in the production and placing in the market of our final products.

We strive to ensure that our products meet and exceed customer’s food safety ex-

pectations.

OBJECTIVES

1. To Establish and Maintain Effective GHP systems. 2. Eliminate Potential Food Hazards. 3. To Ensure effective sanitization regime is implemented and maintained. 4. To ensure staff are continuously trained on food safety.

…………………………. CHAIRLADY

Date of Issue …………………….






SHOP LAYOUT AND EQUIPMENT DISPOSITIONING

SKETCH MAP FOR 3 X 3 M SHOP






OPERATIONAL PLAN The shop shall be run by three (3) workers. They will be in-charge of the daily activities in the shop as it may be required. All the fish will be received at the shop, washed clean and stored in the shop’s freezers as fish selling goes on daily. The shop shall be opened every day in the morning early enough to allow cleaning of the shop and the surfaces and preparation before receiving of fish and selling starts. The shop in-charge will co-ordinate the two workers to clean all the utensils and the surfaces therein. At the end of the day all utensils and surfaces shall be well cleaned and put in order. ORGANIZATION CHART DUTIES AND RESPONSIBILITIES SHOP IN-CHARGE: 1. Overall in-charge of the shop’s daily activities and answerable to any authority in question. 2. Receiving and checking of all raw fish orgarnoleptically. 3. Taking and keeping of total kilos of fish received every day. 4. Filling in all checklists and forms as pertaining to the shop activities. 5. Assigning duties to the two workers in the shop. 6. Stock taking of all fish and its products in the shop. 7. Reconciliation of received, processed and sold fish on daily basis. 8. Selling of fish at the shop. 9. Collecting, keeping and banking of all cash after fish sale. 10. Ensuring all the equipments, utensils and machinery are used accordingly and maintained in

good condition of order and serviced regularly. WORKER 1 AND 2: 1. Receiving and weighing of all fish coming to the shop. 2. Processing of fish and fish products. 3. Cleaning and washing of the shop, equipments, utensils and the shop surroundings. 4. Preparation of ice for collection of fish from the landing sites. 5. Loading and unloading of fish from cooler boxes. 6. Packing of sold fish into the appropriate packaging. 7. Helping the shop in-charge in some duties as it may be required from time to time.

SHOP IN-CHARGE

WORKER 2 WORKER 1






SANITATION STANDARD OPERATING PROCEDURES (SSOP) Sanitation is the process by which public health is protected by proper disposal of waste matter. In the food industries, all waste must be removed, followed by cleaning and disinfecting of the processing areas and its surroundings. It is necessary to document a sanitation standard operat-ing procedures (SSOP) plan for each Food handling outlets so as to clearly detail how sanitation is carried out. Lack of adequate hygiene and sanitation in food processing/ handling areas are usually the cause of most food-borne illnesses. For this reason, all food contact surfaces must always be kept clean so as to avoid contamination to food. Some examples of sources of contamination are water, personnel and equipments. In this document, all the sanitation processes at fish shop are covered. The document is divided into four sections as follows: 1. Good Manufacturing Practices (GMP) 2. Cleaning Procedures 3. Personnel Hygiene 4. Pest Control Program GOOD MANUFACTURING PRACTICES (GMP) The production of safe food products requires that the HACCP (Hazard Analysis Critical Con-trol Points) system be built upon a solid foundation of prerequisite programs. Each segment of the food industry must provide the conditions necessary to protect food while it is under their control. This has traditionally been accomplished through the application of GMPs. These con-ditions and practices are now considered to be prerequisite to the development and implementa-tion of effective HACCP plans. Prerequisite programs provide the basic environmental and operating conditions that are neces-sary for the production of safe, wholesome food. Common prerequisite programs may include, but are not limited to: Examples of Common Prerequisite Programs Facilities. The shop should be located, constructed and maintained according to sanitary design principles (with easy to clean surfaces). There should be linear product flow and traffic control to mini-mize cross-contamination from raw to processed materials. Supplier Control. Each facility should assure that its suppliers have in place effective GMP and food safety pro-grams. These may be the subject of continuing supplier guarantee and supplier HACCP system verification.






Specifications. There should be written specifications for all ingredients, products, and packaging materials. All the detergent and packaging material used in the shop should have its material safety data sheet (product information) from supplier kept well kept within the shop. Production Equipment. All equipment should be constructed and installed according to sanitary design principles (easy to clean surfaces). Preventive maintenance and calibration schedules should be established and documented. (The equipment maintenance log has to be updated every six months on Pg 31) Cleaning and Sanitation. All procedures for cleaning and sanitation of the equipment and the facility should be written and followed. (See Pg 10). A master sanitation schedule is given on Pg 12. Personal Hygiene. All employees and other persons who enter the shop should follow the requirements for per-sonal hygiene. (See Pg 13). Training. All employees should receive documented training in personal hygiene, GMP, cleaning and sanitation procedures, personal safety, and their role in the HACCP program. (See Pg 13). Chemical Control. Documented procedures must be in place to assure the segregation and proper use of non-food chemicals in the shop. These include cleaning chemicals, fumigants, and pesticides or baits used in or around the shop. (Provided by hangouts in the shop) Receiving, Storage and Selling. All raw materials and products should be stored under sanitary conditions and the proper envi-ronmental conditions such as temperature and humidity to assure their safety and wholesome-ness. See fish receiving and sorting on page 16. Traceability and Recall. All raw materials and products should be lot-coded and a recall system in place so that rapid and complete traces and recalls can be done when a product retrieval is necessary. See pg 18. Pest Control. Effective pest control programs should be in place. (See Pg 22)

Other examples of prerequisite programs might include quality assurance procedures; standard operating procedures for sanitation, processes, product formulations and recipes; glass control; procedures for receiving, storage and shipping; labeling; and employee food and ingredient han-dling practices. Ice Manufacturing and Transport to the Landing Sites Fish will be caught and appropriately handled in a boat equipped with enough flake-ice/ ice






cubes made from potable water. The ice will always be solicited from designated plants with good hygienic practices after which they will be packed in clean and sanitized gunny bags. The gunny bags containing ice shall always be transported to the landing site within tightly closed, cleaned and sanitized cooler boxes. Fish Handling Good practices for fish handling will start at a point at which it is taken out of water. The fish is carefully bled and stored in flaked ice immediately onboard. The fish are handled carefully at the landing site to prevent any trampling upon, standing on, throwing about and bruising of the fish; the fish texture will always be maintained in good quality. The fish will always be handled under shade and within an enclosure to prevent drying/heating effects of the sun and wind. Fish will always be kept within ice in layers in the cooler boxes. The fish will be well arranged in layers of flake-ice/ ice cubes to arrest bacterial growth and a subsequent deterioration of quality.

The cooler boxes used in transporting fish to the shop from the landing sites will always be kept in sound state of repair, good hygienic and sanitation conditions. We emphasize on processing our fish at the post-rigor stage to help achieve best quality frozen whole fish and fish fillets by curbing the poor quality effects of rigor mortis such as gaping, toughness and excessive drip loss.

WATER SUPLY

An adequate supply of potable water with appropriate facilities for its storage, distribution and temperature control, should be available. The water temperature can be controlled by putting up a shade over the water tank to at least maintain it at room temperature.

Potable water should be as specified in the latest edition of WHO Guidelines for Drinking Water Quality, or water of a higher standard.

Non-potable water shall have a separate system and shall be identified and shall not con-nect with, or allow reflux into, potable water systems.

The water used at the shop comes from the Kilifi Water and Sewerage Company it is then pumped to an overhead water reservoir tank with a capacity of 500ltrs for incase of water shortage but otherwise the water from the main supply is used directly.






CLEANING PROCEDURES Cleaning and disinfection procedures are very vital in fish processing if food material is to be produced under safe hygienic conditions. Here at Uwezo Fish Shop the targeted soils are:- In fish handling areas. Gross loose sand particles carried by fish. Foreign matter carried by fish. Oily substances got after processing fish. Guts and fish debris. In Ablution block: Soap foams on walls Slimy matter. Urine and faecal matter in toilets Visible dirt. In open areas: Dust Physical matter

1. CLEANING OF WATER TANKS Ensure that the tank to be cleaned is empty and both the inlet and outlet valves are closed. With a hand brush scrub the inner surfaces of the tank using water to remove any adhering mat-ter. Then with a suitable detergent scrub with the brush to clean the surfaces of all the adhering matter. Wash with water to clean all the detergent, then wash again with a 20 ppm Chlorine solution (a half full tea spoon of chlorine powder in 20 liters of water) and let it stay for 15 minutes to com-pletely sanitize. Wash with water to rinse the sanitizer, then drain the tank and wipe dry with a clean piece of cloth. Wash clean the outer surfaces of the tank and the surrounding floor and then wipe the tank dry and open all its valves. The Tank should be cleaned after every four months. 2. CLEANING OF TRAYS AND WATER CONTAINERS. Wash with water to remove loose soil and any other visible dirt. With a hand brush scrub the surfaces using a suitable detergent. Rinse all detergent with water and then wash with a 20 ppm Chlorine solution and let it stay for 15 minutes to sanitize. Wash all the sanitizers with potable water and leave equipment to dry. Trays and water containers are washed after every workday and are sanitized and rinsed before start of days work. 3. CLEANING OF WALLS AND FLOORS. Wash to remove any physical debris. Using a brush, sweep away all the debris, then with the aid






of a suitable detergent, scrub the walls and floor to loosen any adhering soils and stains. Wash the deter-gent with water. Sanitize the walls and floor using a 20 ppm Chlorine solution with a con-tact time of 15 minutes. Rinse the sanitizer and leave to dry. Wash the walls and floor before and after every days work. 4. CLEANING OF TABLES With water wash all the physical debris and dirt away. Then with a hand brush and a suitable de-ter-gent, scrub the surfaces to clean. Wash the detergent with water and then sanitize with a 20 ppm Chlorine solution with a contact time of 15 minutes. Then rinse all the sanitizer with potable water and let the tables to dry. Wash all tables before and after every use. Sanitize tables and then rinse clean before the use. 5. CLEANING OF FREEZER/ FRIDGE. After every use make sure the freezer / fridge is switched off one hour before then scrub all the ice flakes inside the freezer and then wash by scrubbing the side walls and bottom using a deter-gent. Rinse clean the detergent and then use a sanitizer to sanitize by giving it a contact time of 15 minutes. Wash out all the sanitize residues and then rinse clean with potable water. Drain all the water out using a clean dry cloth and leave chamber to dry. Switch freezer/ fridge one hour before use. 6. CLEANING OF COOLER BOXES With the Cooler boxes wash the inside clean with water and remove any remaining ice flakes before scrubbing with a brush and detergent to completely clean any adhering soils. Wash clean the deter-gent and sanitize boxes with a sanitizer by giving it a contact time of 15 minutes. Then rinse all the sanitizer clean using potable water. Wash the cooler boxes lid the same way and leave them to dry. Wash cooler boxes after every use. 7. CLEANING OF FREEZING TRAYS AND KNIVES Wash with water to remove gross soil. Soak in detergent water and scrub off adhering soils using a hand brush. Rinse the detergent with clean water. Sanitize the trays in 20 ppm Chlorine solution with a contact time of 15 minutes. Rinse out the sanitizer with potable water and let them dry. Wash freezing plates and knives after each use. Sanitize and rinse freezing plates and knives before use. 8. CLEANING OF TOILETS Flush the toilets clean. Scrub the toilets thoroughly using a hand broom to loosen any dirt on the floor and side walls using a suitable detergent. Wash with water to rinse the detergent. Then wash with a 20 ppm Chlorine solution and let it stay for 15 minutes to sanitize. Rinse all the sanitizer with clean wa-ter and leave toilets to dry. Clean the toilet daily in the morning. Wash the toilets every day in the morning, and in between if the toilets are badly used.






9. CLEANING OF APROANS AND GUM BOOTS. Wash with water to remove gross soils and then soak them in a detergent to ease stain removal. Scrub the aprons and boots with brush to ensure no visible dirt. Then wash with water and sani-tize with a sanitizer (chlorine) by letting them stay in the sanitizer for 15 minutes. Rinse clean with potable water. Then spread aprons to dry and dry gum boots in open air. Cleaning of aprons and boots is done after every shift. 10. CLEANING OF DRAINAGE SYSTEM Wash drainage system with water to remove gross soils and then with a detergent scrub the drainage side walls and floor with a broom to ensure no visible dirt. Then wash with water to rinse and sanitize with a sanitizer (chlorine) SANITATION SCHEDULE

ITEM/ AREA DETERGENT FRE-QUENCY

CLEANING TOOLS

CLEANING METHOD

RESPONSI-BILITY

Water Tank Omo/ Ariel washing powder

Every 4 months

Scotch Brite Scrubbing Shop in-charge

Trays & Water Containers

Omo/ Ariel washing powder

After every shift

Brush and Scotch brite

Scrubbing Shop in-charge

Walls & Floor Omo/ Ariel washing powder

Before and after every shift

Brush and Scotch brite

Brushing & scrubbing

Shop in-charge

Tables Omo/ Ariel washing powder

Before and after every shift


Freezer & Fridge


After use & monthly

Scotch Brite & wiping cloth

Scrubbing & wiping

Shop in-charge

Cooler Boxes Omo/ Ariel washing powder

After every use


Freezing Trays & Knives


After every use


Toilet Omo/ Ariel washing powder

Daily in the morning

Hand broom Sweeping Shop in-charge

Apron & Gumboots


After every shift

Hand brush Brushing Shop in-charge

Drainage sys-tem


After every shift

Hand broom Sweeping Shop in-charge






PERSONNEL DISEASE CONTROL Medical examinations for personnel working directly in the fish processing areas are done every six months. Here stool and urine specimens are taken for lab testing and then vaccinations against Typhoid are given before the fish handlers are issued with a Health Certificate. The shop in-charge would check and report any person who, by medical examination or super-visory observations show to have, or appears to have an open lesion including boils, sores and infected wounds. They are then immediately excluded from any food related operations, until their condition is corrected. Any person falling sick/ill would visit a doctor, and the treatment and prescription which will be filled by a doctor is returned to the shop for filing. They will again visit the doctor to bring a clean bill of health when condition is corrected so as to be allowed back for processing activi-ties. The shop in-charge would also check all the staff before entering the processing area in each shift for any visible illness, dirty finger nails, unkempt beards etc. In order to suspend any non-compliant worker till they have rectified the situation. See checklist Pg 32. PERSONAL HYGIENE All persons working in direct food contact, food contact surfaces and the packaging material must conform to hygiene practices while on duty. Wearing the appropriate provided clean uni-forms. Maintaining personal hygiene, such as short and clean finger nails, hair is tied back neatly or kept short, etc. All workers must have a shower before beginning their shift. Wash their hands with antibacterial soap on entering their respective work stations. Remove all jewel-lery, wrist watches, or any other object that might fall into food, equipment or food packaging material. No chewing Gum, Spitting, Eating, Drinking, or Smoking is allowed in the processing area where fish is handled. Restraining the use of cosmetics, nail vanish or any other medicines/lotions applied to the skin. These routine checks will be done daily before each shift begins by the shop in-charge. PERSONNEL TRAINING New food handlers (trainees) are given a training of two (2) weeks on the job and any additional training whenever there is an update. The shop in-charge is encouraged to read the available Operation manual during her free time and will be annually tested. On occasion, educational lectures are given to all the fish handling personnel on techniques, food protection principles, and on good house keeping. A personnel training record is filled for each staff who has been trained and filled properly. An in-house training for the personnel will be conducted after every six month by the In-charge.






PROCESSING OF FROZEN WHOLE GUTTED FIN FISH/ FILLETS. This entails Gutting, Gilling (optional), and then Scaling (optional) of the whole fish, the clean-ing of the fish before freezing and storage in deep freezers at a temperature of ≤ − 18° C. TABLE OF FISH SPECIES

ENGLISH NAME SCIENTIFIC NAME SWAHILI NAME

Red Snapper Lutianus sanguineus Shogo

Grey Snapper Lutianus rivulatus Cheusi

Reef Cod Epinephelus macrospilus Tewa

Parrot Fish Callyodon cuttatus Pono

Scavenger Lethrinus variegatus Changu

Trevally Carangoides malabaricus Kole Kole

Dorado Coryphaena hippurus Fulusi

Barracuda Sphyraena japonica Thengesi

King Fish Scomberomorous sommersoni Nguru

Shark /Black Shark Carcharhinus melanopterus Papa

Yellow Fin Tuna Thunnus alabacares Jodari /kiboma

Rabbit Fish Siganus oramin Tafi

Grey Mullet Mugil cephalus Mkizi

Goat Fish Pacudeopeneuc Mkundaji

Sail Fish Intiophorun giadius Sulu suli

Grey/ Black Skin Gaterin sordidus Fute

Red Snapper Lutijanus argentimaculatus Kiunga

Cat Fish Tachysurus dussumieri Fumi

Spotted Grunter Poradasyn opercuiare Pamamba

Milk Fish Chanos chanos Mwatiko

Octopus Octopus vulgaris Pweza

Prawns (Black) Penaeus monodon Kamba

Prawns (White) Penaeus indicus Kamba






FLOW DIAGRAM FOR FISH PROCESSING

PROCESSING PROCEDURE REQUIREMENTS: 1. Fresh wholesome fish (fin fish) in ice, with a temperature less than 3° C. 2. Chilled potable water for cleaning and washing of fish. 3. Clean and sanitized equipment and utensils required for processing of fish. 4. Personnel – complying with all the requirements for a food processor.

RECEIVING

SORTING/ GRADING

WEIGHING

1ST WASHING FILLETING

WEIGHING & SELLING

FREEZING

2ND WASHING

SCALING(OPTIONAL)

GUTTING/GILLING & CLEANING

TRIMMING

SKINNING

REJECTS

SCALES

GUTS

PRE-COOLING IN FRIDGE FOR IMME-

DIATE SELLING

PACKING & LABELING






RECEIVING Fish arrives in cooler boxes together with ice of ratio 1:1. As a Critical Control Point, the prod-uct is checked for any possible source of contamination from any undesirable matter. Then small lots of fish are offloaded into the sorting and grading tray. SORTTING AND GRADING Here the fish is sorted to remove all the rejected fish and then sorted into fish types and species be-fore it is graded into different size categories. The rejected fish are sorted out on the basis of organoleptic checks i.e. sensory evaluation. The quality checks here include:- 1. Bad smell or fish smell 2. Impaired eye refractive index i.e. dull eyes. 3. Pale or Green gills, which are slimy. 4. Softness of the fish tissue 5. Damaged or injured fish. WEIGHING: Make sure your weighing scale is calibrated to zero setting. Then weigh each size category of a different fish species separately and record the weight. This is for incoming goods records. 1ST WASHING Wash all weighed fish individually with clean water under running tap. Washing should be done in such a way that no sand or any foreign matter remains on the fish and in the gills. Clean fish is then taken for gutting and the next processing step. GUTTING, GILLING AND CLEANING: With a sharp, clean knife, make a straight cut under the fish belly to open it up. Then com-pletely remove all the guts manually from the belly then wash clean with potable water. Also re-move all gills (optional) through the operculum by pulling them out with the aid of a knife. SCALING (OPTIONAL): With a knife, pluck all the scales out of the fish skin under slow flowing water to protect the scales from scattering all over. Remove all the scale on both sides of the fish. 2ND WASHING: Wash the De-scaled fish under running water to completely remove all loose scales of the fish skin.






FREEZING Take all freezing trays/ crates with the product into an already pre-cooled freezer. After loading the freezer with the product, let the freezer run to acquire the set temperature. WEIGHING AND SELLING The frozen product is now ready for weighing into the desired weights as requested by buyers. Weighed product will be packed nicely into polythene bags and sealed. The finished product is now ready for selling. FISH FILLETING It takes a certain amount of touch to fillet a fish, but expending a little more effort at the clean-ing stage is worth it because it means no bones at the eating stage. When you get the hang of filleting, you can zip through a pile of fish pretty quickly, and it gives you a sense of accom-plishment that you can do something as well as the old-timers. Don't worry too much if you don't get absolutely all the meat off the fish when you first start filleting. The idea at the beginning is to get some. If you skin the fish, as recommended, you do not have to scale it first. Obviously, if you are going to use the skin, scale it unless you like to eat scales. Figure 1 shows the basics of filleting a small fish (up to about 2 Kgs).

1. Cut off the head just behind the gills. 2. Hold the fish by the tail. With the knife blade pointing away from you and across the body of the fish, begin to cut toward the head (or at least where the head used to be). Use the backbone to guide your knife.

Figure 1: Filleting small fish.






3. To take the skin off, begin by holding the fillet by the tail, skin side down. 4. Hold the knife crosswise across the fillet and insert the knife between the skin and the flesh. Don't worry if you don't get this perfect at first. 5. While holding the skin, cut in the direction of where the head used to be. When you have a larger fish, the tail-to-head method of filleting can be a little awkward. In this case opening the fish like a book is an effective method, as shown in Figure 2.

Follow these steps (shown in Figure 2) to fillet a larger fish: 1. Make a deep cut just behind the gills (about halfway through the thickness of the fish). 2. Cut a slit a few inches in length along the top of the fish (the dorsal side). 3. Using the tip of the knife, separate the flesh from the bones, as illustrated. The fish should open up just like a book. 4. When completely open, finish cutting away the fillet by moving the knife along the "spine of the book." PACKING AND LABELING: The shop in-charge is to ensure fish sold is nicely packed into weight lots into polythene bags and nicely sealed then into cartons (if need be), and strapped using a nice tape. Ensure that the packed product is correctly labeled as it is required. A sticker is put on the sealed packet of the frozen fish and with a marker pen the date of freez-ing, net weight, type of fish and the best before date (six months from date of freezing) are indi-cated.

Figure 2: Filleting larger fish.






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PROCESSING PROCEDURES FOR FROZEN GUTTED OCTOPUS RECEIVING The boxes are opened and checked to ensure that the raw material is completely covered in ice. If the raw material is not to be processed immediately, it is to be transferred to clean cooler boxes and completely re-iced. SORTING Sensory evaluation The shop in-charge is to sort the raw material by hand and by sensory evaluation reject material that is not acceptable. Freshness assessment for raw Octopus

Rejected raw material is to be kept in marked containers to be returned to the suppliers. WEIGHING The shop in-charge is to crosscheck the accuracy of the scale before start of process The shop in-charge is to weigh the raw material in plastic crates and pass them to the gutting/ washing table. WASHING This is a most crucial operation because of the possibility of contamination on the skin of the product due to improper handling at the beaches. A thorough and accurate washing of the product before gutting removes most of the bacterial load that can be associated with sand or soil that might be on the surface of the product. Each individual product is washed under a shower with adequate pressure so that all sand, weeds and threads are removed. GUTTING The shop workers are to gut each product, and rinse under running water The pouch of the octopus is to be inverted (turned on the outside). The intestines are to be pulled out by hand or cut with a knife. The product is then rinsed under

Parameters Acceptable Not Acceptable

Colour Skin Bright Bleached

Meat Pearly white Black, reddish, pinkish

Adherence Adherent to the meat Easily separated from the meat

Texture Meat Very firm, firm Soft

Tentacles Resistant to tearing off Can be torn off easily

Odour Fresh, slight or no odour Sour






running water. Octopus have a small bladder full of black liquid (ink) sometimes by removing the intestines the bladder is pierced and the liquid comes out. The liquid is edible and not con-taminating but the product has to be washed thoroughly for better appearance. PRE-COOLING AND FREEZING The octopuses are set on the trays in orderly manner to make their look attractive once frozen. The trays once filled with octopuses are put on the into the freezer for freezing and some in the fridge to be pre-cooled and immediate selling. The octopus is wrapped in polythene sheets in lots of standard weights like in 2kgs per pack and frozen for future selling. WEIGHING AND SELLING The frozen product is now ready for weighing into the desired weights as requested by buyers. Weighed product will be packed nicely into polythene bags and sealed. The finished product is now ready for selling. PROCESSING PROCEDURES FOR FROZEN WHOLE PRAWNS RECEIVING/ SORTING All prawns will be received packed together with enough ice in clean cooler boxes. Prepare chilled water (ice in water) in water containers. Sort all fresh and good quality prawns at the same time grade them into size category. The sorted prawns are then put in the chilled water for washing.

WASHING, PACKING & FREEZING Wash the prawns in the chilled water by stirring them gently to loosen all sand and any foreign matter. Then arrange prawns straight in a standard packet of 2kg each with a lining of polythene sheet inside. Tie the packet firmly using rubber bands and place them in the freezer ready for sale. Note that prawns should not be stored temporary in the fridge since it is highly perishable (goes bad faster if not frozen hence does not keep for long). The prawns are now ready for sale.

Quality checks for prawns: Grade all the prawns in the following size groups:

1. No black spots on the heads. 2. No broken or loose head. 3. No bad smell (should smell fresh

prawns). 4. Skin should be intact.

Giant:- 5 pcs/kg Jumbo:- 6-10 pcs/kg King:- 11-15 pcs/kg Tiger:- 16-20 pcs/kg Special Queen:- 21-30 pcs/kg Queen:- 31-40 pcs/kg Cocktail:- 41-60 pcs/kg






WASTE MANAGEMENT WASTE DISPOSAL Waste material is handled in such a manner as to avoid contamination of operators, fish and fish contact surfaces. These wastes include: scales, rejected fillets/fish, guts, trimmings mixed with soil, rejected fish frames, and affluent containers for waste are identified. A suitable constricted refuse trough is in place at a strategic disposal site. Immediately after disposal of waste receptacles used for storage are cleaned and disinfected. Waste water from the processing tables is ducted into the drainage system which is finally piped to the shop’s soak pit. Processing floor is designed so as to ensure waste water is adequately drained to the sewer line to a void backflow. The drainage system is thoroughly washed to remove soil which may cause blockage. SEWAGE DISPOSAL The sewage for the shop is all collected on the septic tank and the soak pit. When the pit is filled, a private sewage disposal company is contracted to empty it. All sewage systems are regularly checked for blockages or infestations. TOILET FACILITIES The shop has adequately provided its workers with readily accessible toilet facilities. The toilets are located at a place where they don’t open directly to the processing areas. RUBBISH AND OFFAL DISPOSAL All rubbish is disposed off immediately to the intermediate waste disposal container before be-ing collected for disposal by the county government garbage collectors. The procedure is regu-lated to minimize development of odour and creation of breeding places for pests. This also protects contamination of food, food contact surfaces and water supplies.






PEST CONTROL No pest, animal or any other vermin of any sort are allowed in any area of the food processing plant. The shop has undertaken effective measures of installing Electric Insect Killers to protect against the contamination of food in the premises by pest. Baiting and Spraying Services are also provided by approved contracted pest control compa-nies. IN-HOUSE PEST CONTROL The premises and its environs have been protected from invasion by pests and rodents, by plac-ing of mosquito mesh all over vents and openings to the outwards of the premises and in all drainage outlets. Some guard gates have been placed to prevent rodents from reaching the premises. The out side area is also kept clean by ensuring grass are cut short and gardens well kept. On top of this the processing and receiving area entrances, some fly killers have been placed to tar-get any flies getting access to the Plant. An inspection of pest activity is done for the in-house pest control once in every week and the observation and recommendations given. All the dead insects in the fly killers are collected and disposed of accordingly weekly.






RECORD KEEPING PROCEDURE

RECORDS AND RECORD REVIEW:

The records kept shall include separate files on the daily monitoring, sanitation records, process deviation records, corrective action records, and customer complaint record. Process-ing and other information shall be entered on the records at the time it is observed. Signatures of personnel recording the information and of the person reviewing it shall be entered with re-spective dates of testification into the record.

Records which documents the daily activities/monitoring of the daily operation, check-

ing of sanitation, deviations and unusual occurrences, and the taking of corrective actions shall be reviewed, signed and dated by appropriately trained personnel from Quality Assurance. The documents shall be reviewed and validated on a timely basis, no later than one week after gen-eration. Below is a list of the related records: Raw Fish receiving note Fish processing records Daily sales record Cleaning and Sanitation Checklist Daily Stock sheet Equipment Maintenance Log ACCESS AND RETENTION: All records pertaining to the shop and its operation shall be kept at the shop custody , in a safe place that will allow prompt access when required for inspection. Records shall be filed separately by name of report, and be made available for regulatory per-sonnel upon appropriate request. The records will be kept for at least three years.






USE AND MAINTENANCE OF EQUIPMENTS The equipments in the shop are as follows: 1. Two freezing Units 2. Two Stainless tables 3. Two electronic weighing scales 4. 1 Piece Ice Maker 5. Cooler boxes 6. Water Containers 7. Plastic Crates 8. Knives. All the listed equipments shall be used as stated in the user’s manual and incase of faulty a spe-cialized technician will be called in to attend and rectify the problem. Regular servicing will be mandatory and the Equipment maintenance Log shall always be filled and kept properly. The equipments shall be checked regularly after every six months by a qualified technician and the maintenance log filled promptly. No one unauthorized will be allowed to operate any machine in the shop without the consent of the shop in-charge. Always switch off electricity and machines/ equipments when not in use. This is to save elec-tricity cost. LEGAL REQUIREMENTS The shop will have to comply with all the legal requirements as it may be required by law. All the necessary Permits and Licenses will be obtained earlier in advance from the County Government to avoid any penalties. The shop in-charge shall ensure all workers in the shop are medically examined and issued with valid Medical certificates as required by law. All the Permits and Licenses renewable yearly shall be applied for early in the beginning of the year. The shop in-charge shall inspect and check all the permits and Licenses for renewal and has to make sure they are done in time.






DEFINITIONS Authorized: Which has been permitted by the Local Government Units or designated official. Chilling : Is the process where the product is cooled to the temperature of 0ºC (32ºF) Environment: Surrounding area/place where fresh fish and fishery products are handled for sale. Equipment and other containers: Include cutting knives, scissors, packaging materials and other utensils used in the handling and sale of fish and fishery products. Fish : Includes all fishes and other aquatic species such as crustaceans (crabs, prawns, shrimps and lobsters), cephalopods (squid, cuttlefish and octopus) and mollusks (clams, mussels, scal-lops, oyster, snail and gastropods). Fish vendor/handler: Any person (the principal vendor or his/her assistant) who directly han-dles fish and fishery products in the distribution chain and is therefore complies with the per-sonal hygiene requirements. Fishery/aquatic products: Include all other edible products of aquatic living resources in any form. Fresh Fish: Fish that have not undergone any treatment or any processing and exhibit a good quality characteristics. Handling: Is the manner of packing, storing and maintaining the quality of fish and fishery products. Ice: A solid state of potable water use to maintain the low temperature of fish and fishery prod-ucts for preservation purposes. Perishable: Rapidly spoiling or decomposing commodity. Potable water: Water that is fit for drinking for human consumption, one that meets the re-quirements as specified in the International Standard for Drinking Water, WHO (1963).






RAW FISH RECEIVING NOTE

DATE FISH TYPE KILOS FISH QUALITY STOCK IN SIGNED BY:






FISH PROCESSING RECORD

DATE FISH PROCESSED (KG)

FILLETS (KG)

STEAKS (KG)

BY-PRODUCTS

SIGNED BY:






DAILY SALES RECORD

DATE TYPE OF FISH SOLD

KILOS SOLD CASH IN (KSH)

FISH SOLD BY:






DAILY STOCK SHEET

DATE STOCK B/F STOCK IN STOCK OUT

STOCK C/F SIGNED BY






CLEANING AND SANITATION CHECKLIST

DATE: CLEANING DONE BY:

ITEM

Satisfactory Re-Clean Checked By:

Raw Material Freezer

Final Product Freezer

Washing Table

RATE CLEANING

Processing Table

Floors and Walls

Cooler Boxes

Plastic Crates

Knives

Water Containers

Outside Area

Back Yard

Others

Remarks: Signed By: _______________________






EQUIPMENT MAINTAINANCE LOG (EVERY SIX MONTHS)

DATE: _________________________

EQUIPMENT CONDITION CHECKED BY

FREEZER NO. 1

FREEZER NO. 2

ICE MAKER

SCALE NO. 1

SCALE NO 2

IDENTIFIED PROBLEM:

SERVICE DONE:

COMMENTS: TECHNICIAN:_______________________ DATE: ___________________






HYGIENE RECORD DATE: ……………………… SHOP INCHARGE……………………

UNIFORMS PRE-START LUNCH END OF SHIFT

1. Complete Set

2. Clean

3. Worn correctly

PERSONAL HYGIENE

1. All staff have showered

2. All staff have short nails

3. All staff have short hair/ head covers

4. All staff have no running nose running stomach

5. All staff have no visible skin lesions

6.All staff have valid medical certificates

7. All staff have washed hands with disinfectant

8. All staff have rinsed hands well

9. All staff have no bungles, rings, watches, etc.

IDENTIFIED PROBLEM

CORRECTIVE ACTION






NAME AREAS TRAINED IN AND RATING

GOOD HYGI-ENIC PRAC-TICES

GOOD MANU-FACTURING PRAC-TICES

FISH HAN-DLING & PROC-ESSING

CLEAN-ING PRO-CEDURES

RE-MARKS

REMARKS: SIGNED BY:

NB: RATING IS FROM 1 TO 5. 1 - Not well Trained and needs re-training. 5 – Well Trained and can train others.

UWEZO FISH SHOP TRAINING RECORD DATE: ……………………… SHOP INCHARGE……………………

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