About Us
A Description Of The Process
This section of the site will explain in detail the characteristics of
the salmon used along with detailed information on the processes followed
in the factory.
Salmon Characteristics
Manufacturing Process
General Rules Applied
SALMON CHARACTERISTICS
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Specie
Fresh Farmed Atlantic Salmon (salmo salar).
Origin
Irish farmed. Alternative supply in case of non-availability (gales,
storms, fallowing, seasonal gap): Shetland/Scotland farmed in fish farms
similar to the Irish ones –i.e. exposed offshore sites low density
<15kg/M3. Allowed yearly limit approved: less than 5% of imported salmon.
Sizes
2 kg gutted minimum to 7 kg gutted maximum.
Fat content
10gr to 15 gr for 100gr of flesh.
Presentation of products at delivery
Quality, ISGA superior, gutted and bleed, (at least 90% year supply).
Organoleptic quality "extra" >/= 2.7.
Free from diseases or deterioration. Skin and flesh free of parasites.
Freshness
Fish bleed and gutted the day of harvest.
Fish kept on ice from the time of harvest.
Delivery to factory:
From packing station within 30 miles (Castletonbeare and Caherciveen)
Fish boxes 1/3 ice 2/3 fish or in fish bins 1/3 ice 2/3 fish covered
with water.
Utilisation within 48 hours of harvest.
From other origins
Isotherm boxes, 1/3 flaked ice 2/3 fish, circled in packing station,
open in factory. Maximum delay between harvest and filleting in factory
- 5 days.
Labelling of containers
Date and site of harvest, number of fish, presentation, specie, size,
batch number.
Sawdust characterisitics
Delivered in sealed bags, guaranteed free of chemicals, 80% pure oak,
possible adjunction up to a maximum of 20% of non resinous wood (beech,
elm, alder, wild cherry, apple or pear tree).
Salt
Natural sea salt, delivered in sealed bags, superior quality, free of
additives and chemicals.
Other products
Catering food grade. Natural cane sugar, spices and dry herbs, groundnut
oil, white wine vinegar.
MANUFACTURING PROCESS
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Reception and preparation of fish
Storage cold room, 0c/2c. Empty containers with their ice have to be
removed together at the end of the filleting process.
Filleting
In specified area 2 (primary processing), fish temperature </= 2c
at the beginning of operations.
Cleaning, heading, filleting with elimination of back bone, elimination
of fat, fins, collar bone, pin bones and tail.
Controls of fillets: elimination of soft flesh fillets, and any fish with
parasites (kutoa, nematodes, copepods) as well as those with blood clots.
Rincing and disposal of clean fillets for salting.
Salting
Dry salt method on trays, storage in salting room (max 12c). Time according
size, salt (NaCl) content between 2% and 3% at the end of process. Salted
fillets are rinsed and the residual water on flesh is dried.
Smoking
AFOS kilns at <27c cold smoke. Semi combustion of saw dust (pyrolyse)
between 400c and 500c to avoid production of 3-4 benzo-pyrene. Trolleys
removed to fridge No 2 for cooling as soon as smoking process is completed.
End result:
Water content < 65%, salt content between 2.5% and 3.5%, total phenols
0.8mg and 2mg per 100g, core temperature 0c to 4c.
Slicing
Slicing in area 6 or 5. Core temperature of products < 10c. Whole
sides checked for remaining pin bones, put on board in plastic sleeve.
Every product ready to be vacuum packed removed to fridge No4.
Vacuum Packing
Within 24 hours of slicing. Labeling according the importing country
legislation and client's specifications.
Vacuum packed products removed to fridge 5 (dispatch).
GENERAL RULES
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One way flow of the processed goods: fresh fish, fresh fillets, salting,
smoking, slicing, vacuum packing and labeling, dispatching.
Quantity of fish to work on is kept to a minimum in order to maintain
the core temperature as low as feasible. Raw material removed to chill
at each break and as soon process or part-process is completed.
Clear separation of primary processing (fresh fish filleting and storing)
and secondary processing (salting, smoking, slicing, packing).
Goods are considered protected once they are vacuum packed and at the
correct core temperature of 0c/+4c.
Zero stock system for fresh food; first in / first out for all stocks.
Less than one week between harvest in fish farm and expedition to client.
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