UNIVERSITY OF CALICUT
REPORT OF INTERSHIP
DONE AT
GRAND MARINE FOODS PVT.LTD
Submitted by
SARATH N M
REG. NO. AIATBVY036
BVOC FISH PROCESSING TECHNOLOGY
MES ASMABI COLLEGE, P. VEMBALLUR
2019-2022
GRAND MARINE FOODS AROOR ALAPPUZHA
GRAND MARINE FOODS -A PROFILE
The Grand Marine Foods is a Partnership firm consituite of 4 patners
(managing patners, factory manager, production manager, purchase manager)
and it is the one of the leading sea food exporter in India, established in 2012.
Grand marine foods is a seafood industry situated in Aroor in Alappey District.
Grand Marine Foods has since grown rapidly to became a global player in the
sea food industry with exports to all the major sea food market including US,
Europe and other non - E. U countries.
The company strives continually to serve the customer by maintaining a
clear understanding of their needs and requirements and endure to provide
products thus meet their expectations. For achieving this, Grand Marine Foods
has implemented HACCP system in the company and also BRC certified.
Individually Quick freezing machinery from M/S. Dantech, Denmark,
were installed in the year 2019 with a capacity of 15 MT/day. The processing
sections are built in accordance with the European Union norms HACCP pre -
requisite standards and USFDA standards and specifications with respect to
hygiene and sanitation.
The factory has separate sections as raw materials receiving section,
preprocessing section, packing section, ice plant, cold storage, quality control
laboratory, machine room, packing material store etc. The main freezing
machineries IQF line with cooker ( capacity 15 ton /day) The main three plate
freezers with enough capacity and five tunnel freezer of 30 tons capacity each
Apart from the company is installed with two flake ice machines and one block
ice plant and two chill room.
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The quality control system and standards are the most rigorous in the
industry. The company has an array of qualified personals to scrutinize each and
every stage of production right from the raw material receiving to the shipment
of furnished product is tested in the laboratory.
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RESPONSIBILITY OF HACCP TEAM
HACCP team consists of members from different disciplines having sufficient
knowledge in their respective fields.
THE HACCP TEAM CONSIST OF:-
Managing partner: Planning entire operation and activities, technical and
financial support
Factory manager:interaction with concerned managers on policy and day
today functioning, implementation of corrective actions
Production manager:plan and execute production of fishery as per laid down
norms
Purchase manager: placing firm orders towards procurements of materials,
purchase all input materials as per company's policy
Q. A manager: leader of HACCP team, responsible for quality and safety of
products processed
Maintenance head: Ensure smooth functioning of all instruments, machineries,
equipment’s, maintain operations of all sections
Online QC: Responsible for execution of quality control in processing
activities in consultation with QAM, Monitor critical control point, Responsible
for entire cleaning and hygienic programs, Responsible for online inspection
and recording
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HACCP PRODUCTS :-
INDIVIDUALLY QUICK FROZEN
▪ IQF Raw shrimps- Sea caught/ aquaculture
▪ IQF blanched shrimps-Sea caught/ aquaculture
▪ IQF cooked shrimp-Sea caught/ aquaculture
▪ IQF cooked cephalopods
▪ IQF blanched cephalopods
▪ IQF raw cephalopods
▪ IQF raw histamine forming fish
▪ IQF raw non histamine forming fish
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BLOCK FROZEN AND BLAST FROZEN
PRODUCTS
▪ Frozen Shrimps / Lobsters – Sea Caught
▪ Frozen shrimps Aquaculture
▪ Frozen Cephalopods
▪ Frozen Histamine Forming Fish
▪ Frozen Non Histamine Forming Fish
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FUNCTIONING OF DEPARTMENT
The factory operates by carrying out different operations in the following
given departments.
● Human resource department
● Finance department
● Purchase department
● Production department
● Quality control department
● Electrical department
● Mechanical department
1) Human resource department
The human resource department provides high quality human resource to
the company to effectively and efficiently run the various business operations in
the company. The human resource department responsible for all the HR
activities that include recruitment, training and development compensation and
benefits, employee relation and working environment of the company .The HR
department which is not directly involved in the manufacturing of the product
but work as an advisor toward all the working procedures in making of a
product. As job responsibilities and duties are assigned by the HR professionals
to the other working staff with the specific terms and conditions and by keeping
in mind the right job for the right person. It is also responsible for the data
collection and keeping all the records related to working staff their salary their
basic information etc. and each and every record about the manufacturing
product on the daily basis.
Human resource department provide such human capital that will be
helpful for running the operation of the company in effective and efficient
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manners, and by caring about the interests of personnel of the company so that
they can become more productive and motivated for their work.
2) Finance department
The main objective of the Finance department in the company is to
arrange the finance for the business operations from various resources, control
the activities that are related with the finance, maintain and update the
company’s accounts.
3)Purchase department
Purchase department working for its objective to provide raw material
and required goods be in the factory on time and successful execution of all
required orders.
4)PRODUCTION DEPARTMENT
Production department is a important department in a production
company. Production means creation of utilities cover all the activities of
procurement, allocation, and affiliation of resources such as labour, energy,
material, equipment, machinery etc.
In Grand Marine Foods ensures the quality and freshness of the product
to customers. The Grand marine foods produces the product with strict quality
control. And ensures strict quality control during transportation also. The duty
of quality control is vested in quality assurance team. This team gives almost
care in every stage of processing. For the efficient and quality production Grand
Marine Foods made technical collaboration with the foreign companies also.
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The production department works 24 hours around the clock in a day. The
profit of the company depends on the production capacity of the company. If the
production is higher the profit will also be higher. The production department is
not like any other department in company. All other department are related with
the external environment of the company but the production department is
directly related to the internal environment of the company. The company has
150 workers, 12 supervisors, 5 technical staffs 12 QC are there in a company in
two shifts, Shift of employee
● First shift 8.30am to 6. 30pm (A shift)
● Second shift 7 pm to 4am (B shift)
The company produces and process a wide range of product in block as well as
IQF form. The processing plants are uniquely designed with separate processing
lines, each line specifically catering to shrimp, cephalopod, fish and fish
products. This separate production line help to avoid cross contamination of
products, also can focus in one product processing at a time.
PRODUCTION DEPARTMENT CONSIST OF:
▪ Raw material receiving section
▪ Pre- processing section
▪ Processing section
▪ Packaging section
▪ Storage
Raw material Receiving section
This is the section where the company receive raw materials which is
purchased from registered fishing vessels. The raw material receiving room is
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having enough space to carry out the activities such as washing, weighting,
inspection etc.
On the arrival of the raw material, after verification of the documents the
material is unloaded to the raw material receiving section where temperature of
the raw material is checked for 4°c or below is acceptable and also materials is
inspected organoleptically for smell, texture, colour, discoloration, blackspot
and damage .
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PRE- PROCESSING SECTION
● In this sectiondifferent product styles are produced
● Grading and chemical treatment and performed in this area
● Gutting, cutting, peeling, splitting, trimming, activities are doing from the
ppc table provided with running potable water from the elbow operated
taps
● peeling is the second section of production. Different variety of products
of different species are produced as per the demand of consumers and
requirements
● Grading Section In this step the purchased raw materials are classified on
the basis of type, size etc. But mainly the grading is done on the size. The
special grading will be done on the basis of requirement of the customers
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Different product styles includes :-
SHRIMPS
● Shrimp whole
● Head less shrimp - shrimp without head
● PUD (peeled undeveined shrimp, No shells, no head with veins
● PD (peeled deveined no shells, no head and no veins
● PD tail off
● PD tail on
SQUID
● Sqiud rings
● Squid whole cleaned
● Squid with tentacle
● Squid without tentacle
● Tentacle only
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CUTTLE FISH
● cuttle fish whole cleaned
● Cuttle fish egg only
● Cuttle fish rectangular piece
● Cuttle fish tentacle
● cuttle fish ink
● cuttle fish cartilage
OCTOPUS
● Octopus whole cleaned
● Octopus tentacle
FISH
● Fish whole only
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TREATMENT OF CHEMICALS
Salt 4.4 %/200 kg is added for chemical treatment
PROCESSING SECTIONS
The processing section is also sufficiently large with all facilities.Tables,
utensils, and other food contact surfaces are made upofstainless steel, and are
smooth and easy to clean and disinfect .Adequate number of utensils and tables
are provided
All reptacles, trays, tanks, and utensils, used are made of plastic and
stainless steel and have smooth surface free from cracks and crevices
FREEZERS:
● Plate freezers:
There are 3 Plate freezers marked as 1, 2 & 3 . freezer 1,2 having a freezing
capacity of 12 tons/day each and No:3 having a capacity of 9 tons/day, takes 45
- 60 minutes for freezing to reduce the core temperature of the slab to - 18
degree Celsius
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● Tunnel freezing
For induvidual freezing of fishery products, there are four tunnel freezers
having operational Freeze capacity of 30 MT /day each. The trays after setting
is arranged in trolleys and loaded into the freezer trolley freezer takes 2-4 hours
to reduce the core temperature of the product to - 18 degree Celsius
IQF (individual quick frozen product)
IQF processing hall includes treatment section, feeding area and cooking section
in low risk area and high risk area where chilling, freezing, glazing, glaze
hardening, metal detection, and final packing activities IQF line has a capacity
of 15 MT /Day.
IQF cooking line consist of following parts:-
● Feeding hopper-IQF Line
● Cooking Line
● Water shower cooler
● Vibrator
● In - feed conveyor
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● IQF - freezer
● Inclining take away conveyor
● Glazer
● Hardening conveyor
● Glaze hardener (IQF Double belt freezer)
● Transfer curve conveyor
● Water double dip glazer
● Water chiller
● Metal detector
● Anteroom
● Cold store
Packing section
The packing is done as per the customer requirement and each one is
displayed with the code. The packed products are stored in a provided building
for storage. The storekeeper is responsible for the security of the products stored
in the store room.
The products are highly perishable products, well freezing is needed for
the preservation of the product. The temperature in the store room is below -
18°c. Processing plant has a capacity of 100 metric tons per day.
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Cold store
● The packed finished product are stored in cold storage
● Temperature is maintained at or below - 18 degree Celsius
● The finished frozen product is inspected by QC personnel to check
whether it meets specification
● Samples are drawn for organoleptic and bacteriological inspection as per
sampling plan
Shipment
● Before shipment condition of the containers checked for cleaning
● working of reefer unit or any leakage on container and after confirmation
the condition of containers checked, the cargo is transferred to container
from the cold store through shipment bay as per shipment approved
issued by the QC
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6) QUALITY CONTROL DEPARTMENT
Quality control is the control of quality during the manufacturing process.
Inspection of the quality of the products manufactured is an important part in
any scheme of production control. Quality of the product should be controlled
during the production process. Control of the quality during the production
process is called as quality control. Quality is inspected during each phase of
the production by the quality control department.
The quality of the product may be defined as the sum of number of
related characteristics such as shape, dimension, composition, strength,
workmanship, adjustment and color. The commitment to deliver only the
highest quality products is the guiding principal of the company. They prepared
fledged laboratory for bacteriological analysis and strict monitoring by qualified
and experienced quality control persons adhering to GMP. SSOP, and HACCP
system ensure quality and perfection of all products. The quality control persons
test the sample of raw materials, ice water etc. Strict monitoring of all
processingstagesare carried out by the laboratories, for chemical, physical,
microbiological and bacteriological analysis, that the company has setup each
production unit.
Duties & responsibilities of senior technologist
● Maintain the laboratory and equipment
● Responsible for testing of sample in the laboratory
● Ensure calibration of laboratory equipment
● Maintain records of analysis and other ISO and HACCP records relating
to laboratory.
● Duties & responsibilities of senior technologist
● Responsible for microbiological analysis
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● Monitoring of personal hygiene.
● Cleaning operation.
● Maintenance of sanitation in the plant.
● Monitoring pest control management.
Quality control is the control of quality during the manufacturing process,
Inspection of the quality of the products manufactured is any scheme of
production control.
Benefits of quality control
● The Quality control department tries to finished products more uniform in
quality and more reliable in service.
● The quality control department inspects the quality of the product in each
step of the production so, it reduces cost of inspection.
● Quality control avoids reduction in the quantities of scrap, rejected parts
or products.
● Quality control is directly responsible to improve relations between a
producer and a consumer in the market place.
● Quality control introduces quality consciousness in the minds of both
management and employees.
● The company can use maximum resources and also reduces the wastage
by the activities of quality control department.
Inspection & testing
Inspection and Testing are the two important activities that should be done by
the quality control department to maintain the quality of the product throughout
the production. The quality assurance department checks the material at all
stages of processing. The inspection and testing of materials are divided into
three stages.
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● Raw material testing
● In processing testing
Raw material testing
At first raw materials are received for quality check. Raw materials
include various varieties of fish. Then test the materials and records the result.
There parts are sent to raw material section with the remark of assisting QA
officer. QA department keep one copy of test result. The quality control
department checks the raw material at the time before the production. In process
testing
In process testing is the other testing procedure. In process testing means
check the raw material at the time of the production. This will help to avoid all
the problems at the time of production. Quality department prepare the sampling
plan, inspection and test schedule and the frequencies given for various stages
of process.
Final inspection
Final inspection means inspect the products after the production before it
is given to the hand of customers. The inspection team collects samples of the
final product. The quality control teams give it to do certain tests on it as
biological test, chemical test, impurity test etc. investigators 36 collect the
sample from packing randomly. The officers concerned do the checking by
scooping the seafood from a number of packets.
The food products are subjected to undergo a number of biological and
chemical tests regarding their toxicity and decayed. The manager of QA decides
the final material acceptance criterion, collects the sample again from packing
selection randomly. They carry out the test again and record and show the
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results to QA worker manager and departmental heads. QA officer decides the
final approval of materials. If the material is rejected investigator record the
specification in the non-confirmation show to concerned show to concerned
personnel.
MICROBIOLOGY
Microbiology is scientific study of microorganism, those being,
unicellular, multicellular, or acellular Microbiology encompasses numerous
sub-disciplines including virology, bacteriology, mycology, immunology and
parasitology.
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MICROBIOLOGY LABORATORY INSTRUMENTS
Autoclave:-
● sterilisation of glasswares and media,
● 121 degree Celsius for 15 -, 20 minutes,
● To kill microorganism and spore
Incubators
● provide temperature controlled environment for growth of
microorganisms
● 37 degree Celsius for 24 to 48 hours
Colony counter
● instrument used for count the colonies of bacteria
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LAF (Laminar air flow chamber):-
● Provide a sterilized environment for inoculation
● LAF provide ultraviolet radiation
Water bath:_
● water bath is laboratory equipment made from a container filled with
heated water.
● It is used to incubate samples in water at a constant temperature over a
long period of time.
BOD Incubator:-
BOD Incubator (Bio-Oxygen Demand) are used to maintain temperature for test
tissue culture growth, storage of bacterial cultures and incubation where high
degree of constant temperature accuracy is required.
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IMPORTANT RULES AND SAFETY MEASURES TO BE FOLLOWED
IN MICROBIOLOGY LABORATORY
1. Treat all microorganisms as potential pathogens
2. Do not engage in playful or unprofessional activities in the laboratory
3. Wear clean laboratory apron, closed toe shoes during the work in the
laboratory
4. Do not eat or drink in the laboratory, nor store food in areas where
microorganisms are stored
5. Wash your hands with soap before and after working in the laboratory
6. Always keep your belongings; paper, pencil etc. out of your work
7. Never pipette by mouth, use pipetting devices for the aspiration and
dispensing of liquid cultures
8. Keep clean as possible in handling the equipment such as microscope,
centrifuge etc.
9. Do not use laboratory wear during eating or drinking
10.Clean the work table tops with disinfectants (eg: Dettol, 10% bleach, 70%
ethanol) before and after work
11.Sterilize all the equipment and materials before commencing the
experiment
12.Label everything clearly with all the applicable information
13.Use good permanent glass marker for labelling on the glass wares used
for the experiment
14.In case, culture is spilled, inform your instructor immediately; follow the
instruction for cleaning, wash your hands with soap
15.After your work in laboratory, keep all the equipment in their places
16.All the cultures at the end of experiment should be discarded after
inactivation according to the instruction of teacher
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17.Agar and the liquid waste should be disposed only with the instruction of
teacher
18.A person who is unwell should not take part in microbiological exercises
19.Carefully read the instructions, collect the materials, organize the work
and then commence the experiment
20.Do not remove any materials from the laboratory without permission of
the instructor
MICROBIOLOGY LAB
Media preparation room:-
Media are prepared in this room. Prepared medias, chemicals, imgridents, glass
wares etc are separately kept in cupboards
Inoculation room:-
Inoculation area is used for culturing, inoculating, streaking, stabbing etc colony
counter and microscopes are provided for counting and easy identification of
bacteria
Incubation room:-
Incubators, water bath, are ordely arranged in appropriate place
Sterilization
Sterilization room:-
Hot air oven and autoclave for sterilisation purpose is placed in appropriate
place
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Discarding room:-
Autoclave for discarding purpose is placed in appropriate place
ELISA LAB:-
It is used to detect antibiotics residues like chloramphenicol and nitro furan
metabolites in aquaculture raw material accepted in the unit
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STAPHYLOCOCCUS AUREUS
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VIBRIO CHOLERAE
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VIBRIO PARAHAEMOLYTICUS
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SALMONELLA
31
E. COLI
32
TOTAL PLATE COUNT
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7) Electrical department.
This department of the company is responsible for the maintenance of
electricity and electrical wiring
8)Mechanical Department
This department of the company works for the maintenance of the
machinery. They are responsible to run all machinery correctly during the
production and make sure that every machine is perfect for the working.
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CONCLUSION
The sea food has a great market in the whole world. The number of sea
food producers and exporters are increasing year by year because of demand.
They are struggling to make an impact on the minds of customers. Grand
Marine Foods is marketing quality products to the market and they have stable
customers. Grand Marine Foods is a leading sea food exporter in India.
The organization study helped to make a valuable conclusion through the
analysis of different functions of various department performed in the company.
Company is ranked at the top with consideration to quality. The core
competences of the organizations are listed as below.
● Professional management
● Effective leadership
● Cordial relationship between employees and top-level management
● The company has got well established network in industry with sound
manufacturing and marketing experience.
● The company had adequate resource available for expansion.
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