How Canned Tuna is Made

Summary

The tuna processing journey begins with the fish being caught and carefully handled aboard the vessel to preserve its freshness. It is then transported to a cannery where it undergoes quality checks, deboning, and steam pressure cooking for sterilization. After cooking, the tuna is categorized, canned with brine or oil, and sealed to maintain freshness. The cans are heat-sterilized, cooled, labeled, and packed for distribution. Despite its decline in popularity, canned tuna remains a significant product with an expected revenue increase from $8.57 billion to $11.89 billion by 2027.

Takeaways

• 🐟 Tuna is immediately bled and gutted on the fishing vessel to preserve freshness and quality.
• 🔥 Some tuna is pre-cooked on board through quick steaming to help maintain flavor and texture before reaching the cannery.
• ❄️ The fish is rapidly chilled or frozen after handling to prevent spoilage during transport.
• 🏭 Upon arrival at the cannery, tuna undergoes strict quality checks including assessment of freshness, size, and overall condition.
• 🧊 Frozen tuna is thawed before processing, then deboned to produce boneless fillets or chunks.
• ♨️ Tuna is cooked in steam pressure chambers (retorts) to sterilize it, remove excess oils, and ensure food safety.
• 🔍 Cooked tuna is inspected again, and any damaged or inferior pieces are discarded before product categorization.
• 🥫 The selected tuna is canned with a regulated amount of brine or oil, then sealed airtight to maintain freshness.
• 🔥 Sealed cans undergo heat sterilization and rapid cooling to eliminate microorganisms and preserve texture and taste.
• 🏷️ Cans are labeled, packed, and shipped under controlled conditions, with strict quality control throughout the entire process.
• 📈 Although tuna is no longer America’s top seafood, the global canned tuna market continues to grow, projected to rise from $8.57B in 2020 to $11.89B by 2027.

Q & A

Why is bleeding the tuna a critical step in its handling aboard the fishing vessel?

Bleeding the tuna removes the blood from the fish, which is crucial for maintaining its freshness and quality, preventing the blood from affecting the taste and texture of the meat.

What is the purpose of pre-cooking tuna aboard the fishing vessel?

Pre-cooking tuna through quick steaming helps preserve its freshness and retain its natural flavor and texture until it reaches the cannery for further processing.

What is the difference between chilling and freezing tuna after on-board handling?

Chilling involves storing the tuna at low temperatures, while freezing exposes the fish to sub-zero temperatures. Both methods preserve the tuna’s freshness, but freezing helps extend its shelf life for longer transport.

Why is quality checking performed on the tuna at the cannery?

Quality checks at the cannery ensure the tuna meets required standards for size, freshness, and overall quality before it is further processed into products like canned tuna.

What is the process of deboning tuna, and why is it done?

Deboning tuna involves removing any remaining bones from the fish to produce boneless tuna fillets or chunks, which are easier for consumers to consume and are preferred in most canned tuna products.

How does steam pressure cooking (retort) contribute to tuna processing?

Steam pressure cooking in large chambers (retorts) cooks the tuna at high pressure and temperature, sterilizing it and eliminating harmful bacteria while also removing excess oils.

What happens to damaged or inferior pieces of tuna during processing?

Damaged or inferior pieces of tuna are discarded to ensure that only high-quality portions are used in the final canned product.

What types of canned tuna products are produced after processing?

The tuna is categorized into different products such as solid white tuna, chunk light tuna, and other varieties, depending on the desired final product.

What is the significance of sealing the tuna cans tightly?

Sealing the cans tightly ensures that no air enters, which helps maintain the tuna’s freshness and prevents contamination. This is crucial for preserving the product’s shelf life.

Why is heat sterilization important in the canning process?

Heat sterilization destroys any remaining bacteria, enzymes, or microorganisms, ensuring the safety of the canned tuna and extending its shelf life by preventing spoilage.

What measures are taken to ensure the quality of canned tuna during production?

Strict quality control measures are in place, including regular testing and analysis of samples to verify that the canned tuna meets industry standards and regulatory requirements.

What factors contributed to the popularity of canned tuna in the United States?

Canned tuna became a staple in American households due to its convenience, long shelf life, and affordability, making it a reliable pantry item for over 50 years.

What is the expected market trend for canned tuna from 2020 to 2027?

The canned tuna market is expected to grow, with revenues rising from 8.57 billion USD to 11.89 billion USD between 2020 and 2027, reflecting continued demand despite a slight decline in popularity.