Vostochny Fish Processing Plant Group of Companies

The process flow is organized such that each production area could support one operation and feedstock could proceed from one area to another only in one direction passing a dedicated control point. Feedstock flows at different process stages do not intercross. Feedstock logistics allow for its temporary accumulation at any process stage, duplication of flows and redundant capacity to be used in case of equipment failure or human errors. Buffer storage is also provided for process equipment items including empty and filled block molds and block liners.

Fish is supplied to the plant by a system of conveyors from a specially arranged area on the shore in 55 meters from the plant or transported by trucks from other locations. It is unloaded via a weighing hopper. The feedstock area is equipped with 7 hoppers having a total holding capacity of 182 m³. Fish is chilled in hoppers by a mix of water with flake ice prepared in two ice generators with a total capacity of 50 tons per day and transported by a specially designed pneumatic system. The cooling water system is of a closed-circuit type, with water treated and released as it becomes too contaminated. Conveyors distributing fish between hoppers are provided with work stations normally used for removal of garbage and by-catch and fish segregation by species. There is an option to load part of received fish to trucks for transportation to the second company plant.

The design of hoppers precludes partial jamming of feedstock, its crushing and mechanical damage due to accumulation of an excessively thick layer of fish, existence of “dead spots” and similar designing and manufacturing errors. Another specific feature of this hopper is that incoming and outgoing flows are independent and may proceed simultaneously. Each hopper can be loaded and discharged independently of other hoppers.

From the raw material receiving area, fish is fed to the sorting area where it is manually sorted by type of processing. Fish to be frozen whole is fed to the area for fish placing into block molds with 14 work stations. This process cycle can be used for any fish frozen whole – smelt, saffron cod, herring, pollock, etc.

Sorted fish is directed to the dressing area. H&G and HOG is produced by three-slot conveyors manufactured by Technological Equipment Company. Fish is directed from the sorting area to a respective machine which precludes repeated sorting. At slot conveyors, roe, milt and waste are extracted separately after which sac roe is directed to sorting and placing into a block liner and milt is either directed to placing into a block liner or together with waste is fed by a system of conveyors to the crusher and then sent by a pump via a pipeline for processing or disposal. Fish heads are sent to the same place.

Sac roe unsuitable for freezing is fed to the roe processing workshop with a daily capacity of 20 tons for production of screened salted roe. Sac roe from the dressing area is fed to a rotary table from where it goes to the receiving conveyor of UPI-800 screening machine (separator). This machine designed and serially manufactured by Technological Equipment Company is capable of processing roe of any fish species without replacement of parts and assemblies and increasing roe yield from soft sacs by at least 10-20% compared with Japanese analogs. Screened roe is salted in bowls and dewatered in special centrifuges.

Then roe is sent to a table where spices are added to it and then proceeds to an inspection conveyor equipped with a special device spreading roe in a layer one egg thick on the moving band backlit by LEDs. Defective eggs are removed by vacuum pincers at 4 work stations. Roe outlet is equipped with a weighing terminal with a container on it. As soon as the weight of this container reaches a preset value, the conveyor stops, the filled container is forwarded for packing and storage, a new container is put on the scale and the conveyor is activated again.

Brine is prepared using an UKhPT-2000 unit. It comprises five blocks: an elevator for mechanical loading of salt or a platform with a ladder for manual loading of salt; salt concentrator in which salt is dissolved and solution is saturated to a density of 1.19; dirty brine drum accumulation of untreated brine with a density of 1.19; control block comprising filter flushing drums, filtering unit, control unit and hydraulic cabinet; and clean brine block for sterile brine accumulation. Brine is centrally distributed to factory consumers via a system of pipelines and flexible hoses.

After gutting, extraction of viscera, kidney removal and washing, fish bodies are sent to the second area for placing into block molds. In the area for fish placing into block molds, fish bitten by sea animals is rejected, remaining fish is placed into block molds, empty and filled block molds are accumulated in a buffer before being sent for freezing in a plate quick freezer. Fish moving pattern before getting to the placing machine table/hopper is circular; the conveyor in this area has high sides, significant length and width and serves as a buffer allowing for continued fish gutting when placers are unable to handle the flow timely. If required so due to production reasons, both dressed and whole fish can be placed into block molds in both placing areas.

Filled block liners and block molds are frozen in 2 freezing areas. Roe is frozen in 2 plate quick freezers and block freezing is performed in 12 plate quick freezers.

Frozen products are discharged from quick freezers to packing areas. Roe is squeezed from block liners by a special machine, packed in boxes and banded. Block-frozen fish is subjected to thawing, demolding and packed. Block molds are returned by a chain conveyor via a washing unit to placing areas or accumulated for buffer storage. Blocks are packed in a polyethylene liner and kraft bag. Packed products are put on pallets, each product type in a separate production area, and transported to warehouse. Separate storage areas are provided for frozen sac roe, screened salted roe and block-frozen fish.

All plant equipment was manufactured and supplied by Technological Equipment Company. Technological Equipment Company has been designing and manufacturing fishing processing plants and refrigerated warehouses, developing and introducing waste free technologies, designing and manufacturing modern high-tech serial equipment for fish processing for 19 years. During its lifetime, the company has implemented 50 major engineering projects in the Russian Far East achieving significant practical results in recovery of Russia’s onshore and higher-level fish processing capacity.