WHOLE BRAIN LEARNING SYSTEM

OUTCOME-BASED EDUCATION

TECHNICAL VOCATIONAL AND LIVELIHOOD

GRADE
AGRI-FISHERY ARTS

FOOD(FISH) PROCESSING 11
SECOND
LEARNING SEMESTER

MODULE WEEK 5-6

0
 MODULE
IN
FOOD (FISH) PROCESSING
SHS

QUARTER 2
WEEK 5-6
DAY 17-24
PROCESSING FOOD BY SALTING,
CURING, AND SMOKING
Finish the Cured Materials
(SMOKED FISH, HACCP, AND GOOD MANUFACTURING PRACTICES)

Development Team
Writer: Charmine Dawn P. Ramos
Editor: Liezl R. Quitoriano
Reviewers: Romeo G. Uganiza Joseph C. Salvador
Illustrator: Nestor M. Lucero
Layout Artist: Nestor M. Lucero
Management Team:
Vilma D. Eda Arnel S. Bandiola
Lourdes B. Arucan Juanito V. Labao
Marju R. Miguel

1
 Lesson SMOKED FISH, HACCP, AND

5 GOOD MANUFACTURING
PRACTICES

What I Need to Know

The lesson deals on finishing the cured materials like smoked products and
explain the Hazard Analysis Critical Control Point and Good Manufacturing practices.
In your journey through the discussions and different tasks, you are expected to:

Content Standard:
Demonstrate understanding on processing food by salting, curing, and
smoking.

Performance Standard:
Demonstrate the procedures of processing food by salting, curing, and smoking
independently.

LO 5. Finish the cured materials.

TLE_AFFP9-12SL-IIc-e-5

Summary of Learning Outcomes:

At the end of the lesson, you should be able to.
1. identify the methods of smoking;
2. discuss hazard analysis control points;
3. explain the good manufacturing practices;
4. perform the smoking and curing procedures and techniques;
5. cook drained cured materials in appropriate cooking medium and cook the cured
and smoked products; and
9. pack the finished products.

2
 What I Know

Before you go over with this module, try answering the succeeding Pre-Test.
This will enable you to find out what you already know and what you still need to know
about the lesson. Good luck!
Pre-Test
Read and analyze each item carefully. Write the chosen letter on a separate sheet of
paper.

1. How will you properly package a smoked fish?

A. Pack them in glass jars.
B. Pack them in metal containers.
C. Wrap the fish with banana leaves.
D. Pack the fish in polyethylene bags.

2. If you are going to pre-cook a fish before smoking, which of the following will you
do?
A. Drain the brined fish.
B. Prepare a saturated brine.
C. Boil the fish in plain water.
D. Dip fish into the boiling saturated brine.

3. How will you properly cool the fish after smoking?

A. Expose to natural air.
B. Place inside a freezer.
C. Aerate with an electric fan.
D. Place inside the setting cabinet for cooling.

4. Why do you need to properly package smoked fish?

A. to improve product appearance
B. to prevent contamination of the product
C. to improve the salability of the product
D. to improve texture of the smoked fish

3
5. What method of cooking is cured meat or fish over a slow fire?
A. curing B. frying
C. hot smoking D. smoking

6. What method is usually used as supplementary to salting and drying?

A. curing B. freezing
C. frying D. smoking

7. What Republic Act refers to food, drug, and cosmetic code?

A. R.A. 1520 B. R.A. 2030
C. R.A. 3720 D. R.A. 4050

8. What is the Administrative Order 208 series of 1974 all about?

A. food processing B. meat preservation
C. set of sanitary procedures D. smoking procedures

9. What is the method of smoking wherein smoke flavor is incorporated in the

pumping pickle for ham and bacon?
A. artificial B. cold
C. hot D. natural

10. What is HACCP?

A. Hazard Analysis Critical Control Point
B. Hazard Analysis Control Critical Point
C. Hazard Analyze Critical Control Point
D. Health Analysis Critical Control Point

What’s In

Activity 1

Before we proceed to our lesson, can you enumerate the good

manufacturing practices you observed during your laboratory?

4
 What’s New

Food processing is the transformation of agricultural products into food, or of

one form of food into other forms. Food processing includes many forms of processing
foods, from grinding grain to make raw flour to home cooking to complex industrial
methods used to make convenience foods. Some food processing methods play
important roles in reducing food waste and improving food preservation, thus,
reducing the total environmental impact of agriculture and improving food security.
Definition of terms:
Control Point any point, step, or procedure at which biological, physical, or
chemical factors can be controlled
Good the practices required in order to conform to the guidelines
manufacturing recommended by agencies that control the authorization and
practices (GMP) licensing of the manufacture and sale of food and beverages
Materials the substances of which something is made or composed
HACCP a system which identifies specific hazard and preventive
measures for their control
Smoked fish a product prepared from whole, eviscerated, or split fish
treated with salt and subjected to smoke produced by
combustion of wood or other smoking materials
Specification something specified

5
 What is It

SMOKED FISH, HACCP, AND GOOD MANUFACTURING PRACTICES

Smoking involves the treatment of fish with smoke. The production of smoke
implies fire and generation of heat. When fish is smoked, it is also dried and is also
slightly cooked. Cooking destroys the action of enzymes and kills many
microorganisms because of the high temperature. Chemicals in the smoke also
destroy microorganisms. Smoke contains a substance called creosote which acts as
a preservative agent.

SMOKING

Smoking and drying are often combined. Most cured meat are smoked. The
prepared sequence is curing followed by smoking. The common method of smoke
generation includes burning damp hardwood, sawdust, heating dry sawdust, or
heating pieces of log. Smoke is gaseous mixture of various chemical compounds and
consists of a dispersed gas phase.
Smoking, on the other hand, is a method usually supplementary to salting and
drying. It involves cooking meat or fish very slowly over a low wood fire. Curing and
smoking preserve food by binding or removing water, to avoid the growth of micro-
organisms. This method imparts a distinctive color and flavoring to food and, in some
cases, eliminate the need for refrigeration.
Each of the major components acts in a particular way. Acids and aldehydes
react with protein and together with phenolics and some other compounds, impact to
the meat a smoky taste and desirable odor. The same smoke can produce different
flavors with different meat. Acetic and other acid, form aldehydes, phenols, waxes,
and resins exert a preservative action and impregnate the meat surface. The partial
drying of the product also contributes to its better preservation. Phenols and some
other substances are active in retarding fat oxidation, the composition of combustion,
and the moisture content in both wood and air and other factors.
Two methods of smoking
1. Natural Method-- The meat is exposed to wood smoke which causes the
disposition of pyroligneous acid on the meat surface that acts as
preservative and flavoring agent.
2. Artificial Method- Smoke flavor is incorporated in the pumping pickle for ham
and bacon at the rate of 1 teaspoon/liter.

6
Smoking and drying cured product
After the curing period, pull out the cured ham, from the pickle. Wash off excess
salt by soaking and scrubbing in warm water. Tie the leg with abaca twine; allow
draining for a while and hanging in the smokehouse. For the small smoking unit, two
empty drums with both ends removed and place one on top of the other will suffice, or
if desired, a concrete type can be constructed. Arrange the pieces of ham so that
spaces are provided between them to allow an even circulation of smoke and heat. To
prevent scorching or case hardening of the products, perforated aluminum or tin discs
should be placed several inches above the source of heat. Place fresh guava leaves
over charcoal embers to produce a good amount of smoke. Smoke ham for 8 hours
and continue the drying process in the same smoke house for 15 days (8 hours a day)
or until the ham acquire a rich, attractive finish and firmness. The heat inside the dryer
or smokehouse during the drying period should be maintained at 43°C (110 °F) for the
first 5 days and gradually increase to 49°- 52°C. A high initial drying temperature
results in a product that is dry outside still moist or fresh inside (case hardened).
Hot smoking is a slow type of broiling wherein fish is placed near the fire at
smoke temperatures ranging from 66˚C to 88˚C. Smoking lasts for one hour to 3 hours
depending upon the size of the fish. The fish are cooked in addition to being saturated
with smoke. This is also referred to as barbecue smoking. There are two hot smoking
methods namely:
1. boiling
2. pressure cooking

Below are some types of not smoke house for not smoking:

Native Pot Type Drum Type

7
Source: DepEd, Competency-Based Learning Material for Second Year Fish
Processing (CBLM), Public Technical-Vocational High Schools.

Cold smoking is done by placing the fish far away from the fish at a distance of
almost two meters away from the source of smoke with a temperature ranging from
32˚C to 43˚C. Below are examples of smokehouse used in cold smoking:

Cabinet Type Smokehouse

Source: DepEd, Competency-Based Learning Material for Second Year Fish

Processing (CBLM), Public Technical-Vocational High Schools.
Differences Between Hot Smoking Cold Smoking
Hot Smoking and
Cold Smoking
1. Distance of fish from Close proximity to the 2 meters away from the
source of heat fire source of fire
2. Temperature 66˚C to 88˚C 32˚C to 43˚C
3. Length of smoking 1 - 3 hours 1 to 2 weeks
4. Finished product Little bit moist and Dry and lighter in weight
heavier in weight
5. Shelf-life 3 days to a week More than a month

8
Procedure in Hot Smoking Fish

Boiling Method of Hot Smoking

a. Weigh the fish and wash them with freshwater.

b. Remove the internal organs by ripping out the gills, making sure the isthmus
is not destroyed. The removal of viscera eradicates the enzymes that cause
autolysis and reduces the microorganisms present.
c. Rewash the fish with freshwater.
d. Soak the fish in saturated brine for two hours.
e. Boil the fish in 10% brine solution for 10 minutes till the eyes of fish become
white.
f. Dry the boiled fish in a cool, shady, and breezy place for 1 to 3 hours or until
a thin slimy skin or pellicle is formed on the surface.
g. Hot-smoke the fish at temperatures ranging from 66OC to 88OC for 1 to 3
hours depending upon the size of the fish.

Pressure-Cooking of Hot Smoking

a. Weigh the fish and wash with freshwater.

b. Remove the viscera by ripping out gills through the operculum. The removal
of viscera leads to the destruction of enzymes and reduction of
microorganisms present in the fish. Be sure the isthmus is not destroyed.
c. Rewash the fish with freshwater.
d. Soak the fish in saturated brine solution for two hours.
e. Pressure-cook the fish at temperature of 240OF or 10 pounds, pressure per
square inch gauge for 90 minutes for milkfish; 70 minutes for short-bodied
and striped mackerel; and 60 minutes for herring and sardines.
f. The pressure-cooked fish are dried in a cool, shady, and breezy place for 20
to 30 minutes or until a thin slimy skin or pellicle is formed on the surface.
g. The fish are hot smoked at temperature ranging from 66 OC to 88OC for 1 to
3 hours depending upon the size of the fish.
h. The smoked products are weighed and packed in waxed paper ready for the
market.

Procedure in Cold Smoking Fish

a. Weigh the fish and wash with freshwater.
b. Remove the viscera by ripping out the gills through the operculum. Be sure
the isthmus is not destroyed.
c. Rewash the fish with freshwater.
d. Soak the fish in saturated brine solution for two hours.

9
 e. Pressure-cook or brine-cook the fish following the instructions in letter e
procedure of hot smoking.
f. The pre-cooked fish are laid on bamboo racks and dried in a shady place for
1 to 3 hours or until the pellicle forms on the surface.
g. Cold-smoke the fish at temperatures ranging from 32 OC to 43OC for 7 to 14
days. Thin smoke is applied during the first two days and thick smoke for
the remaining days.
h. Weigh and pack the smoked products in waxed paper ready for the market.

Packaging of Smoked Fish

Smoked fish is packed either in bulk or in retail packaging materials.

1. Bulk packaging refers to those intended for wholesale or institutional
distribution.
2. Retail packs contain the product until it reaches the ultimate end-user or
consumer.

Procedure for Bulk Packaging

1. Sort cooled smoked fish according to size.
2. Pack or transfer smoked fish in bulk packaging materials by arranging the
fish in a manner that heads and tails are in uniform position.
3. When the packaging material is nearly full, weigh the whole pack (container
and smoked fish) to check product weight attained. Total weight minus
weight of container will give the weight of the smoked fish.
4. Close or seal the pack and store at refrigeration temperature (3°C to 5°C) or
in a cold storage.

HAZARD ANALYSIS CRITICAL CONTROL POINT (HACCP)

Hazard Analysis is the identification of selective ingredients critical process
points and relevant human factors as they effect product safety. Critical Control Point
is a point in time or a physical location at which failure of control or preventive measure
will expose the consumer to unacceptable health risks.
To be able to manufacture products with high level of assurance that they are
safe, it is necessary to understand fully the criticality of the process, the ingredients
and all other components that make up the contract. This is the goal of HACCP.
HACCP concept is more likely to detect the hazard during the food production
by having control over the process, the raw materials, the environment, and the people
beginning as early in the production as possible. Furthermore, this allows to determine
the type of controls to be done in the area determined to be critical.

10
 HACCP concept was developed jointly by the American Food Industry and
governmental agencies in the 1970's for the use in the food processing industry, was
devised as an attempt to apply zero-detect program to food processing. It is also a
concept important in sanitation and hygiene, a preventive system of control because
we want to pre-empt contamination into getting in the system.
HACCP (Hazard Analysis Critical Control Points) Concepts
1. It is a preventive system of control particularly on biological hazard.
2. It is a system approach tor estimating the risks in producing a food product.
3. It is universally organized system as the most effective way to prevent food-
borne illness. Groups control groups.
4. It is a science-based systematic, identifies specific hazards and measures
for their control to ensure food safety.
5. It is capable of accommodating change, such as advances in equipment
design, processing procedure and technology departments, and can be
applied throughout the food chain from the primary producers to the final
consumer.
6. It is applicable to establishments that produce, process, pack, trade,
transport and involved in food productions.
7. It has become synonymous with Food Safety.
HACCP (Hazard Analysis Critical Control Points) Principles
The 7 HACCP principles are as follows:
1. Hazard analysis
2. Identify critical control points
3. Establish control limits
4. Monitor critical limits
5. Establish corrective action in case of deviation from established critical limits
6. Establish verification procedures to ensure that the system is consistent
7. Establish record keeping procedures

Why is HACCP (Hazard Analysis Critical Control Points) Necessary?

HACCP is necessary because:
1. it has been proven as the most effective method of instituting food safety;
2. critical areas are closely monitored so that risks of manufacturing, selling
unsafe products are reduced to the minimum; and

11
 3. quality benefits due to increased awareness of hazards and participation of
people involved in the operation.
Other Benefits of HACCP (Hazard Analysis Critical Control Point)
1. Mechanisms that control safety also control food quality in general
2. HACCP requires individual accountability, proper documentation, and
efficiency of operation and thus improves productivity.
3. HACCP is targeted to benefit the consumer and is therefore essential to good
business practice.

CODE AND REGULATIONS

Good Manufacturing Control Points
Good Manufacturing Practices (GMP) provide the sanitary infrastructure for food
safety that:
1. plants, grounds, and buildings facilities emphasize pest control;
2. equipment designs should particularly ease in cleaning and maintenance;
3. personal hygiene practices and facilities; and
4. process control, storage, and warehousing.
Contamination of food can be substantially minimized if good manufacturing
practices are adhered to. GMP embodied in Administrative Order 208 (series of 1974)
is a set of sanitary guidelines recommended for compliance in the MANUFACTURE,
PROCESSING, PACKING, HOLDING AND STORAGE OF FOODS. This is applicable
to all food processing plants, institutional and domestic kitchens or food service
establishments at all levels of operations.
GMP helps ensure the production of pure and unadulterated food, which is a
major provision of the FOOD, DRUG AND COSMETIC ACT OF THE PHILIPPINES
UNDER REPUBLIC ACT 3720. Sanitary inspectors from the BFAD, some
municipalities, cities or provinces are responsible for enforcing the general provision
of the act.
Current GMP Regulations
1. These tell what kind of buildings, facilities, equipment, and maintenance
needed, and the errors to avoid and ensure sanitation.
2. They also deal with such matters as building designs and construction,
lighting, ventilation, toilet, and washing facilities, cleaning of equipment,
materials handling and vermin control.

12
 Many food materials are intended for further processing and manufacture into
finished foods. Such processing does not relieve the raw materials from the
requirements of cleanliness and freedom from deleterious impurities. Foods that are
free from contamination when they are shipped sometimes become contaminated in
route. This emphasizes the importance of existing proper storage conditions in
vessels, railroad cars, or other conveyances. All shippers should pack their products
so as to protect them against spoilage or contamination in route and should urge
carriers to protect the merchandise by maintaining sanitary conditions and segregating
them from other cargoes which might contaminate it.
GMP (Good Manufacturing Practices) covers:
1. plant and grounds
2. equipment and utensils
3. sanitary facilities and control
4. sanitary operations
5. process and control
6. personal hygiene

What’s More

Activity 2
A. Fill in the blanks with the correct words or phrases. Write your answer on a
separate sheet.

1. It is a preventive system of control particularly on ___________.

2. It is a _________ for estimating the risks in producing a food product.
3. It is the universally-organized system as the most effective way to prevent
_________. Groups control groups.
4. It is the science-based systematic, identifies specific hazards, and measures
for their control to ensure __________.
5. It is capable of accommodating change, such as advances in equipment
design, processing procedure and ________ departments and can be
applied throughout the food chain from the primary producers to the final
consumer.

13
 What I Have Learned

Activity 3
Answer the following briefly but comprehensively. Write your answer on a separate
sheet.

1. What did you understand about HACCP?

_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
________________________________________________.

2. Why do you need to follow the good manufacturing practices?

_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________.

3. Which of the following types of smoking is easier to apply? Explain your answer.
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________.

14
 What I Can Do

Activity 4
Direction: Arrange the following procedures by writing an Arabic number on the space
provided before each item. Rank 1 to the first step, 2 to the second step, and so on.
Use a separate answer sheet.

A. Pressure-Cooking of Hot Smoking

_______ A. Pressure-cook the fish at temperature of 240OF or 10 pounds, pressure

per square inch gauge for 90 minutes for milkfish, 70 minutes for short-
bodied and striped mackerel, and 60 minutes for herring and sardines.
_______ B. The pressure-cooked fish are dried in a cool, shady, and breezy place for
20 to 30 minutes or until a thin slimy skin or pellicle is formed on the
surface.
_______C. The fish are hot smoked at temperature ranging from 66 OC to 88OC for 1
to 3 hours depending upon the size of the fish.
_______D. The smoked products are weighed and packed in waxed paper ready for
the market.
_______E. Weigh the fish and wash with freshwater.
_______F. Remove the viscera by ripping out gills through the operculum. The
removal of viscera leads to the destruction of enzymes and reduction of
microorganisms present in the fish. Be sure the isthmus is not destroyed.
_______G. Rewash the fish with freshwater.
_______H. Soak the fish in saturated brine solution for two hours.

B. Procedure in Cold Smoking Fish

_______A. Weigh the fish and wash with freshwater.

_______B. Remove the viscera by ripping out the gills through the operculum. Be sure
the isthmus is not destroyed.
_______C. The pre-cooked fish are laid on bamboo racks and dried in a shady place
for 1 to 3 hours or until the pellicle forms on the surface.
_______D. Cold smoke the fish at temperatures ranging from 32OC to 43OC for 7 to
14 days. Thin smoke is applied during the first two days and thick smoke
for the remaining days.
_______E. Weigh and pack the smoked products in waxed paper ready for the market.
_______F. Rewash the fish with freshwater.
_______G. Soak the fish in saturated brine solution for two hours.

15
_______H. Pressure-cook or brine-cook the fish following the instructions in letter e
procedure of hot smoking.

Assessment

Now that you are through with the module, CONGRATULATIONS! You are
ready for the Post-Test and find out how well you have gone through the module.
Compare your score with that of the Pre-Test. If you get higher, that means that you
have learned something. GOOD LUCK!

Post-Test
Direction: Read and analyze each item carefully. Write the chosen letter on a
separate sheet of paper.

1. What method is usually used as supplementary to salting and drying?

A. curing B. freezing
C. frying D. smoking

2. What Republic Act refers to food, drug, and cosmetic code?

A. R.A. 1520 B. R.A. 2030
C. R.A. 3720 D. R.A. 4050

3. What is the Administrative Order 208 series of 1974 all about?

A. food processing B. meat preservation
C. set of sanitary procedures D. smoking procedures

4. What is the method of smoking wherein smoke flavor is incorporated in the pumping
pickle for ham and bacon?
A. artificial B. cold
C. hot D. natural

5. What is HACCP?
A. Hazard Analysis Critical Control Point
B. Hazard Analysis Control Critical Point
C. Hazard Analyze Critical Control Point
D. Health Analysis Critical Control Point

6. How will you properly package a smoked fish?

16
 A. Pack them in glass jars.
B. Pack them in metal containers.
C. Wrap the fish with banana leaves.
D. Pack the fish in polyethylene bags.

7. If you are going to pre-cook a fish before smoking, which of the following will you
do?
A. Drain the brined fish.
B. Prepare a saturated brine.
C. Boil the fish in plain water.
D. Dip fish into the boiling saturated brine.

8. How will you properly cool the fish after smoking?

A. Expose to natural air.
B. Place inside a freezer.
C. Aerate with an electric fan.
D. Place inside the setting cabinet for cooling.

9. Why do you need to properly package smoked fish?

A. to improve product appearance
B. to prevent contamination of the product
C. to improve the salability of the product
D. to improve texture of the smoked fish

10. What method of cooking is cured meat or fish over a slow fire?
A. curing B. frying
C. hot smoking D. smoking

17
Answer Key

18
References
Books
DepEd, Competency-Based Learning Material for Second Year Food Processing NC
II (CBLM), Public Technical-Vocational High Schools.
DepEd, Competency-Based Learning Material for Second Year Fish Processing
(CBLM), Public Technical-Vocational High Schools.
Online Sources:
Wikipedia. Food Processing. Accessed December 18, 2020.
https://en.wikipedia.org/wiki/Food_processing

Wikipedia. Good Manufacturing Practice. Accessed December 18, 2020

https://en.wikipedia.org/wiki/Good_manufacturing_practice

19
For inquiries or feedback, please write or call:

Department of Education – Schools Division of Laoag City

Curriculum Implementation Division
Brgy. 23 San Matias, Laoag City, 2900
Contact Number: (077)-771-3678
Email Address: [email protected]

20