FOOD AND AGRICULTURE ORGANIZATION OF THE UNITED NATIONS

TRAINING COURSE FOR THE PREPARATION OF FISH

TRADITIONAL PRODUCTS TO THE FISHERMEN’S WIVES

IN THE ISLAND OF KALYMNOS

08 - 12 OCTOBER 2012, KALYMNOS, GREECE

OCCASIONALPAPER 01

RREPORT OF THE TRAINING COURSE FOR THE PREPARATION OF FISH TRADITIONAL PRODUCTS TO THE FISHERMEN’S WIVES

IN THE ISLAND OF KALYMNOS

08 - 12 OCTOBER 2012, KALYMNOS, GREECE

GCP/INT/041/EC – GRE – ITA Athens (Greece), October 2012

FOOD AND AGRICULTURE ORGANIZATION OF THE UNITED NATIONS

Scientific and Institutional Cooperation to Support Responsible Fisheries in the Eastern Mediterranean

Preface

EastMed

longer-term objective

immediate objective

Publications

Preparation of this document

ABSTRACT

Thunnus alalunga

vi

Table of Contents

1. Introduction and Objectives of the course ..................................................................... 1

3. Fishes conservation procedure using ice by Stamatis Nikos ........................................ 2

4. Fishes conservation procedure by freezing by Stamatis Nikos .................................... 2

8. New products: fish sticks by Stamatis Nikos ................................................................. 3

9. Quality of the fishes and degradation by Stamatis Nikos ............................................. 3

10. Quality control of the fishes based on chemical, microbiological and organoleptic

criteria by Stamatis Nikos ............................................................................................. 4

11. HACCP System by Stamatis Nikos ................................................................................. 4

12. Nutritional value and chemical composition of the fishes by Stamatis Nikos .............. 4

13. New type canning by Stamatis Nikos ............................................................................ 4

14. Marketing of the fishes – Definition of common standards by the European Union

(Regulation 2406/1996) by Stamatis Nikos .................................................................. 5

15. Practical lectures by Massimo Bernacchini and Andrea Bartoli .................................... 5

Annex I. List of participants........................................................................................................ 7

Annex II. Agenda ........................................................................................................................ 8

Annex III. Recipes ..................................................................................................................... 11

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TRAINING COURSE FOR THE PREPARATION OF FISH TRADITIONAL PRODUCTS IN THE ISLAND OF KALYMNOS (GREECE)

KALYMNOS, GREECE

08 – 12 OCTOBER 2012

1. Introduction and Objectives of the course During the third Co-ordination Committee meeting of the EastMed project held in Bari, Italy, from 19-20 April 2012, the countries proposed new activities to be carried out in the 3rd year of the project. Within the Greek proposals, there was also the organization of a training course for the preparation of fish traditional products in the island of Kalymnos. The aim of the training course was to educate the wives of the fishermen of Kalymnos island (Greece) for the preparation of traditional fish products using canning technology after thermal process and preservation in saltwater or sunflower oil. The goal was to make use of low value fish such as albacore (Thunus alalunga), atlantic bonito (Sarda sarda) or other tuna like species, fished by small scale fishery in Kalymnos and involve fishermen’s wives to add value in the products in order to improve the welfare not only of the family but also of the community. During the seminar basic knowledge on chemical, microbial and organoleptic control was presented. The training course for the preparation of fish traditional products was held in Kalymnos, Greece, from 08 to 12 October 2012. It was attended mainly by the wives of the fishermen. The list of participants is given in Annex I.

2. Opening of the course Mrs Konstantina Karlou-Riga, Coordinator of the EastMed Project, welcomed the participants and thanked them for attending the course. Then, she presented the scope and objectives of EastMed Project and expressed the intension of the Project to fulfil the needs of the participating countries as well as those of the local communities. To this line the Project has been requested to support the initiative on familiarizing the local community with canning techniques. After the presentation, the agenda (Annex II) was introduced and was adopted by the participants without any changes. The participants were informed that theoretical lectures and practical lectures will be run by the consultants, which will be followed by practice in the field.

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3. Fishes conservation procedure using ice by Stamatis Nikos The properties of ice as well as the major advantages of the use of ice in the fishes’ conservation were presented by the consultant. Using several examples, the consultant then made an analysis regarding the storage of fish in ice, the calculation of the amount of ice needed for a catch to be stored properly in ice and the parameters which must be taken into consideration during the storage process, such as the thickness of the fish, for how long the fish is intended to be stored in ice, the storage methods, the shelf life of the fish species etc. Furthermore, he referred to the manufacture of ice, including the types of ice and ice makers, as well as the conditions of the ice production factories. 4. Fishes conservation procedure by freezing by Stamatis Nikos Basic definitions regarding the procedure of freezing were clarified by the consultant. After the definitions, the consultant referred in details to the various stages of freezing, using examples and figures; for instance, he explained how to calculate the theoretical amount of energy required to freeze the fish. He then listed the freezing methods and the several types of equipment which can be used, such as air blast freezers, batch freezers, contact freezers (horizontal and vertical plate), immersion freezers, indicating the freezing procedure in each case. Finally, the consultant presented the different storage methods explaining the conditions of storage and a table regarding the shelf life of the frozen fish according to its type. 5. Processing of fishes by Stamatis Nikos Several processing methods, which include the raising of the temperature (involving cooking the fish by canning, boiling or smoking) or the removal of moisture (involving natural drying, mechanical drying, smoking, salting) were presented by the consultant. Besides, the production of fish sauces and pastes, fish marinates and the choice of the processing method, consumer preference, cost of the product, available facilities and the raw material availability were analytically introduced. The new biotechnological methods for producing high added value products with application in medicine, cosmetics and the pharmaceutical industry were explained. 6. Canning and salting of the fishes by Stamatis Nikos

The consultant presented analytically the stages of canning process, including sealing, sterilization and freezing. After the presentation of canning and packaging of the fishes, the consultant discussed about the salting procedure and its general characteristics. He explained that salting process is lately used in combination with smoking and drying processes which would be presented later. He then referred to the various types of salt according to specific parameters, such as the source or the production mode. Several methods of salting have been discussed. Finally, the consultant talked about the storage

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of salted products and explained that depending on the proportion of salt and water, the conservation period of the product varies. 7. The procedures of drying, smoking, salting and marinating of the fishes by

Stamatis Nikos

The detailed presentation of the salting procedure was followed by the drying, smoking and marinating processes. Drying is a traditional conservation method typically used in combination with other processing methods. The consultant explained the basic characteristics of the process, the factors which can affect the drying rate of the product, the various drying methods, as well as the parameters which must be assessed during the quality control of the dried products. The discussion was then focused on the smoking procedure, which also constitutes a traditional conservation method. The consultant listed several smoking methods and described in details the smoking process giving the example of grilled smoked tuna, how the smoked product can be stored and preserved, as well as the parameters that must be taken into consideration during the quality control. The consultant then noted that equally important is the marinating procedure (through vinegar and salt). It aims to extend the conservation period, as well as the special taste of the product. He referred to the various categories of the marinated products (cold marinates, cooked marinates, fried marinates) and explained the differences between them. 8. New products: fish sticks by Stamatis Nikos The consultant continued to discussion regarding processed new products, such as fish sticks. He explained in detail the manufacturing process of the new product, he listed the different names for fish sticks used across the world, like Chikuwa (boiled), kaen surimi (with salt), kamaboko (grilled), muen-surimi (without salt), tempura (fried) e.t.c. and he walked the group through the physical and chemical quality control processes. 9. Quality of the fishes and degradation by Stamatis Nikos The consultant started by defining quality in terms of the marketability and value of the end product. Typical quality indicators include chemical (levels of ammonia, trimethylamine, histamine e.t.c.), microbiological (total viable count, enterobacteriacae e.t.c.) and organoleptic criteria (such as smell, colour, taste e.t.c.). Due to the high water content, quality deteriorates rapidly via enzyme and microbiological reaction. To maintain quality during processing the following parameters should be taken into account: customer preferences, fish suitability, climate conditions and infrastructure. The

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consultant also emphasized the importance of the facilities, hygiene and waste management. Afterwards, the main causes of quality degradation were laid out such as microbiological, enzymatic and non-enzymatic (e.g. rancidity) along with the main parameters that affect spoilage such as temperature and the chemicals used. It was stressed out that spoilage is also heavily dependent upon the processing method (smoking, canning, salting, drying, marinating and cooking). To illustrate, the consultant highlighted the fish utilization in Greece with respect to the quantities and cost values per frozen or processed fish species. 10. Quality control of the fishes based on chemical, microbiological and organoleptic

criteria by Stamatis Nikos The consultant then discussed the specific criteria of quality control. In particular chemical analysis focuses on the presence of industrial pollutants, heavy metals and toxins – especially on shellfish. On the other hand microbiological analysis is used to identify the presence of pathogenic bacteria. Finally, organoleptic controls focus on the appearance and colour, smell, taste and texture. As for example, the consultant presented the organoleptic controls for cod according to the EU Quality Index Method. A discussion of the suitability of consumption and the health benefits of the end products ensued. 11. HACCP System by Stamatis Nikos An overview of the Hazard Analysis Critical Control Points (HACCP) system, its principles, applications and the implementation phases were presented by the consultant. The HACCP inspection approach is used to identify control points in the processing operations, to determine the hazard associated with each point, and to establish adequate control measures and an adequate monitoring plan for each point. Examples of Critical Control Points of HACCP were given and the main differences of HACCP with the existing conventional quality control system were pointed out. Finally, the legal framework and benefits of HACCP were summarized. 12. Nutritional value and chemical composition of the fishes by Stamatis Nikos A description of the chemical composition and nutritional value of fishery products was given with emphasis on the main components as well as their variability, depending on various parameters, such as species, age, seasonality, sex, locality, e.t.c. Furthermore the nutritional value for some locally interesting fish species was analyzed.

13. New type canning by Stamatis Nikos The consultant presented the various packaging materials and methods which have been used so far, as well as the development of high technology modern packaging materials

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not only for fresh but also for frozen and processed fish products. In particular the consultant mentioned traditional packaging materials e.g. round baskets made from natural plant fibres, wooden boxes, metal bowls, cardboard boxes for dried fish, modified atmosphere or vacuum packages for retail packaging, some shellfish packaging, air freight packaging e.t.c. He also listed the parameters on which the choice of the appropriate packaging should be based and illustrated the replacement of wooden crates by plastic ones, which are lighter, hygienic and more robust. He finally discussed the labeling framework with references to the regulation of the European Union and the USA. 14. Marketing of the fishes – Definition of common standards by the European Union

(Regulation 2406/1996) by Stamatis Nikos The course was finished by a presentation on EU common standards of commercial fish species, which are related to the freshness and size categories. 15. Practical lectures by Massimo Bernacchini and Andrea Bartoli The consultants continued to practical lectures by processing the local fish available. The species which was used was Thunnus alalunga. The fish after cleaning, cutting and slicing were subject of the following processing techniques. BOILING Tuna fish fillets were boiled in saltwater (6% w/w) for twenty minutes. This is needed as pre-step of the product conservation. Afterwards the fillets were immersed in the glass jars with screw cup and a filling solution (saturated salt water, spices and olive oil. The jars were then pasteurized. The shelf life of the final products could vary from six to twelve months, depending on the method of further sterilization. SALTING The tuna fish fillets were put for forty eight hours in dry salt. This is also used as first step of processing - preservation. Afterwards the salted fillets were immersed in the glass jars with screw cup and a filling solution (saturated salt water, spices and olive oil). The jars were then sterilized (30 min at 120 oC and ca. 1 bar). The shelf life of these final products would be more than one year. SMOKING The tuna fish fillets were put for forty eight hours in dry salt. The process was followed by warm (2 hours at 75 oC) or cold (6 hours by 45 oC). Afterwards the salted - smoked fillets were put in the glass jars with screw cup and a filling solution (saturated salt water, spices and olive oil). The final products were sterilized (30 min at 120 oC and ca. 1 bar). The shelf life of these final products would be more than one year.

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COOKING Small fish pieces were used for making fish sauces. After cutting of the fish fillets in small pieces, spices, water, tomatoes and olive oil were added. This mixture was cooked for 20 min. The above cooked mixture was then put in the glass jars with screw cup. The final products in the packages were sterilized (30 min at 120 oC and ca. 1 bar). The shelf life of these final products would be more than one year. The trainees were experienced in the above techniques and extended them particularly in cooking by using local recipes (Annex 3), where local products and ingredients were used

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Annex I. List of participants

LIST OF TRAINEES Fotini Kampouri Maria Kyriaki Mouzouraki Themelina Mouzouraki Despoina Dounia Kardoulia Eudokia Katsotourchi Marietta Vrouvi Souniou Eirini Mamouzelou Katerina Vavla Agapi Chalkidou Kleopatra Kountouri Giorgos Tiliakos Eirini Koulia Eudokia Poniri Galatiani Pizania Themis Pizania Themelina Lyra Korfia Katerina Parimerou Kalliopi Amorginou Nomiki Amorginou Anna Chatzidrosou Marina Koukouva Ioanna Makarouna Kalotina Makarouna Nikolas Makarounas

CONSULTANTS Massimo Bernacchini Seafood processing industry manager Orbetello – Pesca Lagunare Tel: +393487304261 E-mail: info@orbetellopesca.it Andrea Bartoli Chairman of Fisheries & Research Cooperative Soc. Coop. Zefiro A.R.L. Tel: +3475183999 E-mail: andreabartoli@virgilio.it Nikos Stamatis Chemist-Fish processing NAGREF-Fisheries Research Institute Tel: +302594022691 E-mail: nikstam@inale.gr Argyris Kallianiotis Director NAGREF-Fisheries Research Institute Tel: +302594023637 E-mail: akallian@inale.gr HOST Giorgos Katsotourchis Federation of small scale fisheries of South Aegean Tel: +306974736282 E-mail: ypapanti2@gmail.com FAO – EASTMED PROJECT Konstantina Karlou – Riga Coordinator FAO – EastMed Project Tel: +302108847960 E-mail: konstantina.riga@fao.org

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Annex II. Agenda

TRAINING COURSE FOR THE PREPARATION OF FISH TRADITIONAL

PRODUCTS TO THE FISHERMEN’S WIVES IN THE ISLAND OF KALYMNOS

Kalymnos, 08-12 October 2012

Annotated Draft Agenda

MONDAY, 08-10-2012 08.45 - 09.00 Registration 09.00 – 10.00 Fishes conservation procedure using ice 10.00 - 11.00 Fishes conservation procedure by freezing 11.00 - 11.30 Coffee break 11.30 – 12.30 Processing of fishes 12.30 – 13.30 Canning and salting of the fishes 13.30 – 14.30 Lunch break 14.30 - 15.30 The procedures of drying, smoking, salting and marinating of the fishes 15.30 - 16.30 New products: Fish sticks

ΥΠΑΑΤ

«ΔΗΜΗΤΡΑ»

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ΤUESDAY, 09-10-2012 08.45 - 09.00 Registration 09.00 – 10.00 Quality of the fishes and degradation 10.00 – 11.00 Quality control of the fishes based on chemical, microbiological and organoleptic

criteria 11.00 – 11.30 Coffee break 11.30 – 12.30 HACCP System 12.30 – 13.30 Nutritional value and chemical composition of the fishes 13.30- 14.30 Lunch break 14.30 – 15.30 New type canning 15.30 – 16.30 Marketing of the fishes – Definition of common standards by the European Union

(Regulation 2406/1996) WEDNESDAY, 10-10-2012 08.45 - 09.00 Registration 09.00 – 10.00 Processing and canning of albacore 10.00 – 11.00 Processing and canning of albacore 11.00 – 11.30 Coffee break 11.30 – 12.30 Processing and canning of albacore 12.30 – 13.30 Processing and canning of bonito 13.30 – 14.30 Lunch break 14.30 – 15.30 Processing and canning of bonito 15.30 – 16.30 Processing and canning of bonito

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THURSDAY, 11-10-2012 08.45 - 09.00 Registration 09.00 – 10.00 Introduction of the smoking technique in albacore and bonito 10.00 – 11.00 Introduction of the smoking technique in albacore and bonito 11.00 – 11.30 Coffee break 11.30 – 12.30 Introduction of the smoking technique in albacore and bonito 12.30 – 13.30 Processing and canning of other species 13.30 – 14.30 Lunch break 14.30 – 15.30 Processing and canning of other species 15.30 – 16.30 Processing and canning of other species FRIDAY, 12-10-2012 08.45 - 09.00 Registration 09.00 - 09.45 Processed and cooked fishes 09.00 – 10.00 Processed and cooked fishes 11.00 – 11.00 Processed and cooked fishes 11.00 – 11.30 Coffee break 11.30 – 12.30 Promotion of the final products on the market 12.30 – 13.30 Promotion of the final products on the market 13.30 – 14.30 Lunch break 14.30 – 15.30 Discussion – Conclusions of the training course 15.30 - 16.00 Adoption of the report

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Annex III. Recipes Tuna in tomato sauce by trainees Ingredients 1 tuna fillet 5 cloves of garlic, chopped 1 small onion, chopped 6 tomatoes, finely grated 2 green peppers, chopped 2 bay leaves Salt, pepper and olive oil to taste Execution Cut the fillet into pieces, season with salt and pepper and let it cure for 20 mins. In the meantime, sauté the onion, garlic and peppers in plenty of olive oil and add the grated tomatoes. Once it reaches a boil, add the bay leaves and season with pepper. Turn down the heat, add the tuna and simmer for 10 mins. It can be served with pasta or rice.

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Tuna meatballs by Mouzouraki Themelina Ingredients 1/2kg minced tuna 1/4 of a loaf of bread (soaked in water) 1 cup of grated rusk 1 egg (optional) 1/2 coffee cup of olive oil 1 large onion 2 cloves of garlic (optional) 2 spoons of flour Chopped parsley and mint (optional) Salt and pepper to taste Savory (to taste) Execution Combine all the ingredients and shape into bite-sized balls, roll them into the flour and deep-fry into vegetable oil. When they form a golden crust, remove from the pan and dry them on paper towels.

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Octopus in vinegar marinade by Amorginou Kalliopi Ingredients 2kg fresh octopus 1 cup of olive oil 1 cup of white wine vinegar 5-6 cloves of garlic Juice of 1/2 lemon 2 bay leaves Savory or oregano to taste Execution Clean the octopus and remove the skin membrane, then cut it in bite-size pieces. Place the octopus in a pressure cooker, cover with water and cook until tender. In the meantime, prepare the marinade by mixing all the remaining ingredients. Place octopus and the marinade into a mason jar, seal and keep refrigerated.

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Cuttlefish 'Youvetsi' style by Parimerou Katerina Ingredients 1kg fresh cuttlefish 1/2kg orzo pasta 1/2 cup olive oil 400gr of chopped tomato 1 spoon of tomato concentrate 1 onion 4 cloves of garlic 1 bunch of parsley 1 bay leaf 1 spoon of cinnamon powder 1 spoon of salt 1 teaspoon of ground pepper Execution Clean the cuttlefish and remove the skin membrane and ink, cut into bite-size squares. Sauté the cuttlefish in olive oil, add the chopped onion, garlic and parsley and once the onion turns golden brown add the remaining ingredients and top up with water (halfway through the pan). Simmer until tender, then transfer to a pan and add the orzo. Cook in the oven until the orzo is tender, add more water if required.

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Spaghetti with swordfish sauce by Amorginou Nomiki Ingredients 1/2kg swordfish 1/2kg spaghetti No.6 1 can of chopped tomatoes 1 spoon of tomato concentrate 1/2 cup olive oil 1/2 cup white wine 1 onion 1 red pepper Basil leaves (dried) Rosemary (dried) Salt, pepper to taste Execution In a deep pan, sauté the onion and pepper in the olive oil. Clean the swordfish and remove the skin and the bone, then cut into bite-size cubes and roll them in flour. In a separate pan, fry the swordfish until golden and then add the fish to the onion and pepper mix. Add the remaining ingredients and top up with water and simmer. In the meantime, boil the spaghetti for 8mins and then transfer to the sauce, increase the heat until it starts boiling and serve immediately.

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Baked Tuna / Swordfish in lemon marinade by Pizania Galatiani Ingredients Tuna / Swordfish fillets 3-4 cloves of garlic 3 lemons (juiced) Olive oil Savory Salt and pepper Execution Cut the fillets into individual portions, wash and place into an oven pan. Add the chopped garlic, crushed savory, olive oil and season to taste. Finally, add the lemon juice, cover with foil and bake at 200 oC for an hour. Garnish with potatoes or rice.

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Fish sauce by Lyra Korfia Themelina Ingredients 1 large onion 4 cloves of garlic 1/2 bunch parsley 2 packets of tomato concentrate 1 teaspoon of paprika 1 teaspoon of sugar 1 small jar of capers Savory Bay leaves 1/4 cup white wine or retsina Execution Boil the fish in a pressure cooker for 10mins with the juice of a lemon and some white wine vinegar, reserve the fish stock and use as needed to make the sauce lighter.