Tell us about your production challenge

Canned tuna, a staple in millions of kitchens around the world, was first manufactured in 1904 by Albert P. Halfhill in California. It has since become a reliable source of protein and omega-3 fatty acids for people around the world. Canned tuna production process consists of multiple stages including thawing, cutting, steaming, deboning and sterilizing, all of which ensure the product quality and long shelf life.

Tell us about your production challenge

When selecting production equipment for a production plant, it is important to talk to someone with experience in your field. Our industry experts have experience with various industrial applications. We’d love to help you!
Contact us

The basics of canned tuna production process – which tuna is used for canning?

Although five different tuna species are used for commercial purposes, only three are used for canning- skipjack, yellowfin, and albacore. The canned tuna classified as light meat tuna comes from skipjack and yellowfin, while white meat tuna comes from albacore. The two differ in omega-3 content, color and taste. Light meat tuna is darker, lower in fat and omega-3s and more flavorful, while white meat tuna is lighter, with a firmer texture and high in omega-3 fatty acids.

The canned tuna production process begins with the frozen tuna arriving from the fisheries at the processing plant. There, the tuna is thawed in large water tanks, sized and sorted to minimize the weight loss from overcooking. The sorted tuna is then cut and subsequently steamed in large pressure-cooking chambers. This initial pre-cooking removes excess oils and makes it easier to separate the fillets from the rest of the meat.

Canning and sterilizing tuna: the crucial steps

After the initial steaming, the meat is cooled down and deboned, separating the loins from the bones and the skin. Then, the meat is transferred into cans by a filling machine. Manufacturers can add salt, water, oil, or marinade to the can, then hermetically sealed.

The filled cans are then cooked and sterilized at a temperature of 121°C for 20 minutes to eliminate harmful microorganisms but still retain tuna’s nutrients.

Sterilization is crucial for canned tuna production. Canned tuna is a low acid food, which supports the growth of microorganisms such as Clostridium botulinum. Clostridium botulinum is found in the intestines of fish, animals, birds, insects and the soil.

Being a heat-tolerant microorganism, it can produce a neurotoxin if the canned fish is underprocessed. Spores, if present in unprocessed canned tuna or if they enter the can after processing, can create issues. The processing time depends on the can size.

Mercury in canned tuna - How much of it is allowed?

Another hazard with seafood consumption is mercury poisoning. Mercury is naturally present in seafood, most often in sharks, swordfish, bluefin, and albacore tuna. Of the two tuna species used for canning, albacore contains more mercury than skipjack due to its larger size; however, both species are considered to have low mercury content.

Canned white albacore tuna typically contains about 0.32 parts per million of mercury. Canned light tuna contains about 0.12 parts per million of mercury. The FDA and the EU allow products that contain 1 part of mercury per million, and have recommended intakes of tuna for children and adults.

Environmental impact of tuna production process

With the increasing public outcry for environmentalist policies and practices, the canned tuna production process has adapted well. A study by The Environmental Working Group determined that canned tuna production produces 6.1 kg of CO2 a day, which is lower than any other meat industry. Most of the produced carbon, 68% total, comes from the fuel used for fishing, while the rest is attributed to subsequent transportation, factory processing and storing.

The way tuna is fished also contributes to the industry’s carbon footprint. With purse seine fishing, the fisheries use a cylindrical net that surrounds a school of tuna and closes the bottom. Purse seine fishing has the lowest carbon footprint per kilogram of caught fish. This fishing technique’s efficiency could potentially lower the number of fishing boats and the fuel needed to support larger fleets.

Tuna waste repurposed: byproduct to pet food

To reduce waste, tuna canning industry repurposes the remaining byproduct. The cannery produces 50 to 70% of solid waste after tuna processing, including heads, guts, gills, red tuna meat, and bones that must be discarded or repurposed.

Only white tuna meat, or loins, is used for human consumption and the remaining red meat is separated and used for animal or pet food. Sometimes, even the other discarded parts of tuna, such as the skin, fat, and organs, are added to pet food, which is especially beneficial for cats in moderation as it is a source of protein, omega-3s, and low-carb.

Moreover, the leftover meat, bones and skin from the tuna canning process can be used to produce fish oil, fish meal, gelatin and fertilizer, which significantly minimizes the amount of waste.

Which canned tuna technology do you need?

Lab can retort for precise temperature and pressure control

Food developers need to test new recipes and packaging mater...

High infeed palletizer for varied product types

When managing high-volume packaging lines, ensuring efficient palletizing ...

Heavy-duty palletizing robot for production lines

In high-volume manufacturing environments, effectively handling and sta...

Electric cooker for preserved food preparation

In the preserved food industry, maintaining the integrity and flavor of ing...

Basket tracking system for automated batch retort systems

In automated food processing, managing the flow and condition ...

Tuna vacuum pre-cooker cooler

Thawing and cooking tuna fish while ensuring a high yield and uniform heat distribution can be...

Gentle can handling ejector for rotary cooker

In high-speed food processing lines, heavy impact can damage metal cans, par...

Tuna precooking optimization software

In the tuna processing industry, ensuring consistent quality and maximizing yield dur...

Automatic tuna can filler

For large-scale tuna canning operations, maintaining high production speeds while achieving precis...

Filling and seaming groups for aluminium and tin plate cans

When producing canned food products or flat soft drinks, ens...

Dual view x-ray inspection for canned goods

In food manufacturing, ensuring the absence of foreign bodies in products pack...

Laboratory pilot sterilizers for food packaging

In food production R&D, ensuring consistent and safe sterilization wh...

Cascading water autoclave for food sterilization

In the food industry, achieving uniform sterilization in various packagin...

Continuous steam cooking and cooling for fish processing

Ensuring high-quality, nutrient-preserved cooked fish products i...

Mpac Alisio casepacker for food

Side Load Case Packer For Packaged Food

Accuracy is a primary concern for case-packing pre-packaged foods such as milk or p...

Autoclave sterilizer for food cans and jars

An autoclave is a must-have machine for canned food production lines. It perfo...

Can leak tester

Every canned pet food producer knows that their product should avoid the growth of microorganisms that could s...

Irregular can seamer

Quite some time can be lost adjusting the seaming process to different can sizes when orders keep follow...

Continuous sterilizer for canned products

Sterilization is a critical operation in the manufacturing of canned vegetables ...

Linear machine for wraparound label

Wraparound labels allow you to offer detailed information using a small space or fit ex...

Autoclave for canned food

Sealing and cooking products in cans, pouches or other containers is a very popular method of pres...

High performance can seamers for the food industry

The wide variation of materials and dimensions used in the food cannin...

All your data is kept confidential

Tell us about your production challenge

We will connect you to our growing network of 20.000+ technical & application specialists working for more than 500 world-leading machine & equipment manufacturers.

All your data is kept confidential