Our Processes

Our highly trained team of expert assessors choose only the best quality seafood for processing. The fresh catch is processed and exported to the buyer within a span of 3 days. Operations are in strict accordance with HACCP Food Safety Management Systems, all EU and FDA Food Safety Regulations and as per the Guidelines of the local authority (Department of Fisheries & Aquatic Resources). This allows us to safeguard our Customers and Workforce, and ensure that delivering high quality products is the number one priority. Our products are packed with plenty of gel ice (+ dry ice) in order to maintain the best product quality. All products are maintained at 0°C until they are dispatched from our factory to ensure total freshness.
We have implemented best in class processing techniques to ensure the highest quality products for our buyers and have established “JAY” as a leading brand in the global seafood markets.

A sneak peek at our operations

The journey of Jay Sea Foods: from sea to the plate

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Unloading, grading and sampling

The fresh catch from the sea is washed and loaded on to refrigerated trucks after reaching shore and transported to JSFP. Chilled fish from refrigerated trucks are unloaded whilst adhering to all hygiene standards. Temperature is measured at the point of unloading, only fish with temperatures < + 4⁰C are accepted. Then the fish is inspected for gaff marks and any external damage. Fish with high temperature and damage are returned immediately to the supplier. The fish with acceptable temperatures undergo a grading test and an inspector cores each fish with a clean corer and pulls out a sample of flesh from the center of the fish. This each sample is used to check quality and to categorize the fish into grades according to colour, texture and various other characteristics. The same sample is then sent for the chemical tests conducted in the inhouse laboratory.

To gilling, gutting & filleting

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To gilling, gutting & filleting

Gilling, Gutting and Filleting

The fish are washed and thoroughly cleaned and the weight of each fish is measured. The fish are stored in chill tanks till the results of the chemical tests arrive. If histamine/mercury is above accepted levels, the fish are taken out from the chill tanks and returned back to the suppliers immediately and if within the accepted levels, are taken for processing. At the primary processing stage, all fish undergo a mandatory gill and gut removing process. Also, at this stage tails and main fins of all fish are removed completely and if it’s a H/G shipment then the heads of fish are removed. Then the fish are scrubbed and washed thoroughly. All fish that are required to be processed (except whole fish/G.G shipments) are initially split in to halves from the center bone (Horizontally). This is called filleting and each half is called a fillet. Then they all undergo a deboning process where the center bone and all other bones are removed.

To Skinning

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To Skinning

Skinning

Each fillet is split further in to halves which are called loins. The skin of each of these loins are removed along with minute bones and dark meat. (If the buyer wishes to have skin on products, the skin will not be removed). Temperature of the loins are taken and recorded.

To Trimming & Portioning

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To Trimming & Portioning

Trimming & Portioning

The skinned loins are further checked for internal damages, cuts, bite marks, cancers, parasitic growths. Thereafter, the loins are processed as per the Buyer’s required specifications e.g. blocks, chunks, brochettes, steaks and saku. After trimming and cutting, these products are wrapped as per the Buyer’s specifications.

To Vacuum Packing

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To Vacuum Packing

Vacuum packing

The finished products (wrapped/unwrapped) are then inserted to vacuum bags (LDPE + Nylon) and passed for labelling. This label contains all details of the product and information required for export. After labelling, all products are vacuum packed

To Chill Storage

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To Chill Storage

Chill storage and Master packing

The vacuum packed products are then stored in ice slurries to maintain a constant temperature of 0⁰C. When ready for export, they are taken out and boxed in to regifoam boxes / corrugated cartons with plenty of gel ice (dry ice can be added additionally on request) and sealed. The box is labelled and then stored in cold rooms till dispatch.

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Interested in importing our product? Drop us a message now

Our Company is committed to supplying only the best, safest, high quality,legal seafood. Best in class processing techniques are implemented to ensure that only the highest quality products are available to our buyers.

All Rights Reserved Jay Sea Foods Processing (Pvt) Ltd 2021

All Rights Reserved Jay Sea Foods Processing (Pvt) Ltd 2021