Smart Tunivac: The Future Of Industrial Tuna Cooking

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In the canning industry, cooking tuna is far more than just another step in the production line: it is the point at which quality, food safety, and process efficiency are defined. With Hermasa’s Smart Tunivac project, the sector takes a decisive step toward digitalization and artificial intelligence, introducing a new generation of cookers capable of learning from and adapting to each batch of raw material.

The challenge was clear: tuna varies widely in size, cut, and freshness, and this variability directly impacts both yield and final quality. Traditionally, operators adjust cooking parameters based on experience, but this approach does not always guarantee consistent results. Hermasa has created Smart Tunivac to transform this reality by integrating advanced sensors and intelligent algorithms that monitor and adjust the process in real time.

To date, the project has achieved important milestones. The validated system now ensures strict compliance with food safety regulations by confirming that every piece of tuna reaches the internal temperature necessary to eliminate microbiological risks. The new digital interface enables operators to manage recipes, alarms, and historical records, making process monitoring and traceability more accessible than ever. Spectroscopy technology (NIR) has also been incorporated to characterize raw materials before cooking, paving the way for even greater process customization.

Tests in industrial practice have produced promising results. Data indicate that the yield after cooking and cleaning is consistent across different cooking modes. However, the algorithm pointed out that the size and type of cut of the fish are the key factors for cooking. The new algorithm helps to prescribe an optimized recipe for each particular raw material, and the vacuum tuna cooker brings the greatest versatility to achieve the required parameters in each case. Significant reduction in steam consumption has also been observed, which is an important step forward in energy efficiency and sustainability.

The path ahead focuses on scaling up the solution. The next phase will involve increasing the number of monitored cooking cycles, refining sensor integration, and validating in practice the artificial intelligence models already created and capable of recommending the optimal recipe for each batch. The ultimate goal is to deliver a platform that not only improves quality and yield but also provides clear, traceable evidence for audits and certifications.

This project by Hermasa has been made possible thanks to public funding programs within IA 360 from IGAPE (XUNTA DE GALICIA) for innovation and industrial digitalization. This support enabled investments in advanced technologies and promoted collaboration among leading companies in the sector. Smart Tunivac thus stands as a strong example of how applied research and a commitment to digital transformation can enhance competitiveness and sustainability in the food industry.