The processing: carried out entirely in Calabria for 100 years
The decision not to delocalize the production process was a strategic choice by Callipo, which has always paid particular attention to ensuring the high-quality of Made in Italy products. The true secret behind the quality of Callipo products lies in the processing procedure, which owes its success to a balanced combination of tradition and technology and the great care that the company pays to all stages of the production process, from the selection of the raw materials, to the maturing of the products and, ultimately, their sale. Join us in discovering how the Callipo Tuna production cycle works.
Watch the video of production phases
The tuna is frozen whole on the fishing boats and then transferred to the plant at Maierato (VV), where the necessary documentary and quality controls are carried out.
Then, after it has been thawed using a flow of running water at room temperature, the tuna is put through the separation line, cut and then processed.
The tuna is steamed so as to preserve its organoleptic characteristics and nutritional values. It is then cooled, transferred to the conditioning cells and dried at a controlled temperature.
The cooked tuna is then transferred to the cleaning section, where it is carefully cleaned and put through a quality selection process which is carried out by women, in line with the traditional process.
Manual jar filling
The workers fill the tuna fillets into jars by hand, using a process that is entirely manual and yet guaranteed by important safety measures.
In order to produce the Tuna Fillets in glass jars, on average the company uses only 50% of the processed slices, in order to guarantee its consumers transparent quality and authenticity.
Once they have been filled, the jars are put through the salt measuring device and the olive oil filling machine.
The products are transferred into the sterilization autoclaves. Once this stage is complete, a number of samples are taken for analysis.
Laboratory and quality control
At the laboratory, the samples undergo a number of controls. These include: determination of the drained weight; determination of the salt concentration; seaming control; stability testing of the finished product; measurement of the temperature, humidity and histamine; and microbiological and chemical controls.
In the packaging division, which is entirely automated, the specific production batch is inserted onto each package. By synthesizing the purchase batches of each component of the finished product and the identification codes of the respective suppliers, this system guarantees the traceability of the supply chain.
LThe maturing process is designed to guarantee the intrinsic qualities of the product, and varies depending on the format. Callipo pays particular attention to the maturing times, which greatly exceed those suggested by the certification bodies.