Polyplan Shrimp Basic Concept Alpha-Maris 2016 · 2017. 5. 31. · [] page 3 of 11 Criteria for an...

2016

Indoor Shrimp Farming

Content:

Our Services ______ 2

Criteria for an indoor shrimp farm_____ 3

Basic conditions ____________ 4

Plant design „αlpha MARIS“ ________ 5

Concept of „Marella“-production 6

Technology behind „αlpha MARIS“ 7

Flow diagram water cycle _______ 8

Key figures 9

The shrimp market 10

[www.polyplan-gmbh.de] page 2 of 11

Our Services

White Tiger Shrimp (5 mg/ shrimp) Post

Larvae of Litopenaeus vannamei

White Tiger Shrimp (25-30 g/shrimp) in

shallow water indoor raceway

White Tiger Shrimp (25-30 g/shrimp), fresh

dead – never frozen

Project development for shrimp aquaculture

� Basic and detailed engineering

� Support for approval planning (only Germany, partly EU)

� Construction supervision (only Germany)

� Standard Operation Procedures

� Training and education of staff in theory and practice

� Support service for starting the operation

Upon start of operation following services can be offered:

1. Assistance or support service in purchasing animals for stocking and feed

2. Surveillance of operational parameters (via digital systems for measurement & control)

3. Support in questions on quality management, hygiene, optimization of production as well as

assistance in marketing and certification

4. Within the scope of quality assurance we can verify the compliance with environmental criteria, as

accepted by the producer (e.g. regarding use of medicaments and feeds)

5. The construction can be realized either by Polyplan GmbH as general contractor or announced

locally at the construction site

6. The liquidity and income preview are affected by many factors and therefore we recommend to

perform a feasibility study in advance, covering these questions and also generating an individual

quote for Your project.

In all questions an experienced team of engineers, biologists and technicians is working for You.


Criteria for an indoor shrimp farm

White Tiger Shrimp (25-30 g/pcs), Litopenaeus

vannamei, prepared

Good reasons for shrimp: Shrimp are a healthy and tasty food and the demand for shrimp has been and still is

increasing, more than in other sectors of animal production. According to the FAO the growth in aquaculture during the past

three decades averaged 8.8% per year, and farmed marine shrimp contributed 55 percent to the total global production of

shrimp in 2010 (FAO The State of World Fisheries and Aquaculture 2012; s.

http://www.fao.org/docrep/016/i2727e/i2727e.pdf, pp. 25 and 36). The species Pacific White Shrimp or „White Tiger“ has

been investigated and bred for traits of robustness and yield in the USA since decades. This species is predestined for indoor

aquaculture, thanks to its less cannibalistic behaviour, lower protein demand and good feed conversion. Produced free of

antibiotics and other chemicals, fresh & never frozen and at a continuous schedule, the shrimp can be marketed as a year-

round available high-value product.

Site selection criteria:

Site: Our systems are operated with artificial seawater and do not require coastal water access. This also reduces the risk of

pathogen entry from ocean water. Proximity to a larger city is favorable, since it eases logistics and shortens the transport to

end consumers.

Supply with heat and electricity: A constant and reliable supply of heat and electricity is indispensable. Thermal energy,

being available as waste heat from e.g. a biogas or (biomass) power plant at low or no costs, considerably reduces the

operational costs and the specific costs of production [€/kg product].

Water supply and wastewater disposal: water supply at drinking water standard and with the lowest achievable mineral contamination (iron) is to be pursued.

Suitability of well water can be verified. The wastewater volume is relatively low, because of a relatively low water renewal rate. It can be disposed off or discharged by

several ways: by directly introducing the volume into the receiving waters (feasible for brackish waters), via evaporation (if waste heat is available), discharge into the

sewer system (upon approval by the authorities) and by further utilizing the nutrient rich water for growing plants as a secondary product (aquaponics using salt-

tolerant plants).

Further infrastructural factors: costs for real estate, level of local public infrastructure and degree of site development, any existing buildings and their suitability or

required re-construction.

Public subsidies: the European Marine Fisheries Fund (EMFF) can support investments in aquaculture, amended by subsidies of the individual countries and regulated

by their authorities. Applications are evaluated differently among the different countries and even within one country (e.g. among the German States). This means that

the chances for approval are insecure. An economical viable investment still is achievable without funding. The impact of other site specific factors, as mentioned

above, is comparable at least or may even be more significant compared to receiving EU subsidies. We are pleased to assist and consult for You in the scope of the

basic engineering phase.

(1 EMFF: http://ec.europa.eu/fisheries/contracts_and_funding/index_en.htm)


Flexible and modular units for application in

rural or industrial enterprises

Operation independent of access to natural

salt water resources and with low demand

for fresh water and low waste water volumes

Trained and responsible personnel to ensure

safe operation

Additional support by the Polyplan GmbH

enhances safety in operation

The system is permanently controlled by a

central operating monitoring with integrated

alarm message function

Safer marketing for partners in the Marella

cooperative – within Europe

Basic conditions

Building ground

The systems can be operated as privileged facilities in "shouting distance" of farm buildings or as warehouses in

industrial areas. For an annual production of 18-20 t, about 4000 m² of warehouse space plus approximately 250

m² of outdoor area are required.

Agriculture or industry

An annual production of up to 20t is suitable for the typical agricultural family enterprise. A properly designed

system can be operated by one full-time employee plus temporary employees. Temporary workers are required

for certain operating activities, such as the acclimatization of new stocking animals or for helping in sale.

Alternatively, large-scale plants, operated as commercial enterprises, can be planned to produce greater annual

tonnages.

Demands on the operator

The responsible person must be reliable, he/she needs to possess a good scientific and technical knowledge,

computer skills, and of course should have experience or at least interest in dealing with living animals. Before the

start of production the operator can attend lessons in theory & practice, being trained on-farm by our staff.

Operational safety

Our team of biologists and engineers is ready to support the operator on the basis of a service contract in the first

few years of operation, in order to achieve the targeted production as quickly and safely as possible. A central

operation monitoring (measuring and control engineering) controls the water recirculation, as well as the water

treatment modules and the feeding. In case of power failure and other critical states, alarm messages are

automatically sent to the relevant people.

Marketing

Within Europe the "Marella" cooperative, which is being founded this year, will keep You informed about new

developments and optimizations relevant to Your system. Furthermore, Marella can assist You in the marketing

and sale of Your product. With appropriate statutes, the cooperative can even offer a purchase guarantee.


.

Plant design „ αlpha MARIS“:

Multiphase Aquaculture in Recirculation Indoor Systems

Concept of constant „Marella“ - Production

Our Design: „αlpha MARIS“ stands for a largely single-story plant design, consisting of sub-divided raceways which provide a year-round almost constant production. This

is achieved by transferring the stocked shrimp in a gentle manner into a more spacious sector of the tank twice during their grow-out phase. Besides an optimized use of

available water volume this multi-phase concept allows for a staggered re-stocking and thereby a more continuous production. The special feature of the design „αlpha

MARIS“ is the subdivision of the animal husbandry sector as well as some integrated technical modules, providing a gentle horizontal transfer and a central feeding. Both

technical solutions have been developed in a R&D project titled „Garnele im Fluss“* and are available for implementation in our indoor shrimp farming projects based on

recirculating aquaculture systems.

Operation: The shrimp grow in artificially prepared saltwater at a temperature of 28° to 30°C. The water is constantly cleaned by passing different filters, acting mechanically

and biologically to remove detrimental substances, and the cleaned water is re-circulated into the raceways. The advantage of this principle is a low water usage and the fact

that the operation does not depend on coastal water supply.

*

The technical concept comprises following functional

modules (no. 1-3 refer to drawing on the left):

1. Building (e.g. greenhouse construction)

2. Animal husbandry in the production raceways

3. Water treatment modules

4. Measurement & control technology

5. Feeding technology*

6. Device for (selective) harvest*

3-D sketch of the plant design „αlpha MARIS“, here with an elevated nursery tank

1

2

3


Stocking & harvest scheme:

The culture begins with the so-called 'post larvae' (PL) with a mean body weight of 3-5 mg/animal and ends with the marketable weight of approx. 25 g/animal. Until

now there are no PL hatcheries established in Europe. Therefore all PL assigned for the grow-out in Germany are delivered by hatcheries in the U.S. that can provide a

health certificate complying with the relevant EU legislation. Through contracts with these suppliers on-time delivery of healthy PL can be guaranteed. Pathogen-free PL

are a key requirement for one of the major quality criteria of “Marella-shrimp”: an antibiotic-free shrimp production.

After stocking, the shrimp will pass three different husbandry tanks, customized in size according to their actual body size in the particular growth phase. After a total

production period of in maximum 30 weeks the shrimp will reach their marketing mature weight of 25-30g. This stocking concept allows a continuous availability of

marketable shrimp sizes, all year round. The residue-free shrimp are fresh, which means there are delivered within 24h after harvest.

For achieving an optimum growth performance continuous feeding is required, which is ensured by an automatic feeding system integrated into the raceways. Upon

arrival, the shrimp are acclimated for several hours to the conditions in the system and get their first feed. The feed is specifically formulated for these shrimp according

to latest research and is particularly optimized for fishmeal replacement by plant materials.

Draft schedule for a staggered stocking mode with re-stocking every 3 months. Each bar represents the time each raceway (or group of raceways) is occupied by shrimp.

Concept of constant „Marella“ - Production


The technology behind „αlpha MARIS“

„αlpha Maris“ stands on three pillars: the central controller, the husbandry technology

and the water treatment.

The head of the plant is the central control system that monitors parameters like ventilation,

operation of pumps, water levels and pH, which are all critical for the circulatory technique and

overall plant conditions. In case of failure or malfunction, alert messages are automatically

sent via SMS to the operator and other relevant third parties.

The base of the plant is the husbandry consisting of blocks of a defined number of raceways,

each divided into at least three sections, as well as a built-in pool feeding system which is filled

centrally. The raceways-sections are separated by walls with sluice gates and can be set dry

separately for the purpose of cleaning. The long-flow raceways can be built as concrete

construction with L-sections or T-sections and lined with 1.5 mm plastic sealing sheet.

The heart of the system is the water cycle: recirculation systems are largely closed water

circuits, which circulate water through the grow-out tanks and the mechanical and biological

modules of water treatment. Depending on the degree of water treatment only 1 to 10 % of

total water volume must be replaced by fresh water per day, to prevent the accumulation of

nutrients and metabolic compounds. This ensures a quality of water, in which the animals can

not only survive, but show a good biological performance.

The αlpha MARIS systems operate at a very low water renewal rate of about 1-2 % per day,

accordingly these systems show a relatively low consumption of fresh water and produce a

correspondingly low volume of wastewater.


The water cycle: The water, the shrimp live in, passes every 2-3h through the water treatment consisting of matched units for

mechanical and biological water treatment. Particles down to the micron range are removed by coordinated water treatment plants.

For biological water treatment, so-called “moving bed reactors” are designed to biodegrade dissolved organic substances and to

transform the, even at low concentrations very harmful and growth inhibiting, ammonium nitrogen into the much more harmless

nitrate. In a bypass to the main water circuit an additional de-nitrification stage is integrated to convert accumulating nitrate into the

dissolved gaseous di-nitrogen by specific bacteria.

Flow diagram water cycle „αlpha MARIS“


Characteristic numbers and specific costs:

The following numbers refer to our basic concept, achieving a yearly production of ca. 20t in several

production cycles.

Production specific key figures for „Marella“- Shrimp:

Area requirement/kg product 0,2 m²/ kg

Energy demand: total 71,0 kWh/ kg

Energy consumption: electricity

Specific costs*: electricity

30,0 kWh/ kg

4,7 €/ kg

Energy consumption heat:

Specific costs** : heat

41,0 kWh/ kg

0 or 2,9 €/kg

Feed consumption

Specific feed costs

2,2 kg/ kg

2,9 €/ kg

Specific costs for post larvae

stocked 2,3 €/ kg

Water usage 430 l/ kg

Specfic personnel costs 4,0 €/ kg

*specific costs for electricity refer to a price of 0,16 €/ kWh

**specific costs for thermal energy - in case of purchasing heat – were calculated at 0,07 €/ kWh

Polyplan GmbH office in Bremen, Germany


The shrimp market

In 2015 562.000t shrimp were imported into EU-member states, raw tropical shrimp contributing 72%, i.e. ca. 405.000t (http://www.fao.org/in-action/globefish/market-

reports/resource-detail/en/c/417580/ [19.10.2016]).

In 2014 every German consumed 14 kg of fish products, with Molluscs and Crustaceans making up ca. 12 %. Expenses for fishery products increased by 3,1 % from 2014 to

2015, amounting to ca. 3,7 billion € and going along with a one-digit rise in sales in all categories of fish industry.

(http://www.fischinfo.de/index.php/markt/datenfakten/4855-structurdata-2016; http://www.fischinfo.de/index.php/markt/92-datenfakten/4856-marktanteile-2016;

http://www.fischinfo.de/index.php/markt/datenfakten/4857-versorgung-und-verbrauch-2016 [19.10.2016]).

In Germany the production by capture fisheries and in aquaculture has accounted for only 11% of the 2,1 Mio t demand for fish and fishery products in 2012, and crustaceans plus mollusks

have a ca. 12% market share (Fisch-Informationszentrum e.V.“ http://www.fischinfo.de/).

With an annual output of 19 tons the proposed production facility could cover only a very small market share in any European market. The unique freshness and pure quality of the

“Marella” shrimp allows the marketing as a first-class and high-value product. For Germany the achievable market volume of this product is predicted to be around 1.000 t/a.

A future increase in demand of this top-quality product, especially on the part of consumers concerned about ecological impacts of intensive shrimp farming and harmful chemical residues,

which so far denied consumption of tropical shrimp, is difficult to predict and to quantify, but most likely to take place.

The “Marella Shrimp Cooperative” provides exclusive support to Your marketing within Europe. In Germany the distribution and the brand “Marella Shrimp” are already well established in

specialized trade and gastronomy. This reference will ease your marketing.

With an annual growth rate of 8,8% in the past three decades global aquaculture shows a much higher increase compared to other sectors of animal foodstuff

production.

In 2014, according to FAO, the total aquaculture production amounted to ca. 74 million t at a value of 160 billion US $. Crustaceans (ca. 7 Mio. t) accounted for

about 9,4% of the volume produced in aquaculture. The bulk of Crustaceans produced in aquaculture were marine species (60%) and their aquaculture meanwhile

is accounting for 55% of the global production (FAO The State of World Fisheries and Aquaculture 2016; http://www.fao.org/3/a-i5555e.pdf S. 18 u. 23 [19.10.16]).

The significant growth of aquaculture farming in tropical producer countries of SE-Asia and Central America implies serious impact to mangrove forests due to

extensive deforestations. Mangrove forests are among the most productive ecosystems of the world, they provide protection against erosion and flooding of

coastal areas and they are an important habitat for an uncountable number of endangered plant and animal species. With an increasing intensity of shrimp

production the use of chemicals and antibiotics rises, and so does the risk of unwanted and harmful residues in the final product reaching the consumer.

The import volume for shrimp into the EU increased by 2% within the 1st quarter of 2016 compared to the relevant period in the preceding year. Nearly 74% of

imports came from non-member countries (Globefish, Shrimp Market Report http://www.fao.org/in-action/globefish/market-reports/resource-

detail/en/c/433408/ [19.10.2016]).


The Polyplan team is ready to serve You with a healthy mix of solid expertise and

innovational spirit

Our team consists of 30 engineers, scientists, technicians and skilled workers.

We are constantly developing new solutions for our customers, because our success is Your success.

You can contact us at: [email protected]

And you can visit our website at: www.polyplan-hmbh.de / or www.polyplan-aquaculture.de

How do we get in touch?

Get in touch, we will find a solution!

The shrimp market is steadily

growing - invest in the future

market of aquaculture

The European market is interesting

for high-value aquaculture products

The Marella shrimp have been

evaluated by restaurateurs as

product of excellent quality

With Marella shrimp You can hold

the exclusive marketing at the

regional level

The short marketing channels allow

for attractive selling prices

The Marella cooperative will

support You in marketing

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