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SUBJECTS TO BE COVERED

SUBJECTS TO BE COVERED. Background information and statistics Resource sustainability and responsible fishing Pollution prevention (clean production) The INTEC/GTZ project Peruvian experience USA experience Preliminary findings in Chile Small seafood plant options Strategy for the future.

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SUBJECTS TO BE COVERED

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  1. SUBJECTS TO BE COVERED • Background information and statistics • Resource sustainability and responsible fishing • Pollution prevention (clean production) • The INTEC/GTZ project • Peruvian experience • USA experience • Preliminary findings in Chile • Small seafood plant options • Strategy for the future

  2. WE WANT TO KEEP AN OPEN MIND

  3. BACKGROUND INFORMATION

  4. EVENTUALLY • Whether we like it or not OR • Agree with it or not • The current effluent regulations will change and will probably get more strict • Eventually at some point in the future we will not be allowed to discharge into the Sea

  5. ANNUAL CHILEAN FISH LANDINGS Source: FAO 2002, Fisheries of the United States 2001, FIS International 2002

  6. ANNUAL CHILEAN FISH LANDINGSBY MAJOR SPECIES Source: INE (Chile) 2002

  7. % CHILEAN LANDINGS BY SPECIESFOR DIFFERENT TIME PERIODS Source: INE (Chile) 2002

  8. % CHILEAN LANDINGS BY REGIONFOR DIFFERENT TIME PERIODS Source: INE (Chile) 2002

  9. % CHILEAN PRODUCTION OF FISHMEAL AND EDIBLE FISH PRODUCTS BY REGION, 5 YEAR AVERAGE

  10. CHILEAN PRODUCTION OF FOOD FISHFROM PELAGIC SPECIES Source: FAO Statistics Database 2002

  11. CHILEAN PRODUCTION OF FOOD FISHFROM NON-PELAGIC SPECIES

  12. Jurel Caballa

  13. Merluza de tres aletas Merluza del sur Merluza gayi (coumun) Merluza de cola

  14. RESOURCE SUSTAINABILITY AND RESPONSIBLE FISHING

  15. RESOURCE SUSTAINABILITY AND RESPONSIBLE FISHING • Insuring that the living we make from the sea will be available to our children and grandchildren • Utilizing 100% of the catch with no waste • Making the maximum beneficial use of the resource

  16. ECOLOGICAL PRESSURES • Bad publicity about pollution or waste leads to consumer pressures on customers • Customers are reluctant to purchase products that are associated with damage to the environment • Lending institutions are reluctant to loan money to industries or companies with poor environmental records • Bad publicity stays on the internet forever and never goes away

  17. POLLUTION PREVENTION AND CLEAN PRODUCTION

  18. What Is Pollution Prevention? Itis not end of pipe treatment It • Maximizes Product Recovery • Reduces Conditions That Cause Losses • Increases Revenues And The result will be a reduction or complete elimination of pollution.

  19. THE END OF PIPE CONCEPT IN WASTE TREATMENT Treatment 1 Treatment 2 Treatment 3 Treatment 4 Treatments 5, 6, 7, 8

  20. PROBLEM WITH END OF PIPE TREATMENT • It does not address the cause of the problem • It only addresses today not tomorrow • It requires continuous add-on equipment as the effluent regulations evolve • It does not offer the option of product recovery or improving process efficiency

  21. FISH COMPOSITION

  22. AS THE FISH AGE • Protein is converted by bacteria and enzymes in the fish gut into breakdown products some of which are volatile and others water soluble • The consistency of the fish changes from firm to soft and eventually to a liquid • And smells develop

  23. The Result From the Aging of the Raw Material • Low quality products • Smells coming from the drier stacks and plant • More product goes with the liquid streams instead of the solid stream • Reduced yields • Higher production costs • Less revenue

  24. The Major Key to Pollution Prevention Raw Material Quality

  25. First Key to Reducing Waste and Enhancing Yields • RAW MATERIAL QUALITY • It is like money in the bank, an investment in the quality of the raw material pays dividends at each stage of the process. • For example, reducing the storage temperature of the fishby 5-6o C extends the storage time by 100%. • Because the biochemical reactions that cause spoilage are reduced by 50%

  26. First Key to Reducing Waste and Enhancing Yields • RAW MATERIAL QUALITY • It is like money in the bank, an investment in the quality of the raw material pays dividends at each stage of the process. • For example, reducing the storage temperature of the fishby 5-6o C extends the storage time by 100%. • Because the biochemical reactions that cause spoilage are reduced by 50%

  27. THE INTEC/GTZ PROJECT

  28. THE INTEC/GTZ PROJECT • 2 Half day seminars to train local consultants in seafood processing • Visit a variety of seafood companies in Regions VIII and XI with local consultants • Discuss the processes and identify the potential problem areas in the plants • Offer suggestions for more efficient and cleaner production • Issue reports in cooperation with local consultants

  29. THE INTEC/GTZ PROJECT • 12 Processing facilities were visited Fish and shellfish canning Fishmeal Filleting Freezing both fillets and whole fish Salmon processing Seaweed

  30. THE INTEC/GTZ PROJECT • Reports and follow-up discussions were held with the processing plants • Meetings were held with CPCC in Region VIII • Two public seminars- one in Concepcion and the other in Valparaiso to discuss the observations and recommendations • Future strategy for work to be discussed

  31. EXPERIENCES IN PERU

  32. PERUVIAN EXPERIENCE • Similar projects were established in Peru during the period 1996-2000 • A Consortium consisting of- US AID the funding agency Ministry of Fisheries (MIPE) CONAM Sociedad Nacional de Pesqueria (SNP) Sociedad Peruana de Derecho Ambiental (SPDA)

  33. PERUVIAN EXPERIENCE • Originally funded for Paracas Bay only • Later expanded to all of Peru • 85% of the fishmeal plants visited during this period • Very little edible food products produced • The US EPA funded seminars in the major cities to discuss waste reduction and by-product recovery from seafood processing

  34. PERUVIAN EXPERIENCE • The major problem area identified was raw material freshness • The major impact was on the pumpwater • The second major problem was blood water • In a few plants, stickwater was also a problem

  35. PERUVIAN EXPERIENCE • The project secured samples for testing • Based on the data a technology package was recommended • New technology was transferred through the Consortium to the other companies • Everyone benefited from this

  36. PERUVIAN EXPERIENCE RECOMMENDATIONS PHASE I • Replace centrifugal pumps with low water/fish ratio pumps such as Pressure Vacuum (step 1) • Install 1 mm screens for the pumpwater (step 2) • Install Dissolved Air Floatation (DAF) systems to recover solids and oil (step 3) RESULT I. Reduction in pumpwater volume and recovery of valuable oil and protein

  37. PERUVIAN EXPERIENCE RECOMMENDATIONS PHASE II • Add water return line to vessel (step 4) • Recycle the pumpwater (step 5) • Replace transport pipes with plastic (step 6) • Retrofit evaporator condensate system to separate cooling water (seawater) from condensate (fresh water) (step 7) • Add a cooling tower (step 8)

  38. PERUVIAN EXPERIENCE RESULT II • Different parts of the technology have been installed but no one plant has installed all the technology • The technology appears to have transferred to Chile since many plants have adopted as much as 75% of the technology

  39. WE WANT TO KEEP AN OPEN MIND

  40. PERUVIAN EXPERIENCE • Learn from their mistakes • Regulatory pressure forced them to purchase process technology that was inefficient • Much of it has been replaced

  41. PERUVIAN EXPERIENCE RECOMMENDATIONS PHASE III • Use evaporator condensate water (freshwater) as pumpwater (step 9) • If necessary add an additional evaporator (step 10) RESULT III Recycle and evaporate in a continuous closed circuit to recover dissolved proteins

  42. PUMPWATER + FISH SCREENS VESSEL CHATA SCREENS SCREENS FISH PUMP WATER RETENTION TANK 1 MM SCREEN SOLIDS PUMPWATER RETENTION TANKS SOLIDS DAF CONDENSATE WATER STICKWATER TANK OIL COOLING TOWER CONCENTRATE EVAPORATOR PROPOSED RECYCLING SYSTEM FOR PERUVIAN FISHMEAL INDUSTRY

  43. CUMULATIVE RECOVERY OF PROTEIN AND OIL IN PUMPWATER (DM BASIS)

  44. CUMULATIVE VALUE OF PROTEIN AND OIL RECOVERED FROM PUMPWATER

  45. Screens for solids removal

  46. RELATIVE DAF SYSTEM EFFICIENCY

  47. DAF Systems

  48. FRESH WATER RETURN PIPE 1 MM SCREENS DAF SYSTEM RECONFIGURE PIPING BUFFER TANK RETENTION TANKS LOW WATER FISH PUMP PVC PIPES FOR FISH COOLING TOWER NEW EVAPORATOR TOTALS $100,000 $ 20,000 $150,000 - $400,000 $ 20,000 $ 10,000 $ 50,000 $150,000 - $250,000 $150,000 $100,000 $1.0 million $1.75 - 2.1 million 1999 price estimates TECHNOLOGY PACKAGE COSTS IN US$

  49. Plastic pipe for fish transport

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