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CLEAN PRODUCTION
IN THE SEAFOOD INDUSTRY IN
CHILE
By
Anthony P. Bimbo
Technical Consultant
Concepcion, Chile January 30, 2002
Valparaiso, Chile January 31, 2002
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
WE WANT TO KEEP AN
OPEN MIND
BACKGROUND
INFORMATION
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
ANNUAL CHILEAN FISH LANDINGS
9
8
7
Million Metric Tons
6
5
4
3
2
1
0
1962 1966 1970 1974 1978 1982 1986 1990 1994 1998
Through week 49 of 2001
Source: FAO 2002, Fisheries of the United States 2001, FIS International 2002
ANNUAL CHILEAN FISH LANDINGS
BY MAJOR SPECIES
8,000,000
6,000,000
Metric Tons
4,000,000
2,000,000
0
1990 1991 1992 1993 1994 1995 1996 1997 1998 1999
Jurel Sardina sp. Anchovetta Caballa Merluza sp. Total
Source: INE (Chile) 2002
% CHILEAN LANDINGS BY SPECIES
FOR DIFFERENT TIME PERIODS
10 Year Average 5 Year Average 1999
Jurel 48 46 22
Sardina sp 12 9 19
Anchoveta 24 25 36
Caballa 2 2 2
Merluza sp 4 6 7
Otros 10 12 14
Source: INE (Chile) 2002
% CHILEAN LANDINGS BY REGION
FOR DIFFERENT TIME PERIODS
10 Year Average 5 year average 1999
Region I 20.33 16.44 17.79
Region II 7.12 5.82 5.74
Region III 3.92 3.75 2.08
Region IV 2.07 2.36 2.48
Region V 6.97 8.40 5.02
Region VIII 53.23 55.17 56.87
Region X 5.06 6.51 7.90
Regions VI, VII, 1.30 1.62 2.12
IX, XI, XII, M
Source: INE (Chile) 2002
% CHILEAN PRODUCTION OF FISHMEAL AND
EDIBLE FISH PRODUCTS
BY REGION, 5 YEAR AVERAGE
% Fishmeal % Food Products
Region I 19 1
Region II 6 2
Region V 9 3
Region VIII 61 20
Region X 1 55
Region XI 0 12
Regions III, IV, 4 7
VI, VII, IX, XII,
RM
Source: INE (Chile) 2002
CHILEAN PRODUCTION OF FOOD FISH
FROM PELAGIC SPECIES
120000
100000
80000
Metric Tons
60000
40000
20000
0
1990 1991 1992 1993 1994 1995 1996 1997
Whole Frozen Frozen Fillets Fillets Canned
Source: FAO Statistics Database 2002
CHILEAN PRODUCTION OF FOOD FISH
FROM NON-PELAGIC SPECIES
900000
800000
700000
600000
Metric Tons
500000
400000
300000
200000
100000
0
1990 1991 1992 1993 1994 1995 1996 1997
Canned and Prepared Frozen Fillets Canned
Frozen Whole Cured
Source: FAO Statistics Database 2002
Jurel
Caballa
Merluza de tres aletas
Merluza del sur
Merluza gayi (coumun)
Merluza de cola
RESOURCE
SUSTAINABILITY AND
RESPONSIBLE FISHING
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
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
POLLUTION PREVENTION
AND CLEAN PRODUCTION
What Is Pollution Prevention?
It is 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.
THE END OF PIPE CONCEPT IN WASTE TREATMENT
Treatment 1
Treatment 2
Treatment 3
Treatment 4
Treatments 5, 6, 7, 8
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
FISH COMPOSITION
Protein 12 - 15%
Fat 1 - 20%
Water 60 - 79%
Minerals 5 - 8%
The composition of the fish varies by species, season, area caught, season of the year and what they are eating
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
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
The Major Key to Pollution
Prevention
Raw Material Quality
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
fish by 5-6o C extends the storage time by 100%.
• Because the biochemical reactions that cause spoilage
are reduced by 50%
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
fish by 5-6o C extends the storage time by 100%.
• Because the biochemical reactions that cause spoilage
are reduced by 50%
THE INTEC/GTZ PROJECT
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
THE INTEC/GTZ PROJECT
• 12 Processing facilities were visited
Fish and shellfish canning
Fishmeal
Filleting
Freezing both fillets and whole fish
Salmon processing
Seaweed
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
EXPERIENCES IN PERU
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)
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
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
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
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
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)
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
WE WANT TO KEEP AN
OPEN MIND
PERUVIAN EXPERIENCE
• Learn from their mistakes
• Regulatory pressure forced them to
purchase process technology that was
inefficient
• Much of it has been replaced
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
PUMPWATER + FISH SCREENS
VESSEL CHATA SCREENS FISH
PUMP
WATER
RETENTION 1 MM
TANK SOLIDS
SCREEN
PUMPWATER
RETENTION TANKS
SOLIDS
DAF
CONDENSATE
WATER STICKWATER
TANK OIL
COOLING TOWER
EVAPORATOR
CONCENTRATE
PROPOSED RECYCLING SYSTEM FOR PERUVIAN FISHMEAL INDUSTRY
CUMULATIVE RECOVERY OF PROTEIN AND OIL
IN PUMPWATER (DM BASIS)
3500
3000
2500
2000
TONS
1500
PROTEIN
1000 OIL
500
0
NONE SCREEN DAF EVAP.
BASED ON 100,000 TONS OF
FISH/SEASON
CUMULATIVE VALUE OF PROTEIN AND OIL
RECOVERED FROM PUMPWATER
1400000
1200000
1000000
US$ 800000
600000
PROTEIN
400000 OIL
200000
0
NONE SCREEN DAF EVAP.
BASED ON 100,000 TONS OF
FISH/SEASON
Screens for solids removal
RELATIVE DAF SYSTEM EFFICIENCY
DAF SYSTEM % PROTEIN % OIL
RECOVERED RECOVERED
MINING INDUSTRY 58 72
DEEP 30 53
RECTANGULAR
CONICAL 15 74
SHALLOW 60 81
CIRCULAR
DAF Systems
TECHNOLOGY PACKAGE COSTS IN US$
FRESH WATER RETURN PIPE $100,000
1 MM SCREENS $ 20,000
DAF SYSTEM $150,000 - $400,000
RECONFIGURE PIPING $ 20,000
BUFFER TANK $ 10,000
RETENTION TANKS $ 50,000
LOW WATER FISH PUMP $150,000 - $250,000
PVC PIPES FOR FISH $150,000
COOLING TOWER $100,000
NEW EVAPORATOR $1.0 million
TOTALS $1.75 - 2.1 million
1999 price estimates
Plastic pipe for fish transport
EXPERIENCES IN THE USA
THE USA EXPERIENCE
• 1972 Clean Water Act
• US EPA met with designated members
from various segments of the seafood
industry
• Processes were diagramed and the best
conventional technology (BCT) identified
for each industry segment
THE USA EXPERIENCE
• For fishmeal, the installation of stickwater
plants was considered BCT
• The industry was given a suitable amount of
time to install the stickwater plants.
• Eventually several plants shut down
because they could not afford the stickwater
plants
THE USA EXPERIENCE
• From BCT the regulations moved to best
available technology (BAT)
• BAT required that pumpwater be processed
or by special permit hauled to the open sea
for discharge
• BAT also required that the plants separate
scrubber water and rain run-off from other
liquid effluent streams
THE USA EXPERIENCE
• Regulations then shifted to the receiving
body of water
• Permits to allow discharge into these bodies
of water depended upon the end use of the
body of water (drinking, industrial,
recreation etc)
• This resulted in the retrofitting of the
evaporator condensers to separate
condensate water from cooling water
THE USA EXPERIENCE
• Discharge parameters were then reduced
resulting in the installation of large aeration
ponds or lagoons, some as large as 3 acres
• Transport of water through these lagoons
took 30-45 days with a reduction in BOD5
of 90% or more
THE USA EXPERIENCE
• When plants were idle for long periods of
time algae growth would push the
suspended solids content of the discharge
over the effluent limits
• Now, the latest regulations again deal with
the receiving body of water but now they
are setting TMDL total maximum daily
loads for the body of water
THE USA EXPERIENCE
• This means that even if you have a clean
operation and your neighbor does not you
could be affected by the TMDL figure for
the receiving body of water.
• The point to all this is that regulations will
continue to evolve and will eventually reach
the point of 0 discharge as is common in the
Scandinavian countries.
PRELIMINARY FINDINGS IN
CHILE
THE WASTE LOAD GENERATED DEPENDS ON THE PROCESS
All Edible Processing Fishmeal Processing
Pumpwater, unloading Pumpwater, unloading
Bloodwater, storage Bloodwater, storage
Blood from salmon Stickwater
Processing water Condensate water
Canning Dryer scrubber water
Head and Gut Evaporator cleaning
Filleting, Skinning solutions
Wash-up Dryer exhaust gasses
Water treatment residues
Solid fish waste or Shells
Solid waste transport in plant
PRELIMINARY FINDINGS IN CHILE
• Because of the limited time it is not possible
to go into much detail here
• All of the companies visited are conscious
of the need to protect the environment
• All facets of the seafood industry in Chile
were visited
• Salmon growing operations were not visited
• Each type of industry and in the case of the
edible seafood industry, each type of
process has unique problems
PRELIMINARY FINDINGS IN CHILE
• Some problems are common to both
industries
• For the fishmeal industry, the pumpwater is
the main effluent of concern
• For the edible seafood industry, water to
fish ratios are as high as 10-15:1
• There appears to be an attitude that water is
free so there is no concern about excess use
• There is very little water management
PRELIMINARY FINDINGS IN CHILE
• Solid waste (heads, tails, viscera, shells) are
a major problem with the smaller plants
• For plants processing salmon, the blood is a
major issue
• A number of plants recycle pumpwater to
reduce the volume but then discharge it
• Some plants are using screens, and DAF
systems for additional product recovery
PRELIMINARY FINDINGS IN CHILE
• At least one plant is replacing metal pipe
with plastic pipe to transport the fish
• Unlike Peru, many of the plants now have
the more efficient pressure vacuum pump
systems
• Plants are conscious of the possible
recovery of additional product (fishmeal)
• For smaller processors without access to
fishmeal plants, production of silage or
compost may be the only alternative
PRELIMINARY FINDINGS IN CHILE
• A number of products of higher value were
discussed with the plants on an individual
basis
RELATIVE SIZE OF THE VARIOUS STREAMS AND
PRODUCTS IN A FISHMEAL PLANT (50 TON/HR,
2000 HOURS)
STICKWATER
BLOOD WATER
PUMPWATER
RAW MATERIAL
FISHMEAL + FISH OIL
0 50000 100000 150000 200000 250000 300000
METRIC TONS
RELATIVE SIZE OF THE VARIOUS STREAMS AND
PRODUCTS IN AN EDIBLE PLANT PER 100000 TONS
OF FISH
SALMON BLOOD
PROCESS WATER LOW
PROCESS WATER HIGH
BLOOD WATER
PUMPWATER
RAW MATERIAL
FINISHED PRODUCT
0 200000 400000 600000 800000 1000000
METRIC TONS
THE FISHMEAL PROCESS
• Reduces what you don’t want so water is
removed
• And concentrates what you want (protein,
minerals and oil) so oil is recovered from
the water and the protein and minerals are
dried to produce fishmeal
• Generates large volumes of pumpwater
Fish unloading and pumpwater pipes
SEAFOOD PROCESSING
• Removes fish parts that are not wanted
(head, tail, viscera) results in 50% or less
yield
• Uses large volumes of potable water to
transport fish, cuttings, and edible portion
• May or may not have access to a fishmeal
plant for disposal of the solid or liquid
waste
SMALL SEAFOOD PLANT
OPTIONS
Options for Using Fish Waste
Extract biochemicals, color additives and other pharmaceuticals
Use mollusk shells in calcium health food supplements
Produce leather from skins and gelatin from skin and bones
Use solid waste in specialty sauces and other Asian products
Use solid and liquid waste in fishmeal and oil production
Use solid waste in advanced silage production
Use solid waste in cold (crude) silage production
Use solid waste in compost production
Use liquid or solid waste directly as fertilizer
Use solid waste for fish bait or chum
Use crushed mollusk shells for road construction
Dispose of liquid and solid wastes in the sea
Take solid waste to landfills. Send liquid waste to sewer system
CRUDE SILAGE PRODUCTION
Fish Waste
Grinder
Reactor Acid Reactor
Crude Silage
Storage Tank
CRUDE SILAGE PRODUCTION
Fish Waste Heat Exchanger
Decanter Solids
Grinder
Centrifuge Oil
Reactor Acid Reactor
Evaporator Water
Crude Silage
Tank
Concentrated Silage
Storage Tank
STATIC COMPOST PILE FOR FISH WASTE
WASTE VEGETABLE MATTER 10 - 15 CM
FISH WASTE 10 -15 CM
WASTE VEGETABLE MATTER 10 - 15 CM
FISH WASTE 10 -15 CM
WASTE VEGETABLE MATTER 10 - 15 CM
FISH WASTE 10 -15 CM
WASTE VEGETABLE MATTER 10 - 15 CM
PVC PIPE FOR AIR INLET, PERFORATED 10 CM DIAMETER
COARSE GRAVEL 10 - 15 CM
STRATEGY FOR THE
FUTURE
STRATEGY FOR FUTURE WORK
• Clean production practices will only
succeed if there is cooperation among the
interested parties
• A consortium should be established to
include:
The seafood industry association
The government regulatory group
The ministry of fisheries
An environmental group
Participating laboratory
STRATEGY FOR FUTURE WORK
• The consortium should have a facilitator or
coordinating group such as INTEC
• There should be agreement within the consortium
that as long as the industry is adhering to an
agreed timetable for improvement in their
effluents there will be no regulatory actions
against them
• In order to establish parameters for discharge it is
necessary to have data that characterizes the
various effluents from the plants
STRATEGY FOR FUTURE WORK
• Data should be collected by an independent
approved laboratory to characterize the
plant effluents, protein and oil should be
determined as well
• This data should be submitted to INTEC as
confidential information. INTEC would
then compile the data and with it’s technical
consultants formulate recommendations for
improving the plant operations
STRATEGY FOR FUTURE WORK
• Since there will be a great deal of collected
information, INTEC should seek outside
funding sources to finance the work
• Since the concepts of cleaner production
and resource sustainability are key issues
today, lending institutions have positive
attitudes towards such projects
STRATEGY FOR FUTURE WORK
• The key to the success of such a strategy is
trust. All participating parties must
understand this.
TIMETABLE FOR FUTURE WORK
• Form the Consortium
• Develop a strategy to obtain funding
• Submit proposals for funding
• Develop workplan phase 1
• Sampling and testing of representative
plants at different technology levels
• Evaluate data and economic feasability
• Develop workplan phase 2
• Select technology combinations for
evaluation
TIMETABLE FOR FUTURE WORK
• Determine if selected technology
combinations exist in plants now
• Sample and test technology combinations
• Evaluate data and economic feasability
• Develop workplan phase 3
• Recommend technology package to
industry
• If possible secure financing base to install
technology
ONE FINAL THOUGHT: POLLUTION
PREVENTION VS END OF PIPE
• ALL OF THE COSTS (US$1.75-2.1 MILLION)
DISCUSSED PREVIOUSLY RELATE TO
TREATING PUMP WATER
• WHERE PLANTS HAVE DEEP WATER
DOCKS, DRY PNEUMATIC UNLOADERS
ARE AVAILABLE. TO UNLOAD 200 TONS
PER HOUR THE CAPITAL COST WOULD BE
ABOUT US$400,000.
Vacuum
Unloading
Systems
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