SUBJECTS TO BE COVERED

CLEAN PRODUCTIONIN THE SEAFOOD INDUSTRY IN

CHILE

Concepcion, Chile January 30, 2002Valparaiso, Chile January 31, 2002

By

Anthony P. BimboTechnical Consultant

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

0

1

2

3

4

5

6

7

8

9

1962 1966 1970 1974 1978 1982 1986 1990 1994 1998

Milli

on M

etric

Ton

s

Through week 49 of 2001

Source: FAO 2002, Fisheries of the United States 2001, FIS International 2002

ANNUAL CHILEAN FISH LANDINGSBY MAJOR SPECIES

0

2,000,000

4,000,000

6,000,000

8,000,000

1990 1991 1992 1993 1994 1995 1996 1997 1998 1999

Met

ric

Tons

Jurel Sardina sp. Anchovetta Caballa Merluza sp. Total

Source: INE (Chile) 2002

% CHILEAN LANDINGS BY SPECIESFOR 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


% CHILEAN LANDINGS BY REGIONFOR 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,IX, XI, XII, M

1.30 1.62 2.12


% CHILEAN PRODUCTION OF FISHMEAL AND EDIBLE FISH PRODUCTS

BY REGION, 5 YEAR AVERAGE

% Fishmeal % Food ProductsRegion 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,VI, VII, IX, XII,RM

4 7


CHILEAN PRODUCTION OF FOOD FISHFROM PELAGIC SPECIES

0

20000

40000

60000

80000

100000

120000

1990 1991 1992 1993 1994 1995 1996 1997

Met

ric

Tons

Whole Frozen Frozen Fillets Fillets Canned

Source: FAO Statistics Database 2002

CHILEAN PRODUCTION OF FOOD FISHFROM NON-PELAGIC SPECIES

0100000200000300000400000500000600000700000800000900000

1990 1991 1992 1993 1994 1995 1996 1997

Met

ric

Tons

Canned and Prepared Frozen Fillets CannedFrozen Whole Cured

Source: FAO Statistics Database 2002

Jurel

Caballa

Merluza de tres aletas

Merluza del sur

Merluza de cola

Merluza gayi (coumun)

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

AndThe result will be a reduction or complete elimination of pollution.

Treatment 1

Treatment 2

Treatment 3

Treatment 4

Treatments 5, 6, 7, 8

THE END OF PIPE CONCEPT IN WASTE TREATMENT

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

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

FISH COMPOSITION

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


• 12 Processing facilities were visitedFish and shellfish canningFishmealFilletingFreezing both fillets and whole fishSalmon processingSeaweed


• 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 agencyMinistry of Fisheries (MIPE)CONAMSociedad 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)

RESULTI. 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 EXPERIENCERECOMMENDATIONS PHASE III

• Use evaporator condensate water (freshwater) as pumpwater (step 9)

• If necessary add an additional evaporator (step 10)

RESULT IIIRecycle and evaporate in a continuous closed

circuit to recover dissolved proteins

VESSEL CHATA SCREENS

1 MMSCREEN

DAF

EVAPORATOR

PUMPSCREENSSCREENS FISH

SOLIDS

SOLIDS

CONCENTRATE

COOLING TOWER

PROPOSED RECYCLING SYSTEM FOR PERUVIAN FISHMEAL INDUSTRY

OIL

PUMPWATER + FISH

WATER

RETENTION TANK

STICKWATER TANK

RETENTION TANKSPUMPWATER

CONDENSATEWATER

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

0

500

1000

1500

2000

2500

3000

3500

TONS

NONE SCREEN DAF EVAP.BASED ON 100,000 TONS OF

FISH/SEASON

PROTEINOIL

CUMULATIVE VALUE OF PROTEIN AND OIL RECOVERED FROM PUMPWATER

0

200000

400000

600000

800000

1000000

1200000

1400000

US$

NONE SCREEN DAF EVAP.BASED ON 100,000 TONS OF

FISH/SEASON

PROTEINOIL

Screens for solids removal

RELATIVE DAF SYSTEM EFFICIENCY

DAF SYSTEM % PROTEINRECOVERED

% OILRECOVERED

MINING INDUSTRY 58 72

DEEPRECTANGULAR

30 53

CONICAL 15 74

SHALLOWCIRCULAR

60 81

DAF Systems

TECHNOLOGY PACKAGE COSTS IN US$

FRESH WATER RETURN PIPE1 MM SCREENSDAF SYSTEMRECONFIGURE PIPINGBUFFER TANKRETENTION TANKSLOW WATER FISH PUMPPVC PIPES FOR FISHCOOLING TOWERNEW 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

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 ProcessingPumpwater, unloadingBloodwater, storageBlood from salmonProcessing water

CanningHead and GutFilleting, SkinningWash-up

Water treatment residuesSolid fish waste or ShellsSolid waste transport in plant

Fishmeal ProcessingPumpwater, unloadingBloodwater, storageStickwaterCondensate waterDryer scrubber waterEvaporator cleaningsolutionsDryer exhaust gasses


• 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


• 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


• 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


• 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


• 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)

0 50000 100000 150000 200000 250000 300000

FISHMEAL + FISH OIL

RAW MATERIAL

PUMPWATER

BLOOD WATER

STICKWATER

METRIC TONS

RELATIVE SIZE OF THE VARIOUS STREAMS AND PRODUCTS IN AN EDIBLE PLANT PER 100000 TONS

OF FISH

0 200000 400000 600000 800000 1000000

FINISHED PRODUCT

RAW MATERIAL

PUMPWATER

BLOOD WATER

PROCESS WATER HIGH

PROCESS WATER LOW

SALMON BLOOD

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

Take solid waste to landfills. Send liquid waste to sewer system

Dispose of liquid and solid wastes in the sea

Use solid waste for fish bait or chum

Use liquid or solid waste directly as fertilizer

Use solid waste in compost productionUse solid waste in cold (crude) silage production

Use solid waste in advanced silage production

Use solid and liquid waste in fishmeal and oil productionUse solid waste in specialty sauces and other Asian products

Produce leather from skins and gelatin from skin and bones

Extract biochemicals, color additives and other pharmaceuticals

Use crushed mollusk shells for road construction

Use mollusk shells in calcium health food supplements

CRUDE SILAGE PRODUCTION

Fish Waste

Grinder

ReactorReactor Acid

Crude SilageStorage Tank

CRUDE SILAGE PRODUCTION

Fish Waste

Grinder

Reactor ReactorAcid

Crude SilageTank

Heat Exchanger

Decanter

Concentrated SilageStorage Tank

Centrifuge

Evaporator

Solids

Oil

Water

STATIC COMPOST PILE FOR FISH WASTE

COARSE GRAVEL 10 - 15 CM

PVC PIPE FOR AIR INLET, PERFORATED 10 CM DIAMETER

WASTE VEGETABLE MATTER 10 - 15 CM

FISH WASTE 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 groupThe ministry of fisheriesAn environmental groupParticipating laboratory


• 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


• 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


• 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


• 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 UnloadingSystems

Documents

SUBJECTS TO BE COVERED