8.1 Requirements for Water and Energy
8.2 Requirements for Material
Handling Equipment
8.3 Quality Control Facilities
8.4 Other Services
8.5 Maintenance
8.6 Labour
Requirements for water and energy are listed in Tables 17 and 18; the figures correspond to the plant capacities quoted in Chapter 4.2. Electricity required for refrigeration installations is not included.
Table 17 Water requirements
Processing plant |
m�/hour |
|||||
Thawing & |
Processing |
Sterilization |
Other |
Total |
Capacity |
|
l. Tuna production | 20 |
10 |
30 |
20 |
80 |
20 |
2. Automatic skipjack line | - |
10 |
20 |
5 |
35 |
10 |
3. Sardines in oil | 15 |
10 |
30 |
15 |
70 |
15 |
4. Pre-smoked small fish | - |
5 |
15 |
10 |
30 |
5 |
5. Fish paste products | 10 |
15 |
40 |
10 |
75 |
10 |
6. Salmon | - |
10 |
25 |
5 |
40 |
8 |
7. Shrimps | - |
20 |
15 |
5 |
40 |
3.6 |
Requirements for material handling equipment are listed in Table 19.
The designations from 1-7, which correspond to the processing plant capacities described in chapter 4.2 are as follows:
Table 18 Energy requirements (approx.).
Processing plant |
Electricity |
Steam |
Fuel oil |
Capacity |
|
Equipment |
Total |
||||
l. Tuna production | 2 000 |
2 700 |
5 000 |
350 |
20 |
2. Automatic skipjack line | 1 700 |
2 200 |
2 000 |
135 |
10 |
3. Sardines in oil | 1 500 |
2 200 |
3 500 |
230 |
15 |
4. Pre-smoked small fish | 600 |
1 000 |
1 000 |
65 |
5 |
5. Fish paste products | 1 800 |
2 300 |
4 500 |
300 |
10 |
6. Salmon | 800 |
1 200 |
2 500 |
170 |
8 |
7. Shrimp | 500 |
900 |
750 |
50 |
3.6 |
Table 19 Requirements for material handling equipment
Processing plant |
1 |
2 |
3 |
4 |
5 |
6 |
7 |
Equipment | |||||||
Fork lift trucks | 4 |
2 |
3 |
2 |
3 |
2 |
2 |
Battery charging unit | 2 |
1 |
2 |
1 |
2 |
1 |
1 |
Pallets for raw material | - |
- |
100 |
100 |
100 |
- |
40 |
Pallets for finished products | 240 |
125 |
300 |
100 |
300 |
150 |
50 |
Boxes | - |
- |
2 000 |
1 000 |
1 200 |
- |
300 |
Hand lifting trucks | 4 |
2 |
3 |
2 |
3 |
2 |
2 |
Crates for autoclaves | 16 |
12 |
24 |
12 |
24 |
12 |
8 |
Tuna cook baskets | 280 |
- |
- |
- |
- |
- |
- |
Tuna racks | 20 |
- |
- |
- |
- |
- |
- |
Containers for thawing | 20 |
fresh |
- |
fresh |
- |
- |
- |
Bins/cages for whole fish | 70 |
50 |
40 |
50 |
- |
||
Trays | 120 | 50 |
Quality control laboratory should be set up to:
A control laboratory should require approx. 40 m� space.
Investment cost is approximately NOK 2 500 per square meter. In addition approximately NOK 200 000 should be provided for purchase of equipment.
The requirements for other service installations, such as first aid-services, security, welfare, refrigeration and wharfs depends on the capacity of the processing plant and the number of employees involved.
Sanitary installations and canteen must be assessed according to the number of employees. See Table 20.
Table 20 Number of toilet rooms with hand-washing facilities a/
No. of employees |
No. of toilets |
1-9 |
1 |
10-24 |
2 |
25-49 |
3 |
50-100 |
5 |
and thereafter for every 30 employees over 100: 1 more toilet |
a/ Based on recommendations contained in CAC/RCP 10-1976.
In addition to the hand-washing facilities available in toilet rooms, washing basins with adequate supply of hot and cold water or clean sea water and liquid or soap powder should be provided, wherever the process makes these necessary.
Rooms containing showers should also be provided for the workforce. Generally, for every 20-25 employees, 1 shower should be provided.
Canteen and changing rooms will also be necessary.
Where workers of both sexes are employed, separate facilities should be provided. Restrooms and canteen may be shared. Space requirements are shown in Table 21.
Investment costs per square meter are estimated at NOK 2500 (including plant pipelines electric installations and equipment).
Consumption of water per 8 hours is usually expected to approximate 80 litres per employee, but experience shows consumption can range between 50 and 100 litres per employee.
Table 21 Approximate space requirements for sanitary installations
Installation |
Net space a/ |
Canteen |
1.2 m� per employee |
Showers |
1.0 m� per shower |
and changing rooms |
2 m� per worker |
Toilet |
2 m� per toilet |
a/ Traffic areas are not included.
Requirement of electric power installed may be up to 0,5 kW per worker.
First-aid services must be provided within the factory area.
Security will depend on the local conditions. Watchmen should always be included.
Fire protection equipment must be installed both inside and outside buildings. Fire extinguishers should be installed at strategic points indoors. Outdoors fire hydrants for engines should be located at strategic sites.
Refrigeration should be provided to suit the condition in which the fish are received for processing, i.e., iced fish, or frozen.
Calculation for energy consumption is shown in "Freezing in Fisheries", FAO Fisheries Technical Paper No. 167 and "Planning and Engineering Data. 1. Fresh Fish Handling", FAO Fisheries Circular No. 735. Investment costs are shown in Table 22.
Table 22 Estimated investment costs for refrigeration facilities
Facility |
Estimated cost (NOK)/m� |
Chill store |
- 3 000 |
Cold store |
- 4 000 |
Air blast freezing (tunnel) |
- 5 000 |
Wharfs
Requirements for wharfs depend on various factors and they will differ according to species involved, cycle in the fishery, size and number of boats, requirements for general fleet services and shipment conditions for products and receiving conditions for cans, etc.
As a rule the following quays may be needed:
The quays mentioned above should at least be constructed to suit loads of 4 000 kg per square meter.
Depth will depend on vessels using the quays. For reefers and cargo vessels the depth should be at least 6-7 m. Similar depth will be required for the largest tuna purse seiners.
Quays length should be thoroughly assessed for each case on its merits.
Throughput depends on the cycle in the fishery, i.e., how often fishing vessels are unloaded. This must be assessed both for low season and peak season. The throughput also depends on the type of unloading system. Investment costs are shown in Table 23.
Table 23
construction material |
Cost/m�(NOK) |
Wood |
2 000 |
Concrete |
4 000 |
Maintenance procedures must be established to avoid repair and costly delays in production. See Table 24.
The following procedures for maintenance may be advisable:
Table 24 Frequency of inspection procedures for maintenance a/
Machines and equipment |
Daily |
Weekly |
Monthly |
Every 3 months |
Every 6 months |
Nobbing machines | X |
||||
Brining machines | X |
||||
Packing lines | X |
||||
Fish cookers | X |
||||
Scales | X |
||||
Seaming machines | X |
||||
Retorts | X |
||||
Fork lifts | X |
||||
Steam boilers | X |
||||
Can washing | X |
||||
Machines | X |
a/ While inspection is recommended as shown, it is not expected that maintenance would be required after each inspection.
Table 25 Estimated number of employees required for canning sardines in oil and pre-smoked small fish
Operations |
Processing plant |
|
Sardines in oil |
Pre-smoked small fish |
|
Thawing/brining | 2 |
1 |
General labour | 1 |
1 |
Rodding | 16 |
|
Smoking/cooking | 1 |
1 |
Head cutting/Nobbing | 6 |
1 |
Handling cans | 1 |
|
Packing | 26 |
12 |
Inspection | 1 |
1 |
Seaming/filling | 3 |
2 |
Seaming machine expert | 1 |
1 |
Retorting/can washing | 3 |
1 |
Internal transport/storage | 1 |
1/2 |
Preparing oil/sauce | 1 |
1/2 |
Foreman | 1 |
1 |
Inspector | 1 |
1 |
Mechanic | 1 |
1 |
Total direct production | 49 |
42 |
Administration | 4 |
2 |
Watchmen and canteen | 2 |
2 |
Factory cleaning | 2 |
1 |
Manager | 1 |
1 |
Total employers | 57 |
48 |
Table 26 Estimated number of employees required for canning tuna
Operation |
Processing plant |
|
Sardines in brine |
Skipjack tuna |
|
Thawing | 2 |
|
Head cutting | 2 |
|
Band sawing | 4 |
|
Machine gutting | 1 |
|
Inspection/manual gutting | 1 |
|
Brining | 1 |
|
Inspection, filling baskets and racks | 4 |
|
Cooking and transport | 2 |
|
Feeding baskets to conveyor | 2 |
|
Cleaning | 40 |
24 |
Weighing | 2 |
|
Packing | 16 |
8 |
Pressing/filling | 4 |
1 |
Inspection | 2 |
2 |
Seaming | 2 |
2 |
Retorting/can washing | 2 |
2 |
Labelling | 1 |
1 |
Internal transport/storing | 4 |
3 |
General labour | 2 |
1 |
Mechanics | 2 |
2 |
Foreman | 2 |
2 |
Inspector | 1 |
1 |
Total direct production | 97 |
51 |
Administration | 5 |
2 |
Watchmen and canteen | 3 |
2 |
Factory cleaning | 2 |
2 |
Manager | 1 |
1 |
Total employers | 108 |
58 |