INDUSTRY PROFILE #8
FISH OIL AND
FISH MEAL
Prepared By
S. Divakaran
Reviewed By
Thomas L. Meade
Robert M. Ingle
Perry Lane
Published By
VOLUNTEERS IN TECHNICAL ASSISTANCE
1600 Wilson
Boulevard, Suite 500, Arlington, Virginia 22209 USA
Telephone: (703) 276-1800,
Fax: (703) 243-1865
Telex: 440192 VITAUI,
Cable: VITAINC
Internet: vita@gmuvax.gmu.edu,
Bitnet: vita@gmuvax
Fish Oil and Fish Meal
ISBN: 0-86619-295-6
[C]
1987, Volunteers in Technical Assistance
INDUSTRY PROFILES
Introduction
This Industry Profile is one of a series briefly describing
small or medium-sized industries. The
Profiles provide basic information for starting
manufacturing plants in developing nations.
Specifically, they provide general plant descriptions,
financial, and technical factors for their
operation, and sources of information and expertise.
The series is intended to be useful in
determining whether the industries described warrant further
inquiry either to rule out or to
decide upon investment.
The underlying assumption of these Profiles is that the individual
making use of them already has some knowledge and experience
in industrial development.
Dollar values are listed only for machinery and equipment
costs, and are primarily based on
equipment in the United States.
The price does not include shipping costs or import-export taxes,
which must be considered and will vary greatly from country
to country. No other investment
costs are included (such as land value, building rental,
labor, etc.) as those prices also vary.
These items are mentioned to provide the investor with a
general checklist of considerations for
setting up a business.
IMPORTANT
These profiles should not be substituted for feasibility
studies. Before an investment is made
in
a plant, a feasibility study should be conducted.
This may require skilled economic and
engineering expertise.
The following illustrates the range of questions to which answers must
be obtained:
*
What is the extent of the present demand
for the product, and how is it now being
satisfied?
*
Will the estimated price and quality of
the product make it competitive?
*
What is the marketing and distribution
plan and to whom will the product be
sold?
*
How will the plant be financed?
*
Has a realistic time schedule for
construction, equipment, delivery, obtaining
materials and supplies, training of personnel, and the start-up time for
the plant
been
developed?
*
How are needed materials and supplies to
be procured and machinery and
equipment to be maintained and repaired?
*
Are trained personnel available?
*
Do adequate transportation, storage, power, communication, fuel, water,
and
other
facilities exist?
*
What management controls for design,
production, quality control, and other
factors
have been included?
*
Will the industry complement or interfere
with development plans for the area?
*
What social, cultural, environmental, and
technological considerations must be
addressed regarding manufacture and use of this product?
Fully documented information responding to these and many
other questions should be
determined before proceeding with implementation of an
industrial project.
Equipment Suppliers, Engineering Companies
The services of professional engineers are desirable in the
design of industrial plants even though
the proposed plant may be small.
A correct design is one that provides the greatest economy in
the investment of funds and establishes the basis of
operation that will be most profitable in the
beginning and will also be capable of expansion without
expensive alteration.
Professional engineers who specialize in industrial design
can be found be referring to the
published cards in various engineering magazines.
They may also be reached through their
national organizations.
Manufacturers of industrial equipment employ engineers
familiar with the design and installation
of their specialized products.
These manufacturers are usually willing to give prospective
customers the benefit of technical advice by those engineers
in determining the suitability of their
equipment in any proposed project.
VITA
Volunteers in Technical Assistance (VITA) is a private,
non-profit, volunteer organization
engaged in international development.
Through its varied activities and services,
VITA fosters
self-sufficiency by promoting increased economic
productivity. Supported by a volunteer
roster
of over 5,000 experts in a wide variety of fields, VITA is
able to provide high quality technical
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This information is increasingly conveyed through low-cost advanced
communication technologies, including terrestrial packet
radio and low-earth-orbiting satellite.
VITA also implements both long- and short-term projects to
promote enterprise development and
transfer technology.
FISH OIL AND FISH MEAL
===================================================================================
PREPARED BY: S.
Divakaran
REVIEWED BY: Thomas
L. Meade
Robert
M. Ingle
Perry
Lane
===================================================================================
PRODUCT DESCRIPTION
1. The Product
Fish oil is the oil from rendering whole fish or from fish
cannery waste.
Fish meal is the clean, dried, ground tissue of undercooked
whole
fish or fish cuttings.
2. The Facility
This profile describes two plants.
The first is a 20-ton per day
plant operating with an eight-hour shift and producing 8,000
tons
of fish meal and 4,000 tons of fish oil a year.
The second is a
40-ton plant operating with an eight-hour shift and
producing
8,000 tons of fish oil and 16,000 tons of meal per year.
GENERAL EVALUATION
Fishery by-products have a big future in both developed and
developing countries because of their multiple uses.
For example,
stickwater, the liquid residue after the fish is rendered,
can be
used by some feed manufactueres, especially those who
produce
pelleted and extruded feed, as water, protein, and binder
components. However,
they must compete with oils, animal feeds,
and fertilizers from a variety of sources.
For example, the glut
in palm oil production and its worldwide supply as well as
the
use of soy protein as a cheaper source of protein for animal
feed
have affected demand for fish oil and meal.
This should be
considered before locating a plant.
Prospects for these products depend upon sufficient market
outlets. Since they
are jointly produced, it should be ascertained
that there is a sufficient market for both of them before
venturing into the production.
The possibility of selling
concentrated fish solubles should also be considered, as
this
would reduce drying costs and some equipment expenses.
1. Outlook
A.
Economic
Fishery products in general have a rising market in the
future
because of their nutritional superiority and greater
availability
than land-based animal products.
However, the operation requires
a moderately large capital investment.
B.
Technical
Competition from microbial processing methods can be
expected
(biotechnology).
Fish silage production is already receiving
attention.
2. Manufacturing
Equipment Flexibility
With some addition and modifications, the machinery can
easily
handle poultry meat processing wastes and slaughterhouse
by-products.
3. Knowledge Base
Before implementation of such a plant, it is very important
to
conduct a detailed biological study of species
abundance. Also, a
record-keeping system needs to be set up to evaluate the
effect
of the activity on basic fish supply.
Records should include
production/unit of effort, size and weight of fish, and
length of
the season.
Knowledge of marine life is also important to
eliminate unwanted species such as copepods and mollusks.
Other
considerations include:
--Knowledge of high
oil and low oil fish to predict meat to oil
ratio.
--Knowledge good
cleaning and manufacturing practices
for
putrescible products.
--Knowledge of
sewage treatment, chemical oxygen demand (COD),
and biological
oxygen demand (BOD) regulations.
--Knowledge of odor
control and stack emissions, if plant is
located near
population centers.
4. Quality Control
Raw materials need to be checked for foreign objects such as
metal, grit, and sand.
In the laboratory, fish meal should be
tested for crude protein and fat, and fish oil should be
tested
for free fatty acids and unpleasant smells.
Standard methods of
analysis such as the Association of Official Analytical Chemists
or country standards should be followed.
5. Constraints and
Limitations
The plant should be designed to handle one-third its
capacity for
lean supply periods.
Restrictions on discharge of high BOD
effluent should be checked.
Sewage treatment could be expensive,
especially for a 20-ton plant.
Fish meal plants emit a strong
odor and should be situated leeward of dwellings.
Water treatment
can be expensive if soft water is unavailable for boiler.
MARKET ASPECTS
1. Users
Mostly domestic consumers and manufacturers of margarine,
animal
feeds, aquatic feeds (e.g., catfish feed), fungicide sprays,
soap, fertilizer, paints, lubricating oil, fat liquor for
leather
industry, oil tanning, manufacturers of fatty acids, and
crude
glycerol for explosives.
2. Suppliers
Fish must be available locally.
Access to fish processing plants
is avisable.
3. Sales Channels
and Methods
Sales are generally made to large dealers of fish meal and
fish
oil with representatives in many countries.
Local sales are
usually made directly to local industries and wholesalers of
animal feeds. Fish
oil and fish meal are easily transported.
4. Geographic Extent
of Market
Domestic - While the product is fairly easy to transport,
freight
cost may be an important factor in limiting the market area.
Export - Market can be international, but quality
specifications
may restrict export.
5. Competition
Quality control can provide an edge over competition.
Domestic - There is usually competition from similar products
derived from other sources.
Delivery price is the determining
factor.
Export - Competition from other oils and protein sources may
affect demand. As in
the domestic market, delivery price is also
the decisive factor.
6. Market Capacity
It is not feasible to estimate the size of the market needed
in
terms of population or other quantitative measure.
The essential
requirement is accessibility to areas where user industries
are
located.
PRODUCTION AND PLANT REQUIREMENTS
____________________________________________________________________________________
Requirements
Annual
Output:
Meal/Oil
Meal/Oil
8,000/4,000T
16,000/8,000T
------------------------------------------------------------------------------------
1. Infrastructure,
Utilities Small
Plant Medium Plant
Land
5 acres
7 acres
Building
100'x200' 150'x200'
Power
Requirement
30 hp 70 hp
(*) Power
Requirement, Boiler 700
hp
1,050 hp
Fuel Bunker C
oil 560
Tons 1,120 Tons
Water
production, sanitation, fire
Other
____________ ___________
(*) Power requirement means that the factory is hooked up to
a power
source capable of handling the HP mentioned.
-------------------------------------------------------------------------------
2. Major Equipment
& Machinery Small
Plant Medium Plant
Units
Units
Tools &
Machinery
fish receiving
and storage system
(bins, dumper,
tipper, etc.)
1 2
screw conveyor
1
2
cooker
1 2
presser
1 2
decanter
centrifuge
1
2
multiple effect
evaporator
1 1
drier (tubular,
direct or
indirect)
1 1
grinder (excludes
motor cost) 1
1
boiler (steam or
thermic fluid; water treatment costs should
be considered if
steam boiler is used.)
(**) TOTAL ESTIMATED COST
of equipment & machinery only
$1,116,000
$2,100,000
-------------------------------------------------------------------------------
3. Materials &
Supplies Small
Plant Medium Plant
Raw Materials
raw fish
40,000
tons 80,000 tons
Supplies
lubricants &
hand tools
2,000 3,000
gas, oil &
maintenance of
truck
15,000 30,000
office
supplies
2,000
3,000
Packaging
bagging &
weighing equipment
15,000 30,000
bags
oil drums &
filling equipment
(Packing and oil drum costs arise for retail outlets.
Wholesale
outlets need containers and oil trucks).
-----------------------------------------------------------------------------------
4. Labor
Small
Plant Medium Plant
Skilled
2
5
Semiskilled
2 4
Unskilled
4 8
Indirect
Manager
1
1
Supervisor
1 1
Quality Control
Assistant
1 2
Office
2
3
Maintenance
1 1
Truck driver
1
1
-----------------------------------------------------------------------------------
5. Distribution/Supply
flow Small
Plant Medium Plant
Amount in/out per
day fish meal 25-27
tons 50-55 tons
Amount in/out per
day fish oil 8-13
tons 16-26 tons
-----------------------------------------------------------------------------------
6. Market
Requirements
Small Plant Medium Plant
(To be assessed
by the manufacturer)
-----------------------------------------------------------------------------------
7. Other
Requirements
Small Plant Medium Plant
Sewage treatment
and red tape management
Export
quarantine health certificates
(**) Based on $US 1987 prices.
The costs provided are estimates and
are given only to provide a general idea for machinery
costs.
They are not intended to be used as absolute prices.
Costs should
be determined on a case by case basis.
Installation costs are not
included, and they are usually 10 percent of total equipment
cost. Other costs
such as licensing fees, additional pollution
and odor control fees, quality control costs, transport,
auditing,
and legal fees must be considered.
Buying used machinery may
possibly reduce costs.
PROCESS DESCRIPTION
1.
Diagram
Figure II Composition of fish material during the process.
Material
Water % Solids %
Fat %
raw fish
70 18
12
press cake
53 44
3
press liquor
78
6 16
dilute stickwater
95 5
<1
concentrated stickwater
65 33
2
fish meal
9 85
6
2. Remarks
There are many methods for processing fish meal.
The method used
to produce most of the world supplies is described
below. The
process is shown by the diagram in Figure 1.
The composition of
08p06y.gif (600x600)
materials at each stage is shown in Figure 2.
The diagrams and
description are extracted from "Introduction to Fishery
By-Products,"
by M. Windsor & S. Barlow, Fishing News Books Ltd.,
Farnham, Surrey, England, 1981.
COOKING: This
ruptures the cells and releases the oil.
Cooking
time should be for 20 minutes at 95-100 degrees Centigrade.
COOKER: This is a
long steam-jacketed cylinder through which
fish are moved by a screw conveyor that can itself be
heated.
Direct injection of steam is not beneficial.
PRESSING: A single
or double screw press is used. The
press cake
has 55 percent moisture and 3-4 percent oil.
Note that very fresh
fish cause problems in pressing due to high content of
slime.
TREATMENT OF PRESS LIQUOR:
Press liquor contains:
Water
78%
Solids
6%
Oil
16%
Stage 1.
Decanter: desludge to remove
fine suspended solids. A
decanter centrifuge separates oil from water fraction.
Stage 2. Evaporation
of stick water: Multiple effect
evaporator
using either double, triple or quadruple effect using 0.6,
0.4,
and 0.3 kg steam per kg of water evaporated
respectively. Stick
water evaporation is complex and expert guidance is
required.
DRYING: Cake with 50
percent moisture is dried to 10 percent
moisture. Drying is
done in direct dryers where heat is supplied
by heated air or steam, usually at 170 [degrees]C.
GRINDING: The dried
material should be ground and sieved to a
uniform mesh size.
SACKING: Sacking in
bags when planning retail outlets in small
plant. The product
may be shipped to user in containers and no
sacking may be needed.
ENERGY CONSUMPTION:
60-70 kg fuel per ton of raw fish.
Percent distribution of energy per process:
cooking
- 21%
pressing -
8%
Stick water drying to 30% solids 33%.
drying
- 38%
TOTAL
- 100%
REFERENCES
Unless otherwise stated, these addresses are in the United
States.
1. Technical Manuals
& Textbooks
Introduction to Fishery By-Products.
by Malcolm Windsor & Stuart
Barlow. Fishing News
Books Ltd., Farnham, England, 1981.
Catelogue
available on request.
Fishi Processing in India.
By M.N. Moorjani. Indian Council
of
Agricultural Research, New Delhi, 1984.
2. Periodicals
"Feedstuffs".
ABC Publishing Co. 13330 Avenue
of the Americas.
New York, New York 10019.
A weekly newspaper.
FAO Fisheries Reports, by Food & Agriculture
Organization
Rome, Italy
3. Trade
Associations
National Renderers Association
O'Hare Lake Office Plaza.
312/827-8151
2250 E. Devon Avenue
Des Plaines, Illinois 60018
The National Fish Meal & Oil Association
2000 M Street, NW, Suite 580
Washington, DC 20036
4. Equipment
Suppliers, Engineering Companies
The Dupps Company, Germantown, Ohio 45327
telephone: (513)
855-6555
STORD Bartz Americas Inc., 309 Regional Road,
South Greensboro, North Carolina 27409.
(919) 668-7727.
Anderson International Corporation, 6200 Harvard Avenue,
Cleveland, Ohio 44105.
(216) 641-1112.
Westfalia Separators, 4740 OELDE 1 W. Germany
Phone (02522) 77-1.
Telex 89474.
5. Directories
Official Methods of Analysis of the Association of Official
Analytical Chemistry.
Edn. 14, 1984.
1111 North 19th Street, Suite 210
Arlington, Virginia 22209
`INDUSTRY PROFILE SERIES'
VITA is pleased to present this series of industrial
profiles.
These Profiles provide basic information for starting
manufacturing
plants in developing nations.
Specifically, they provide general
plant description, financial, and technical factors for
their
operation, and sources of information and expertise.
Dollar values
are listed only for machinery and equipment costs, and are
primarily based on equipment in the United States.
The price does
not include shipping costs or import-export taxes, which
must be
considered and will vary greatly from country to
country. No other
investment costs are included (such as land value, building
rental,
labor, etc.) as those prices also vary.
The series is intended to be useful in determining whether
the
industries described warrant further inquiry either to rule
out or
to decide upon investment.
The underlying assumption of these
Profiles is that the individual making use of them already
has some
knowledge and experience in industrial development.
These profiles should not be substituted for feasibility
studies.
Before an investment is made in a plant, a feasibility study
should
be conducted. Each
profile contains a list of questions to which
answers must be obtained before proceeding with
implementation of
an industrial project.
All profiles are available in English only.
They are priced at
$9.95 each. You may
take advantage of the introductory offer and
order any three Profiles for just $25.00 or order the entire
set of
teen profiles for a bargain price of only $150.00.
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