Wwf Binary Item 5360

7/30/2019 Wwf Binary Item 5360

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COMPOUNDED FISHCOMPOUNDED FISHMEAL BASED ONMEAL BASED ON

TILAPIA PROCESSTILAPIA PROCESS

WASTEWASTE Alfonso Alfonso Delfini,EDelfini,E..

Vice President Vice President

AQUAMAR AQUAMAR

GuayaquilGuayaquil, Ecuador, Ecuador



FACTS ABOUT FISH MEALFACTS ABOUT FISH MEAL

•• Approximately 75% of world fish production is Approximately 75% of world fish production is

used for human consumption and the remainingused for human consumption and the remaining

25% is used to produce fish meal and oil.25% is used to produce fish meal and oil.

•• The end products from fish processing may beThe end products from fish processing may befresh, frozen fillets, canned fish, fish meal, fish oilfresh, frozen fillets, canned fish, fish meal, fish oil

or fish protein products, such as surimi.or fish protein products, such as surimi.

•• Fish meal and fish oil are commodities used asFish meal and fish oil are commodities used asfeed for livestock such as poultry, pigs and farmedfeed for livestock such as poultry, pigs and farmed

fish.fish.



FACTS ABOUT FISH MEALFACTS ABOUT FISH MEAL

•• Virtually all fishmeal is used as a high protein (60 Virtually all fishmeal is used as a high protein (60

to 72%) ingredient in feed for farmed landto 72%) ingredient in feed for farmed land

animals and farmed fish. Fish oil is used mainly inanimals and farmed fish. Fish oil is used mainly in

the feed of farmed fish and in very smallthe feed of farmed fish and in very small

quantities in land animal feed. Fishmeal is not fedquantities in land animal feed. Fishmeal is not fed

straight (undiluted).straight (undiluted).

•• The typical inclusion rate for fishmeal in farmThe typical inclusion rate for fishmeal in farm

animal diets is 5% of dry matter.animal diets is 5% of dry matter.



FACTS ABOUT FISH MEALFACTS ABOUT FISH MEAL•• Fish meal is derived from the dry components of Fish meal is derived from the dry components of

the fish, and the oil from the oily component.the fish, and the oil from the oily component.

Water, which makes up the rest of the fish matter,Water, which makes up the rest of the fish matter,

is evaporated during the process.is evaporated during the process.

•• Most fish meal and fish oil production processesMost fish meal and fish oil production processesare automated and continuous, and compriseare automated and continuous, and comprise

several process lines, each with a certainseveral process lines, each with a certain

processing capacity.processing capacity.•• Fish meal production rates and availability varyFish meal production rates and availability vary

considerably, according to the season and types of considerably, according to the season and types of

fish being processed.fish being processed.



Fish meal provides the following basicFish meal provides the following basic

nutrients:nutrients:

1.1. PROTEIN:PROTEIN: A concentrated source of high A concentrated source of high

quality protein with a high proportion of quality protein with a high proportion of essential highly digestible amino acids likeessential highly digestible amino acids like

methionine and lysinemethionine and lysine

2.2. FAT:FAT: Rich in omega 3, DHA and EPA fatty acidsRich in omega 3, DHA and EPA fatty acids

CHARACTERISTICS OF FISH MEALSCHARACTERISTICS OF FISH MEALS



CHARACTERISTICS OF FISH MEALSCHARACTERISTICS OF FISH MEALS

3.3. ENERGY:ENERGY: Fish meal provides a concentratedFish meal provides a concentratedsource of highly digestible energy.source of highly digestible energy.

4.4. MINERALS AND VITAMINS:MINERALS AND VITAMINS: Relatively highRelatively highcontent of minerals like phosphorus incontent of minerals like phosphorus inavailable form. It also contains high levels of available form. It also contains high levels of

B complex including choline, B12 and vitaminsB complex including choline, B12 and vitamins A and D. A and D.



THREE METHODS OF UTILIZATIONTHREE METHODS OF UTILIZATION

OF AQUATIC WASTEOF AQUATIC WASTE

Either from aquaculture or wild stock Either from aquaculture or wild stock are:are:

1.1. Manufacture of fish meal/oilManufacture of fish meal/oil

2.2. Production of silageProduction of silage3.3. Manufacture of organic fertilizerManufacture of organic fertilizer



TWO TYPES OF FISH MEALSTWO TYPES OF FISH MEALS

1.1. Produced from fishery wasteProduced from fishery waste(salmon, tilapia, etc.)(salmon, tilapia, etc.)

2.2. When specific fish (herring,When specific fish (herring,

menhaden, etc.) are harvested tomenhaden, etc.) are harvested toproduce fish mealproduce fish meal



TWO CONCEPTS IN FISH MEALTWO CONCEPTS IN FISH MEAL

PROCESSINGPROCESSING

The fish or waste material can be:The fish or waste material can be:

1.1. Cooked prior to drying and oilCooked prior to drying and oilextractingextracting

2.2. Dried directlyDried directly



TYPICAL CONVENTIONAL FISH MEAL PLANTTYPICAL CONVENTIONAL FISH MEAL PLANTLAYOUTLAYOUT



ADVANTAGES: ADVANTAGES:

•• Simple processSimple process

•• No cooking of raw material involvedNo cooking of raw material involved

•• No pressing involvedNo pressing involved

•• Less odor because it is attached to the dryLess odor because it is attached to the drygraingrain

•• Lower production costs and lower maintenanceLower production costs and lower maintenance

costs involved since less pieces of machinerycosts involved since less pieces of machineryare required in the processare required in the process

•• No need to extract soluble proteins or fish oil,No need to extract soluble proteins or fish oil,

they will bind to the dry grain materialthey will bind to the dry grain material

Compounded Feed ProductionCompounded Feed Production

(fish meal + dry grain material)(fish meal + dry grain material)



DISADVANTAGES:DISADVANTAGES:

•• Lower protein content in final product thanLower protein content in final product thanconventional fish meals (shown in massconventional fish meals (shown in massbalance)balance)

•• Need to invest in high volumes of dry grainNeed to invest in high volumes of dry grainstocksstocks

•• Nutrient profile of final product is dependantNutrient profile of final product is dependant

on dry grain used (higher protein=soybeanon dry grain used (higher protein=soybeanmeal, lower protein=wheat middling)meal, lower protein=wheat middling)

•• Supply of dry grain material has to be securedSupply of dry grain material has to be securedto insure the constant quality of final productto insure the constant quality of final product


(fish meal + dry grain material)(fish meal + dry grain material)



TYPICAL COMPOUNDED FISH MEAL PLANTTYPICAL COMPOUNDED FISH MEAL PLANTLAYOUTLAYOUT



Compounded Feed ProductionCompounded Feed ProductionGENERAL OVERVIEWGENERAL OVERVIEW

•• Fresh tilapia wastes are collected separately asFresh tilapia wastes are collected separately asthey are released from processing plantthey are released from processing plant

•• Wastes are fed to the grinder in the sameWastes are fed to the grinder in the same

proportions as they are released from processproportions as they are released from processplantplant

•• Wastes are ground and crushed to reduce itsWastes are ground and crushed to reduce its

size and facilitate mixing and dehydrationsize and facilitate mixing and dehydration•• Dry grain is fed to a mixer together with tilapiaDry grain is fed to a mixer together with tilapiawasteswastes



GENERAL OVERVIEWGENERAL OVERVIEW

•• The mixing process has to be thorough toThe mixing process has to be thorough toensure final product uniformityensure final product uniformity

•• Raw mix is ground to fine particles as they enterRaw mix is ground to fine particles as they enter

a dehydratora dehydrator•• Dehydrator consists of a steel agitator withDehydrator consists of a steel agitator with

blades that will pulverize the raw mix into fineblades that will pulverize the raw mix into fine

particlesparticles•• Pulverization will facilitate the dehydrationPulverization will facilitate the dehydrationprocessprocess




GENERAL OVERVIEWGENERAL OVERVIEW

•• Pulverized and dried product is picked up by aPulverized and dried product is picked up by ablowerblower

•• Dried product in passed through a rotary sieveDried product in passed through a rotary sieve•• Fine particles will be collected and baggedFine particles will be collected and bagged

•• Lager particles will be reLager particles will be re--processedprocessed

•• Bagged product is set to cool overnightBagged product is set to cool overnight•• Bags are stored in warehouse before shippingBags are stored in warehouse before shipping




Suggested Profile of Dry Grain MaterialSuggested Profile of Dry Grain Material

•• Constant AvailabilityConstant Availability

To assure the continuity of the processTo assure the continuity of the process

Compounded fish meal plant should includeCompounded fish meal plant should include

enough storage capacity for dry grain materialenough storage capacity for dry grain materialto assure uninterrupted process of tilapiato assure uninterrupted process of tilapiawastewaste

Non processed waste can not be sold at aNon processed waste can not be sold at areasonable pricereasonable price



•• Highest Possible Protein ContentHighest Possible Protein Content

To improve the overall quality of compoundedTo improve the overall quality of compoundedfish mealfish meal

To improve amino acid profile of compoundedTo improve amino acid profile of compoundedfish mealfish meal

Amino acid profile will depend on final product Amino acid profile will depend on final productend user’s necessitiesend user’s necessities




•• Lowest Possible Fat ContentLowest Possible Fat Content

Because tilapia waste already has a very highBecause tilapia waste already has a very highcontent of fatcontent of fat

Fat levels on final product over 15% can causeFat levels on final product over 15% can causeinflammation inside the dehydration chamberinflammation inside the dehydration chamber




•• Lowest possible costLowest possible cost

To reduce the production cost of theTo reduce the production cost of thecompounded fish mealcompounded fish meal

Price of compounded fish meal is a limitationPrice of compounded fish meal is a limitationfor its commercialization due to its low proteinfor its commercialization due to its low protein

content when compared with conventional fishcontent when compared with conventional fishmealmeal





•• Best available qualityBest available quality

To maintain the quality of final product andTo maintain the quality of final product and

retain its most important nutritional valueretain its most important nutritional value= freshness= freshness

= low levels of histamine= low levels of histamine




•• HygroscopicHygroscopic

To facilitate de homogeneity of the raw mixTo facilitate de homogeneity of the raw mix

To facilitate overall dehydration processTo facilitate overall dehydration process

To maximize the retention of water solubleTo maximize the retention of water soluble

proteins within the grainproteins within the grain



Compounded Fish Meal ProcessCompounded Fish Meal Process

CalculationsCalculations

1.1. Nutrient Composition of Raw MaterialsNutrient Composition of Raw Materials

2.2. Nutrient Composition of Dry GrainsNutrient Composition of Dry Grains

3.3. Mass BalancesMass Balances

A. A. Tilapia Waste + Wheat MiddlingsTilapia Waste + Wheat Middlings

B.B. Tilapia Waste + Broken RiceTilapia Waste + Broken Rice

C.C. Tilapia Waste + Soybean MealTilapia Waste + Soybean Meal

D.D. Tilapia Waste + Corn FlourTilapia Waste + Corn Flour

RAW MATERIALRAW MATERIAL



RAW MATERIAL:RAW MATERIAL:

Nutrient Composition of TilapiaNutrient Composition of Tilapia

Process WastesProcess Wastes

RAW MATERIALRAW MATERIAL



RAW MATERIAL:RAW MATERIAL:

Nutrient Composition of Different Dry GrainNutrient Composition of Different Dry Grain

MaterialsMaterials

Mass Balance: 55% Tilapia Waste + 45% Wheat MiddlingsMass Balance: 55% Tilapia Waste + 45% Wheat Middlings



Mass Balance: 55% Tilapia Waste + 45% Wheat MiddlingsMass Balance: 55% Tilapia Waste + 45% Wheat Middlings

Mass Balance: 55% Tilapia Waste + 45% Broken RiceMass Balance: 55% Tilapia Waste + 45% Broken Rice



Mass Balance: 55% Tilapia Waste + 45% Broken RiceMass Balance: 55% Tilapia Waste + 45% Broken Rice

Mass Balance: 55% Tilapia Waste + 45% Soybean MealMass Balance: 55% Tilapia Waste + 45% Soybean Meal



Mass Balance: 55% Tilapia Waste + 45% Soybean MealMass Balance: 55% Tilapia Waste + 45% Soybean Meal

Mass Balance: 55% Tilapia Waste + 45% Corn FlourMass Balance: 55% Tilapia Waste + 45% Corn Flour



Mass Balance: 55% Tilapia Waste + 45% Corn FlourMass Balance: 55% Tilapia Waste + 45% Corn Flour



TILAPIA MEAL ANALYSISTILAPIA MEAL ANALYSIS

COMPOUNDED FEED ANALYSISCOMPOUNDED FEED ANALYSIS



COMPOUNDED FEED ANALYSISCOMPOUNDED FEED ANALYSIS

55% Tilapia Waste + 45% Wheat Middlings55% Tilapia Waste + 45% Wheat Middlings

Production CostsProduction Costs



Production CostsProduction Costs



MARKET OF COMPOUNDED FEEDMARKET OF COMPOUNDED FEED

FEED MILLS FOR:FEED MILLS FOR:

1.1. PET FOOD (cats and dogs) HIGHEST MARKETPET FOOD (cats and dogs) HIGHEST MARKET

VALUE VALUE2.2. CHICKEN FEED (can be used up to latterCHICKEN FEED (can be used up to latter

stages of growth due to low omega 3 content)stages of growth due to low omega 3 content)

3.3. SHRIMP FEED (low quantities due to high fiberSHRIMP FEED (low quantities due to high fiber

content)content)



MARKETTING VALUESMARKETTING VALUES

1.1. HIGH LEVELS OF OMEGA 6 FATTY ACIDSHIGH LEVELS OF OMEGA 6 FATTY ACIDS

2.2. FRESH PRODUCT COMPARED TO SEA CATCHFRESH PRODUCT COMPARED TO SEA CATCH

FISH MEALFISH MEAL3.3. HIGH LEVELS OF ATTRACTABILITY HIGH LEVELS OF ATTRACTABILITY

4.4. LOW LEVELS OF HISTAMINELOW LEVELS OF HISTAMINE

5.5. HIGH QUALITY PROTEIN DUE TO FRESHNESSHIGH QUALITY PROTEIN DUE TO FRESHNESS



MARKETTING SETBACKSMARKETTING SETBACKS

1.1. LOW PROTEIN CONTENTLOW PROTEIN CONTENT

2.2. HIGH LEVELS OF FATHIGH LEVELS OF FAT

3.3. UNABILITY OF COMMERCIAL FEED MILLS TOUNABILITY OF COMMERCIAL FEED MILLS TO APPRECIATE ITS NUTRITIONAL VALUE APPRECIATE ITS NUTRITIONAL VALUE

4.4. NUTRITIONISTS TEND TO CONSIDER IT A NUTRITIONISTS TEND TO CONSIDER IT A

SIMPLE MIXTURE OF FISH MEAL AND GRAINSIMPLE MIXTURE OF FISH MEAL AND GRAIN

IMPORTANT CONSIDERATIONIMPORTANT CONSIDERATION



IMPORTANT CONSIDERATIONIMPORTANT CONSIDERATION

•• TILAPIA FEED REQUIRE AS LOW AS 5% OFTILAPIA FEED REQUIRE AS LOW AS 5% OF

FISH MEAL TO MAKE UP FOR AMINO ACIDFISH MEAL TO MAKE UP FOR AMINO ACIDREQUIREMENTS NEEDED FOR GROWTHREQUIREMENTS NEEDED FOR GROWTH

•• STUDIES PROVE THAT TILAPIA CAN GROWSTUDIES PROVE THAT TILAPIA CAN GROWWELL WHEN FED SOYBEAN PROTEIN BASEDWELL WHEN FED SOYBEAN PROTEIN BASED

DIETS SUPPLEMENTED WITH ANIMO ACIDS.DIETS SUPPLEMENTED WITH ANIMO ACIDS.

•• AVERAGE ACCUMULATIVE FEED CONVERSION AVERAGE ACCUMULATIVE FEED CONVERSIONRATE IN TILAPIA CULTURE IS 1,80 : 1RATE IN TILAPIA CULTURE IS 1,80 : 1

(Kilograms of feed per Kilogram of Live Fish)(Kilograms of feed per Kilogram of Live Fish)



CONCLUSSIONSCONCLUSSIONS



CONCLUSSIONSCONCLUSSIONS

•• Tilapia meal production is a viable and profitableTilapia meal production is a viable and profitable

alternative to the waste disposal problems facedalternative to the waste disposal problems faced

by the processing industryby the processing industry•• Tilapia meal production can help alleviate theTilapia meal production can help alleviate the

pressure on wild catch fish meal demandpressure on wild catch fish meal demand

•• Compounded fish meal production is aCompounded fish meal production is aenvironmentally friendly alternative toenvironmentally friendly alternative to

conventional fish meal processingconventional fish meal processing

•• There is a need to further evaluate theThere is a need to further evaluate the

nutritional value of tilapia meal and its potentialnutritional value of tilapia meal and its potential

market valuemarket value



THANK YOU !THANK YOU !

In representation of:In representation of:

Aquamar S.A. Aquamar S.A.

Guayaquil, EcuadorGuayaquil, Ecuador

Wwf Binary Item 5360

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