IMPROVING PRODUCTION EFFICIENCY IN FISH PRODUCTION
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1 IMPROVING PRODUCTION EFFICIENCY IN FISH PRODUCTION ADVISORS PROJECT MEMBERS Levent KANDİLLER Yalçın ÖZTÜRK Merve DEMİRALAY Goran LESAJA Tuncay SEVİNÇ Raif USTA Bahar TURAN Eda YALÇINKAYA Erşan ÜK
2 CONTENTS COMPANY INFORMATION Introducing Yaşar Holding Introducing Fish Farming Facility Management System in Çamlı FISH PRODUCTION Life Cycle of Fish Feeding System in Off-Shore Cages THE PROBLEM Main Performance Indicator Symptoms Problem Definition Goal 2/28
3 COMPANY INFORMATION Introducing Yaşar Holding Yaşar Holding carries on its business by focusing its strategy on core fields of its activities by focusing on 5 main sectors. 20 companies 7,000 people Yaşar Holding Since 1971 Founder City Country Location Web Site Selçuk Yaşar İzmir Türkiye Şehit Fethi Bey Cad. No: /28
4 Food and Beverage Paint Group Agriculture Livestock and Trade and Service Tissue Paper Group Fisheries Group Group Group
5 Introducing Fish Farming Facility Since 1985 On an area of 48,500 m²; 12,000 m² in land and 36,500 m² marine space with a production capacity of; 7,900 tons of seabream (çipura) & seabass (levrek) 84 million fry (yavru balık) 5/28
6 Management System in Çamlı 6/28
7 FISH PRODUCTION Fish production has two main steps; 1. Hatchery (kuluçkahane) 2. Growing in off-shore cages Off-shore cages: System is based on feeding the fish in big cages which are at least 50m sea deep, durable to open water conditions. 7/28
8 Life Cycle of Fish 8/28
9 Off-Shore Cages FCR: Feed Conversion Ratio 9/28
10 Feeding System in Off-shore Cages Two types of feeding system is used in off-shore cages; Semi-automatic System Two employees sail by ship. Feed is placed into machine. Machine takes water, repulses it with feed. 10/28
11 Feeding System in Off-shore Cages Barge System Cameras placed in cages. An employee controls cages by cameras. Feeding is done automatically by controlling with cameras. 120 tons of feed capacity. Feeding for days. 11/28
12 Comparison of Feeding Systems 12/28
13 THE PROBLEM Main Performance Indicator Feed conversion ratio (FCR) is a measure of how well a batch converts feed intake (feed usage) into live weight. FCR is calculated as 13/28
14 Why FCR? Why FCR is the major measurement in fish production? 60% of total production cost is feed cost. 14/28
15 Symptoms Vary of FCR from cage to cage, Use of insufficient quality of feed, Insufficient area of land space, Insufficient area of marine space, Undernourishment, High mortality and cannibalism. 15/28
16 Problem Definition High FCR, Inefficient production, Lack of integrated monitoring for processes. What are we going to do? Analyze the fish production process data and come up with mathematical model, Determine the major factors that impact FCR, Suggest possible improvement both for FCR and production process. 16/28
17 Cause and Effect Diagram for FCR 17/28
18 Management Cages For efficient growth, In 20 meter diameter cages 150,000 fish at most In 30 meter diameter cages 300,000 fish at most Currently, In 20 meter diameter cages 185,156 fish In 30 meter diameter cages 342,556 fish are placed in cages according to our data. 18/28
19 Preliminary Improvement Suggestion for Cages Using 20 meter diameter cages is more efficient for use of area. 19/28
20 Management Stock Control Stock means the quantity of growing fish in cages and quantity of larvae in hatchery. Overbalance in hatchery Fry fish are taken to off-shore cages when their optimum weight Hardly adapted to sea and high mortality Placing more fish than optimum level High mortality 20/28
21 Management Vaccination and Standardization 1. All fish must be vaccinated to decrease the ratio of mortality and disease. For seabream in hatchery For seabass during standardization process 2. Standardization is a process done on a platform in sea that provides placing same size fish in same cages. Should be done few times during growing process for seabream Not enough employees Not enough area By applying the improvement for cages that we suggested, enough area for this process can be provided 21/28
22 Feed Diet Program Sufficient diet program must be applied to fish How much to feed When to feed Which size of feed Initial Observation for Insufficient Diet Program CAGE NUMBER SPECIES FISH QUANTITY AVG. WEIGHT (thousand) (g) FEED SIZE (mm) GIVEN FEED (kg) 1 SEA-BREAM SEA-BREAM SEA-BREAM SEA-BREAM SEA-BREAM SEA-BREAM SEA-BASS GRANYOZ SEA-BASS SEA-BREAM GRANYOZ SEA-BASS SEA-BASS Total Given Feed (kg) /28
23 Feed Ingredients Use of high quality BioAqua Fish Feed that is produced in Çamlı Yem Potential problems with feed ingredients Digestive problems for fish Deformation problems for feed Fry Feed Size&Ingredients FRY FEED Minumum Analaysis Value Size (Micron) Raw Protein % 60 Raw Oil % 10 Raw Cellulose % 1,5 Humudity % 8 Ash % 11 FRY FEED Size Minumum Analaysis Value (1 mm) Raw Protein % 55 Raw Oil % 14 Raw Cellulose % 1,5 Humudity % 9 Ash % 11 23/28
24 Ingredients Pre-Growing Feed Size&Ingredients Pre-Growing FEED Size Size Minumum Analaysis Value (2 mm) (3 mm) Raw Protein % Raw Oil % Raw Cellulose % 1,5 2 Humudity % 9 10 Ash % Vitamin (Kg/Feed) Fry Feed 2 mm 3 mm Vitamin A (IU) Vitamin D3 (IU) Vitamin E (kg) Vitamin C (kg) Energy (kcal) Micron 1 mm 1,2-1,5 mm 2 mm 3 mm Gross E. (kcal/kg) Digestible Energy DP/DE (mg/kj) ,5 27,3 27,3 22,9 21,7 24/28
25 Ingredients Growing Feed Size&Ingredients Growing Feed Size Vitamin (Kg/Feed) 4-12mm Minumum Analaysis Value (4-12 mm) Vitamin A (IU) Raw Protein % 45 Raw Oil % 20 Raw Cellulose % 2 Vitamin D3 (IU) 2500 Vitamin E (kg) 200 Vitamin C (kg) 200 Humudity % 10 Ash % 11 Energy (kcal) 4-12 mm Gross E. (kcal/kg) 4800 Digestible Energy 4224 DP/DE (mg/kj) 27,3 25/28
26 Nets Two types of nets: Dynema net, Nylon net Pollution Pollution on nets prevents oxygen transition to cages Undernourishment To prevent pollution, nets are painted Painting cost depends on the weight of nets. Nylon nets are averagely 100 kg weighted, dynema nets are averagely 80 kg weighted. Use of dynema nets provides 20% profit on paint cost. 26/28
27 Goal Improving production efficiency in fish production, Improving FCR Current FCR Target FCR = 2 27/28
28 Thank you for your attention Merve DEMİRALAY Raif USTA Erşan ÜK 28/28
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