8. SERVICES AND LABOUR


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


8.1 Requirements for Water and Energy

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 &
dressing

Processing
line

Sterilization

Other

Total

Capacity
(tons raw fish/8 h)

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

8.2 Requirements. for Material Handling Equipment

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:

  1. Processing tuna in brine: 20 tons raw fish per 8 hours.
  1. Automatic skipjack production line: 10 tons raw fish per 8 hours.
  1. Processing sardines in oil: 15 tons raw fish per 8 hours.
  1. Processing pre-smoked small fish: 5 tons raw fish per 8 hours. .
  1. Processing fish paste products: 10 tons raw fish per 8 hours. ,
  1. Processing salmon: 8 tons raw fish per 8 hours.
  1. Processing shrimps: 3.6 tons raw fish per 8 hours.

Table 18 Energy requirements (approx.).

Processing plant

Electricity
(kWh per 8 h)

Steam
kg/h

Fuel oil
(litre/h.)

Capacity
(tons raw fish/h)

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      

8.3 Quality Control Facilities

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.

8.4 Other Services

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
(kitchen not included)

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

8.5 Maintenance

Maintenance procedures must be established to avoid repair and costly delays in production. See Table 24.

The following procedures for maintenance may be advisable:

  1. Keep an inventory of specifications, technical data, maintenance procedures, etc..
  2. Set up procedures for maintenance to suit the manufacturers specifications and manufacturing experience.
  3. Keep records on the type of maintenance conducted and the type of and reasons for repairs.
  4. Maintain adequate stocks of share parts.
  5. As is necessary, the maintenance procedures should be revised and adjusted.
  6. Inspection of the machines should be carried out according to the maintenance schedule.

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.

8.6 Labour

Table 25 Estimated number of employees required for canning sardines in oil and pre-smoked small fish

Operations

Processing plant

Sardines in oil
(capacity 10 tons per 8 h)

Pre-smoked small fish
(capacity 5 tons raw fish per 8 h)

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
(capacity 20 tons raw fish per 8 h)

Skipjack tuna
(capacity 10 tons raw fish per 8 h)

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