Because of the high technology involved some special equipment should be imported, and special care in the choice and assembly of materials and service plants should be taken.
CAPITAL COSTS:
1. Land. 4.0 ha of land will be purchased at 4,800 US$/ha. The ground level should be between 0.5 and 2.00 a.s.l., thus minimizing earth works and pumping costs.
2. Site preparation. Includes digging of 2,100 m3 in water and 7,500 m3 on land. Filling-up, especially for dikes, should be achieved by carrying earth from outside (hypothesis of 0.5 m a.s.l.). Allow 50,580 US$.
3. Services. Approximately 440 kw will be required. A 5 km-line installation complete with cable, poles and a 500 KVA transformer is estimated at 68,000 US$. Fresh water supply (50 m3/day), a sewage drainage network and an external lighting/service power network estimated at 26,080 US$.
4. Roads, fence. 2 km of roads for on-farm transport and a fence made by barbed wire estimated at 26,180 US$.
5. Water supply system. Two rocky/concrete block breakwaters will be constructed either for water intake or outlet channel protection. Almost 12,000 t of rocks are necessary for off-shore, estimated cost 152,025 US$. The pump well will be made of concrete: allow 1,658 US$.
6. Pumps. Of three submersible/horizontal pumps provided, two will be in operation and one acting as spare at any one time. Maximum unit flow will be 0.85 m3/sec, head 6 m. A continuous speed variator will be provided to get flow lower than 0.85 m3/sec. Allow 132,360 US$, complete with a generator set (270 kw).
7. Raceways. Allow 56,042 US$ for concrete distribution and discharge channels. 484 m3 of concrete will be used with an iron reinforcement of 100 kg per cubic meter. Allow 382,174 US$ for reinforced concrete raceways (3 325 m3 of cement, 100 kg of iron per each m3, 4 394 m3 of pure cement for inner slope and plaster). The raceways are coupled, each couple having one wall in common. Between two couples there will be a walkway.
8. Vehicles. A tractor with crane and a 5 t refrigerated truck are envisaged: allow 42,400 US$. A smaller tractor for feeding purposes at 12,000 US$. A minibus and a station wagon for transport at 25,600 US$.
9. Service building. Complete with hydric, electric and heating plant at 85 US$/m2. G.E. cabin at 1,692 US$. Furniture at 4,000 US$.
10. Accommodation. 160 m2 building at 136 US$/m2. Furniture and various equipment (kitchen, bedrooms) at 16,000 US$.
11. Hatchery. Prefabricated shed complete with hydric, electric and heating plants at 253,760 US$. Autonomous 170 kw generator set at 16,800 US$. Complete hatchery equipment at 359,660 US$, including the following.
Transport, custom duties, assembling and spare parts are also included.
12. Equipment. A 18 m2 chilled room (0°C) and a 7 m2 deep freeze (-25°C) are allowed at 18,480 US$. An ice machine at 15,520 US$. Tractor-pumps, scales, boats at 8,000 US$. Solar-powered feeder at 127,680 US$.
13. Miscellaneous. Protective clothing, fishing equipment and workshop machinery at 12,300 US$.
14. Project/Engineering. 5% of civil works, water systems, tanks, buildings: 83,296 US$.
15. Contingencies. 10% of capital costs.
TABLE 22 MODEL 3: SEA BASS FARM - CAPITAL COSTS
| CAPITAL COSTS (US$) | ||
| YEAR | ||
| 0 | 1 | |
| REARING. Land. Site works. Services. Water systems. Raceways. Pumps. Vehicles. Service building. Hatchery. Equipment. Miscellaneous. Project. Contingengies | 1,098,024 | 972,720 |
| MARKETING. Vehicles. Equipment. Service building. Miscellaneous. Project. Contingencies. | - | 67,760 |
| ACCOMMODATION. Building. Project. Contingencies. | 37,760 | - |
| TOTAL | 1,135,784 | ,040,480 |
OPERATING COSTS:
- Overhead costs
1. Full-Time staff
| - Managing director | 1 | at 16,560 US$/Y |
| - Secretary/accounter | 1 | 3,312 US$/Y |
| - Supervisor for on-growing | 1 | 8,832 US$/Y |
| - Supervisor for hatchery | 1 | 8,832 US$/Y |
| - Qualified technicians | 5 | 4,416 US$/Y |
| - Workers/drivers/guards | 11 | 1,325 US$/Y |
2. Technical assistance. Allow 50,400 US$ for training of personnel (18 m/months). Allow 270,800 US$ for professional consultancy and know-how transfer (29 m/months).
3. Administration. Allow 12,000 US$/Y for telephone, telex and fax expenses.
4. Travel expenses. Allow 4,800 US$/Y.
5. Maintenance. 1% of capital costs.
6. Depreciation. 5% annual rate for site works, civil work and land. 14.3% annual rate for pumps. 10% annual rate for hatchery, project and contingencies. 20% annual rate for roads, vehicles, equipment.
- Variable costs
1. Food. Crumble feed price: 2,2 US$/kg. Pellet feed price: 75 US$/kg. Assume 3.5:1 Conversion Factor for year 1, and 3:1 from year 2 on. Artemia cysts at 96 US$/kg. Trash fish at 0.24 US$/kg.
2. Part-time staff. Assume 52 m/months per year at 6,173 US$/Y.
3. Power. For the hatchery assume 440,000 kwh/year on full year at 0.072 US$/kwh. For the on-growing assume 920,000 kwh/year on full year. For miscellaneous use assume 219,000 kwh/year. Fuel for water and air heating: assume 81,000 kg of gasoline at 0.32 US$/kg.
4. Packaging. Assume 0.24 US$ per kg of market size fish.
5. Distribution. Assume 1.1 US$ per kg of market size fish (air cargo delivery).
6. Insurance. Assume a premium accounting for 3% of average stock value. (12 US$/kg of fish as average value).
7. Fry. Assume a price of 0.16 US$ per each 1 g wild fry, and 0.40 US$ per each 75 g wild yearling.
TABLE 23. MODEL 3. SEA BASS FARM - OPERATING COSTS
| OPERATING COSTS (US$) | |||||
| YEAR | |||||
| 0 | 1 | 2 | 3 | 4 | |
| Overhead/fixed | |||||
| Full-time staff | 37,867 | 74,189 | 74,189 | 74,189 | 74,189 |
| Technical assistance | 68,400 | 59,600 | 58,800 | 17,200 | 6,000 |
| Administration | 6,000 | 12,000 | 12,000 | 12,000 | 12,000 |
| Travel expenses | 4,800 | 4,800 | 4,800 | 4,800 | 4,800 |
| Maintenance | 11,359 | 21,763 | 21,763 | 21,763 | 21,763 |
| Depreciation | 98,504 | 208,000 | 208,000 | 208,000 | 208,000 |
| Variable | |||||
| Food | 9,475 | 90,921 | 185,647 | 275,632 | 313,320 |
| Part-time staff | - | 6,176 | 6,176 | 6,176 | 6,176 |
| Power | 6,955 | 58,082 | 95,603 | 132,116 | 145,570 |
| Packaging/distribution | - | 30,152 | 60,300 | 115,240 | 134,000 |
| Insurance | - | 6,894 | 12,688 | 20,412 | 22,932 |
| Seed | 60,000 | 32,000 | - | - | - |
TABLE 24. INTENSIVE ON-GROWING OF SEA BASS: INCREASE OF POPULATION AND WATER NEED
| Month | No. of Individuals | Aver. In. Weight (g) | Total Weight (t) | Total Weight of stock (t) | Water need l/min/kg Total m3/sec | |
| Apr. | 500,000 | 1 | 0.5 | 29.8 | 2.45 | 0.4 |
| June | 400,000 | 10 | 4.0 | 44.8 | 1.55 | 0.75 |
| Oct. | 375,000 | 60 | 22.5 | 113.5 | 1.08 | 1.4 1) |
| Dec. | 365.000 | 75 | 27.4 | 127.6 | 0.50 | 0.25 |
| Apr. | 345,000 | 85 | 29.3 | 0.75 | ||
| June | 340,000 | 120 | 40.8 | 0.94 | ||
| Oct. | 337,000 | 270 | 91.0 | 0.80 | ||
| Dec. | 334,000 | 300 | 100.2 | 0.78 | ||
1) To which a safe margin of 20% should be added. Total safe flow needed: 1.68 m3/sec.
FIGURE 18. INTENSIVE ON-GROWING OF SEA BASS: EXPECTED GROWTH PATTERN
TABLE 25. SEA BASS/SEA BREAM HATCHERY - YEARLY FRY PRODUCTION
| SEA BASS | SEA BREAM | |
| Total production per crop | 500,000 | 300,000 |
| Number of crops per year | 1.8 | 1.2 |
| Total yearly production | 900,000 | 360,000 |
| Selection rate | 15% | 15% |
| Actual yearly production | 765,000 | 306,000 |
TABLE 26. SEA BASS/SEA BREAM HATCHERY - BIO-TECHNICAL DATA OF HATCHERY PRODUCTION
| Stage | Age Months | Mean Indiv. Final Weight | Individuals Per Year (× 1 000) | Survival Rate (%) | Mean Indiv. Final Weight | Individuals Per Year (× 1 000) | Survival Rate (%) | Tanks | |
| SEA BASS | SEA BREAM | ||||||||
| Breeders | - | 0.5 – 3 kg | 0.5 – 3 kg | 6 circular plastic | 30 m3 | ||||
| Eggs | - | - | 7 600 | 7 700 | 6 FG cylindric | 13 m3 | |||
| 90 | 90 | ||||||||
| Hatching | 0 | - | 6 820 | 6 899 | 30 cylindro-conic FG | 2 m3 | |||
| 15 | 6 | ||||||||
| Larvae | 1.5 | 0.1 g | 1 023 | 0.1 g | 414 | 30 cylindo-conic FG | 2 m3 | ||
| 88 | 87 | ||||||||
| Fry | 4 | 1–2 g | 900 | 1–2 g | 360 | 16 raceway FG | 10 m3 | ||
TABLE 27 SEA BASS7SEA BREAM HATCHERY - BIO-TECHNICAL DATA FOR A SINGLE CROP
| Production Phase | No. of crops per year | Duration of crop | Age at crop end | Initial no. of indivs. | Survival rate | Final no. of indiv- | Final aver. unit weight | Final total weight | Max. density | Tank volume | Tank no. per crop | ||
| weeks | days | × 1 000 | % | × 1 000 | g | kg | IN | FIN | UN | TOT | |||
| ind/l | m3 | ||||||||||||
| LARVAL REARING | |||||||||||||
| Bream | 1.2 | 6 | 45 | 7 700 | 6 | 414 | 0.1 | 41.4 | 110 | 6 | 2 | 70 | |
| 30 | |||||||||||||
| Bass | 1.8 | 6 | 45 | 7 600 | 15 | 1 023 | 0.1 | 102 | 75 | 10 | 2 | 102 | |
| WEANING | |||||||||||||
| Bream | 1.2 | 11 | 120 | 414 | 87 | 360 | 2 | 720 | 2 | 1.7 | 10 | 210 | |
| 16 | |||||||||||||
| Bass | 1.8 | 11 | 120 | 1 023 | 88 | 900 | 2 | 1 800 | 3.8 | 3.3 | 10 | 270 | |
Figure 20. Intensive on-growing of sea bass: suggested farm layout
Figure 21. Sea bass/sea bream hatchery: suggested layout
