3. Do You See…?
•Increasing feed costs
•Increasing energy costs
•A depressed economy
•Unfair competition from imports
•Increasing environmental mandates
•Lower prices to growers
4. Is This You ?
(As we fish for complementary sciences.)
◊ LEFT: Depressed, shrunk, reduced phospholipids.
◊ RIGHT: Normal after 30-90 days of omega-3’s.
◊ CRITICAL for brain development and maintenance.
◊ Controlling every cell, enzyme, and sense, e.g. vision
◊ A game-changer for growers, fish, & consumers.
5. What I See
A massive, solar-powered, food machine
where harvesting yields new life.
Micro Algae: 80% of all settleable solids
---8 liters/min/raceway flowing in.
---Valuable lipids for feed, biodiesel, etc
---Excellent amino acid profiles
---The freshwater source of all omega-3
6. What Else I See
Zooplankton:
1.2 Billion live zooplankton, weighing
about 100 Lbs./hr./raceway.
Bio-accumulated omega-3’s critical for
fingerlings, immune systems & marketing
An on-farm, renewable source of high-
value nutrients.
A perfect example of sustainable,
Integrated Multi-Trophic Aquaculture.
I see all this and more because in-pond
raceways enhance observation & control.
8. Recent In-Pond Raceway
History
Two basic types: Floating & Non-Floating
Work “Spearheaded” by Dr. Michael Masser
with floating raceways in the mid 1990’s +
Major contributions by Dr. Dave Brune of
Clemson with the (non-floating) PAS
Numerous other contributors, including those
working with “split ponds”.
9. (More) Recent History
An aluminum, floating raceway developed
by Dr. Hansen and colleagues at Auburn,
about 2008.
Construction costs “above our pay-grade”.
10. Current History
Dr. Jessie Chappel, colleagues, & growers
from Auburn , about 2009, concrete.
Their most recent work: a 2-cell, poly
(40-60 mil) lining over steel framed wall
sections, 2011.
11. More Current History
The practical and affordable solution?
Floating or Sit-0n-Bottom; 1/8 in. thick HDPE. ANY Size.
Early 2000’s; Patented to Jay & Bonnie Warecki in 2006.
Years of successful use studied by Dr. Hartleb and colleagues,
University of Wis. (2004-2007).
World Aquaculture Conf., Aquaculture Magazine, Amer. Fish Soc.
Listed in “Best Management Practices for Aquaculture…” 2006
13. Production Level Assumptions
3 raceways/6 acre pond.
IPRS: 30,000 Lbs/acre 180,000 Lb/pond
O-Pond: 8,000 ” ” 48,000 ” ”
8,000Lbs/acre is Alabama average—catfish.
5,200Lbs/acre is North Carolina ave.-catfish.
8,000Lbs/acre (approx.) Texas ave.-catfish.
14. Harvest Densities, Catfish
1.8Lbs/gal achieved, Auburn, IPRS, 2010 +
Harvest densities > 1.8 achieved for many
species.
Assuming 1.55Lbs/gal for “Tables 1&2”.
A 40,000 gal (usable water) IPR can yield
62,500 Lbs.
Thus, 3 IPR’s can yield 30,000Lbs/acre, or
180,000Lbs/6 acres/cycle, while only
carrying 15,000Lbs/acre at a time, which is
only ½ of the pond’s estimated
30,000Lb/acre carrying capacity.
15. Feed Conversion Ratios (FCR’s)
Most Alabama catfish farmers: 2.8-3.0:1
Texas channel catfish farmers: 2.4-2.9:1
Texas HSB farmers, estimated: 2.6:1
Raceway users elsewhere routinely
achieve 1.1-1:1.
Auburn researchers/growers achieved:
1.2-1.5 in 2010
1.1-1.2 in 2012
We have assumed a 1.2 FCR for
“Tables 1 and 2”.
16. High-Tech Feeding Systems
Feed the fish, not the pond.
Critical for achieving optimal FCR’s.
Feeding many times daily and at night.
Feeding only when fish eagerly feed, using an
automated feed verification system.
Automated, computer assisted, labor-saving
systems with safe-guards work.
17. Feed Costs
Assume feed costs will increase.
At $500/ton (Aug. 2012), and a 2.8 FCR,
feed cost=$0.70/Lb. harvested.
At $500/ton and a 2.8 FCR, every $100/ton
feed increase=$0.14/Lb. product increase.
HOWEVER
At $500/ton and a 1.2 FCR, every $100/ton
feed increase=$0.06/Lb. product increase.
This also holds for $600/ton and higher.
Clearly, more expensive feed MANDATES
better feed management.
18. Survivorship
Fingerling costs are about 20% of all
variable costs.
Survivorship in open-ponds: about 55%.
Survivorship in IPRS: about 90%.
19. Fingerling Stocking Costs
45% fewer fingerlings needed in IPRS.
45% reduced feed costs from Day 1.
Reduced fingerling costs (alone) can
equal savings of $0.05/Lb harvested,
assuming a $0.13/fingerling cost.
Growth assessment and survivorship
easily observed in raceways.
20. Electrical Costs
Oxygenate the fish, not the whole pond.
Modern, diffuser grid airlifts much more
efficient than paddle wheels.
At first glance, 24/7 raceway aeration
costs similar to short-term, intermittent
whole pond aeration.
Long-term objective and savings:
Significant reduction in acuity of D.O.
swings.
21. Harvesting Costs
Fish pumps and/or raceway seining are
much easier, thorough, and fish-friendly
than pond seining.
Net savings in harvesting costs estimated
@ about $0.02/Lb.
22. Medicine and Chemical Costs
Water treatment and chemical costs can
approximate 2.5% of variable costs.
Early observable problems in raceways can
often be effectively mitigated and
controlled at a fraction of the cost of open-
pond treatments.
The above can include the reduction of off-
flavor issues.
24. Table 2
Return on Investment & Viability
Total
Feed Cost Selling Est. Fixed* $/Harvest Lb Viability** ROI**
$/ton Price____Cost @ $0.17/Lb_(Bottom Table 1)__________________
(Note: Bold print below is for in-pond raceway method. Italics print is for open-pond
method.)
Raceways 500 0.80 0.17 0.43 Yes <1 yr.
Open-pond 500 0.80 0.17 0.90 No ------
Raceways 500 0.90 0.17 0.43 Yes <1 yr.
Open-pond 500 0.90 0.17 0.90 No ------
Raceways 400 0.80 0.17 0.37 Yes <1 yr.
Open-pond 400 0.80 0.17 0.76 No ------
Raceways 400 0.90 0.17 0.37 Yes <1 yr.
Open-pond 400 0.90 0.17 0.76 Marginal ------
**Does NOT reflect approx. $6,300/acre income from pond fish (e.g. tilapia, paddlefish, etc.) in IPRS.
*Examination of Dr. Carole Engle’s “Breakeven Costs of Catfish Production”, Univ. of Arkansas, P.B. supports this.
25. IPRS Projected Capital Expenses
(Assumptions Used for ROI Estimates)
A set of (3) 48,000 gal floating or sit-on-
bottom, HDPE, approx 1/8” $25,500
(Volume pricing available.)
Lumber for walkways, est. $2,700
(3) 3-Grid Airlifts w/frames, est. $3,000
(3) 1.5 hp. Blowers est.@ $800 = $2,400
(Estimated) TOTAL For 3: $33,600
(Est.) “Bonus Fish” Income/Pond $37,800
