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SMEDA Sea Food Processing Plant
SMEDA Sea Food Processing Plant
September, 2008
DISCLAIMER
The purpose and scope of this information memorandum is to introduce the subject
matter and provide a general idea and information on the said area. All the material
included in this document is based on data/information gathered from various sources and
is based on certain assumptions. Although, due care and diligence has been taken to
compile this document, the contained information may vary due to any change in any of
the concerned factors, and the actual results may differ substantially from the presented
information. SMEDA does not assume any liability for any financial or other loss
the content of this memorandum should not be relied upon for making any decision,
carry out his/her own due diligence and gather any information he/she considers
necessary for making an informed decision. The content of the information memorandum
DOCUMENT CONTROL
Document No. PREF-12
Prepared by SMEDA-Balochistan
Approved by Head of Department
Issue Date September, 2008
Issued by Library Officer
Pre-feasibility Study
1 INTRODUCTION TO SMEDA
The Small and Medium Enterprise Development Authority (SMEDA) was established
with the objective to provide fresh impetus to the economy through the launch of an
aggressive SME support program.1i
Since its inception in October 1998, SMEDA had adopted a sectoral SME development
approach. A few priority sectors were selected on the criterion of SME presence. In depth
research was conducted and comprehensive development plans were formulated after
identification of impediments and retardants. The all-encompassing sectoral development
strategy involved recommending changes in the regulatory environment by taking into
consideration other important aspects including financial aspects, niche marketing,
technology upgradation and human resource development.
SMEDA has so far successfully formulated strategies for sectors including, fruits and
vegetables, Marble and Granite, gems and jewelry, marine fisheries, leather and footwear,
textiles, surgical instruments, urban transport and dairy. Whereas the task of SME
development at a broader scale still requires more coverage and enhanced reach in terms
of SMEDA’s areas of operation.
Along with the sectoral focus a broad spectrum of business development services is also
offered to the SMEs by SMEDA. These services include identification of viable business
opportunities for potential SME investors. In order to facilitate these investors, SMEDA
provides business guidance through its help desk services as well as development of
project specific documents. These documents consist of information required to make
well-researched investment decisions. Pre-feasibility studies and business plan
development are some of the services provided to enhance the capacity of individual
SMEs to exploit viable business opportunities in a better way. This document is in the
continuation of this effort to enable potential investors to make well-informed investment
decisions.
1
For more information on services offered by SMEDA, please visit our website: www.smeda.org.pk
3 PROJECT PROFILE
The project involves processing of Seafood, including fish, shrimps, lobsters etc. for
domestic and international markets. Processing of fish involves primarily the application
of preservation techniques in order to retain quality and increase shelf life of the product.
It may also deal with value-adding to produce a variety of products. The quality
production will ultimately increase the product demand of sea food in Pakistan as well as
in international markets.
The major scope of processing activities will include post fish catch activities i-e pre-
cooling/icing, grading, cutting and cleaning, packing, and freezing. Sea food processing
unit can also provide processing services on rental basis to other exporters of sea food in
terms of provision of processing facility, provision of cold storages and transportation
service up to the port of exit. Beside this, local fish suppliers, dealers, contractors and
boat owners will also be the potential rental costumers of the plant, where they can get
processing services for their catch through paying a service charge as a rent..
3. 1 Project Brief
The project is about a Processing Plant which will process / freeze sea food (Fish and
shrimps etc.) The final product will be supplied to the food markets of major cities of
Pakistan that include Lahore, Sialkot, Islamabad, Karachi, Peshawar and Quetta. Export
quality products will be shipped to the international sea food markets of European Union,
Japan, USA, and Russia. Beside this, restaurant chains and 5 star hotels across the
country are also one of main consumers of the sea food. The processing plant would be
used to process the sea food catch mainly coming from the Arabian Sea through fishing
boats, launches and international fishing trawlers.
As a source of white meat, consumption trend and level of fish is very low as compared
with chicken. The prime reason for this low consumption is the scarce supply, low quality
and less availability of fish in the meat markets of major cities in Pakistan. Effective
supply chain of fishery products in domestic markets can increase the demand of fish in
local markets.
The process would include undertaking value-added activities, which will increase the
quality and shelf-life of sea food for the national and international market. The plant
should be located at the coastal area of Pakistan ideally near a fish harbor. Pakistani sea
food products have significant demand in the international market, however, the export of
sea food products is far less as compare to the available potential. It has been observed
that in order to increase the international export markets size, good quality sea food
production will require adequate physical infrastructure facilities like modern processing
units, cool chain, and other supply related logistics. Attaining international quality
standards and getting quality certificates is a mandatory requirement in Sea food
processing industry
Fish represents a valuable source of proteins and has a significant nutrient value in the
daily diet. Fish is an important part of the daily food intake of most of the countries in the
world and its importance in contributing to food security is rising significantly.
The total food supply available from fisheries in live weight terms is estimated to be
slightly higher than 16 kilos per year for each of the world's inhabitants. Fisheries and
aquaculture make an important contribution to the animal protein supplies of many
communities in both the industrialized and developing worlds.
Significant supply of fish exists along the Balochistan and Sindh coast. Some of the
species with major production along Pakistan coast are as follows,
Fish is a major component of the sea food that provides a source of vitamin-rich diet.
Fish is very perishable food commodity that requires proper handling and preservation to
increase its shelf life and retain its quality and nutritional attributes.
The principal components of the fish muscle - water, fat and protein - must be preserved
with little or no changes. The protein content is usually in the region of 15-20 percent,
whereas the fat content varies widely from species to species and from season to season.
It can be as low at 0.5 percent in lean starved fatty fish and can reach over 20 percent in
some species. In lean fish the bulk of the fat is stored in the liver and not in the muscle.
Water is the main constituent, with considerable variations, typically 80 percent in lean
fish and 70 percent in fatty fish. Carbohydrates, minerals, vitamins and some water
extractable components are examples of other minor substances present.
3. 3 Opportunity Rationale
After minerals and agriculture, fishery is the third largest sector in playing a vital role in
the economy of Balochistan. Coastal belt of Balochistan provide a significant supply of
the sea food to Pakistan and also have the potential to play an important role in
international sea food market. Balochistan and Sindh coastal areas happened to be on the
migration routes of the various varieties of marine species which have a considerable
demand in local as well as international marine food markets. There exist more than 30
species of shrimps, 10 species of crabs, 5 species of lobster and about 70 commercial
species of fish including sardine, Hilsa, shark, Mackerel, Butterfish, Pomfret, Sole, Tuna,
sea bream, Jew fish and Cat Fish, Shark, and Eel.
Pakistan’s exports of fishery products stand at about 0.25% of world exports. According
to estimates, Pakistan total export potential from this sector is near US$ 1.0 billion from
existing natural resources. Pakistan share signifies that a wide growth opportunity exist in
export markets. Pakistan’s domestic consumption is termed as one of the lowest in the
world, at 1.6 kg per person per year (compared to world average of 16.2 kg per person
per year), this figure also portrays tremendous growth opportunity for the local
consumption of sea food.
Hence, most of the fish catch goes to fish meal that is treated as wastage to the product.
Prime reason for the low national sea food consumption and low export share in sea food
export market is attributed to the absence of proper processing, storage and transportation
facility in the coastal belt.
Properly developed cool chain and fish processing plants will help to significantly
decrease spoilage and ultimately increase the supply of quality fish to local and
international markets. Development of fishery can also play an important role in
provision of employment and growth opportunities to many small and middle size
communities along the coastlines.
Fish processing operations continues through out the year however it is recommended
that plant should be ready for operation during the months of July to March so that it can
avail full fish catch of the sea. As the peak fishing season starts from the months of
September
3. 5 Proposed Business Legal Status
The business can be started as sole proprietorship or partnership. Comparatively fewer
complications are involved in forming, administering and running the sole proprietorship
or partnership businesses.
The sea food processing plant is designed to house and process the fish catch for export
market. In order to facilitate the fish suppliers on regional and national level, the plant
also has the capacity to provide processing facility on rental basis.
Major operations of this processing plant will be grading, washing, cutting, blast freezing
and packaging of fish catch from Balochistan and Sindh coastal areas. The final product
will be supplied through a cool chain to national and international markets.
Rental value of the plant is one of the main contributing factors to the revenue. The plant
can offer its production and processing services to the local fishermen and investors on
rental basis. The plant can charge production charges on per kilogram of the final
product.
Project will also be facilitated through an internet website. The website of the company
will facilitate the national and international buyers in selecting the fisheries product of
their choice and will enable them to streamline the supply of consistent product to the end
users/exporters in a given time frame.
3. 7 Project Capacity
The plant will store the fish catch and process the same in the same cycle. The plant will
be able to handle approximately 60 tones of fish catch of varying varieties in 24 hours.
It will have a wider cold storage facility. Cold store of the project will be 10 times the
size of the processing plant i-e it should have the capacity to store the product order of 10
days as such the cold storage of the plant will be of 600 tons capacity.
3. 8 Project Investment
The total project investment is Rs. 120,521,267 which includes capital cost of Rs.
91,416,722 and working capital of Rs. 29,104,545. It is assumed that the project would be
partially equity financed (50%) and partially debt financed (50%).
3. 9 Recommended Project Parameters
Table 3.9.1
Human
Capacity Resource Technology/Machinery Locations
60,000 tons/year 15 Imported / Local Made
Gwadar, Pasni , Ormara, Jiwani,
Damb, Karachi, Korangi,Gharo.
Financial Summary
Project Cost IRR Pay Back Period NPV
Rs. 88 m 41% 4.1 Years Rs 100 m
3. 10 Recommended Locations
The proposed location for the establishment of such a facility could be the areas with in
the proximity of Balochistan and Sindh coastal belt. If the project is closer to a fish
harbor it will have an added advantage of being nearer to the raw material supply.
The harbors and main landing points with their provincial location and relative
importance are as follows,
NAME PROVINCE Relative Importance
Gwadar Port:
With the operation of Gwadar port. The locations associated with Gwadar port are
recommended for establishing sea food processing plant. These areas are Pasni ,
Ormara and Surbendar.
Karachi Port and Port Qasim:
The locations associated with Port Qasim and Karachi Port is recommended for
establishing sea food processing plant in Sindh. The areas are Korangi Fish
Harbour ( Ibrahim Haydery) and Gaddani.
Availability of vast range and variety of fish and marine food in Arabian Sea waters
along the Pakistan coast.
Proposed areas for the processing plant have quite considerable number of skilled
fishermen and boat owners.
Significant number of suppliers exists for the production.
Large and established world markets
Growing trend in sea food consumption nationally and internationally.
Rehabilitation in Afghanistan.
5-Stars hotels and restaurant chains are in continuous need of quality sea food supply.
Improved technological changes available.
Ample opportunity for exports.
International recognition of the plant will boost the export orders.
3. 12 Strategic Recommendations
The location plays an important role, as the facility should easily be accessible to the
nearest port and towns.
Effective supply and cool chain will increase the market accessibility.
International quality certifications i-e HACCP, ISO can increase the product
credibility internationally.
Emphasizing on excellent quality standards and producing quality assured products
and timely order fulfillment.
New machinery should be purchased in order to increase the efficiency and lower the
maintenance cost.
Adapt to the rapid, social, economic and technological changes.
Well-trained/experienced staff adding in the efficiency of the facility.
About 38% of world fish production is traded internationally. In 2001, total exports of
fish and fishery products were US$ 55.9 billions in value terms. About 74 percent of
world fish production is used for direct human consumption, whereas the remainder
(about 26 percent) is utilized for various non-food products, mostly for conversion to
fishmeal and oil.
In 2004, the per capita food fish supply was estimated at 13.5 kg, excluding China.
Overall, fish provided more than 2.6 billion people with at least 20 percent of their
average per capita animal protein intake. The share of fish proteins in the total world
animal protein supplies grew from 14.9 percent in 1992 to 16.0 percent in 1996. In 2003
the percentage was 15%.
The estimates for 2005 indicate that the total world fishery production was 142 million
tones, an increase of one million tones over 2004, and a record production. The total
amount of fish available for human consumption has increased to 107 million tones.
China is the largest producer, with fisheries production of 47.5 million tones in 2004,
16.9 million tones capture and 30.6 million tones aquaculture.
Developing countries, supplied more than 50% of the world fisheries production. Shrimp
is the main fish commodity traded in value terms, accounting for about 19% of the total
value of internationally traded fishery products. In 2001, more than 80% of the total
world import value was concentrated in developed countries, in particular in Japan, the
USA and in several EU countries.
Japan was the major importer accounting for about 23% of total import value. USA was
the second main importer with a share of 17%, followed by Spain, France, Italy,
Germany and the UK. (Source: FAO)
10
(Million tonnes)
PRODUCTION
INLAND
MARINE
UTILIZATION
Per capita food fish supply 16.0 16.2 16.1 16.3 16.6 16.6
(kg)
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consumption was fresh fish (a share of 53.7 percent), followed by frozen fish (25.7
percent), canned fish (11.0 percent) and cured fish (9.6 percent).
Pakistan has a total coastline of 1,090 km and a total fishing area of approximately
300,000 sq. kms. Pakistan’s fishing waters are termed as highly rich in marine life with a
vast variety of species having commercial value. However, this potential is not reflected
in the export earning from fisheries sector. The exports of “Fish and Fish Preparation”
were at $134.5 million (with a volume of 93,214 tons) in 2002-03.
European Union countries, Japan and U.S.A are some of the big export market for sea
food. Pakistan fisheries export’s ultimate aim will be to capture a bigger percentage in
EU and US markets. However, the quality standard and restrictions for these markets are
very stiff. In order to meet EU and US quality standards, processing plants and supply
chain management of Pakistan sea food products should be up to the these standards.
Pakistan’s exports of fishery products stand at about 0.25% of world exports. In 2006
Pakistan’s seafood exports registered more than 40 percent growth last year, reached $
196.15 million up from $ 138.94 million exported during 2004-05. Pakistan exported
seafood worth $ 188 million during the financial year 2006-07, which was almost four
percent less against $ 196 million of 2005-06. August-September is the peak period of the
season and before the ban Pakistan used to export over 90 percent seafood products to the
EU in these months. Due to the EU ban, the shrimp exporters had explored some markets
in the Middle East, China and Korea
The EU is a big market for Pakistani seafood and Pakistan is not getting a foreign
exchange of $ 47 to $ 50 million since 2005-06. There are also some US restrictions on
seafood exports, which needed to be lifted. The EU has banned seafood exports from
Pakistan since April 2007. The action was taken after its inspectors’ visit to Pakistan.
They found the industry’s food processing below their standards. The EU had also raised
complaints against fishing vessels, auction halls and processing units, which have still not
been addressed by the fishermen community.
The European countries are the largest buyers of Pakistani seafood, mainly shrimps, for
more than two decades, sharing 53 percent of the total export to the world. Of the total 60
percent are exported through the fish harbor auction hall.
12
0.25
99.75
Total World Fis hery Products Export Pakis tan Fis hery Products Export
Sea food processing plants play a vital role in the development and economy of the
fisheries sector. The fisheries industry can only attain its target production when
internationally standardized quality of the fisheries product is produced.
In the prevailing circumstances the industry is unable to produce quality product for the
export markets. One of the major reasons has been the absence of appropriate technology.
There are quite few processing plants in the Balochistan and Sindh coastal belt. The
existing processing plants also face problems attaining quality production certificates and
technological up gradation. Most of the processing units in the country are equipped with
local versions of the processing machinery with little or no calibration, high electricity
consumption and low quality production
These plants have limited production capacity with Primitive technology. These plants
are most of the times incapable to process large fish catch and cannot facilitate large
orders placed by the importing firms.
Another factor involved is the lack of skills among the processing workers, who have not
been provided with required training on handling fish catch.
This situation was mainly attributed to unorganized nature of private sector, lack of focus
in Government policies and little institutional investment (in public and private sector
projects) in this sector.
As there is no proper cool chain established, therefore, there exists a parallel distribution
system for the fresh fish reaching the processing plants. As an industry practice, the
processing units acquire fish catch supplies either, directly from the boat owners in small
lots, or from the auction hall. This results in spoilage and degradation of fresh fish. As a
result, the final product fails to attain its target price.
International Certifications:
As part of the food product, export of sea food to international market is subject to the
rules and international certifications. Most of the sea food processors in Pakistan either
do not have the knowledge to get international certificate or do not comply to meet the
certification requirements. Therefore the final export product is sold at lower the market
rate.
14
Product hygiene training for fishermen is a must for good quality processing. Due to lack
of training and development in this area, the processing industry is not showing the
required results.
Lack of skilled work force for sea food processing plant is also another issue that pose
problems for the processing industry.
4. 4 Regional Distribution
More then 30,000 people are associated directly with fisheries sector employing about
6200 fishing boats. All boats are wooden with inboard mechanized engines.Gwadar
district annual production of fishery is more than 107,568 metric tons. Boat
manufacturing units are operating in Gwadar from very old times and still manufacturing
wooden boats of various sizes and kinds, starting from small fishing boats to heavy
fishing and cargo vessels. Town wise distribution of fish catch, boats and fishermen is as
following in the table 4.4.1.
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5 MARKET INFORMATION
Statistics for 2001, regarding international import and export markets is as follows
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Karachi, Lahore, Islamabad, Quetta and Peshawar are some of the markets which show a
potential for sea food supply. At present, only the Karachi markets have availability of
fresh sea food in terms of variety and quality because of existing supply chain and
production. Lahore, Quetta, Peshawar and Islamabad can be target market if a cool chain
system is attained.
5-Star Hotels and restaurant chain owners in the said cities are also a potential market for
local sea food supply. The supply can be increased through an effective cool chain and
consistent production of variety of sea food product.
Sea Food Supply Chain can be categorized into three different types:
1. Sea Food distribution to different areas of Balochistan and Sindh from Harbor.
2. Sea Food processing in Gwadar and Karachi for Export Market.
3. Sea Food exports from Gwadar and Karachi port.
Role of Stakeholder
Following are the stakeholders in the seafood supply:
Fishermen
Middlemen
Local Mandi/ Market
Processing Plant owners
Transporters
Middlemen Karachi
Exporters
Retail Shop keepers
End User
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HACCP certification is the most important certificate for the sea food processing plant. In
order to get a share in EU, US and Japanese markets following are some of the important
quality certifications that help in attaining a product share in the said markets.
The HACCP process involves the identification of specific hazards throughout the entire
process involved in the production of a food product and focuses on the preventative
measures for their control to assure the quality and safety of the food. This includes
analysis of raw material sources and usage, processing equipment, operating practices,
packaging and storage, together with marketing and conditions for intended use. There is
less reliance on the traditional system of end product testing and food safety is built into
the product from conception through design and distribution.
HACCP shifts the responsibility to the food producer to ensure that the product is safely
consumable.
The following is a list that is included (at a minimum) in the hazard analysis:
Ingredients and raw materials: source, composition, handling, transportation, and
storage
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Activities conducted in the process and handling system: steps identified on the
flow diagram
Annexure I of the report gives the addresses of the HACCP certification issuing authority
and associated certifications for HACCP qualification.
5.4.2 FDA Certification:
The U.S. national regulatory authority for public protection and seafood regulation is
vested in the Food and Drug Administration (FDA). The FDA operates an oversight
compliance program for fishery products under which responsibility for the product's
safety, wholesomeness, identity and economic integrity rests with the processor or
importer, who must comply with regulations promulgated under the Federal Food, Drug
and Cosmetic (FD&C) Act, as amended, and the Fair Packaging and Labeling Act
(FPLA).
Frozen fish is packaged according to the international requirements. Mainly the fish
product is packed into 10kg cotton boxes with names and company brand on it, whereas
for national supply fish is packed into bags of weight ranging from 2 kg to 10 kg packs.
Appearance.
Freshness.
Packaging.
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H Improper handling of the fish catch at An effective cool chain after the processing
sea or mismanagement in keeping the can make an H grade product highly
cool chain makes the fish turning into H acceptable to the local market. Local retail
grade. This grade has less chances of markets will be the target market for the H
getting accessibility for the export. grade.
Whereas local fish markets of Pakistan
is supplied mostly with H grade fish.
Most of the H grade is also converted to
the fish meal that is treated as a
wastage.
(Source: Industry analysis and experts opinion)
5. 6 Target Customers
The target customers for a Sea food processing Plant mainly include:
International Export Markets of European Union, USA and Japan.
The processing plant can also exploit the growing consumer market of
Afghanistan.
Sea food supply market of Pakistan.
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6 TECHNICAL ANALYSIS
6. 1 Fish Spoilage:
As soon as a fish dies, spoilage begins. Spoilage of fresh fish is a complex process and is
caused by a number of inter-related systems, some of which are suppressed by others.
The factors which principally contribute to the spoilage are the degradation of protein
with a subsequent formation of various products like hypoxanthine, trim ethylamine,
development of oxidative rancidity and the action of micro-organisms.
The first obvious way to avoid spoilage and loss of quality is to keep caught fish alive
until cooking and consumption. Fish begins to spoil immediately after death. This is
reflected in gradual developments of undesirable flavors, softening of the flesh and
eventually substantial losses of fluid containing protein and fat. By lowering the
temperature of the dead fish, spoilage can be retarded and, if the temperature is kept low
enough, spoilage can be almost stopped.
Phase I Fish just caught is very fresh and has a sweet, seaweedy and
(Autolytic changes, delicate taste. There is very little deterioration, with slight
caused mainly by loss of the characteristic odour and flavour. In some
enzymes) tropical species this period can last for about 1 to 2 days or
more after catching.
Phase II There is a significant loss of the natural flavour and odour of
(Autolytic changes, fish. The flesh becomes neutral but has no off-flavours, the
caused mainly by texture is still pleasant.
enzymes)
Phase III The fish begins to show signs of spoilage. There are strong off-
(Bacteriological flavours and stale to unpleasant smells. Texture changes are
changes, caused significant, flesh becoming either soft and watery or tough and
mainly by bacteria) dry.
Phase IV Fish is spoiled and putrid, becoming inedible.
(Bacteriological
changes, caused
mainly by bacteria)
6. 2 Chilling Process
Chilling is the process of cooling fish or fish products to a temperature approaching that
of melting ice.
The purpose of chilling is to prolong the shelf-life of fish, which it does by slowing the
action of enzymes and bacteria, and the chemical and physical processes that can affect
quality. Reducing the temperature at which the fish is kept lowers the rate of
deterioration. During chilling the temperature is reduced to that of melting ice, 0 °C/32 °.
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All species of fish, when properly chilled, will stay fresh for longer periods than those
that are not preserved in any way. The use of chilling techniques such as ice, therefore,
effectively prolongs the length of time of the catch. Products brought to market in a well-
preserved condition will generally command higher prices, both at wholesale and retail
levels, and thus give better returns to the fishing operation.
Most effective method employed for chilling process is a combination of ice and water.
Ice is widely used for the purpose. For the purpose of fish handling, flake ice
recommended for chilling process as the physical shape of the flake ice favors fish
6. 3 Freezing:
Freezing and frozen storage of fish can give a storage life of more than one year. It has
enabled fish processing plants to keep the product for long periods. Freezing allowed the
stockpiling of fish during periods of low demand and high catching rates, as well as
widened the market for fish products of high quality.
Blowing a continuous stream of cold air over the fish - air blast freezers.
Direct contact between the fish and a refrigerated surface - contact or plate
freezers.
Immersion in or spraying with a refrigerated liquid - immersion or spray freezers
Batch air blast freezers. Batch air blast freezers use pallets, trolleys or shelf
arrangements for loading the product. The freezer is fully loaded, and when freezing is
complete, the freezer is emptied and reloaded for a further batch freeze. Apart from this
difference in mode of operation, the batch freezer gives rise to bigger fluctuations in the
refrigeration load than continuous or batch-continuous freezers.
Because of compatibility and efficiency in the present industry structure, freezing
technology recommended for the proposed project will be batch air blast Freezers.
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Plate freezers and air blast freezers are the types of freezer most commonly used for
freezing fish in industrial countries. Plate freezers do not have the versatility of air blast
freezers and can only be used to freeze regularly shaped blocks and packages.
Plate freezers can be arranged with the plates horizontal to form a series of shelves and,
as the arrangement suggests, they are called horizontal plate freezers (HPF). When the
plates are arranged in a vertical plane they form a series of bins and in this form they are
called vertical plate freezers (VPF).
In this freezer, the product is brought into direct contact with the refrigerant.
The fish on the stainless steel conveyor belt initially come into contact with the counter
current flow of nitrogen gas at a temperature of about -50°C. Alternatively liquid
carbondioxide can also be sparyed on the fish as refrigerant at a temperature of about -50
C. As the fish progress through the precooling stage of the freezer, the gaseous nitrogen
partially freezes the fish and up to 50 percent of the product heat is extracted. The
product then passes below the liquid spray where freezing is completed by the boiling
liquid. The last stage in the freezer provides a few minutes for the fish temperature to
reach equilibrium before the fish are discharged.
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This method is considered the most advance and expensive practice in freezing
technology. This method is employed in those countries which have regular supply of
liquid nitrogen or liquid carbon dioxide
6. 4 Packaging of Frozen Fish:
After fish has been frozen, it can be subjected to many forms of deterioration between
production and eventual consumption. Contamination from humans, animals, insect and
atmospheric sources are possible. To prevent or reduce losses in product quality, it is
essential that the frozen product is packaged in such a way as to provide an effective
barrier with sufficient impact and compression strength to prevent damage. The
packaging material must have adequate barrier properties to reduce losses due to
dehydration and pick-up of taints. The range of packaging material for frozen fish is very
wide and is dependant on the form of the product being packed.
For the export market in fisheries sector, primarily plastics and Cartons are employed for
packaging frozen fish products. However for local supply across Pakistan, the fish
product can be packages in Bags as well. A brief of the packaging material is as follows,
The primary package in contact with the frozen product is generally a plastic derived
from a natural hydrocarbon source. The choice of which plastic wrapper is dependant on
the type of barrier required, and if the product is to be cooked or heated in the container
6.4.1.2 Cartons:
Cartons are also regarded as primary packages when used as a protective sleeve to the
product. The boards for the cartons can be made of :
Kraft boards. These are frequently used for packaging frozen foods and are
usually made from fully bleached materials. They are strong, of good appearance
and are suitable for direct contact with food.
Folding box boards. These usually have one fully bleached side which is suitable
for direct contact with food.
6.4.1.3 Bags:
Due to its availability and cost effectiveness, frozen fish and shrimps can be packed
directly into bags made from materials with good gas vapor and moisture barrier
properties. The level of sophistication can range from manual weighing and loading to a
highly sophisticated form-fill-seal technology where a specified weight, volume or count
of product is filled into a formed bag which is heat sealed. Such equipment can be used
for packing peeled shrimp and fish fingered.
24
The process flow chart for the Sea Food Processing Plant is given below
F
R
E
E
Z
I
Packaged Processing Hall N
Transportation Product Lots Re-Packaging G
into Cold Store and Grading
25
Although the machine installation costs are included with the respective machine costs
but some of the installation costs would be borne by the owner of the plant such as Rs 2.5
million as calculated for the project. Installation will require at least 4 months time. Once
the machinery is purchased, the operation can be started after at most 6 months.
Processing Hall
26
7 .2 Maintenance Costs
7. 3 Vehicle
The facility will require 2-open Trucks with 2-referigerated containers and a pickup
shezor. To carry its final product for shipment the factory usually works on hired
transportation. Whereas the factory truck will operate on daily basis to transfer fish catch
from the near by areas to the plant in case of heavy fish landing. The Shahzor trucks is
used for daily operations of the factory that include workers transportation and other
associated jobs.
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28
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11 PROJECT ECONOMICS
Working Capital
Equipment spare part inventory 79,063
Raw material inventory 26,881,250
Upfront insurance payment 644,233
Cash 1,500,000
Total Working Capital 29,104,545
30
31
32
33
12 KEY ASSUMPTIONS
Table 13-1 Direct Costs/ Ton
Description Cost/Ton in Rs.
Direct Labor Cost
Machine Maintenance Cost
Direct Electricity Cost
Direct Water Cost
Direct Fuel (Tractor Diesel) Cost
Total Direct Cost/Ton
34
BAL-PREF-06/January, 2005
Pre-feasibility Study Marble &Granite Warehouse
Fish are caught from October to June, the peak being March to May. Ribbon fish, croakers, sole and some other species are
exported to South Korea and China. Indian mackerel are exported to Thailand, Malaysia and Indonesia, while chilled fish are
exported to Singapore and the Middle East.
35
BAL-PREF-06/January, 2005