Importation of Highly Innovative, Fully Automated Oyster Grading Equipment for Technology Transfer to the BC Shellfish Processing Industry

AIMAP-2009-P15
Odyssey Shellfish Ltd.

Table of contents

• Executive Summary
• Introduction
• Methods / Solution / Results
• Conclusion

Executive Summary

Currently, all shellfish processors in Canada grade millions of oysters individually, by hand. Given the volume of oyster production in BC alone, this system is both inefficient and inconsistent. New mechanized grading technology has been developed overseas that promises the significant benefits of (1) increased productivity & reduced labour cost; (2) reduced labour effort; and (3) a more consistently graded product. This project involved the early adoption of mechanized grading technology that has lead to improved industry- wide productivity, elevated grading standards and quality assurance for BC shellfish.

Introduction

In Canada, processing oysters involves a line of workers using strictly visual inspection to grade, and manual labour to count and bag, every single animal that is shipped to market. Given the volume of oyster production in BC alone, this system is both inefficient and inconsistent. Specifically, Odyssey Shellfish Ltd. forecasts increasing production from 27,000 to 50,000 oysters per day, throughout the year without changing the labour force. For this to be achieved, the system requires mechanization. New mechanized technology (incorporating software that grades based on visual inspection to specifications that a human can not – including length, width, and depth parameters) was sourced in Tasmania that promises the significant benefits of (1) increased productivity & reduced labour costs; (2) ease of labour effort; and (3) a more consistently graded product.

The goal of this project involved the early adoption of new grading technology that will lead to improved standards for shellfish grading and quality assurance in the BC shellfish processing industry. Given the objectives of the AIMAP program, specifically to increase sustainable production in Canada’s aquaculture sector, this project is viewed as an excellent success story by the proponent. It has vastly achieved the project goals and has exceeded expectations in terms of benefits to the company and the sector in general.

Methods / Solution / Results

We proposed a short-term project involving the purchase, delivery, modification, and execution of advanced technology automatic oyster grading machinery. Shellfish Equipment Pty Ltd (Tasmania, Australia) is a world leader in design and manufacture of this technology and through industry consultation and trade publication review, was determined as the best option for provision of this equipment. Given differences in grow- out and packaging systems between Australia and British Columbia, this machinery did require some modifications. In addition to the stock units proposed for purchase, an after-market ‘tray tipper’ was custom designed and built to accommodate the local tray design, and the sorter was modified locally to accommodate local packaging standards. Specific objectives as proposed and delivered are described below.

Increased Productivity & Reduced Labour Cost: On average, three workers can hand- grade 2,250 dozen oysters per day (five hours actively grading). The cost of labour (three workers) for grading oysters is averaged at $0.25 per dozen. In contrast, the new mechanized technology is capable of grading an average of 1,200 dozen per hour (translates to 6,000 dozen oysters per day, three workers, five hours processing). With all other costs (labour, overhead, etc) remaining the same after the capital investment, it has been determined that processing costs have been reduced from $0.25 / dozen down to $0.08 / dozen (cost savings of approximately 65%). The new grading machine has exceeded expectations for productivity, and on Monday, December 28th, 2009 the company graded, packed, and shipped 80,000 (6,666 dozen) oysters in one day. The new technology has increased production by nearly three times the amount of hand-grading, with labour and overhead costs remaining the same.

Ease of Labour Effort: Generally, women make up the processing line work-force. Prior to the arrival of the new machine, Odyssey oyster trays were loaded with less than capacity product to enable women to lift the trays from their stacks. The addition of a custom ‘tray tipper’ that automatically tips the tray stack onto the grader, saves the workers from lifting loaded trays vertically off the tray stack and onto the bench. Removing this manual task greatly eased the workload and benefited worker safety – while at the same time allowed increased productivity. The trays can now be loaded to a higher density of 15 litres (a 50% increase from the formerly acceptable load of 10 litres).

More Consistently Graded Product: This new vision technology promises high grading standards and consistency unmatchable by human workers. Markets demand consistency in both product quality and the ability to make regular shipments. Indeed, many markets will only accept product if there can be a promise of regular, high volume deliveries.

Conclusion

For shellfish processors to increase productivity and ease the workload on workers, the process needs to incorporate high technology mechanized equipment. In this successful project, the proponent’s expectations were exceeded. He was able to increase productivity by nearly three times, without altering the workforce or changing any overhead costs. This translates into orders of magnitude of profitability, and employee job satisfaction. This new technology has set new benchmark for oyster processing in Canada. Indeed, it has exceeded expectations of (1) increased productivity & reduced labour cost; (2) reduced labour effort; and (3) a more consistently graded product.