Aquamax Net Manager: Commercial Development of an Economical Green Technology for Aquaculture Net Management 

Table of contents

• Executive Summary
• Introduction
• Methods/Solutions
• Objective 1: Drafting and redesign of the Aquamax Net Manager production prototype
• Objective 2: Fabrication and construction of major components
• Objective 3 Assembly of components
• Objective 4 Pilot deployment, refinements and modifications
• On-Site Test Results
• Quality Assurance On-Site Testing
• Going Forward Into the Future
• Conclusion
• Acknowledgement
• Reference

EXECUTIVE SUMMARY

Campbell River based Shorelink Enterprises and Deane Larson received funding through Fisheries and Oceans Canada Aquaculture and Innovation and Market Access Program (AIMAP). Total dollar amount received for the project was $350,000.00 from AIMAP.
The Aquamax net manager is a transportable net cleaning system that is moved by vessel or barge from aquaculture site to aquaculture site as the on-site nets require cleaning. It can be moved over land via its own customized transport trailer. It can also be partially disassembled for easy placement in shipping containers for long distance travel.
Readying the Aquamax for commercialization involved four distinct stages:  

1. Preparing the prototype redesign and purchase of equipment for all following phases;
2. Fabrication and construction of major components;
3. Assembly and alignment of major components;
4. On-site testing at the Sablefish Canada farm site on the west coast of Vancouver Island, further refinements and modifications deemed desirable as a result of testing.

Anticipated future positive impacts on the aquaculture industry include:

• Availability of alternative net cleaning technology that utilizes environmentally friendly, non copper-treated nets;
• Limiting of use of divers for net inspections, thereby decreasing potential for human error associated with underwater visual inspections;
• Decreased cost to producer companies through less costs associated with cleaning nets and regularly dipping nets in copper based anti-foulants;  
• Reduction in cost of new nets for farm sites 
• This method of cleaning untreated nets gives industry the choice of looking into new options for nets that are many times stronger than those currently used.

As we move forward, we are willing to work with all regulatory bodies as required.  Initial contact has been made with Work Safe BC regarding safe operation of the equipment.

Consultations were held with a local representative of the Habitat and Enhancement branch of the Department of Fisheries and Oceans regarding the potential environmental ramifications of the organic matter that is removed from the nets during the operation of the Aquamax. After receiving additional information from Deane Larson, the Habitat and Enhancement Branch expressed the opinion that cleaning non-copper treated nets with small quantities of bio-fouling will not cause harmful alteration, disruption or destruction (HADD) of fish habitat as outlined in Section 35 of the federal Fisheries Act.

Discussions were held with the Marine Department of Transport Canada regarding the issue of registering the Aquamax as a vessel under their regulations. In an email received from Transport Canada, it is stated that because the Aquamax is not used for navigation and is secured inside the fish pen at all times, registration as a vessel is not applicable in this case and therefore not necessary

INTRODUCTION

In an attempt to control fish pen biofouling it has become common practice to treat nets with a copper based anti-fouling chemical. However, there are significant environmental concerns and high production costs associated with this process.

Within minutes of a fish net pen being immersed in the water, the process of biofouling begins. Bacteria, unicellular algae, protozoa and fungi colonize on the net within hours, creating a biofilm. On top of this biofilm, macro-fouling organisms begin to colonize. These macro-fouling organisms consist of larger algae, barnacles, mussels and tunicates (among others). Gradually biofouling begins to restrict water flow through the net, thus impeding oxygen exchange for the fish being reared in the unit. Not only can the fish succumb directly to low oxygen levels but increased levels of physiological stress can also make the fish more susceptible to disease. In addition, the close proximity of benthic organisms on the nets provides a potential reservoir of hosts that can transmit parasitic diseases to fish stock. Furthermore, the accumulated weight of biofouling organisms on the cage structure can be quite substantial if left unchecked. It can lead to increasing risk of net breakage and the potential for fish escapes.

A common approach to limiting the amount of biofouling on net pens is to apply a biocidal coating to the surface of the net such as a copper based anti-fouling agent. Initially the biocidal coating is quite effective at reducing biofouling but the copper precipitates out of the coating as copper oxide, thereby reducing the effectiveness of the biocidal agent. Eventually over the course of a production season biofouling will occur. The leaching copper oxide can bio-accumulate in the sediment below the cages and has raised concern over its possible effect on benthic marine environments. Not only a threat to the surrounding benthic community, copper oxide is highly toxic to fish and may provide an additional physical stress to fish stock. In addition, since biofouling still occurs on these nets, they still require washing, which further complicates the matter of disposal of the waste from the net washers in an environmentally responsible way, since the biomass is contaminated due to having grown on the antifouling agent. Based on BC’s current level of yearly farmed salmon production, it is understood that approximately 552,300 litres of copper dip is used annually.

In addition to the environmental costs of using copper based anti-fouling agents, there is also the economic impact of removing the nets, washing and drying and then treating the nets with anti-foulants each season. The integrity of copper-treated nets deteriorates much faster than a non-treated net, therefore requiring the purchase of new nets more frequently and risking possible breakage and escapement during subsequent production cycles if the nets are not replaced. At present there is no economically viable alternative to copper dipping for controlling bio-fouling on aquaculture nets. The objective of this proposed project is to develop a commercial-scale model of an existing prototype net cleaning system.

To address both the biofouling issue and the use of copper based anti-fouling agents, issues, Deane Larson has developed the Aquamax Net Manager, a machine that will clean non-chemically treated nets on aquaculture farm sites without requiring the removal of the cage systems during the fish grow-out production cycle. Deane Larson (Shorelink Enterprises Ltd.) has manufactured a production prototype improving on the original concept prototype that was successfully tested. In order to address production level challenges and other challenges identified with the concept prototype this demonstration project will deliver a production prototype of the unique technology that will be ready for commercial application.

The Aquamax Net Manager project addresses the goals of the AIMAP program through its dual focus. Firstly, it recognizes the aquaculture industry’s commitment to reducing its environmental footprint wherever possible and striving for continual improvement in how it conducts business (green technology). Not only that, it concentrates on the needs of the industry to be productive in a way that is friendly to the environmental (sustainable development).

METHODS/SOLUTIONS

There were four objectives to be met during the course of this project:

1. Drafting and redesign of the Aquamax Net Manager production prototype;
2. Fabrication and construction of major components;
3. Assembly of components;
4. Pilot deployment, refinements and modifications

The project was schedule to begin in July 2009, however, due to delayed funding, it began in September 2009. This delay did not adversely affect project completion.

Objective 1: Drafting and redesign of the Aquamax Net Manager production prototype  

The Washer Module was converted from a four washer unit to a five in order to provide better cleaning at the top of nets and in corners. The shape of the Washer Module frame was also changed to allow for better control and maneuverability. A portion of the Washer Module was replaced with lighter weight parts. 

The initial drawings for the Flotation Gantry paid particular attention to stability factors, including the inclusion of three sealed compartments designed to make the unit unsinkable. The necessary accommodations for bio-security and sanitization were worked into both the assembly and disassembly design.

During work on the first objective, selection and purchase of the major equipment for the following stages was also done.

Objective 2:  Fabrication and construction of major components

This stage was the fabricating and construction of the Aquamax’s major components. This included the manufacturing of the Flotation Gantry and its lifting boom as well as the replacement of the diesel engine in the Power Pack with a new 200 horse power unit. At this stage, some delays in arrival of parts were experienced, however, by the end of this stage, the new motor and other components were ready for plumbing and wiring.

Objective 3 Assembly of components

Fabrication work continued on the Flotation Gantry, including the manufacturing of the hydraulic reservoir tank, fuel tank, electrical panel. The location of the oil and engine cooling systems and pumps were chosen and formed for installation.

The trim and stability tanks on the Flotation Gantry were pressure tested against leaks. The Power Pack was outfitted to accommodate fork-lift use and a one point balanced lifting position.

The unit was successfully tested at dock side. This was followed by disassembly, galvanizing, reassembly and readying for the addition of the housing.

Objective 4 Pilot deployment, refinements and modifications

All components of the Washer Module were in place, including the rotating unions, washer discs, and thrusters by March 31, 2010. This was completed later than expected due to a slight delay in receiving the custom made parts for the Washer Module. 

All parts are installed on the Flotation Gantry, including its wireless remote controls, instrumentation wiring and video monitoring equipment. Challenges with engine ignition were identified and corrected following extensive testing and cross-checking the Flotation Gantry’s electronic system.

A second test run in early May identified a minor over-heating issue that was subsequently easily corrected.

Shorelink is concerned with the performance of the Aquamax as it relates to habitat issues. As a result, we consulted with Kerra Hoyseth, Senior Biologist with DFO’s Oceans, Habitat and Enhancement Campbell River office. Ms. Hoyseth required information about the possible environmental ramifications of the organic matter that is removed from the nets during the unit’s operation. Deane Larson met with Ms. Hoyseth on Monday, May 31, 2010, at her office in Campbell River.  During the meeting her concerns were addressed by Deane Larson in their entirety. Upon the meeting’s conclusion, Ms. Hoyseth indicated she would contact Sean Irvine of DFO’s Vancouver office to let him know this.

In an email received on June 7, 2010 from Ms. Hoyseth, she states, “It is my understanding that you will be cleaning nets that have minimal bio-fouling on them, in order to ensure that there will be no violation under Section 35 of the Fisheries Act from net debris accumulating on the seabed underneath the farm, which could cause harm to fish or fish habitat. As long as you are operating in such a manner that the nets are being washed when fouling communities are small and they have not been treated with copper based anti-foulants, DFO does not believe this equipment will cause a harmful alteration, disruption or destruction of fish habitat and in fact could be an improvement on current options available for net maintenance.” 

Shorelink Enterprises is concerned with ensuring all regulatory concerns are addressed. The issue of registering the Aquamax as a vessel with Transport Canada was raised by Sean Irvine of DFO Vancouver. However, upon further investigation, it was confirmed that this is not necessary. Deane spoke with John Gilbert in the Nanaimo office of Transport Canada and was subsequently referred to Gavin Brown of the Registry of Small Craft department in Transport Canada’s Kelowna office.

Mr. Brown confirmed to Deane Larson via phone on or about May 17, 2010 that the unit does not qualify as a vessel. As a result, registration is not required. On June 21, 2010 an email confirming this was received from Mr. Brown. He states:

“The definintion (sic) of a vessel as per the Canada Shipping Act is:

“vessel” means a boat, ship or craft designed, used or capable of being used solely or partly for navigation in, on, through or immediately above water, without regard to method or lack of propulsion, and includes such a vessel that is under construction.

Your net cleaner cannot be described as such because

1. it is not used for navigation;
2. it is secured inside the fish pen at all times and;
3. the only approved 'special purpose vessel' (at this time) is a river raft”

ON-SITE TEST RESULTS

The unit was tested on-site at Sablefish Canada on May 26, 2010 following minor modifications of individual components in Campbell River the week of May 17, 2010. The work done prior to the testing in Kyuquot Sound allowed for more efficient testing the following week.

The Aquamax has performed favorably in the water and responded well to all commands. The Washer Module connects and disconnects from the Flotation Gantry  as it was designed to do.

Minor adjustments were made to the hydraulic thrusting system following the Aquamax’s May 26 testing. In addition, small changes were made to the unit in order to make its operation more efficient for farm site staff who may be operating the unit. This involved moving the lifting winch and hydraulic hose reel to the deck level, making the unit more rigid in the water.

The performance measurement applied was a timed run of the Aquamax from one side of the net pen to the other. This took five minutes. Based on this data, it is felt that under normal circumstances, a standard 100 x 100 foot net pen can be cleaned in approximately two hours. This speed is of course dependent on the amount of organic growth on the net.

QUALITY ASSURANCE ON-SITE TESTING

Terry Brooks of Sablefish Canada was present during both on-site tests. He was satisfied with the outcome of the testing.

The aquaculture industry in Canada, like all other progressive economic sectors, is continually striving to carry out routine, preventative maintenance in the most cost-effective manner possible. This positively impacts profit margins.

The contractors used in this project have proven themselves capable of delivering local, top-quality work in Campbell River. Employees and managers would welcome the opportunity to continue their involvement with manufacturing additional Aquamax units as demand increased.

The very real potential of the aquaculture industry to eliminate the use of anti-fouling agents on nets certainly exists. When this is realized, the Aquamax is capable of delivering quality net cleaning through its unique technology.

GOING FORWARD INTO THE FUTURE

Sablefish Canada, under the direction of Terry Brooks, has committed to using the Aquamax following completion of the project terms.

Other potential clients are located on the west coast of Vancouver Island and will be contacted in due course.  

Membership in local, provincial, and country-wise business organizations and associations will provide first-rate opportunity for networking. Contact regarding membership for Shorelink Enterprises will be made with the BC Salmon Farmer’s Association. The BCSFA has represented an ever-expanding range of sectors of the BC industry, including producers, since its creation in 1984. The Campbell River and District Chamber of Commerce, with close to 500 members, will also be contacted regarding membership.

The Canadian Aquaculture Industry Alliance (CAIA), based in Ottawa, is a Canada-wise industry association that represents the interests of aquaculture operators, feed companies and suppliers, across the country as well as provincial finfish and shellfish aquaculture associations. Membership in CAIA opens up the potential market for the Aquamax to potential clients not only outside BC but beyond finfish as well.

Development of professional quality marketing material, including but not limited to brochures, a website, spec sheets, and an overview of test results, are under consideration. A respected Campbell River based graphic design company with a proven track record of producing quality products is being considered.

CONCLUSION

The development of the Aquamax net washing equipment has the potential to positively impact the aquaculture industry not only in BC, but throughout Canada and the international industry as well.  The industry is looking for technological advances that will not only improve company efficiency but which also factor in product quality – in this case, fish quality.

The Aquamax provides for this through utilization of the unit by skilled individuals who know that company profits are maximized when necessary farm site maintenance is carried out in an efficient and safe manner.

Additionally, decreased fish stress exists when growth of organic material on the nets is kept under regular control, thus maintaining optimal oxygen levels for the fish. “…reduced fish welfare brought about by low oxygen concentration due to poor water exchange, (and) increased stress through frequent net changing” is an acknowledged issue in aquaculture (Corner et al, 2007).

The Aquamax is ready for market and Shorelink welcomes inquiries from customers.  

ACKNOWLEDGEMENT

I’d like to express my gratitude to the staff of the Department of Fisheries and Oceans and Minister Gail Shea on behalf of Shorelink Enterprises and the local companies we used during the course of this project for providing our AIMAP funding and for recognizing the importance of environmentally friendly advances within the Canadian aquaculture industry.

Our contractors, MacTavish Welding, Powerserve Energy, and York Machine Shop, have taken a personal interest in this project and have done their best to keep their costs low in order to help us stay on budget. Their support is much appreciated.

REFERENCE

Qualitative Assessment of Initial Biofouling on Fish Nets Used in Marine Cage Aquaculture. Richard A. Corner, Donna Ham, James E. Bron and Trevor C. Telfer, Institute of Aquaculture, University of Stirling, Stirling, Scotland, 2007.