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

AIMAP 2009-P38
Limberis Seafood Processing Ltd.

Table of contents

• Executive Summary
• Sequence of Project Events
• Results and Conclusion
• BEFORE
• AFTER

Executive Summary

This project utilized contributions from Limberis Seafood Processing Ltd (LSPL) in conjunction with AIMAP to develop Manila clam processing equipment to further improve the competitiveness of the Canadian aquaculture industry. The equipment was developed and manufactured in Italy by Aerre Automazioni, in concert with LSPL. Upon implementation of the new machinery, overall labour costs have gone down and productivity has increased exponentially.

A lot of time, effort and money have been dedicated to the research and development of the shellfish farming and harvesting aspects of shellfish companies, yet little or no attention has been spent on the processing aspect of these clams once they reach the plant. Research and development of the mechanization and modernization of clam processing techniques is needed to improve the competitiveness of the Canadian aquaculture industry on a global scale; this will be achieved through increased productivity and reduced production costs directly realized by adapting new processing technology, currently being utilized in Italy.

In Canada, the processing of Manila clams is extremely time-consuming, and due to the antiquated processing machines currently in use, very costly in terms of labour and loss of product due to breakage. The previous machines used at the Limberis plant were built in 1994 in the USA. These machines were the best available at the time.

The previous machines used by LSPL were in dire need of an upgrade for the following reasons:

• machines were constantly breaking down – this costs money not only in terms of repair costs, but downtime as well (less downtime translates to more savings and greater production)
• machines were very slow – processing a maximum of 1000 pounds per hour
• machines took up to five people to properly operate – this is a problem due to lack of space in the processing room
• machines were very hard to properly clean, as they were not on wheels and could not be moved to clean awkward locations
• machines had a large footprint and there was very little space left in the processing room to manoeuvre
• machines were not modular and could not be configured for various operations

The new processing machines were specifically built to process Manila clams. Manila clams have a unique and distinct oblong shape, which makes them difficult to process. These technologically-advanced machines were not available in Canada or the USA. Research was performed by the BCSGA to find fabricators of Manila clam processing equipment in Canada. Numerous people associated with aquaculture in Canada were contacted, and no one knew of any manufacturers of this equipment in Canada.  Research indicated that our American counterparts were acquiring their cost-effective Manila clam processing machines from Italy. After considerable research of the manufacturing companies in Italy, Manila clam processing machines were found that completely addressed all of the concerns and performed all of the tasks needed by LSPL.

These new Manila clam processing machines are:

• capable of washing, grading, weighing, and packaging Manila clams
• modular and on wheels (able to be moved around and properly cleaned, and also to remove / add different components specific to certain processing tasks required)
• able to meet and/or exceed stringent CFIA and USFDA regulations
• capable of processing in excess of 5,000 pounds per hour, greatly exceeding any machine currently being used in the BC shellfish industry
• proven performers currently being used in Spain, Turkey, Italy, USA, and other countries
  
• designed to minimize breakage of the clams (the annual cost savings that will be realized by LSPL in purchasing these machines in breakage alone is approximately 2.5 cents per pound, for a savings of $17,160 for one year at current production levels)
  
• able to realize an annual cost savings concerning labor to be approximately 3.1 cents per pound, which translates to $20,000 for one year at current production levels Currently, it takes 4 people 11 hours to process an order of 7700 pounds, which translates to 6.3 cents per pound to process this amount. With the new machines, it will take 4 people approximately 4 hours to process the same amount, costing 3.2 cents per pound.

The Italian manufacturing company, Aerro Automazioni, custom-built the machines to  best  suit  our  specific  applications,  and  to  fit  within  the  dimensions  of  the processing room. Since the Manila clam was introduced into BC in 1930, there have never been proper, efficient, all-encompassing processing machines to wash, grade, weigh, and package the Manila clam. Machines fabricated by individual companies, are one-dimensional and cannot multitask; overall, they are wholly inadequate. LSPL is a fully integrated company that farms, processes, depurates, and distributes Manila clams. Our company has spent a substantial amount of time and money stocking its beaches with Manila clam seed with the intention of greatly increasing production and sales, yet our previous processing equipment (and that being used by other processors in the BC shellfish industry) was causing a bottleneck in the process flow. The previous machines simply could not process a greater volume of Manila clams to meet the objectives of LSPL.

The clam industry in Italy is huge. Manila and Littleneck clam sales in BC are estimated at approximately five million pounds annually, whereas the Italian industry is approximately 100 million pounds in sales annually. It would be impossible to attain this level of production without the sophisticated Italian processing machines.

The Italians have been processing clams for many years and have tried every conceivable configuration of the machines to come up with the most optimum system. The machines they have developed are a marvel of ingenuity and workmanship. LSPL did not want to spend many years of trial and error, and a large amount of money and frustration to attempt to recreate these machines, without guaranteed success.

A lot of time and energy has been spent on new harvesting technology for clams (i.e., new clam digger approved proposal submitted by BCSGA). However, there was a need for new processing technology for the clams after harvest once they reach the processing plant.

These new clam processing machines will put the BC clam industry into the future and will provide demonstrable industry-wide benefits that can be implemented by all processors. In addition, it will allow LSPL to continue to help the community grow by providing steady employment not only to our plant workers, but also to others in the community involved with clam harvesting, such as the local First Nation groups, and groups and businesses indirectly involved with our business that would benefit from our continued success.

Sequence of Project Events

The project commenced upon approval by AIMAP in July 2009, with all spending completed by March 31, 2010.

• processing rooms electrical and plumbing was roughed in prior to the machines arriving from Italy
• machines were shipped from Italy by ship on March 19
  
• machines arrived at the Port of Vancouver on May 4
  
• machines arrived at the LSPL plant, Ladysmith on May 6 via a 40 foot box van
  
• machines were unloaded within two hours at the top of the Limberis driveway – the truck was too big to come down the hill so we had to hire the services of a flat bed crane truck
  
• machines were completely covered in shrink wrap – the shrink wrap was removed and the machines were placed in the plant for temporary storage until the installer arrived from Italy
  
• one of the machines was too large to fit in the door so it had to be left outside until the installer arrived
  
• installer arrived from Italy on May 10
  
• first task was to fit the machines into their proper locations
  
• electrical and plumbing contractors were called back in to make the final hookups of the machines
  
• electrical and plumbing contractors were available (for six days) to the Italian installer for various modifications
  
• most of the machines worked well with the exception of the tumbler grading machine. The other machines (conveyor belts, hopper lift belts, etc) are manufactured on a regular basis and are common in the Italian clam industry; however the tumbler-sizer is a one-off machine. This machine was designed and built specifically for Limberis as per our requirements. It was evident very soon after the first use that the auger system for unloading the hopper was not working properly, particularly with the large size clams. It seems that large clams harvested in BC waters are unheard of in Italy and therefore the machine could not be tested with large clams. In order for the machine to function a local fabricator had to be hired to temporarily modify the system until a new design could be manufactured and shipped from Italy
  
• new pieces arrived from Italy on May 14 and were installed
  
• after the Italian installer returned to Italy, he instructed the electrical contractor to modify some of the internal components of the machines
  
• after 12 days the replacement parts arrived from Italy and were installed on the machines. These new modified replacement parts solved the problem
  
• after one month another representative from Italy arrived and sorted out any remaining issues with the machines

Results and Conclusion

The machines have now been fully operational for two months. They appear to be working very well. There are a few minor problems which will be resolved over time by the manufacturers in Italy. The manufacturers will be sending a few small parts for the machines to enhance their performance

BEFORE 

• old machines very slow (process approx 750-1000 pounds per hour)
• old machines very loud
• old machines caused excessive amounts of breakage of product
• old machines constantly breaking down and take time to fix (required constant adjustments)
• old machines occupied a lot of space in processing rooms
• old pre-depuration machine did not size-grade clam

AFTER

• new machines very fast (can process approx 4000 pounds per hour)
• new machines extremely quiet
• new machines have visually no breakage
• new machines required minor initial adjustments upon arrival, but nothing needed since then
• new machines use smaller footprint providing ease of movement in rooms
• new pre-depuration machine efficiently grades the clams to a consistent, correct size

The overall efficiency of the pre and post-depuration aspects of LSPL’s operation has been greatly improved due to the arrival and implementation of the new machines, the purchase of which was aided in part by AIMAP. For example, in the same length of time during a processing day, only one aspect of the job would be able to be completed (i.e., either incoming washing or outgoing orders); with the advent of these machines, we are now able to undertake and complete both aspects and even do them in less time than before. Due to this, we will be confidently able to pursue larger markets and more companies throughout the world.

The overall process of the incoming washing of clams (prior to loading them into the depuration tanks) has also been made more ergonomically efficient (i.e., heavy bags are not lifted above employees’ heads to load the hopper; they are now just below waist height). This helps reduce the strain on employees’ backs.