system
Grand Shrimp developed and ran a prototype system for over two years in their design firm partner, PACE, headquarters location in Fountain Valley, CA. From this prototype, design refinements were made that further optimized the operation of the system. As part of that process, specialized equipment was identified and sourced and a manufacturing process was developed that makes installation of these quads simple and cost effective by pre-fabricating each major component prior to transport to the shrimp aquaculture production facility location. Additionally, two patent applications were filed in 2017 and are under review, based on the system’s treatment process to protect the innovative and proprietary design elements that will further enhance the value of Grand Shrimp.
Closed Loop Treatment System Promotes Health and Safety of Water
Shrimp are comprised of 78% water by weight and therefore, careful water quality management during their growth and harvesting is critical for ensuring a clean, safe shrimp product free of disease, chemicals and dangerous bacteria and pathogens. Grand Shrimp’s production system treats and reuses all of its water and produces no sewer system discharge. The close-looped process has a number of benefits including disease prevention, no salt import, and no need for discharge permits, which are difficult to obtain for water with high salt content. High water quality to maintain an optimal growth environment is achieved by disinfecting the water every 90 minutes to maintain low pathogen, high clarity water. Additionally, automatic mechanical cleaning trays continuously remove waste. Each batch is also separated for bio-security.
Water Quality Managed by Sophisticated Automated Controls
Water quality management mechanisms are automated using a robust Supervisory Controls and Data Acquisition (SCADA) system that allows operators to monitor all aspects of system operation and water quality conditions and make operational changes remotely. The entire operation of the shrimp production system is highly automated including water flow, oxygenation, solids removal, raking, lighting, crowders and feeders. Redundant equipment ensures continuous operation and sophisticated software featuring a smartphone app with text message alerts allows for remote monitoring and operation of the system. Computer controlled dosing delivers feed in three dose levels associated with shrimp growth stages to optimize growth rate. The system is controlled and managed using integrated sensors reporting to a central computer system. Monitoring of the process is constant, and corrective action is pre-programmed for various operating conditions that are outside of acceptable ranges.
Uniform Manufacturing
Equipment is produced in a controlled manufacturing environment. This assures the standardization and inspection of materials, finished equipment and parts. Grand Shrimp quads will be shipped as modules as a complete turnkey solution.
Consumer Trust
The shrimp produced meets all of the standards of the USDA and FDA hazard analysis and critical control points (HACCP) protocol. Healthy, great tasting shrimp are produced without harming the environment where the production system is located. Shrimp will be distributed in the region local to where it is raised.
Modular Configuration
The system’s proprietary design contains a modular layout with flexibility to scale the production according to market demand. Each quad is capable of producing between 60,000 and 75,000 lbs per year on a footprint of approximately 0.12 acres (60 feet x 90 feet). Currently, deployment plans call for a minimum two quads to be deployed together at each location to maximize production economies of scale. Two quads operate on a combined footprint of approximately 0.2 acres (60 feet x 145 feet) and includes laboratory and administrative offices.
Contamination and Disease Prevention
The majority of shrimp currently sold in commercial markets contain alarming levels of antibiotics and antibiotic-resistant bacteria, but Grand Shrimp’s indoor, enclosed and protected environment with continual water infiltration and disinfection significantly reduces the risk of disease and eliminates the need for antibiotic treatment. The limited requirement for employee intervention due to operational automation prevents cross contamination risk. Minimal water is required with the continuous recirculation of the water supply, which also eliminates the import of salt.
Minimal Staffing Requirements
This system structure provides a stress-free environment to maximize shrimp growth rates. The operation of each quad requires only two full-time equivalent (FTE) trained staff members to operate the system approximately 12 hours per day, seven days per week and remote access to controls operations and monitoring provide greater flexibility and ease of operation 24 hours per day, seven days per week. With the deployment of two quads together at each location, the manpower required is only nominally higher at three FTE operators.
