Source: GREENE PRAIRIE AQUAFARM, L.L.C. submitted to
PRODUCING SHRIMP IN A MODIFIED PARTITIONED AQUACULTURE SYSTEM USING ON-SHORE TANKS AND EARTHEN PONDS
Sponsoring Institution
National Institute of Food and Agriculture
Project Status
COMPLETE
Funding Source
SMALL BUSINESS GRANT
Reporting Frequency
Annual
Accession No.
1015929
Grant No.
2018-33610-28284
Cumulative Award Amt.
$99,834.00
Proposal No.
2018-00374
Multistate No.
(N/A)
Project Start Date
Jul 1, 2018
Project End Date
Feb 28, 2019
Grant Year
2018
Program Code
[8.7]- Aquaculture
Project Director
Teichert-Coddington, D. R.
Recipient Organization
GREENE PRAIRIE AQUAFARM, L.L.C.
10150 US HWY 43
BOLIGEE,AL 35443
Performing Department
(N/A)
Non Technical Summary
The U.S. is the largest importer of shrimp in the world, and in order to compete with foreign imports, production efficiencies need to be drastically improved. A principle problem that affects profitability, and ultimately, sustainability of inland shrimp farming in Alabama and other regions is highly unpredictable survival. Survival can be affected by stock-out success of post larval shrimp or by unexplained mortality later during grow-out. Poor survival upon stocking can be assessed early and compensated with additional stockings of expensive shrimp young. Late term mortality is economically devastating, because no time is available for compensatory action, and much costly resources will already have been lost in the production cycle. We have discovered that both early and late term mortality can be greatly reduced when shrimp are produced in tanks located on shore, even when supplied with water from ponds where mortality is high.In this research project we propose to change our penaied shrimp culture system from semi-intensively stocked, static water, earthen ponds to one that combines intensive on-shore confinement of shrimp with natural water treatment in earthen ponds. This is a modified partitioned aquaculture design where the cultured animal is intensively confined and physically separated from water treatment compartments. Water from on-shore tanks is circulated through earthen ponds where metabolytes and organic wastes are naturally decomposed. Confining shrimp on shore will give us better management control of aeration, water quality and feeding processes. We hypothesise that use of this modified partitioned aquaculture system will significantly increase survival and yields, while using land and water resources more efficiently.
Animal Health Component
100%
Research Effort Categories
Basic
(N/A)
Applied
100%
Developmental
(N/A)
Classification

Knowledge Area (KA)Subject of Investigation (SOI)Field of Science (FOS)Percent
30737211060100%
Knowledge Area
307 - Animal Management Systems;

Subject Of Investigation
3721 - Marine shrimp;

Field Of Science
1060 - Biology (whole systems);
Goals / Objectives
Our goal is to gain more control of our shrimp culture system by confining the shrimp on shore out of the mud where they can receive greater vigilance, be fed more efficiently, aerated more thoroughly and efficiently, and harvested relatively easily without having to mechanically transfer water to drain a pond.A primary objective of Phase I research is to evaluate tank stocking densities so that expected yields can be economically evaluated with respect to costs of production. We expect that yields of at least 10 kg/m3 will be necessary to justify costs of constructing tanks. However, the increased survivals and better management should directly decrease variable costs of production while increasing predictable yields and income. The technical objectives of this proposal include:Determine survival, growth, and yield of marine shrimp produced in a modified partitioned aquaculture system at three different stocking densities using on-shore tanks with pond water treatment and compare to semi-intensive production in traditional earthen ponds.Determine water quality characteristics of on-shore tanks with pond water treatment utilized to produce shrimp at three different densities and compare to semi-intensive production in traditional earthen ponds.Evaluate the economics of raising shrimp in a modified partitioned aquaculture system compared to semi-intensive production in traditional earthen ponds.
Project Methods
We propose to confine shrimp in culture tanks on the side of a 1.1-ha pond and evaluate three stocking densities of shrimp to estimate what yield we should expect using water recirculated though a treatment pond. Nine, 10,650 l plastic tanks will be placed on the pond bank to replicate each stocking density three times. We will stock shrimp to produce 5, 10, or 15 kg/m3 using tank exchange rates of 1.25, 2.5, or 3.75 volumes per day; i.e., 1.25 volumes of water will be exchanged daily for each 5 kg/m3 of intended yield. Stocking numbers will assume a target harvest size of 25 g and an assumed survival of 75%. Initial stocking rates for low, medium and high densities will be 266, 533, and 800 shrimp/m3.The water treatment pond will also be stocked with enough shrimp to reach a total target harvest weight of 3900 kg/ha inclusive of shrimp in tanks and pond. This is the standard target harvest yield for our earthen production ponds. Three conventionally managed ponds will be stocked with the same number of shrimp per area as the water treatment pond for comparison purposes. This pond stocking rate will result in an initial density of 28 shrimp/m2.Water for the nine pond-side tanks will be supplied with a single, variable speed, 3-hp pump, with an intake in the water treatment pond. Each set of on-shore treatment tanks (low, med, high densities) will be calibrated to receive the predetermined volume of exchange water. Input water in each pond will be discharged through down-spouts that are equipped with All Aquaculture TM air injection nozzles (Samocha et al., 2017) that are designed to inject 3 parts air for each part of water pumped (Bob Advent, personal communication). Tanks will therefore be aerated with circulation water pumped into the tanks. Higher density tanks will be provided with additional nozzles to maintain DO above 50% of saturation. In addition to aerating tanks, the air injection system mixes and circulates the water constantly. The water pump will be equipped with a back-up generator power source and automatic switch-on. Dissolved oxygen in one tank of each treatment will be monitored continuously with automated data loggers that are standard in GPA ponds.All nine pond-side tanks, the water treatment pond, and three control conventional ponds will be stocked at the same time with the same batch of previously acclimated shrimp post larvae (Litopenaeus vannamei) of at least PL-19 age. The average size of the post larvae will be estimated with replicated counts and weights using a balance that can weigh to 0.1 g. The PLs are then stocked into ponds and tanks by weight.Shrimp survival, yield, feed efficiency and electrical use from the tanks, treatment lagoon, and other production ponds will be recorded. Feeding amounts will be calculated with the same procedure for all systems based on average weight of animals, an assumed FCR of 1.3 and weekly weight gain of 1.6 g, and an assumed survival that decreases weekly. Ponds and tanks will be sampled weekly to determine weight gain. Ponds will be fed with a 32% (CP) feed and the tanks will receive a 35% (CP) feed, both fabricated by Cargill (Franklinton, LA). The ponds receive a lesser protein feed because they are semi-intensively stocked and expected to receive significant nutrition from natural pond biota (Anderson et. al. 1987). The ponds will be fed twice a day, but tanks will be equipped with automated belt feeders that dispense feed continually.Shrimp diseases have become more prevalent as shrimp farming has expanded worldwide. A potential advantage of locating shrimp farms inland is the separation from diseases transmitted from natural populations of shrimp or diseased foreign product processed in coastal processing plants. However, the potential impact of disease organisms on our shrimp cannot be discounted. Shrimp health in on-shore tanks and control ponds will be monitored monthly by Dr. Benjamin Beck and the USDA Aquatic Animal Health Laboratory in Auburn, AL. Samples of shrimp will be obtained to test for Vibrio sp. using both culture techniques (i.e., differential media) and sensitive molecular tests (i.e., polymerase chain reaction (PCR) and/or real-time PCR). More frequent analyses or other tests (histopathology) may be performed depending on results or if a problem is noted. Dr. Beck's research team has been instrumental in providing aquatic animal health support to commercial aquaculture producers in Alabama, including shrimp farmers. As such, facilities and personnel are available to provide a comprehensive assessment of shrimp health throughout the production season.Water chemistry will be determined weekly in culture tanks, treatment pond and control ponds by Dr. Roy's laboratory at the Alabama Fish Farming Center (AFFC) Samples will be transported on ice to the water quality lab at the AFFC. Water samples will be analyzed for total ammonia (APHA, 1995), nitrites (Parson et al., 1985), salinity, chlorophyll a (Lloyd and Tucker, 1988) and total settleable solids (APHA, 1995)). Measurements of pH will be conducted in situ at 60 cm depth in the morning before 800 hr and later that same day between 1600 and 1700 hr. Oxygen and temperature will be continuously monitored with automated data acquisition equipment already used on the farm (In Situ sensors and Campbell Scientific Instruments hardware). An on-set HOBO temperature logger (Bourne, MA) will be deployed in one representative tank of each treatment, the treatment pond, and control ponds to track temperature every hour throughout the trial.In addition to routine water quality measurements, sodium (Na), potassium (K), calcium (Ca), and magnesium (Mg) will be tracked in the modified partitioned aquaculture systems and control ponds throughout the trial according to Roy et al. (2010). An initial pond water sample will be collected at the beginning of the production season to determine baseline ion levels and molar Na:K ratios in each pond water source. Sodium and K will be measured using a flame photometer and Ca and Mg will be measured according to established techniques (Roy et al. 2007). Following determination of baseline ionic levels, supplementation of pond waters will be conducted with muriate of potash and potassium magnesium sulfate as needed according to established techniques to optimize culture of shrimp in inland low salinity water (Roy et al. 2010). Ions will be measured twice throughout the experimental trial to ensure they are at levels and concentrations optimal for production of shrimp in inland low salinity waters. Dr. Allen Davis' will serve as a collaborator in this study and his laboratory at Auburn University will provide logistical support and assist with data analysis and interpretation of results. Dr. Davis' group has a long history of providing support to Alabama shrimp farmers and will also serve as a technical advisor for the research component of this proposal and expansion of this system during Phase II.The economics of pond-side production at three harvest densities will be compared with that of conventional semi-intensive production in earthen ponds. Data collected over the project period will be used to develop variable and fixed cost production estimates for shrimp produced in on-shore tanks and compared with costs and returns to produce in conventional earthen ponds. This economic information will form the basis for predicting the costs and returns to build and operate a scaled up version of this system for commercialization in Phase II. Briefly, the cost to set up and operate the modified partitioned aquaculture systems will be tracked throughout the trial as will production in three control ponds on the farm. Standard partial enterprise budgets will be developed to compare production in the modified partitioned aquaculture system to semi-intensive culture in traditional earthen ponds.

Progress 07/01/18 to 02/28/19

Outputs
Target Audience:While the project was underway, it was viewed primarily by university-based researchers who were curious about how the project was set up and how the results were shaping up. After the project was harvested, a presentation was made at the annual Alabama Inland Shrimp Producer's meeting in January of this year. Portions of the results will be discussed at the annual World Aquaculture Socienty Meeting attended by scientists, famers and business people from all over the world. Changes/Problems:Shrimp production in Alabama usually begins the first of May and ends by the 1st of November. Shrimp are a warm water animal that do not tolerate the cold temperatures that bound this growing period. It was anticipated that this study would begin by the middle of June, but we were not able to stock our on-shore tanks until the middle of July because of delayed funding. The result is that the study was about a month shorter than what it should have been to resemble a commercial shrimp operation. The survival and yields of the on-shore tanks were significantly lower than anticipated.Total yields would have been greater if the study had begun a month earlier, but survivals would have been further reduced. Shrimp in the tanks became stessed when handled. This indicates that the water chemistry was not optimum for them. This study will be repeated in 2019 with some modifications. First, the stocking densities will be reduced by 50%. Second, the water treatment lagoon will be boosted with magnesium in addition to potassium to try and reduce stress to high-density shrimp in the tanks. A consultant in aquacultural engineering was budgeted to helpmodify the culture system for commercialization. The consultancy was significantly reduced, because the system had not yet been adequately tested. Therefore, there werefunds left unspent in the project's balance. What opportunities for training and professional development has the project provided? Nothing Reported How have the results been disseminated to communities of interest?The results of this study have been discussed extensively with persons within the local research and academic communities. They were presented at an annual meeting of the Alabama Inland Shrimp Producers Association. They will be presented as part of a paper at the World Aquaculture Society meeting in New Orleans, 2019. What do you plan to do during the next reporting period to accomplish the goals? Nothing Reported

Impacts
What was accomplished under these goals? ? Impact The concept of circulating water from a treatment lagoon through on-shore tanks stocked with high densities of shrimp was only partially validated in this study. The physical system that included tanks outfitted with air siphoning water inlets and a variable speed water pump to continuously circulate water worked well. The water quality was maintained at acceptable levels by the system at all stocking densities. However, shrimp performed poorly in the system at all stocking densities. Survival and yield were worst at the highest density. The reason behind the poor performance was not identified. Future studies will repeat this season's work, but at lower stocking densities. Future studies will also reevaluate the role that major ions, like magnesium, may play in shrimp survival at high density culture in low salinity water. Methods Three stocking densities of shrimp were evaluated in 12, 7.1 m3, round, plastic tanks. Shrimp were stocked in tanks at 303 (Low), 606 (Medium), or 909 (High) shrimp/m3. Water for the tanks was supplied by a 3-hp pump with an intake in the water treatment pond. Water flow was metered through down-spouts equipped with air injection nozzles that aerated while exchanging water. Dissolved oxygen (DO) in one tank of each treatment was monitored continuously with an automated data logger. Three traditional production ponds were included in this study to provide for a comparison of production with on-shore tanks. One pond (N3) was the waste treatment pond. Two other ponds were traditional split ponds in which shrimp were confined at relatively high densities in one pond and its water was circulated through a waste treatment lagoon. Water chemistry including total ammonia, nitrites, and salinity, and were determined weekly in tanks and ponds at Dr. Roy's laboratory. Temperature and DO were continuously monitored with automated data acquisition equipment and pH was determined in situ at 60 cm depth morning and afternoon once a week. Results The on-shore tanks were harvested 98 days after stocking. Survival and production were low at all stocking densities. Survival was significantly lower in the high density (H) versus the medium (M) and low (L) densities. Mean production was significantly higher at the M versus L and H densities. Because survival was low, mean FCR was high at all densities but was significantly higher at the H versus M and L densities. Mean average shrimp weights were similar at all densities. Weekly weight gain of shrimp at all densities was slow and did not increase until later in the season, probably because of density reduction through mortality. Yields were lower than targets and were highest in the M density. Mean weekly growth of low-density shrimp appeared to be faster than shrimp in M and H densities. However, mean weights at harvest were not significantly different among treatments because of high variation among replicate tanks. Water quality (WQ) in tanks remained in acceptable ranges during the season. There were no significant differences among treatments for any of the WQ variables. Mortality in tanks was evident within 2 weeks of stocking. When handled shrimp seemed especially fragile, turning white quickly as though from a water chemical or ionic imbalance stress. Although the K concentrations in the supply water were within the range considered acceptable, more potash was added until there was less cramping. The FCRs were exceedingly high for all treatments, but particularly for the high density, because the rate of mortality was severely underestimated. Mortality was observable, but not practically calculable. The WQ in tanks was good, so we did not want to hinder growth by further underestimating survival and unduly limiting feed. Low survival and poor growth were surmised to be related to a common factor, possibly an ionic imbalance in our low salinity water. Ponds Mean yield for the 3 ponds was 1,969 kg/ha, well short of the 3,200 kg/ha target (Table 3). Only N3, the water treatment pond for the on-shore tanks, came close to the target yield. Survival and mean yield of these ponds were like what was achieved by the whole farm which averaged 35.9% and 2,181kg/ha, respectively. Weight gain over time was typical of pond-raised shrimp. Growth was similar in all ponds for the first 10 weeks. Thereafter, shrimp in the high-density control-split pond N6 became noticeably slower, and shrimp in S8 seemed to increase, probably because of low survival numbers. Pond S8 was harvested after only 13 weeks because sample numbers indicated that survival was relatively low. Pond WQ Pond WQ remained in acceptable ranges. The survival differences among ponds was not apparently related to water quality, since it was similar across ponds. Historical information and these data indicate that survival becomes lower as stocking density increases. Comparison of Tanks with Ponds Survival and yield of shrimp in the on-shore tanks were low, while survival and yield of shrimp in the pond (N3) that served as a waste treatment lagoon for the tanks was high relative to the farm average. The higher the density of shrimp in the tank, the worse the survival and yield. Weight gain was obviously faster in the ponds versus tanks. It took 4 to 5 weeks for pond shrimp to reach 5 grams, but it took 6 to 7 weeks for tank shrimp to reach the same weight. The water circulation through tanks from the waste treatment lagoon aerated the water as designed and maintained acceptable TAN and nitrite concentrations. Shrimp in tanks exhibited signs of stress when sampled, but shrimp in N3 did not cramp and turn white upon handling. Concentrations of unionized ammonia and nitrite, which can reach toxic levels in aquaculture conditions, were similar in tanks and ponds. Therefore, we presume that the high mortality and poor yields in tanks were not because of these known toxins. Additional studies will have to be carried out to elucidate this issue. The economics of raising shrimp in on-shore tanks was not accurately assessible from the data produced in this study. We think that much higher yields are attainable at high densities in on-shore tanks, but more work will have to be done to prove this. Tank Circulation We intended to exchange water through tanks at rates that increased concomitant to increased stocking density. In fact, water was exchanged at higher rates than anticipated. Water was circulated through nozzles designed to aerate water by venturi effect. The nozzles required a minimum rate of water flow to siphon air, which was about 2.5 times that intended for the low-density system. The medium density tanks received about 33% more water than designed. A second water nozzle with siphon tube was added to each high-density tank to maintain DO greater than 50% of saturation, and exchange was about 1.6 times higher than designed. The water exchange system became impeded by a bryozoan that populated the interior of supply and discharge pipes. Eventually the supply pipes required daily flushing to expel the material. Pieces of the bryozoan would occasionally break off and clog the narrow throat in the venturi water supply nozzles. One tank of shrimp in the medium treatment was eventually lost to this problem. It is recommended that a commercial tank system be equipped with air blowers in combination with air siphoning nozzles to reduce the chances of low DO from water circulation failure. Conclusions A Phase II expansion of the modified split-pond concept as tested in this Phase 1 study is not yet justified. Additional testing of the concept will be done this coming year and then it will be reevaluated for commercialization.

Publications

  • Type: Conference Papers and Presentations Status: Accepted Year Published: 2019 Citation: Luke A. Roy*, David Teichert-Coddington, Benjamin H. Beck, D. Allen Davis, Sunni Dahl, Jesse James. 2019. EVALUATION OF OPTIMAL STOCKING DENSITY AND DIETARY FISH MEAL INCLUSION LEVEL FOR INTENSIVE TANK PRODUCTION OF PACIFIC WHITE SHRIMP Litopenaeus vannamei. World Aquaculture Association, 2019, New Orleans, LA, USA.