Progress 09/01/15 to 08/31/18
Outputs
Target Audience:The target audience of this project is the agriculture/aquaculture community. The small farm/business audience has been reached through tours, presentations, Small Business Incubator events, industry workshops, the Ohio Aquaculture Association and the Ohio State Extension Office. Changes/Problems:
Nothing Reported
What opportunities for training and professional development has the project provided?- Ohio State University Extension Tour groups and workshops - Ohio State University School of Engineering - Purdue University Schools of Engineering and Agriculture - Cornell University Aquaculture Workshops - Ohio Aquaculture Association (OAA) conferences, tour groups and workshops - World Aquaculture Society conference and presentation (Las Vegas, NV) - Ohio University featured business video - Individual Technical Tours to prospective fish farmers (more than 50) How have the results been disseminated to communities of interest?- Ohio Secretary of State/ Ohio Business Profile - Various school Group Tours - Various 4-H Club Tours - Community Library Presentations - Muskingum County "Shark Tub Event" - Muskingum County Chamber of Commerce Tour - City of Columbus, Ohio Chamber of Commerce Tour - Brian Hill, Ohio House of Representatives Tour - Local Radio Station - featured business interview - Farm Services Agency Tour - Muskingum County Farm to Table Event - Rotary Club Presentation - Genesis Hospital Volunteer Workers presentation - Sertoma Club Tour - Fly Fishing Club of Newark Tour - Article in "Ohio Farmer" Magazine - Article in "Ohio Cooperative Living" Magazine - Article in "Columbus Dispatch" Newspaper - AAA Bus Tours - Amish Community School Group Tours What do you plan to do during the next reporting period to accomplish the goals?
Nothing Reported
Impacts
What was accomplished under these goals?
1. Construct two additional raceways to further research engineering design questions related to the mixed cell raceway. Ripple Rock Fish Frams operates in a 6,000 sq. ft. indoor, pole building. The original design for Phase I utilized approximately one-half of this building. In Phase II, we have constructed two additional raceways, each improving on the previous designs. Modifications in the second year include the following: - Raceways 1-4 are fully up and operational. Oxygen generators replaced liquid oxygen as the primary source of aeration in the raceways. RESULT: Summer heat is no longer creating dissolved oxygen alarms, as the generators are keeping levels at or above desired targets of 4 mg/L. In addition, the generators are less expensive to operate than liquid oxygen delivery. - Center drain covers were added for the initial 3 weeks of cohort growth to prevent small fish clogging the drains. RESULT: Drains remain clear until fish size is not a risk factor. - Construction plans changed to use 2 x 6 boards, in place of 2 x 4 boards for the raceway frame. RESULT: Framework is better able to support the weight of 11,000 gallons of water. 2. Growout trials will be conducted on the raceways, as well as existing fry and fingerling systems, to investigate engineering design and operation/management questions of the complete recirculating aquaculture system. - Validate system performance in terms of growth rate, feed conversion, fish health and risk management. Initially, growth rates lagged, as densities and feed demand increased over the production period. Maintenance protocol has been fine-tuned to address this issue and production results have improved significantly. Specifically, the moving bed bio-reator is stirred regularly, pipes are flushed weekly and water is tested daily. Feed size has been reduced to help with water quality issues. According to damon Seawright, PhD in Fisheries Science and President of Ameriulture, Inc. (the provider of our fry), the tilapia should grow to market ready size in 34-40 weeks. Growth rates continue to improve and now range from 36-40 weeks. - In-Raceway Aeration. Modifications to aeration include implementation of home use oxygen generators, replacing industrial use liquid oxygen. Not only is this safer for the producer, but it is also significantly less expensive. As a result, even in the peak summer months, oxygen levels are no longer a limiting actor and range above 4.0 mg/L. - Side-wall and End-wall Discharges. The side-wall and end-wall discharges have been eliminated in all raceways and replaced with PVC drains. As a result, there is less pocketing of feed, as well as ease of construction and maintenance. 3. Monitor energy consumption and Investigate options for better management and reduction of overal electrical demand. Purdue University visited the farm in January and August, 2017 to collect data and make recommendations regarding energy consumption and efficiencies. Studies were also conducted on farm with the following results: - Low BTU Gas Well - Gas levels were not sufficient to reduce overall electrical demand. - Heat recovery technologies - a heat recovery unit was installed and was successful in bring a continuous supply of fresh air into the building while exhausting an equal amount of moist indoor air, thus effectively controlling condesation and humidity. - Energy efficient pumps - options available 1) step down to a 3/4 hp pump for constant speed delivery and 2) change to a 3 phase pump with variable frequency drive (VFD) - Electrical usage - The Energy Detective (TED) has been installed to monitor the power consumption of individual pumps and systems. Data collected indicate that the blower and the pumps are the greatest draw on electricity. 4. Bi-Product Utilization - possibilities include 1) effluent mixture, bottled and sold as fertilizer 2) fish waste, dried and ground up, to be sold as fertilizer 3) liquid fish waste, bottled and sold as fertilizer. All products will require additional research to fine tune the process for effectiveness and profitiability. 5. Create Set of Manuals - A set of manuals have been created and submitted for copyright registration, as follows: 1) Business Plan Workbook - Primary author is Traci S. Bell, CPA (PD). Components of this book include sections on aquaculture industry, prodeucts and services, marketing plan, management plan, operating plan, and financial plan. Digital templates have been developed to allow the user to prepare custom financial statements, for use by lenders and investors. Research for this manual includes facts and figures related to RAS, as well as diagrams and visual representations which can be duplicated in the preparation of an individual business plan. 2) Daily Operations Manual - Primary author is Co-Director, Craig M. Bell. This manual includes the "how-to" for successfully operating an RAS system to raise tilapia. Each chapter provides step-by-step instructions for daily backwash, routine maintenance, feeding protocol, water quality management, sorting, transporting, and more. Videos are also provided to support the written documentation and allow a visual demonstration of the actual tasks being performed. 3) Design/Construction Manuals - Primary authors are Craig M. Bell (Co-Director) with input from Dr. James Ebeling. This manual includes the design calculations and complete drawings for the raceway, as designed by Dr. Ebeling and modified by Craig Bell (see Objective #2 above). Of note, the raceway was determined to be most effective by raising one cohort of fish, as opposed to "mixed" cohorts. In addition to the drawings, these manuals itemize all parts required for construction and price list per part. 6. Develop, implement and manage a Franchise Model The culminating objective of this research project invloves a Support Model capable of mentoring the small farmer upon start-up in the aquaculture industry. Although a traditional "franchise model" was deemed impractical due to long distances between farms, a contract arrangement has been customized to meet the needs of the farmer. Under this arrangement, Ripple Rock will provide a technical tour, the design & construction plans, business plan workbook, daily operations manual, phone support, cohort management software, pricing discounts on feed and fry, purchase discounts on filters and pump equipment, and two site visits. The producer will agree to attending a technical tour on site, build and operate the system as designed, record water quality tests, operate using best management practices and risk management protocol, and sell fish cooperatively with Ripple Rock (optional).
Publications
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Progress 09/01/16 to 08/31/17
Outputs
Target Audience:Target audience consists mainly of the agricultural/aquaculture community. The small farm/business has been reached through tours, presentations, SmallBusiness Incubator events, industry networking, the Ohio Aquaculture Association and the Ohio State Extension office. Changes/Problems:
Nothing Reported
What opportunities for training and professional development has the project provided? Oct, 2016 - Dr. Michael Timmons and Dr. James Ebeling visit and research April, 2017 - Dr. James Ebeling visit and research How have the results been disseminated to communities of interest? October 25, 2016 - Cambridge City Schools Tour October 29, 2016 - Presentation, Ohio State University South Centers, Piketon October, 2016 - Eric England, Ohio State University, Meat Science, research study on the nutritional content of RAS Raised Tilapia January29, 2017 - Presentation at the Ohio Aquaculture Association Annual Workshop February 17, 2017 - Participant in "Up and Coming New Business" video project by Ohio University March 2, 2017 - Shark Tub Event, Muskingum County Business Incubator June 26, 2017 - Became members of the "Ohio Proud" certification for locally grown products August 10, 2017 - Purdue University research project participant on the topic of RAS facilities management What do you plan to do during the next reporting period to accomplish the goals? Continue experimenting with feed/growth rates, as they relate to oxygen and nitrification. Complete Construction, Operation and Business manuals for the purpose of marketing a complete system package, with training and support. Finalize and implement plans for the franchise operation going forward. Continue to meet with the consultants at Tech Growth Ohio to draw up legal contracts and create a framework to franchise this operation.
Impacts
What was accomplished under these goals?
1.Construct two additional raceways to further research engineering design questions related to the mixed cell raceway. Ripple Rock Fish Farms operates in a 6,000 sq. ft. indoor, pole building. The original design for Phase I utilized approximately one-half of this building. In Phase II, we have constructed two additional raceways, each improving on the previous designs. Modifications in the second year include the following: March, 2017 - Raceways #1-4 are fully up and operational. Oxygen generators replaced liquid oxygen as the primary source of aeration in the raceways. RESULTS: Summer heat is no longer creating dissolved oxygen issues, as the generators are keeping levels at or above desired targets of DO > 4mg/L. In addition, the generators are less expensive to operate than liquid oxygen delivery. 2.Growout trials will be conducted on the raceways, as well as existing fry and fingerling systems, to investigate engineering design and operation/management questions of the complete recirculating aquaculture system: Validate system performance in terms of growth rate, feed conversion, fish health and risk management. Initially, growth rateslagged, as densities and feed demand increased over the production period. Maintenance protocol has been fine-tuned to address this issue and production results have improved significantly. Specifically, the Moving Bed Bio-reactor is stirred bi-weekly, pipes are flushed weekly and water is tested daily. Feed size has also been reduced to help with water quality issues. According to Damon Seawright, PhD in Fisheries Science and President of Americulture, Inc. (the provider of our fry), the tilapia should grow to market ready size in 34-40 weeks. Growth rates continue to improveand now range from 36-42 weeks. In-Raceway Aeration: Modifications to aeration include implementation of home use oxygen generators, replacing industrial use liquid oxygen. Not only is this safer for the producer, but it is also significantly less expensive. RESULTS: Even in the hottest summer months, oxygen levels are no longer a limiting factor and range > 4.0 mg/L. Side-wall and End-wall Discharges: have been eliminated in all raceways and replaced with PVC drains, with less pocketing of feed, as well as ease of construction and maintenance. 3. Monitor Energy Consumption and investigate options for better management and reduction of the overall electrical demand. Purdue University visited the farm in January and August, 2017, to collect data and make recommendations regarding energy consumption and efficiencies. They are working on a comparison amongst indoor fish farms in the Midwest and we should have results within the next six months for items a,b,c, below: Low BTU Gas Well - (Purdue University is researching) Heat recovery technologies - a new heat recovery unit has been installed and will be in operation as soon as the weather turns cold. Data will be collected to determine the efficiency of the unit. (Purdue University is researching). Energy efficient pumps - (Purdue University is researching) Electrical Usage - The Energy Detective (TED) has been installed to monitor the power consumption of individual pumps and systems. Data, currently being collected, will be analyzed in conjunction with research findings from Purdue University. 4. Bi-Product Utilization- no further results. 5. Create Set of Manuals A set of three manuals are in the process of being written as follows: 1) Construction Manual, 2) Operation & Maintenance Manual, 3) Business Plan & Finance Manual. Construction Manual - primary author is Dr. James Ebeling, with input from Co-Director, Craig M. Bell. Currently being written, this manual includes the design calculations and complete drawings for the mixed-cell raceway, as designed by Dr. Ebeling and modified by Craig Bell, as documented in Objective #2 above. Changes and improvements will improve performance and increase fish production capabilities. These changes are in the process of being written and included in the Construction Manual. Operations Manual - primary author is Co-Director, Craig M. Bell. Nearing completion, this manual includes the "how-to" for successfully operating an RAS system to raise tilapia. Currently in digital format, the manual will provide step-by-step instructions for daily backwash, routine maintenance, feeding protocol, water quality management and more. As an extra feature, videos are being produced to provide visual instruction, to support the written documentation. Users will not only be able to read about RAS operations, but they will be able to watch the actual tasks being performed. Business Manual - primary author is Traci S. Bell, PD. A draft copy of this manual is now complete and is currently in the editing process. Components include sections on aquaculture industry, products and services, marketing plan, management plan, operating plan, and financial plan. Digital templates have been developed to allow the user to prepare custom financial statements, for use by lenders and investors. Research for this manual includes facts and figures related to RAS, as well as diagrams and visual representations which can be duplicated in the preparation of an individual business plan. 6. Develop, implement and manage a Franchise Model A "franchise" type model is currently being explored, with the help of business development consultants from "Tech Growth Ohio" located on the campus of Ohio University in Athens, Ohio. An initial meeting took place in July, 2017 to introduce the concept and the people who will be involved in creating a franchise model. The next meeting, scheduled at the end of August, is intended to fine-tune the direction and future of the franchise model plan. Jane New, director of Tech Growth Ohio, is bringing experience and leadership to the table. The next 6 months will allow the model to take shape and solidify the ideas from the SBIR Phase II grant. Research assistance is being provided by graduate students at Ohio University thru Tech Growth Ohio to help understand markets for live fish and transportation regulations.
Publications
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Progress 09/01/15 to 08/31/16
Outputs
Target Audience:Target audience consists mainly of the agricultural community. The small farm/business has been reached through tours, presentations, Small Business Incubator events, industry networking and associations, and the Ohio State Extension office. Changes/Problems:
Nothing Reported
What opportunities for training and professional development has the project provided? December 14-16, 2016 - USDA Presentation and Training, Washington D.C. February 22-26, 2016 - World Aquaculture Society Conference and Presentation May 1-7, 2016 - Dr. James Ebeling visit and research How have the results been disseminated to communities of interest? July, 2015 Amish Women Bus, Tour August 31, 2015 - Muskingum County Farm to Table event October 8, 2015 - Day Break Rotary, Presentation January 21, 2016 - Shark Tub Event, Muskingum County Business Incubator May, 2016 - Genesis Hospital Volunteers Presentation, Zanesville June, 2016 - 4-H Club of Adamsville, Tour July 2016 - Fly Fishing Club of Newark, Tour What do you plan to do during the next reporting period to accomplish the goals? Continue experimenting with feed/growth rates, as they relate to oxygen and nitrification. Explore energy consumption options for better management and reduction of overall electrical demand. Install septic for waste water capture and explore bi-product utilization on a larger scale. Create manuals for future marketing of duplicate systems. Establish network of cooperative growers.
Impacts
What was accomplished under these goals?
1.Construct two additional raceways to further research engineering design questions related to the mixed cell raceway. September,2015- Raceway #3 - experimented with one, end-wall drain, as opposed to the original design of three side-wall drains, sending water to the sump.RESULTS: Side-wall drains tended to collect feed, preventing consumption by the fish. This problem was eliminated. Other advantages of end-wall drains include: Material costs are reduced by eliminating 50 ft. of pvc piping. Ease of installing "off the shelf" fittings versus creating custom made, plastic welded, square boxes. End-wall drains also eliminate the need to puncture the liner in multiple locations, helping to maintain the integrity of the liner. October, 2015- Raceway #3 operational. November, 2015- Raceway #1 and #2 were modified to incorporate the new end-wall design. Also, replaced custom-made bottom drains with commercially manufactured "Koi Toilets."RESULTS:Previous seepage was eliminated, creating a better seal in each of the three bottom drains. Also, made installation easier. January, 2016- Raceway #4 - design was again improved by using 2 x 6 boards, rather than 2x4's, thus providing significant strength to the structure, with a modest increase in cost. Also, the end-wall screen was replaced by a bulk-head fitting, which T's off to screened pipes.RESULTS:Less pvc pipe, smaller holes in the liner, ease of installation, with no restriction of flow. January, 2016- Raceway #4 operational. May, 2016- Raceway #4 - the Moving Bed Bio-Reactor (MBBR) was modified to increase the effectiveness of the nitrification process. Additional holes were added to the tubing inside the MBBR to increase the flow of oxygen within the tank.RESULTS:Oxygen improved, but not sufficient for our needs. June, 2016- Raceway #4 - MBBR was modified to add air stones directly to the bottom of the tank.RESULTS: Circulation of beads improved, as well as oxygen supply to the bacteria. However, the nitrification continued to struggle to keep up with feed rates, limiting overall system performance. July, 2016- Raceway #4 - MBBR was again modified, plumbing the inlet side of the tank to create agitation, allowing for more efficient nitrification conversion.RESULTS: Beads are circulating, feed rates are ramping up and no negative alarms have been noted thus far. Final conclusions are still to come. 2.Growout trials will be conducted on the raceways, a. Validate system performance in terms of growth rate, feed conversion, fish health and risk management.Growth rates have lagged, as densities and feed demand increase over the production period. According to Damon Seawright, PhD in Fisheries Science and President of Americulture, Inc. (the provider of our fry), the tilapia should grow to market ready size in 34-40 weeks. We are seeing growth rates of approximately 40 -48 weeks. Current oxygen needs are limiting our feed rates. This situation is being addressed by re-working the MBBR, as explained in goal #1 above. b. Water Quality:The limiting factor in water quality is Ammonia. Excess ammonia is toxic to the fish and is a result of high feeding levels that are not properly converted to non-toxic nitrates (the nitrification process), due to low levels of oxygen. To address this issue, automatic feeders have been installed, with the help of Dr. James Ebeling, to spread out the feed into smaller quantities, more often throughout the day. This has been found to minimize oxygen demand spikes, while pushing feed rates to more aggressive levels. The challenge is to determine the optimal feed quantities and time spans throughout the day. Through observation, we have learned that the fish do not eat when the building is dark. Overhead lights will likely be installed to extend daylight hours, particularly during winter months, for feeding purposes. System Hydraulics:SonTek Flow Tracker 2D Doppler Velocimeter was leased to characterize the water velocity profile in the raceways. Sampling proved to be very time consuming. Measurements were taken in a 0.5 m grid at the bottom of each cell. The data is still being processed by Dr. James Ebeling. First impressions indicate that more force toward the bottom of the tank would support more oxygen absorbed into the system, and contribute to the quest for more efficient growth rates. This can be pursued in the Down-leg Design Optimization. Down-leg Design Optimization:Using the data from the velocity profile in (c), above, it was determined that additional oxygen can be gained by increasing the number, total flow and discharge velocity at the bottom of the down-leg orifices. Options still to be explored include a Venturi Valve. In-Raceway Aeration:As part of the construction of raceways #3 &4, research was conducted on a self-made Speece cone. Installation involved a different plumbing scenario (bypass) which allowed oxygen to continue running through the system during the shut-down for daily backwash. In comparison, the oxygen shut down period during backwash dropped from 15 minutes, to only 7 minutes. Part of the success of this Speece cone has been determined to be its placement, 8 ft above ground. Side-wall Discharges:have been eliminated and replaced with end-wall drains, with less pocketing of feed, as well as ease of construction and maintenance. Selective Harvest:grader bars have been tested at three different sizes (2.00 in., 1.75 in, and 1.5") depending on the harvest desired. Research shows that the length of time allowed between setting the grader bar and harvesting tilapia plays a significant role in the success of the grading. Based on experience, the grader bar that is placed for a minimum of 8 hours (overnight) provides the best management practice for harvesting fish under low stress conditions. Monitoring and Back-ups Systems:YSI has been engaged in creating a "cloud" based data monitoring system specific for our indoor Recirculating Aquaculture System (RAS). Originally, the YSI 5400 was installed. However, a lightning storm seized the monitor, which was later replaced with a YSI 5500 system. The 5500 has been taken off 110v and is now powered by 12v, to add a layer of protection from power surges. 3. Monitor Energy Consumption and investigate options for better management and reduction of the overall electrical demand. Low BTU Gas Well- still to come Heat recovery technologies- still to come Energy efficient pumps- still to come Electrical Usage -The Energy Detective (TED) has been installed to monitor the power consumption of individual pumps and systems. Data is currently being collected to be analyzed in the near future. 4. Bi-Product Utilization:Experiments have been made to determine the most effective form of fertilizer (liquid or powder) in terms of additional labor and packaging involved. Liquid/concentrate form is simple to capture, but requires "de-gassing" for proper storage. Shelf-life is limited and odor is strong. As a fertilizer, the liquid concentrate is very effective and is likely most marketable in large quanties for agricultural use. Trials were made to dehydrate the solids waste into a powder form. Large 4' x 6' screens were constructed to dry the collected waste in the open air and sunlight. Although this made improved the packaging issues, the labor involved to dry the waste was fairly excessive. This form is most likely marketable in small quantities to gardeners. ?5. Create set of Manuals Still to come 6. Develop, implement and manage a Franchise Model Still to come
Publications
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