Re-designing Blue Archipelago Berhad Intensive Shrimp Farm in

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RE-DESIGING BLUE ARCHIPELAGO INTENSIVE SHRIMP FARM
IN MALAYSIA
BIOSECURE MODULE SYSTEM COMBINED WITH BIOFLOC TECHNOLOGY
Nyan Taw*, Poh Yong Thong, Ling Teck Ming, Chatree Tanabatra, Kamel Zikry Sallah
& Mohd Afiq Md Razi
Blue Archipelago BHD
www.bluearchipelago.com
June 6 -10, 2011
NATAL CONVENTION CENTER
NATAL, BRAZIL
BACKGROUND
Shrimp (L. vannamei) farming has become competitive and as such technology starting from
biosecure farm design and operation system utilized is essential for sustainable production. This has
been proven by re-engineering from pond base culture to module base biosecure system at a large
shrimp farm in Indonesia (Nyan Taw et.al., 2007). The basic concept of biofloc technology was
provided by Avnimelech (2000, 2005a&b). The system was successfully applied in commercial
culture of shrimps by McIntosh (2000a, b & c, 2001), McNeil (2000), Nyan Taw (2004, 2005, 2008
& 2010). Smith et al (2007) successfully used biofloc technology on Penaeus monodon in earthen
ponds in Australia. Shrimp farm biosecurity was given by Nyan Taw (2010). Successful redesigning
and production using biosecurity and biofloc technology was also provided very recently by Nyan
Taw (2011).
Blue Archipelago intensive shrimp farm, Arca Biru SDN, is located at Kedah, northwest of Kuala
Lumpur. The farm was established in early 1990s for Penaeus monodon culture. However, the farm
was faced with serious viral (WSSV) outbreaks. In early 2010, the farm was re-designed from pond
base to biosecure module base system including two modules lined with HDPE. For the remaining
modules, only pond dikes were lined. The farm was operated with minimum water exchange, semibiofloc and biofloc technology. The main objective of the cycle was to have a bench-mark for future
production cycles as such a number of commercial trials were tried.
Arca Biru (BAB) Shrimp Farm, Malaysia
Seawater source 2.4 KM
Farm Location West Malaysia
1999
Module Base system
THE CHANGES
CPB Lampung
Modules Earthen & HDPE
lined ponds (0.5ha).
Recirculation system
Nyan Taw WAS 2005 Bali Farmer session
Nyan Taw, Shrimp Farm Indo GAA 2005
Module Base system
Dipasena WM
2000
Pond Base in rows
2006
1995
Nyan Taw et al Reengineering
Dipasena GAA 2008
Dipasena
Pond base in rows changed to
Module base operation system in
2006 – reservoirs and culture ponds
NT Dec09
Before Re-designing – Module ? Biosecurity ?
Bird scare lines
Reservoir pond
Reservoir pond
Not used
Reservoir pond
Reservoir pond
Fish
Dead WSSV shrimps
after harvest – not
removed
Crabs
SI Canal –cannot dry
Out let leaks
Sludge center pond –
not removed
Nets – 1000 micron
Sub Inlet gate - leaks
Crab fence – not
maintainted
Nets – 1000 micron
Nets – 1000 micron ?
Out let gates - Leaks
Black sludge now
removing
BIOSECURITY
What we are protecting from ?
Basic WSSV Characters
1. Mass mortality: DOC <45 days
2. Temperature >30 less prone; <29 more prone; <26 dangerous.
3. Onset of heavy rain (season) with low temperature trigger outbreaks.
Seasonal occurrence is well document.
4. Virus dies in free water in 72 hours
5. Crustacean are carrier (crabs) – lives with virus.
6. Virus lives in freshly dead, indefinitely in fresh processed frozen condition
7. Virus can live and a very few can survive after mass mortality
8. No evident of wind carrying WSSV from pond to pond
9. Bacteria white patch (spots) on carapace can be mistaken as WSSV spots.
Arca Biru SDN BHD - Layout
2 Module HDPE + 6.5 Module HDPE At Dyke + 0.5 Module LDPE At Dyke – 9 modules
Operated only 1 Module HDPE + 6 Modules HDPE at Dike – 7 modules
Bio-secure Module system – Arca Biru
Arca Biru, Malaysia
Biosecure module - after re-designed
Biosecurity – crab fence & bird scare lines
HDPE lined ponds with center drain, secured outlet gates & Main supply canal
Pond out let gate
Sub inlet
250 & 1000 micron screen net
HDPE Lined secondary supply canal
Module Biosecurity – Water treatment system
(Control WSSV)
Physical barrier for viral
carriers – use 250 micron
screen net
Treatment
Reservoirs ponds
Chemical application
– kill viral carriers.
Apply crusticides
Culture ponds
Kill free water bore
virus (aging) - dies in
72 hrs without host
Treated water ready for
use for culture (apply
same procedure)
Module Base Close Water System
Basic (SOP) Procedure for Biosecurity (Summary)
Parameters
Closed Water
Semi Closed Water
Open Water
Fill in Water
Treatment (unit 1 & 2)
and Culture ponds (Max.
level > 120 cm)
1 - 45
All ponds/
Crustacide 0.5 – 1.0 ppm
Chlorine 25-50 ppm
Yes - approximately 5–
10 days
All ponds minimum 3
(72 hours) days
Yes – at all critical
points: Main inlet,
between TP units TP &
Main TP or Supply
canal. TP & CP
No
Within module only
Started fill in to Treatment
(unit 1 & 2) and Culture ponds
(optimum level >100 cm)
46 – 90
Chlorine 25-50 ppm
or whenever possible
Started fill in to Treatment
(unit 1 & 2 and Culture ponds
(Max level > 120 cm).
91 - harvest
Chlorine if possible
Yes – approximately 5-10
days
Minimum 3 days (72 hrs)
Check if required
Yes – at all critical points:
Main inlet, between TP units;
TP & Main TP or Supply
canal. TP & CP
Yes – at all critical points:
Main inlet, between TP units;
TP & Main TP or Supply
canal. TP & CP
Minimum (topping up only)
Start open to outside
Maximum
Open to outside
DOC (Day of Culture)
Apply
Crustacide/chlorine
To Kill WSSV Carrier
Bio assay
Check toxicity
Aging water
To Kill WSSV in water
Screening: 250 – 300
micron. Prevent carrier
entering module
Water exchange
Water source
Minimum 3 days (72 hrs)
Basic of BFT in Shrimp Farming
1.
2.
3.
4.
5.
6.
7
8.
9.
High stocking density - over 130 – 150 PL10/m2
High aeration – 28 to 32 HP/ha PWAs
Paddle wheel position in ponds
HDPE / Concrete lined ponds
Grain (pellet)
Molasses
C&N ratio >15
Biofloc controled at <15 ml/L
Expected production 20–25 MT/ha/crop
200
100
0
1
3
5
7
9
11 13
15
17
19
21
23
Feed & grain application and biofloc
High aeration
High density
Biofloc
Grain pellet
Bioflocs
Dark Vannamei
Red Vannamei
Environment AB Summary
Salinity, Alkalinity (x10 ppm),
Temp (am), Temp (pm)
pH (am), pH (pm), Nitrite, TAN,
DO (am), DO (pm)
9
35
8
30
7
25
6
20
5
4
15
3
10
2
5
1
0
0
May
June
July
August
September
October
November
pH (am)
pH (pm)
Nitrite
TAN
Salinity
Alkalinity (x10 ppm)
DO (am)
DO (pm)
°C (am)
°C (pm)
December
Arca Biru (BAB) farm performance
Arca Biru Performance
20
(HDPE Full and Dyke Lined Pond)
Growth
15
21.89
Metric ton (MT/Ha)
25.00
20.00
16.19
12.09
12.05
10
5
15.00
10.00
0
40
5.00
-
Grams
DoC
Dyke 0.4 ha Dyke 0.8 ha Full 0.4 ha
50
Density 80 (Dike)
60
70
Density 110 (Full)
80
90
100
110
Density 130 Biofloc
Full 0.8 ha
PRODUCTION PERFORMANCE OF ARCA BIRU FARM
Production Parameter
No of Ponds
PWA Energy (Hp)
Stocking Density
DOC (days)
SR (%)
MBW (gr)
FCR (x)
ADG (gr/day)
Avg Harvest tonnage (kg)
Production (Kg/Ha)
Prod per power input (Kg/Hp)
System/size/type
Biofloc 0.4 ha HDPE Semi-Biofloc 0.8 ha HDPE Conven 0.8 ha HDPE Dyke
2
19
119
14
24
20
130
110
83
90
101
111
89.16
81.35
83.19
18.78
18.31
17.80
1.39
1.58
1.77
0.21
0.18
0.16
9,006
12,950
9,616
22,514
16,188
12,019
643
540
481
Nyan Taw, et.al. GAA March/April
2011
Arca Biru (BAB) Production Performance by Tonnage (1.0 Ha)
45
39
40
35
32
No of Ponds
30
25
21
20
19
20
17
16
15
18
18
18
18
18
19
19
19
20
19
16
14
15
10
5
0
0
1-2
2-3
3-4
4-5
5-6
6-7
7-8
8-9
Total pond
0
1
1
3
3
0
3
5
10
9
7
10
16
17
26
20
3
3
4
3
1
0
0
0
0
1
Full lining
0
0
0
0
0
0
0
0
0
0
1
1
2
0
3
3
2
0
4
3
1
0
0
0
0
1
Dyke lining
0
1
1
3
3
0
3
5
10
9
6
9
14
17
23
17
1
3
0
0
0
0
0
0
0
MBW
38.76 32.10 13.63 20.30
9-10 10-11 11-12 12-13 13-14 14-15 15-16 16-17 17-18 18-19 19-20 20-21 21-22 22-23 23-24 24-25 25-26
20.65 19.08 15.81 15.18 16.01 17.36 17.62 17.92 18.05 18.07 17.68 18.72 18.62 19.07 18.59
Tonnage range
0
20.00
Biofloc in shrimp farming
50,000
45,000
40,000
35,000
30,000
25,000
20,000
15,000
10,000
5,000
Kg
0
Belize, C
America 2000
Lampung Indo
2003-05
Medan, Indo
2008
Commercial Kg/ha
Java, Indo
2008
N Bali, Indo
2009
Max Record Kg/ha
BAB Malaysia
2010
BAB Malaysia
2010 Trial
Nyan Taw Shrimp farming Indonesia GAA Aug/Sep 2005
Acknowledgements
The authors would like to sincerely thank Mr. Abu Bakar Ibrahim
(CEO), Dr. Shahridan Faiez (former CEO) and Mr. Christopher Lim
(COO), Blue Archipelago for their interest and support .
The staff and members of Blue Archipelago, Malaysia for their diligence
and hard work to make this work possible specially engineers Mr.
Noorazam Ismail and Mr. Sukirno.
Thank You
Nyan Taw and Team
7 June 2011
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