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January 2001
Summary
A detailed investigation into water usage and wastewater generation
at Tony's Tuna International, which produces sashimi tuna primarily
for the Japanese market, identified possible improvements in both
quality and quantity, particularly in the washdown and pilchard
thawing areas. As a result of this consultancy and changes in
its practices the company has reduced annual water usage significantly
and saved $24,874 in 2000 on pilchard thawing alone.
Business Profile
Tony's Tuna International (TTI) is a major tuna processing
company based in Port Lincoln that produces sashimi tuna primarily
for the Japanese market. It is one of the most modern tuna processing
plants operating in Port Lincoln, having undergone major upgrades
in the past five years. The tuna industry currently dominates
aquaculture in South Australia and has an economic value of over
$500 million.
Financial assistance provided
Flinders University of South Australia carried out the
consultancy with a grant of $15,000 from the SA EPA and funding
through the Coast and Clean Seas scheme. The consultancy covered
eight major processing facilities in Port Lincoln.
Technology implemented
A detailed investigation of water usage and wastewater
generation (both quality and quantity) identified areas where
major savings could be made, particularly in washdown and pilchard
thawing. An investigation into the optimum regime for temperature
exchange during pilchard thawing showed that significant savings
could be made by changing the water inlet to the base of the thaw-out
bins and by pulsing water exchange via solenoid valves. Australian
Quarantine Inspection Service requirements are maintained through
the use of backflow prevention valves on the main inlet pipe.
Cleaner production motivators
Waste minimisation was considered important for continuing
economic operation of the facility, and the Coast and Clean Seas
project was an important driver for the study.
Traditional approach
During the period March 1999 to March 2000, TTI used 26,877 kL
of mains water, mostly for pilchard thaw-out. The traditional
approach to pilchard thawing was to defrost pilchards using cold
water in open tanks with water running continuously. This approach
was inefficient and required more than 12 kilolitres of water
per tonne of pilchards. Traditional washdown practices also used
water inefficiently and wastefully.
Cleaner production initiatives
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| Pilchard thaw-out |
Benefits recommended and implemented
Pilchard thaw-out process improvement
The process used for pilchard thaw-out was improved significantly
and water usage has decreased from more than 12 kilolitres to
approximately 3.73—5.6 kilolitres per tonne, depending on
mains water temperature, with no increase in processing time.
Monitoring
A thorough review of all on-site water usage and wastewater generation
was instigated in the program, identifying opportunities for minimisation.
Use of water for sashimi tuna processing is low, but possible
additional savings during washdown have been identified and further
changes in operational procedures should save more water and improve
ongoing waste treatment charges in the future. The activities
identified for continuing savings in water usage include cleaning
freezer rooms, harvest bins, pilchard thaw bins, vehicles and
net cleaning. Hosing down after scrubbing with cleaning agents
is now done through flow regulated nozzles.
Benefits
| Environmental |
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| Water usage |
- A reduction from >12 kL to 3.37—5.6 kL/t
in water for the thawing of pilchards.
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| Waste reduction |
- Reductions in nutrient load in wastewater will have
significant benefits for the re-use of wastewater treatment
plant effluent being implemented in the Coast and Clean
Seas initiative.
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| Economic |
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| Productivity |
- Productivity and cost efficiency have increased significantly
as a result of changes implemented.
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| Water usage costs |
- Water usage has decreased, resulting in direct savings
in excess of $24,000 per annum for pilchard thawing alone.
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| Future waste treatment costs |
- Future trade waste discharge fees to sewer will be based
on both volume and strength; savings in charges through
waste minimisation, separation of high nutrient streams,
use of screens etc. will result in significant future
savings.
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| Payback period |
- Costs associated with the new pilchard thawing system
are low, totalling <$ 1000 for new piping, solenoid valves,
bin adaptations.
- Payback period for measures aimed directly at waste
minimisation is estimated to be less than one month.
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Where to find additional information
Eco-efficiency Team
Environment Protection Authority
GPO Box 2607
Adelaide SA 5001
Phone: (+61 8) 8204 2004
www.epa.sa.gov.au
Mr Trampas Culter
Plant Manager
Tony's Tuna International
Pine Freezer Road
Port Lincoln SA 5606
Phone: (+61 8) 8682 2266
This page was last modified 14-08-2007
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