Specific Hatchery Background

20 ... Treeeearrd Foz

Specific Hatchery Background

The following abstract appeared in the Journal of theWorld Aquaculture Society, Aquaculture Communiques Volume 18, Number 1, page 20A, Cornrnuniquc number72, 1987!.

72. The Establishment of a Successful Penaerrs

monodorr Hatchery in Jepara, Java.TREECE, GRANVlL D., Texas Marine Ad-

visory Service, Texas A&M University SeaGrant College Program, CollegeStation, Texas77843; FOX, JOE M., Central Java EnterpriseDevelopment Project, Gedung BAPPEDA, Jl.Pemuda 127, Scrnarang, Indonesia,

A short-term technical assistance and in for-

mation transfer subcontractbetween Develop-rncnt Alternatives, Inc., Washington, D.C., theUnited States Agency for International Devel-opment, the Central Java Enterprise Develop-ment Project and the Texas Agricultural Exten-sion Service-Sea Grant Advisory Program re-sulted in the establishment of a successful

Perraeus moitodori hatchery in Jepara, Java. Theha tchcry is now opera ting as a "model" train-ing facility for the country and is also produc-ing an average of one million nauplii per daywith only two maturation tanks in use,

Shortly after construction of the state-of-the-art hatchery was completed, an intensivetechnical information transfer was initiated.

Broodstock was purchased from local fisher-rnen, female shrimp were ablated and produc-tion began in less than onc week. Twenty rnil-lion nauplii were produced in the first 15 daysand some of thebroodstock had spawned threetimes in two weeks. After a production strat-egy was initiated, which took into consider-ation the hatchery's larval production needs,and a continuous scheme of production wasestablished, the hatchery staff members weretrained using techniques to sustain produc-tion. Three training sessions were conductedwith neighboring ha tcheries invited. Hatcheryprocedures were incorporated into a trainingprogram for future trainces by documentingactivities specifically needed at that hatchery.The procedures were compiled into a training-operating manual, which can be used as aguide or tool in future training programs.

The successful establishment of this model

hatchery should go a long way in assisting thedevelopment of a private sectorhatcherycapa-bility in Java, using both formal and informaltechnology transfer methods.

The following two paragraphs are from the May 16,1988, report of Development Alternatives, Inc,, YayasanDian Desa, and the Central Java Enterprise DevelopmentProject.

Indonesian Hatchery Development Program

In Bandengan Jepara, there are two hatch-ery units referred to as Unit I and Unit II. UnitI is a model hatchery whose construction waspartially funded by USAID and which hasreceived most of the CJEDP program supportfor hatchery development. Unit II is also oper-ated by Yayasan Dian Desa YDD! and wasbuilt without USAID support, based on thedesign of Unit I. YDD thereby doubled itsoperational capacity and also doubled its fa-cilities dedicated to the research and develop-ment of appropria te hatchery technology

In general, both Unit I and Unit II have beenperforming as expected during the past quar-ter. Unit I was res ta rted a fter being ternpor a rilyshut down for cleaning, If the water qualityholds into next quarter, it is hoped that thehatchery will achieve a combined output of 4million postlarvae per month.

Unit I was constructed in 1986 by Yayasan Dian Desafor approximately $90,000 U.S.!, and had aii estimatedproduction capacity of 3 million postlarvae per morith.The hatchery is located on the island of Java in the Repub-lic of Indonesia scc Figure 1!, A recent NASA satellitesurvey has shown that Indonesia, also referred to as TheEast Indies, Malay Archipelago or The Spice Islands, ismade up of nearly 20,000 tropical isles instead of the 13,677isles which it was once thought to have. In the words ofone writer, these isles "gird the Equator like a string ofemeralds," and they comprise the most extraordinarycollection of places, peoples, sights, tastes and naturalwonders on earth, The model hatchery project of YayasanDian Desa is more specifically located on the north shoreof Java near Bandengan Jepara see Figure 2!.

The basic layout and design of the hatchery was rnod-eled after the "ladder system" described by Liao �984!,taking advantage of water levels and gravity. Even with"state-of-the-art" design, and a good location, successdepends on good management practices. Management isthe key to a successful hatchery opera tion, and it should bestressed that each hatchery will have its own proceduresfor optimum production.

Figures 3 through 20 give details of the hatchery, itsseawater system, tanks and production areas, as well astanks and systems used in other hatcheries.

Central American Facility Hatchery Example!Figures 20A through 20M depict a Central American

hatchery that was designed to produce 10 <nil!ion P.varrnarrrei postlarvac pcr month.

There are many similarities between this hatcherydesign and the Indonesian one Figures 1-20!. The presentday �991! costs are given in Chapter 9, and represent halfthe costs of a fancier hatchery in Ecuador, which is alsodesigned to produce 10 million PLs per month, Thc!ndo-nesian hatchery, on the other hand, was built for half thecost of the Central American hatchery approximately$90,0�.00 V.S.!.

Design, Operation and Training ... 2 !

Figure 1. Location of Java

22 ... Treece and Fox

Figure 2. Location of Hatchery on Java

Photo 4. Bamboo fishing platforms offshore ' nets are lowered at nightwith light above to attract catch!.

Photo 6. Fishing vi! lage located next to hatch-J-

Photo 5, Palm leaf barrier " pound net" ar-rangement! with fisherman's platform at endwhere net is raised.

Photo 7. Proud fishermen who bring in broodstock shrimpwhen yellow flag is flying an hatchery is i n need of new stock.

Figure 3 I3ian Desa Hatchery

Photo 8. Dian Desa Hatchery front entrance..

Photo 10. Maturation room Unit ll!, lower left, generation or build-ing, center; seawater settling, lower right,

Desig~, OPeration and Training ... 23

Photo 9. Dian Desa Hatchery side view.

24 ... Treecz and Fax Figure 4. FrOnt and Side View with ElevatianSFigure 5 Front and Sack View with Elevation

SeawaterPumps e

stionGan-set

AlgaePumpnous*

Lab,FoodPrep

OverllowAlgae

SettlingPond�00m't

StorageSlaw SandF II ter�00m t

Outdoor A gee Area

Malurstion Tank undinetPrima rp

Reservoir D re i riag I uottenElevated Reservoir�0 ml Standpipe Re<>roc sting

pump,uV SteniikeliOn

Dial o ma cecalsaris litters

Functional Areas within the Hatchery

System/AreaAlgae Culture

Figures 9 and 11!

Algae Laboratory Figures 9 and 10!

Artemia Culture

Figure 8!

Larval Rearing Figures 16-19!

Postlarval Rearing Figures 14 and 20!

Harvesting

Aeration

Photos11 and 12!Seawater

Figures 7a and 7b!Electrical

Photo 3!

Maturation

Figures 12, 13 and 15!

Figure 6. Hatchery Overview with Detail

DescriptionProvides feed algae! to the larval rearingtanks LRTs!. Shrimp larvae consume algaein their early stages.Serves as a multi-purpose room For cultureof small volumes of algae; counting; micro-scopic work; storage and weighing ofchemicals, Artemia, artificial diets; washingof glassware.Provides Arternia nauplii for feeding to lar-vae in the LRTs. Shrimp larvae consumeArterrtia in their latter stages,!Contains elevated conical tanks used forthe culture of larvae. Postlarvae from hereare transferred to postlarval rearing tanksor "raceways."

Contains shallow cylindrical tanks used forproduction of postlarvae. From here PL 18stage shrimp are transferred to growoutponds.Contains tanks used for maturing maleand feinale shrimp so that they will matein captivity. Mated females are transferredinto spawning tanks where they releasefertilized eggs spawn!. These eggs areallowed to hatch and the nauplii trans-ferred to the LRTs.Designed for harvesting postlarvac beingtransferred to pond for grow-out.Used to provide air to the various produc-tion areas.Provides filtered seawater to all productionareas.

Provides electricity for operatio~ of pumps,air blowers, light banks, room lighting andair conditioning.

Design, Operation and Training ... 25

Photo 11 Air blower for Llnit l Hatchery highvolume low pressure!, later moved inside.

Photo 12. Close up of air blower and filteredin take.

26 .�Treece arrd Fox

Photo 13. Two Schedule 80 3-inch PVC intakePipelines one intake in shallow water aruf onein deeper water!,

Seawater Pump

M alu rat i 0 n

PumpPressurized Sand Filter

Figure 7a. Original Seawater SystemCart ridge Filter

Photo 15. Seawater pumps work on a demarul system and use isrotated only one runs at a time!,

Sub SandFilter

I

+ � Concrete Anchor

DiatomFilter

Photo 14. Concrete holds intake Pipes in place, visible at tow tide.

~Algae Production andLarval Rearing

Photo16. "Home-made" sand filter used in1986,which werereplaced by slow sand filWs in 1987 Photo 29!.

Photo 18, Primary Reservoir: Note organic matter floating andfinished product iclear wafer!.

SettlingTank

S ow SandFilter

To Algae~ Predudtien

and LarvalRearing

Pu

1 gym Cartridge Filter 1ym Cartridge Filter

Depth Cartridges

Figure 7b. Fina Seawater System

Photo 77. Cement settling tank and cement slow sarrd fili'ers,primary reservoirs and overflows,

~ Seawater Line/

..:=:=-=-T': �. -- - 3 � �-+I

~-- Concrete AnchorSub SandFilter



Photo 19. Close up of primary, settling, slowsand and clean water in overflow.

Photo 27. Unit I, outside postlarval holding and rearing tanks,elevated reservoir.

Photo 20. Elevated reservoir �0 MT! acts as aconstant head device for Unit I and Unit II U.V. treafment fakes place in head device res-ervoir and pumps, and D,E.filters are housed instructure below elevated reservoir!.

Photo22. Diatomaceous earth filfers housedinside elevated reservoirstrucfure.

1J 1. ITable Side

Table Tcp

Figure 8 Arremi* PrOduCtian Area

'i jjIjj~, '!<I. -,,l jj'j i ffjll tII jill' '. j,Jil

300 Liter Poly Tank Al gee Culture!

Photo 23. Algae production in 300-liter fiberglass tanks,

LrFlourescent Lights

�, --, ri

Arrerrria cysts placed inbottles containing seawater

with aeration

Figure 9. Laboratory and Algae Production in Fiberglass Polytanks

Design, Operation and Traint'ng ... 29

ji j�l


Figure 10 Laboratory Work Bench

Aeraticn via PVC& plastic tubing

Figure t t Carboy Stand tor Algae Production

Floureaoent Lightslocated behind .

bottles

5 gallon clear plastic bottlesfor algae culture

IiPhoto 24. Algae production in 29-liter, or 5-gallon, cfear plastic bottles these are safer tohandleand transport than theglass but aremoredifft'cult to clrMn!.

Main Seawater SystemlF iltered Water!Filtration

System

~ Drain ..SupplementarySea Water

~ Drain

Drain DrainDrain

Alternative 2 Recirculating System

ead

Figure 12. Varicus Maturation Systems not drawn to scale!

,a -Valve

Figure 13 Maturation Tank Detai400

~erro Cement5

/90

20 40tini!P 6,

55+

02

40

' <By

Bi = Drain

<i

Sea WaterPump

Alternative 1: Open. Warm/Coo Climate

W>Float Vat~ve Sea Water Puinp

Alternative 3: Open, Warm Climate

! tst Slope tOCenter Drain

Design, Operation and Training . 31


� WateHarvester

ECO

Top View

Figure 14. TypiCa Aaceway Design postlareae!

40 45 5fi

". FerroCement

Photo 25. Rectangular larval rearing and postlarval rearingand holding tanks in use at nearby hatchery.400

CcP

Air Manifold

pc.

Figure 15. Spawning Tank Detail

120 5 50 5 120 5 45 40ii 1

! = Drain


DiatomFitter

ldw Saltdliter

sett llntfTank

da Sandliter

Ocean!

Larval Rearing Approach 1 bate i feeding!

L ~ 'pppupmumrpl ~P mp

Lmp ~puemprprprppur p

Photo 26. Hatchery effluent flow returning toocean udownstrearnu of intake.

34 ... Treece arid Foz

ipe DrainAeration Line

Flex bi

Half-Barrel ShapeCylindro-Conical

tand Pipe Drain

At atoneGentle Slope

Square or RectangularLarval Raceway

Figure 1 tt. Various Larval Rearing Tanks

Figure 19, Larval Rearing Tank Detail

200 5 �5 40,40 45 5

Ferro Cement

30

02"�

55'

QA! = Drain400

Design, Operation and Training �, 35

Figure 20. Raceway Tank Detail

$ ilS'

QD = Drain

Figure 20A

CENTRAL AMERICAN HATCHERY FACILITY

36 �. Treece and Fox

Figure 20B

CONCEPTUAL DRAWING OF SEAWATER INTAKECENTRAL AMERICAN FACILITY

Figure 20CCENTRAL AMERICAN

HATCHERY FOUNDATION /LEVELS


Figure 20D

CENTRAL AMERICAN HATCHERY

ROOMS AND DIMENSIONING

�0 Million PL/Mo. Production!

Figure 20E

CENTRAL AMERICAN HATCHERY TANKS/LOCATION

38 �. Treece and Fox

FOR GROWOUT PONOS FOR HATCHERY

SEAWATERSOURCE

SC REENE D INTA KE FILTER

~6000 GPIV! AXIAL PUMP

2,500 MT RESEVOIR

E LEVA T E D!

+SAND FILTERSHEADER MATVRATIGN II

CYCLONIC SEPARATORSCYCLONE HYDRAULIC FLOWMETER

200 GPM CENTRIFUGAL PUMPS

WIER

Figure 20F

CONCEPTUAL DRAWING OF CENTRAL AMERICANHATCHERY SEAWATER TREATMENT

Figure 2QG

CENTRAL AMERICAN HATCHERY SEAWATER

ELEVATED HEADER DISTRIBUTION SYSTEM

$ SCREENED INTAKE FILTERSPONOS 6,000 GPM AXIAL PUMP

UV STERILIZERPALL FILTERS ~ 12.0 IvIT

CONTACT PUMPSMATV PATIO N I

QVARINTINE, SPAWNING, MAT LABLARYICVLTVFIE. ALGAE LAB


Figure 20H

CENTRAL AMERICAN HATCHERY

MATURATION FACILITY SEAWATER DISTRIBUTION

Figure 201

CENTRAL AMERICAN HATCHERY BLOWER AERATION SYSTEM


Figure 2OJ

CENTRAL AMERICAN MATURATION FACILITYAERATION DISTRIBUTION SYSTEM

Figure 20K

CENTRAL AMERICAN HATCHERY DRAINAGE SYSTEM


Figure 20LCENTRAL AMERICAN FACILITY

MATURATION TANK DESIGN

Figure 20M

C ENTRAL AMERICANHATC HE RY LARVA L R EA R IN G TANK

42 �, Treece and Fox

Appendices A through C give water analysis results for a potential hatchery site in South Texas in July 1990. Appendix D, excerptedfrom the Safe Drinking Water Act of 1986, gives drinking water maximum-contaminant levels for metals and should be used forcorn pa ra tive purposes only. Appendix E gives seawater parameters for comparative purposes. Appendix F gives primary componentsof seawater Riley and Chester, 1971!, Appendix G gives values for concentrations of trace elements in seawater Quimby-Hunt andTurektan, 1983!, Appendix H presents elements in seawater Spotte, 1970!, and Appendix I gives examples of pesticide tevets toxic topenacid shrimp.

ysis Results for an Existingn South Texas Jul 1990!.

App

Sam

Param

SilverBariuCadmChromArsenSelenLeadMercu

CoppeTinZincBoronU-Uudgiven

Samp

Appendix D. DrinkingwaterMaxilnulnContaminanLevels for Metals to be used focorn aritive osesonl !

Concentration Found! PPB parts per billion!

Benzene 0,01 UToluene 0.01 UEthyl Benzene 0.01 UXylenes 0.02 UU-Undetected, indicating not found above detection limitgiven.Sample ID; Low Tide Intake Site!

Concentration FoundColnpound pg/L! PPBBenzene 0.01 UToluene 0.01 UEthyl Benzene 0.01 UXylenes 0.02 UU-Undetected, indicahng not f ound above detection limitgiven.Sample ID: High Tide Intake Site!

Concentration FoundCompound !tg/L! PPBBenzene 0.01 UToluene 0.01 UEthyl Benzene 0,01 UXylenes 0.02 UU-Undetected, indicating not found above detection limitgiven,

Maxilnum ContaminantNonchlorinated Water Level"

Primary Standards p.g/L or PPMArsenic AS! 0.05Barium Ba! 1.0Cadrniurn Cd! 0.010Chrorniurn Cr! 0.05Lead Pb! 0.05Mercury Hg! 0.002Nitrate N! 10.0Nitrate NO3! 45.0Selenium se! 0.01Silver Ag! 0.05Copper Cu! 1.0Iron Fe! 0.3Manganese Mn! 0.05

Zn! 5.0

rpt from Safe Drinking Water Act of 1986levels adopted at 0,005 ppm �990!

Detection limits for Arsenic in two samples are differ-e to sample matrix effect.

Parameter Mg/L! PPM parts per million! ISilver 0.05 UBarium 1.0 UCadmium 0.01 UChromium 0.05 UArsenic 0.3 USelenium 0.16 ULead 0.566Mercury 0.0002 UCopper 0.009 UTln 2.25 UZinc 0.075 UBoron 3.75

U-Undetected, indicating not found above detection limitgiven.

Sample ID: High Tide Potential Intake Site!Concentration

Paralneter Mg/L! PPM parts per million!Silver 0.270 � Standard

0.0003 Mg/LBarium 1.0 UCadmium 0.01 UChromium 0.050 UArsenic 0.12 USelenium 0.16 ULead 0.452 � Standard

0.004 Mg/LMercury 0.0002 UCopper 0,09 UTln 2.25 UZinc 0.075 UBoron 3.70

U-Undetected, indicating not found above detection limitgiven.


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Design, Operation arai Training �. 45

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Design, Operation and Training ...47

or Concentra tions of Selectedevents in Seawater a t S alintiyt with Standardized Nutrient

Reference'

ki an �983!�979!; B, Landing and Bruland1982!; D. Knauer et al., �982! E.s and Burton �980!; G. Mukherjiule and Patterson �98'I!

ncentr ation

ngfkg!330

10

40

2

480

120390

170

70

61

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C D E E E F EG H


I DDT; Diazinon

Appendix J. Example of soil investigations at twopotentiai hatchery sites in Indonesia. These soil analyses wereconducted by a reputable laboratory and excerpts of the results can be seen in this appendix.

Soil Physical SamplingSoil sampling for physical tests was taken on the excavation hole at the depth of 0.5 m and 1.0 m through a 150 mm

thinw all and treated as undisturbed sample.The thinwall was put in a plastic can and sealed by a plastic band so the moisture content was kept constant.The crust soil at site 1 showed a layer of soft silty clay with a trace of shell. The ground water level ranged between

0.7- 0.9 m below the surface.

At site 2 the crust soil was a very soft silty clay with a trace of shell and inundated with water.The results of the soil laboratory tests could be summarized as follows:

Physical Characteristics Site 1 Site 2

Natural M.C. %! 40.00-54.00 54,30-65,9Specific gravity 2.52 -2.57 2.50-2.53Bulk density gr/cm3! 1.57-1.75 1.46-1.59Natural void ratio 1.06-1.47 1.46-1.84

Degree of saturation 92.50-97,70 89.50-94.20Liquid limit %! 98.70-101.70 102.5-105.0

. Plastic limit %! 37.80-41.50 40.0-41,5

~ Plasticity index %! 59.0-61.7 62.5-64.1Passing sieve ¹200 %! 97.0-99.0 94.0-99.0Cohesion kg/cm ! 0.27 0.06

�,1 ppb4.8 ppb

2 ppb8.0 ppb0 ppb5 ppb9 ppb11 ppb

4,0 ppb0.0 ng/l0 ppb2ppb0 ppb0 ppb1974; B. Coctal.,19IVI. Lowe

28 days96 hr.96 hr.96 hr.48 hr.48 hr.96 hr.

96 hr,48 hr,24 hr.

7 days48 hr.96 hr.96 hr.

mortality50% mortalitylow growth50% mortality50% mortality50% mortality50% mortality50% mortalitymortality50% mortality25% mortalitymortality25% mortaility25% mortality

P. duorarum F

Mysidopsi bahia GMysidopsi bahia GP. aztecus GP. aztecus PLs HP. aztecus adult HP. aztecus lP, durorarum

penaeids KP. stylirostris nauplii LP. duorarum M,N,OP. duorarum K

Crangon septimspinosa PPalaemonetes vulgaris P

Selected Ref erences

13. Quimby-Hunt, M,S. and K.K. Turekian. 1983. Distribu-

14

15

16

17

18

19

20. Treece, G.D. and J.M. Fox. 1987. The establishment of

l.

2.

3,

4.

5.

6.

7,

8.

9.

10

11

12

Bruland, K.W. 1980. Oceanographic distributions ofcadmium, zinc, nickel and copper in the north Pacific.Earth Planet. Sci. Lett. 47: 176-198.Cranston, R,E. 1979. Chromium species in naturalwaters. Ph.D. d issertation, University of Washington,Seattle, Wash., U.S.A.Cruz, C.R. 1983. Fishpond Engineering: a technicalmanual for small and medium scale coastal fishfarms in S,E. Asia. South China Seas Fisheries Dev.

and Coordinating Program, manual No, 5,, S.C.S.,Manila, Philippines.For st ner, U. and G.T.W. Wittmann. 1979. Metal pollu-tion in the aquatic environment. Springer-Verlag,Berlin, Germany.Fujirnura, T. 1989. Mangement of a Shrimp Farzn inMalaysia. InProceedings of the Southeast AsiaShrimp Farm Management Workshop. Ed. DeanAkiyama, American Soybean Assn., pp. 22-41.Grasshoff, K�M. Ehrhardt and K. Kremling. 1983.Methods of seawater analysis. Verlag Chernie,Weinheim, Federal Republic of Germany.Knauer, G.A., J.H. Martin and R.M. Gordon. 1982.Iron in northeast Pacific waters. Nature. 297: 49-51.Landing, W.M. and K.W. Bruland. 1980. Manganesein the North Pacific. Earth Planet. Sci. Lett. 49: 45-56.Liao, I.C. 1984. A brief review of the larval rearingtechniques of penaeid prawns. Proceedings of theFirst International Conference on Culture of PenaeidPrawns/Shrimp. Iloilo City, Philippines, p. 65-78.Measures, C.I. and J.D. Burton, 1980. The verticaldistribution and oxidation states of dissolved sele-niurn in the northeast Atlantic Ocean and their rela-

tionship to biological processes. Earth Planet. Sci.Lett. 46: 385-396.

McLeese, D.W. 1974. Toxicity of copper at two tern-peratures and three salinities to the American lobster Homarus americanrts!. J. Fish. Res. Board Can. 31:1949.

Mukherji, P. and D.R. Kester. 1979. Mercury distribu-tion in the Gulf Stream. Science. 204: 64-66.

tion of elements in sea water, The Oceanogr. Rep.Eos, Trans. Am, Geophys. Union. 64: 130-131.Riley, J.P. and R, Chester. 1971. Introduction to Ma-rine Chemistry. Academic Press, London, 465 pp.Rosenberry, B. 1992. World Shrimp Farming. Aquac-ulture Digest, San Diego, Calif., U,S.A.Spot te, S.H. 1970. Fish and invertebrate culture. Watermanagement in closed systems. Wiley,!nterscience,New York, London-Sydney-Toronto. p. 90-91.Strickland, J.D.H. and T.R. Parsons. 1972. A practicalhandbook of seawater analysis. Bulletin of the Fish-eries Research Board of Canada, No. 167, Alger PressLtd., Ottowa, Canada.U.S. Environmental Protection Agency, 1986. TestMethods for Evaluating Solid Waste. EPASW-846.U.S. Environmental Protection Agency. Methods forChemicalAnalysisof Waterand Wastes.EPA600/4-79-020.


a successful Penaeus monodort hatchery in Jepara, Indonesa. World Aqua. Soc. 18th Annual Conf. p. 35.

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23. Yuan, Y.X., C.N. Gaoand D.X. Zhang. 1992. Metamor-phosis to postlarvaeof P. chinensis Osbeckby removalof heavy metals from rearing systems with polymericabsorbent. Journal World Aqua. Soc. 23�!: 205-210.


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Specific Hatchery Background