TECHNO-ECONOMIC FEASIBILITY STUDY FOR FISH SMOKING ENTERPRISE FISHERIES DEVELOPMENT PROJECT-HURGHADA RED SEA GOVERNORATE
UNITED NATIONS DEVELOPMENT PROGR/iry_i - FOOD AND .AGRICULTURE ORCylt. OF THE UNITED NATIOIJS RAB/81/002/l
TECHNO-ECONOMIC FEASIBILITY STUDY FOR FISH SMOKING ENTERPRISE FISHERIES DEVELOPMENT PROJECT-BURGHADA RED SEA GOVERNORATE
Prepared by
I.H.Feidi M.A.Moharram Economist/Investment Analyst Counterpart Econ/Invest.Analyst
With participation of
Z.E.z El Din Counterpart Fish Processing
FOOD AND AGRICULTURE ORGANIZATION OF THE UNITED NATIONS
PROJECT FOR DEVELOPMENT OF FiSHERIES IN AREAS OF THE RED SEA AND GULF OF ADEN
Cairo-Egypt December 1982 t l ~l. i· ~·l ~ f ·~ ~.~t L ;. I t~~.. ~-j ~· 1...- t..
r1 if' l 'f; I ~ ; l ~E~rJ fr;: r.== ~t i ~ ~·l B 't~~·t II \;;. Et [ &- --> -- I ~ :· (; -- l t - .-\ill ~ ..- r - .-() 01 .r So. v - _._ 0 \.-· r ;- r - .- ~ r·. k L-
. ~ ·~fi [ cz '.:::i t ~ 1: c;_ u;- ~ 1' t:. v· 0 t f." · I 4 " ~ (r r· {' ~E\'t'>r;;:' G. I ~ E:. .~l y;- [ ~·r - lL. er ~ . 1f' \b r.:"j '1-- c.- !• ~· (;! LI l IE - t C - V "1£>, .C- !I <"'c,, - ~ Q>: " ·v '1- t'.. J- '( w • [ <:-- """" ~ 0_... ~ t>.l. 01 - \:&"" 01 • &> · [
v v t r· - (:" ~-~-'& ~ ..'.J '[ ~·~ ~.l '" c:_. f. f ~~~ k r .. 1 rr h~ L~'i l { r. r.. r1"1t.- t'f'"' .{ 1. t. l ·\ .. ~ .r .!' (_. ~f. .- - l 1 lL. c:- ~,( :r ~.c;_ ~ _ f \- 1 • E 0 ~ <1... y f. r r r.:- (1 -i 't ~, r• Cl,. [ x 11• !:: ~ ~·--.,- ~ E: l&1 I 1• 1• • ·~~ r 4 Go. f.' ~ 1 t ~ 1. :l' ~ '-~·L I \- • - 't: t Go. ~ . "'. 1. ~ .r.·rq---rr ~r ~rrc~t~r~r~·itc.:tJ-1 ~=i·;. ~ = . t. ! &i · ~ r- 01 c ... t. ~. L c:i; ;( Cf,· · p ~ - I> fT - [ I I t: t' · . ..'..· v 6 c· .. f ~<1. l -< ~~ ['._ ~l .r v_.1r i C,.. ~·~ ~-e- - l ~ [; ,!I~ .J4>' )!I ..~ >+1! ..l.;!~ o.. :10..n (J~ ~.)I ~I~ ':JI 0-4 ,. ~ L...... h..) ·.) I J&. I J >t;.. 04 o....._, W:i.-. ~ ~ .l l..a.:i9 f 6 l ...> ! ~ a L !J .l • IP.'" I , 0 .:-...r. .. c._:;,; .~.• \t J_,~4~WIOs.l.L.o~ ~~ ~L.9~ 0!7~
• ;; t~,.J---'.aA~~ ~ (JJ -:.,.t~
o :11911 i..!1J ~6-....!J~ i~I J !"' ~ 0 tbL>ll 1.i.a. V<>J ,. ! 11 - - . .! I L ~ .. tl - ... 'I - ~ - I I . - L., II - I .. - ,, ( lJ , 9 (; ..,_:1-, c..!)..).)-""-' • ~·OJ~ ~ (J~ O....!::). -'.·.; ~ ~..) i...aJ.9 /;'
~Wlc.i~I~ •I '·.1~ o ~~ ~ 0 ,ocl..l>J Q.gW,~o.h:J:ll o .k
~o~c_}o .:s~ ....:i1~;; :1•.).:).J~i :1?-bJ)!f~;l!_, _,b::J
i.._-l,~I · .· 1- b.....'.Hc'-L.: It · ~b..JI ·· 1.9 , - ..; o~c ~°-:H.- ~~ ~ "
LJ..)_,_.;J~c,~)l.3L-l.9~ o .l.J"r4 1..~c.IJ~ ·~ ~ , ~I(; yi
fi, L-9~0..9.lriJl~~I .o!.l~~·L:.JILSJ~Jo--.bO• ~
• p .:I ob~·:; J.>l:uf
~... -. -~.: ...... ,o (J.J ~'° J l..pc. l, i..SJ--~.~_,_.h...... ,:il I o I ~ )! I I 3-yJ '1 I .S\... ~
/j ' -r_ __., ~ • <-5~'.) !J b:dl I J.y-1 L_... L. I L-9 .ljij~ o§,,, ... ll o3p_Jt
(?~I ~ d L...... ;ll ~~o ~ •! ~11 ~ ~ ~;; ... l.>~I o .i.a. ..)t..~I
J6 o- o o .l J?- C~I ~ bJI <..-9~~ c .!::--rul 6..9lbu! 3 °"---9.l_p.j~ 16 '\ _" ) r1..!J~1 J,,~ ~ . ;; !"'lto.)L...... ~ li 1.;..~t ..!.lk....;ll o.)~...i-.J!~L.ll~ 06 ~WU.t ·C,-0 t>9 ~~ ~..:1.-?0~ {~I ~ cL .. ds~ ~(~I ~ o_,o - tp) '---vJ d~I~ ~~ r<::-1 \' • • • • vl!_r.. 4~1..tb t 1 • u-3~ ) '\ Y'\ fb o .l~I OJ.>~( cl L ~I
<.J, ... lyJ 19 ~ b.J 'l I 4-.:iS lb j,, ~ ~r.w I ~ _ul f o ..l.>J ~ c::- in 1l..oLJ- 3 w k ~ te..:1 ) rt>. o .:i L-...o vb r • • u-1 !,.> vJ 1 (;, ~ ~J? ~ • o..i>.:MJld\...... 'tl04d~~Ub\O• ~~ pJiJ o~I ~I 04 o.J 1.9 (J~ I I .i.a, ~ o~ I u 4-::---1 ~ o.b9 u I Oj9 ~ ~ - 'f ,. 1..~ Jl--'411 0;~11-...l!b.J~JI cl~I .i:>-1 ~t Ll_,~I o .i.e l-~o .. h9l~I
----~.. ~~(?~W~~l~IJ9.17..)0I" r~ol" ~ ,. o~L.o L...LL-9~ J-llc.L...l_,~I o-3.A. ..ll..~I i}~J4->'Jl~I
uwb:o'JI .l.?.~ o~l~.r-JI .l.?.WI~ 6.\6:..:ill ~o) .... ~IJ..)!JSJI
( .J--4> ')I ~I ob.9 ~ ) l.Y.:-~;; .... o ll ~ ~ o+ru I o ~ o..o_;>U I o...._, l.o.:i.J..u 'i I
~ .i;)L L...,ul ~')I~~ ·...o l-'..l---->w!.1at ')!~ 3~1 L·:-i~ I •. • J .F:;-.;r V • .r'!" \.., - • ~ ..
• ~ l.:W ~ ~I J.> I.>" i) I ~I O.h> L.9 I ~ "I
,. l.SJ .;.'Jlwl~~ ~~I 0 1,,,91~ ~ ~lolSpl w~~ " ,. ,___~.,a.;"":!·.! I JSJI W' r1 L..J I 00 o9 b ;.,JI J_, ~I u9 d L...... ')I J_, I ~ ~ o.hp~I
J. .!!"' ~ clJ~ 4>Ulc..l~I ~•• :t.k:.,1S"~I o~ LS~I o-4 j~d->'- 8 ,. ii 9b~c.h~ 1-~~c..ts"~I o~ ~01.Jo'i-;. .. oll ~J • Jl:b.H
• ; .!9.nll ·~ ~ .~o.L;lW~
.. ,. ~ o---...... ~I '.'1 h.ll ~ ok!J.o(:'°U"'·~ . ...l~ JI~~ 0-lli~ L~I" o.s.;-ih:; ,. • ( ;;...... _ ...... ,.;.jo cl Lo....l) ~WI ~I~ ( i ) ABSTRACT One of the objectives of the Project for Development of Fisheries in Areas of the Red Sea and Gulf of Aden, is to conduct economic and investment research work and studies through the preparation of feasibility studies aiming at developing and modernizing fisheries industries in the participating counctries of the Projec{ of which the Arab Republic of Egypt is a member. With this objective in mind a feasibility study RAB/77/008/21) on the technical and economic aspects was prepared for upgrading and expanding the activities of the Fisheries Development Project' in Hurghada, Red Sea Governorate. The study centred on adding new fishing- units and the establishment of some shore facilities needed for improving and activating productive, servicing and marketing operations. A comprehensive and integrated study was prepared for this purpose complete with financial and economic analysis and evaluation. In response, the Red Sea Governorate has taken some positive steps to implement sections of the study. The purchase of refrigerated transport trucks,construction of 50 ton capacity cold stores in Hurghada and the ongoing construction of an ice plant of 20 ton/day capacity are among these positive steps. Complementary to these developmental steps, and as the 'Fisheries Development Project' in Hurghada constitutes the basis of planned development, this study has been prepared on the feasibility of establishing a fish smoking unit in Hurghada. This unit will have a medium capacity to produce good, locally acceptable smoked fish products, to be sold at reasonable prices ( L.E 2-3 per kilogram). Such products are to be very competitive with similar imported products which are currently sold on the local market for L.E 4.50- 5.50 per kg. In 1979 the total quantities of imported smoked fish is reported to be about 460 tons at a cost of L.E 620 OOO. The fish smoking unit will require about 300 cons fresh weight raw material ( pelagic, and hook and line species) to produce about 150 tons smoked fish as final product. In addition to producing a local quality product a part of important substitution saving foreign currencies could be achieved. The capital investment requirements for the unit is estimated at about L.E 100 OOO, 25% of which is to be self financed by the Fisheries Development Project and the balance could be obtained by procuring a Food Security loan. ii The financial evaluation proved that the fish smoking unit is feasible giving a financial rate of return ( F.R.R.) of 40%. Moreover, the economic reate of return ( E.R.R.) is 31%. The sensitivity analysis proved that when raising costs by 10% the return is 13%. On reduction of benefits the rate is 10%. In addition, the proposed fish smoking unit will provide 24 new job opportunities for a total gross income of L.E 33 ,OOO annually. To schedule operations it is proposed that production of smoked fish can commence in December 1983. ( i i i ) Table of Contents Page 1. Introduction 1 2. Background 2 3. Justification 3 4. Technical background on fish processing and utilization 8 4.1 Background 8 4.2 Smoke curing of shark and other large fish: procedure and results 8 4.2.1 Preparing shark fillets 8 4.2.2 Preparing other large sized fish 9 4.2.3 Treatment of fillets before smoking 9 4.2.4 Smoking procedure 9 4.2.5 Losses during filleting and smoking 10 4.2.6 Fuel supply in Egypt 11 4.2.7 Results 1i 4.2.8 Marketability 12 4.3 Transportation costs 12 4.4 Related experiments 13 5. Financial and Economical Evaluation of proposed enterprise 13 5.1 Investment components 14 5.2 Project Financing 15 5.3 Schedule of project implementation, operation and planned production 18 5.4 Requirements of raw material and evaluation of production 5.4.1 Cost of raw material 18 5.4.2 Yield of final products per year 19 5.5 Cost structure and costs of production during full capacity period 21 5.6 Schedule for expected annual cost of production, profits and marketability 24 5.7 Enterprise Financial Internal Rate of Return 28 5.8 Economical and Sensitivity analysis of the Enterprise 30 References 32 Appendices (iv) List of Tables Table No. 1. Quantities produced by existing vessels during 1980 - 1981 fishing season 5 2 . Fish landing composition in Hurghada 6 3 . Imported Smoked Herring in 1979 7 4. Processing ~asses 10 5 . Transportation ~osts 13 6. Loan repayment 17 7. Schedule for annual cost of production and profits 25 8. Financial Analysis df Proposed Fish Smoking Enterprise 29 9 . Economic Analysis of Proposed Fish Smoking Enterprise 31 ( v ) I . Table 1: Total Egyptian Meat and Fish Consumption. Table 2: Fish landings at Hurghada Landing Site during 1981 Table 3: Recorded loss of weight and labour needed to process one ton live carp into smoked carp portions Table 4: List of fresh fish controlled prices in Red Sea Governorate Table 5: Flow Diagram for Smoked Fish Processing Operation II. Some Useful Tables III. Some Related Fish Smoking Experiments in the Mediterranean Sea IV. Addesses of Companies Manufacturing Smoking Kilns and AFOS Co. Offer 1. INTRODUCTION One of the objectives of the UNDP/FAO Project for Development of Fisheries in Areas of the Red Sea and Gulf of Aden (RAB/81/002) is to identify and prepare economic and investment-oriented studies. This is achieved through the formulation of feasibility studies aime~ at the ~evelopment and modernization of fisheries in the participating countries. The Arab Republic of Egypt is one of the participating countries of the prcject. In this context a technical and economic feasibility study is prepared to ~evelop the activities of the already existing Fish Wealth Development Project in Hurghada. (Report No. RAB/77/008/21 by M. MOHARRAM in October 1981). The study dealt with the optimum utilization of the already existing assets, and expansion by adding new fishing units and some necessary and vital shore facilities to develop production, servicing and marketing. These are closely related ~ctivities that can be planned, financed, implemented., operated and evaluated as a unit~ The financial internal rate of return of the above mentioned Project was over 50% and the economic internal rate of return was 32%. Both rates surpass alternative opportunity cost in the society .. Positive steps had been taken by the Hurghada Project from the beginning of 1982 in order to modernize the existing typical Fleet, replacement of the ice plant machinery, two refrigerated trucks of 10 ton capacity each were purchased, two cold stores of 25 ton capacity each have been constructed and several marketing channels. have been established either inside or outside the Red Sea Governorate. On the other hand, no plans were made to add new fishing vessels as originally proposed. Therefore, it is not expected that any additional increase in the catch will be landed by the existing fishing units. (Three purse seiners producing about 440 tons a year sold at wholesale price of L.E. 400/ton). - 2 - Out of this new situation a new project idea emerges in order to improve the marketing value of the landed catch by the Project's Fleet (Indian Mackerel and Sardinella sp.) by adding a fish smoking unit by which the end products will fetch a reasonable price in the local markets. Furthermore, the profitability of the Project will be improved especially with the existing and 0perating above mentioned shore facilities. 2. BACKGROUND 2.1 In the last few years the annual landings from the Egyptian Red Sea Fisheries have been estimated at about 23,300 tons 1/. The annual purse seine landings have been about 16~500 tons, of which 14,500 tons. were taken from the Gulf of Suez and landed at Ataka~ The remaining 2000 tons were taken mainly from Foul Bay in the far south, and mostly landed at Hurghada. The species composition of the purse seine catches from outside the Gulf of Suez is spotted sardinella (Sardinella sirm) 35%, Indian mackerel (Rastrelliger ~igi£~£!i)~30%~-Golden striped sardinell;-(~~£~Ig~ll~ g!QQ£~~) 20% and Horse mackerel (Q~~~£!~~~~ ~~~au~~l) 15%. Included in the annual trawl catch of 4,500 tons ne~rly all of which is taken from the Gulf of Suez and landed at Ataka, are some pelagic spec~es representing some 6% of the total trawl landings. The artisanal hook and line fishery contributes about 2,300 tons of the annual catch. The southern area is very lightly exploited, although the areas presently fished could produce about 2,000 tons more. Likewise the mostly unexploited southern grounds~ 2.2 The preservation of fish for huw.an consumption, by smoking, has been in practise for many years. Slight improvements in technique were introduced very gradually with respect to the timing of the process, temperatures used and positioning of the fish relative to the fire, but it was not until the recent deve~opment of modern smokehouses and mechanical smoking equipment that any real advances were made over the original primitive methods. 1/ Source: M.J. Sanders, Egyptian Red Sea landings of Pelagic species, 18/8/1981. 3 - 2.3 Experiments in smoked sharks, mackerel tuna and other large sized coral reef fish species have been carried out by the Fish Processing Counterpart in Quseir and marketing trials have been carried out successfully, selling to consumers at a price of L.E. 2 - 3 per Kg. 2.4 Eased on the above information and findings, and during a meeting with the Project Manager (RAB/81/002), the Governor of the Red Sea, requested a feasibility study for a fish smoking unit and a complete shark utilization unit~ This study covers the fish smoking unit, while the shark utilization unit is the subject of another study under preparation by the authors. 3. JUSTIFICATION 3.1 Fish production and the exploitation of marine fisheries receive high priority in food security projects in Egypt. On the other hand, fish consumption in Egypt increased from 99,000 tons in 1973 to 162,000 tons in 1978 and fish consumption' contributes about 25% to the total animal protein consumption. (See Table No. 1, Appendix I). The rising trend in the annual increase of fish consumption is due not only to the consumer behaviour but also to its relatively low price compared with other sources of animal protein~ 3.2 Selection of Hurghada as a ~uitable location for the proposed enterprise is governed by the following factors:- a) The enterprise is an expansicn to the already eiisting Fish Wealth Development Project in Hurghada. b) The existing storage (50 tons capacity cold store) and transportation facilities (two refrigerated trucks 10 tons capacity each) will reduce the capital, operating and marketirtg costs of the fish smoking unit on the one hand, and on the other hand will increase the Project profitability by improving the marketing value of the end products. c) Touristic activities in Hurghada will activate marketing possibilities at a reasonable price. - 4 - d) Proximity to main road. e) Availability of manpower, also fresh water and electrici.ty 1/. 3.3 Total landed catch by the existing typical fleet (three fishing vessels, light attraction fishing, 25 metre in length and h.p. 222 engine each during 1980 1981 season was about 440 tons at wholesale price L.E. 400/ton on average. If only 50% can be processed (about 200 tons fresh weight) as smoked fish a reasonable profit will be made by selling it at L.E. J .5/Kg. end product. Table 1 shows the monthly landed catch by the existing fleet during 1980 - 1981 and average price per ton at wholesale price. 3.4 The-Fisheries Development Project in Hurghada already runs a monopoly on fish marketing activities in Hurghada. It is easy to process the large size low price fish in order to increase its value. Composition of fish landed in Hurghada Fishing Centre in 1977 and 1978 has been on average 13%, 12.3%, 7.1% and 6.2% Mackerel Tuna, Parrot Fish, Sharks and Greasy Grouper species respectively. (See Table 2)~ The official producer prices for the same species are L.E. o.g5, 0.50, 0.35 and 0.5s/Kgi respectively. 2/ This means that about 38.6%~of the total composition catch are low price large sized fish. Experiments on smoking of shark fillets, Mackerel Tuna and other large sized species have been carried out by the Fish Processing Counterpart in Quseir and marketing trials have been carried out successfully a_nd selling to consumers at a price of L,E. 2 - 3 Kg. Also Parrot Fish and Shark meat are suitable for sun drying. 3.5 There are various suitable marketing channels for the smoked products in the Egyptian domestic market. However, to the advantage of the producer of the end product, it would seem preferable to hand 1/ New power station 10 MW has been constructed at Hurghada city and already operating since the beginning of 1982. The station will provide industrial activities with electricity requirements for~a long time {recent Hurghada requirements 2 MW only). Also, it will secure regular current withcut any variation in voltage. 2/ See Table 4 Ap. I, sellirtg price from fisheries Development Project to Marketing Co., - 5 - Table No. 1: Quantities Produced by the Existing Vessels During 1980 - 1981 Fishing Season, Total Price and Average Price Total production av. whole- av. whole- by month sale price sale price ton Kg. Month Quantity Value {Ton) (L.E.) (L.E.) (L.E.) Sept. 1980 31 121Ll2 393 0.39 Oct. 53 18988 360 0.36 Nov. 76 25383 336 0. 3LI Dec. 94 3559LI 379 0.38 Jan. 1981 6 LI 265Ll8 LI 16 c. Ll2 Feb. 65 30973 475 O.Ll7 March 50 22716 45LI 0.46 April 9 43Ll3 49LI O.Ll9 May· - - - - TOTAL 442 176687 LIOO O.LIO Source: Fisheries Development Proje~t, Hurghada, Red Sea Governorate. - 6 Table No. 2: Fish Landing Composition in Hurghada Fishing Centre in 1977 & 1978 1977 1978 Aver-age Species M.T. % M. T. % M. T. % Emperors 61 21.8 76 22.7 68 22.l Groupers 46 16.4 57 17.0 52 16« 9 Mackerel Tuna 41 14.7 38 11. 3 40 1·3 .·o Parrot Fish 30 10.7 46 13.7 38 i2.3 Sharks 19 6.8 24 7.2 22 7.l Greasy Grouper 25 8.9 13 3.9 19 6.2 Jacks 9 3.2 24 7.2 17 5.5 Rabbit Fish 13 4.7 20 6.0 16 5.2 Goat Fish 9 3.2 7 2.1 8 2.6 Emperors 6 2.1 9 2.7 7 2.3 Sea chubs 6 2.1 6 1. 7 6 1.9 Others 15 5.4 15 4.5 15 4c.9 TOTAL 280 100 335 100 308 100 Source: By A.A. BARRANIA & M.A. El-SHENNAWI Report No. RAB/77/008/1, The Exploratory Socio-Economic Survey of the Egyptian Red Sea Fisheries - 7 - ever production to the national food security companies that exist in Egypt at gate prices. These companies in turn, will distribute the products through their own existing marketing channels. Producer prices are reasonable and consumer prices will be ccmpetitive for smoked fish specially if co~pared with similar impcrted products- 3.6 The tctal imported smoked Herrings was about 461 tor.s ir. 1979 valued at about L.E. 621,000. This means that the price of the imported product was L.E. 1350/ton on average. Consumer price in 1982 averaged in L.E. 4.5 - 5.5/Kg. (This is due to the inflationary trend during 1979 up to 1982). Table No. 3 shows the imported quantities of smoked Herring by country of origin and prices since 1979:- Table No. 3: Imported smoked Herring in 1979* Country of Origin Quantity Price Av. Price/ton (Ton) ( L. E. '000) (L,E.) Sweden 23 32 1390 Norway 24 31 1290 U .K. 251 353 1410 Holland 163 205 1260 Total 461 621 1350 A SQ% relative inflation in the period between 1979 to 1982, this means that importation price will be increased from L.E. 1,350/ton in 1979 to L.E. l,7se1ton in 1982. 3.7 Capital investment in fish smoking equipment and plants is rather modest, and to some extent proportionate to capacity. Smoking of fish can therefore, be regarded as an economically feasible processing method on either an artisanal, semi industrial or industrial scale. * Source: Central Authority for Mobilization And Statistics, Annual Foreign Trade Statistics, Cairo 1979. - 8 - Because of this, it is possible to preserve by smoking relatively small quantities of fish landed by individual fisherwen or small fishermen's cooperatives, thus increasing the marketing value of fish which would otherwise be preserved by a less remunerative method. 3.8 A Fish smoking unit with a capacity of one ton per working day raw material fer 250 annual operating days will be suitable for the proposed enterprise~ It will produce abcut 150 tons end prcduct (smoked fish). In additio~, the e~d product will be sold at suitable a~d reasonable consumer price (L.E. 2 - 3 Kg.). This price will be ccmpetitive when compared with the price of similar imported products. 4. TECHNICAL BACKGROUND ON FISH PROCESSING AND UTILIZATION Experiments on smoking fish have been carried out in Quseir Fishing Centre by the Fish Processing Counterpart in order to improve fish utilization and increase its marketing value. The marketing of large non-commercial fish such as Sharks, Parrot fish, Tuna Mackerel and Greasy Grouper is difficult in the local market either inside or outside the Red Sea Governorate due to their large ~izes and quality of flesh. Also, a family of 5 persons, on average, prefer to cons~me a maximum of 1 - 2 Kg. fresh fish. Trials havS been made in Quseir Fish~ng C~ntre in order-to produce and develop fillets from shark and large fish· species of·high quality, followed by investigation into the marketability of these products and finding suitable market 0utlets. The carcass of the sharks are first washed, beheaded and gutted. The belly cavity is carefully cleaned by means of water and brush. All traces of * Fish smoking Internal report, by Z. Ez-El-Din, Fish Processing Counterpart. - 9 - blood and dark flesh are removed. The fins are removed and c~llected in a container. The meat is cut into fillets and slices. The fish are first washed, beheaded and split open cutting along the line of the dorsal fin. After that a cut is made to clear the flesh from the ribs by passing the knife over the edge of the ribs towards the tail to remove fillets. The fillets are skinned, but the skin is left on species with softer flesh as the flesh tears easily. a. Shark fillets: The fillets are cut into thin slices. The slices are then immersed in a solution of 5% saturated brine and 0.2% acetic acid in a plastic container. The fillets are soaked for 10 - 30 minutes in 10% salt solution, the time needed depends on the size of fillets. All fillets are then placed on trays and allowed to drip for one hour. During summer months when ambiant temperature is high (40°C+) the fillets are placed on trays and kept for one hour in the cold room. After the brine treatment, the longer the fish are allowed to drip after after washing, the better the gloss on the product. 4.2.4 ~~£~l~g_E£££~£~£~=- (hot smoking using Torry Kiln) The cured fillets are laid on smoking frames and washed. After that the frames are placed in the kiln and left for a period of one hour approximately at a fairly low temperature, not above 40°c (104°F). This procedure is desirable so as to toughen the flesh so that it will not tear during subsequent cooking at higher temperatures. - 10 - Woo~ shavings, dry wood chips and moist saw dust of beechnut wood are used as smoke producers. The temperature is increased gradually to 70°c and maintained for 1.30 hours. During this time the product attains the smoked flavour. After the temperature is raised to so 0 c and kept so for another 1.30 hours or more for cooking. The smoking time varies according to the size of the fish but usually ranges from 4 to 6 hours. Care should be taken to avoid over-cooking. In order to obtain uniformity of cooking, the frames containing the flesh should be turned over from time to time. After the smoking time is ccmpleted, the product is taken out of the kiln immediately and introduced into the cold room before packing. The percentage of losses during processing are shown in the following schedule:- Table No. 4: Processing losses for some large sized fish species % of losses % of losses % of losses during by end of Species on making smoking time smoking time fillets fr. filleted from whole weight fish weight Plectropomus maculatus (Saddleback grouper) 52 34 68 Epinephelus microdon (Black-spotted grouper) 54 44 74· Pristipomoides typus (Sharp tooth snapper) 53 34 69 Scomberomorus commerson (Narrow-barred Spanish mackerel) 45 35 65 Lutjanus bohar (Two spot red snapper) 61 29 72 * Shark 60 30 74 * Estimated for whole sharks (before heading and gutting) Source: Z. Ez-El Din, Fish Processing Counterpart, RAB/81/002, Fish Smoking Report. - 11 - 4.2.6 Egypt in not known for producing wood. However, wood of different species is imported for various uses. For fish smoking fuel, investigations were carried out with the local carpentary and woodwork shops to find out the extent of residual wood shavings, small cubes, and fine & coarse sawdust. The indications are that such supplies are freely available with no limits throughout the year in various parts of the country. The main wood species available are beachnut Fagus Spp.) and pine wood Pinus sppJ, imported from Rumania, Yugoslavia, Russia, Germany and U.S.A. The wood residuals are normally packed in jute sacks costing about L.E 10 per ton, ( producer's price) It should be noted that by- products of various agricultural produce( maize 1 barley, sugar cane) are also widely available which could also be used as fuel additives. Experiments could be carried out to produce different flavours of smoked fish if required. 4.2.7 Results: The Results of experiments for all fish species that have been smoked were encouraging, Shark fillets, however, needed additional treatment. The concentration of 5 to 10% sodium chloride and one percent glacial acetic acid for a period of 12 hours appears to be acceptable for treating shark meat with good keeping quality for a period of one week at room temperature. The product attained good flavour and taste and could still be sold at a reasonable price ( L.E 2 - 3/Kg.) The trials made in smoking shark meat indicate that smoking can produce a new range of products with a palatable flavour from an otherwise unacceptable and underpriced product i.e shark meat. from the local consumer point of view). - 12 - 4.2.8 Marketability:- Investigations at Egyptian supermarkets and hotels revealed substantial outlets at prices that are competitive and gave reasonable profits. Marketing trials have been carried out successfully by the project Fish Processing Covnterpart for the smoked product of large sized fish species ( Table No. 4) at a producer price of L.E 2/Kg. for smoked shark meat and of L.E 3/Kg. for smoked fish meat. 4.3 Transportation costs Table No. 5 shows cost of transportation (ton/km) by refrigerated trucks with different loads. The existing two refrigerated trucks of Hurghada Project are of 10 tons capacity each. This means that each ton will cost about L.E 0.087/ kilometer. Since the distance from Hurghada to Cairo is about 550 km., the transportation of smoked fish from Hurghada to Cairo markets will cost L.E 48 per ton. -13- 1~£!~-~2~-~: Transportation costs (ton/km) by Refrigerated Trucks (L.E.) Load (ton) Cost Items (9-25) ( 5) ( 2 ) Average Fuel, oil, spare parts & maintenance 0.022 0.019 0.076 0.026 Salaries & fl.dmini- strative costs 0.042 0.092 0.081 0.060 Taxes & Insurance 0.011 0.013 0.009 0.012 Depreciation 0.012 0.101 0.011 0.034 TOTAL .... " ..... 0.087 0.225 0.177 0.132 Source: Egyptian Fish Marketing Corporation, Planning Department, Cairo. In addition to experiments carried out by Project RAB/81/002 on Fish Smoking which are pertinent to this study; experiences in this field for other fisheries in Egypt such as along the Mediterranean coast may be referred to. In Appendix II, some of the technical experiments which are relevant f.or the Red Sea coast are included. 5. FINANCIAL AND ECONOMICAL EVALUATION OF PROPOSED ENTERPRISE In order to investigate the possibility of the commercial application of the fish smoking experiments which ~ere carried out in Quseir and mentioned in the preceeding section, it is necessary to identify the - 14 - investment components for such an enterprise and its sources of funding. The evaluation also points out the construction schedule, cost of production and expected earnings during life expectancy of the enterprise. Out of these inputs, and in order to evaluate the extent of the feasibility of the enterprise, the financial and economical feasibility must be evaluated. The financial analysis reflects the investor's point of view, while the economical analysis reflects the the social point of view. A . Mach~nery & Equipment 1/ L .E, us $ 2/ Kiln galvanised/painted with automatic smoke producer 25 500 31 100 Trolleys, aluminium (8) 2 880 3 512 Trays for trolleys nylon coated (400) 4 200 5 122 Kiln cleaning fluid spray 135 165 Drip trays (s/steel) for bottom of trolleys (16) 480 585 Spares 750 915 C & F costs using 40' open top container to Suez Por.t (approx.) -----5 OOO -----6 100 Sub-total: (Kiln cost) 38 945 47 499 Cold store pre-fab (5 ton 0 capacity, temp.-10 C) 8 200 10 OOO Plastic fish boxes 1 OOO 1 200 Installation on site ------5 OOO ------6 100 Rounded 53 OOO 64 800 1/ Equipment costs estimated from the available offer submitted by AFOS Co. England (attached). In addition, Appendix No. IV lists addresses of similar companies which could be investigated if required. 2/ Rate of Exchange us $ 1 L.E. 0.82 £ 1 L.E. 1.50 - :J-5 - B. Civil works Building for kiln (10 m length x 5 m depth x 4 m 2 height) concrete base, at Hurghada prices (L.E. 200m ). approx. L.E. 10 OOO Raw fish processing sheltered yard. (~ashing,filleti~g, brining and tendering operations) lOOm at L.E. 100/m . approx. L.E 10 OOO Smok2d fish process~ng sheltered yard. (Packing) 50 m at L.E. 100/m costing. Approx.L:E·5 OOO Sanitary rooms and stores(Salt,sawdust § packaging material stores 50m2·at L.F. 1EO,ffi2 costing appox. L. E 7 500 Washing and brining tanks and filleting, tendering and packaging tables. approx. L. E· 7 500 Total civil work costs (US S 48 780)L.E 40 OOO Therefore, investment cost components can be divided as follows:- Foreign currency equivalent at official price (Importation of machinery and erection on site). A. == L. E. 53 OOO ( 55%) (us $ '54 800) Local currency B. 40 OOO ( 45%) (US $ 48 800) (For civil work and local equipment) TOTAL CAPITAL COSTS 93 OOO ( 100%) (US $113 600) Food security easy term loans are available in Egypt for this type of project. Terms of such loans can be summarized as follows:- 16 a. 75% of tot~l investment requirements. b. includes local and freign currencies. c. local currency is at 6% rate of interest. d. foreign currency (at tourist exchange rate) is at 13% rate of interest. e. short term loans are at interest rate of 15% f. a one year grace period is granted (only interest is paid). g. repayment is over a five year period. h. collateral is only on project and equipment. i. tax exemption up to 5 years after production commences. Therefore, the loan required is 75% from the total invested capital i.e ( 93 OOO x 0.75)= L.E ZQ_QQQ 45% of the loan is paid in local currency=LE 32.000 55% paid in foreign currency =LE ~8.000 ( See table 6 for Loan Repayment details). The balance of the inv~sted capital (LE 23 OOO) should be covered through self financing by the Hurghada project. Table 6: ~~~~-~~E~l~~~~-~~~~~~~~~~~~- ~~~~~-~~~~~~~l-~~~~-~~E~l~~~! ~~~~~~~-~~~~~~~l-~~~~-~~E~~~~~! Fiscal Loan Loan AnnUal Sub Loan Loan Annual Sub Total year value Inte~est loan re total value Interest loan re total Annual 6% payment 13% payment ~::E~~~.:;.:::!~ 1982/83 32 OOO 1 920 1 920 38 OOO 4 940 4 940 6 860 1983/84 1 920 6 400 8 320 4 940 7 600 12 540 20 860 1984/85 1 536 6 400 7 936 3 952 7 600 11 552 19 488 r 1985/86 1 152 6 400 7 552 2 964 7 600 10 564 18 116 r-l 1986/87 768 6 400 7 168 1 846 7 600 9 446 16 614 384 6 400 6 784 988 7 600 8 588 15 372 1987/88 Total 32 OOO 7 680" 32 OOO 39 680 38 OOO 19 630 38 OOO 57 630 97 310 ======~ ======-18- 5.3 §~Q~~~!~-~!_2~~1~~!-~~2!~~~~!§!~~~~-22~~§!~~~-~-E!~QQ~~ 2~~~~~!~~~ a. A period of &- mo-n.:tn-iz· is required for this proposal to be studied, discussed and if accepted by the authorities to order, deliver and install the equip- ment on site, provided that financing has been arranged. Therefore, in view of the activities of Project RAB/81/002 it is suggested that the &mon±hs ·period should commence Jan. 198 3- June 1983 so that start of cons true ti on can begin in mid-1983 ( start of fiscal year 1983/ 1984). b. Annual operating days .250(1.5 shifts/day) c. The raw materials needed, 300 ton fresh fish per year (1.2 ton/day) d. The raw materials will be available the whole year round ( Table No. 2, Appendix I shows fish landings at Hurghada landing site during 1981 by different fishing methods and productive sectors). e. One ton raw material will produce 500 kg smoked end product on average. Table 3, Appendix I (recorded loss of weight and labour needed to process one ton raw material ) indicates that the overall yield smoked end product was 51.6 % offal for fish meal amounted to 31.1% labour involved was 8 min/kg of raw fish, or 15 min/kg of final smoked product. f. The annual needs of raw material will be 300 tons/ year of which 90% are expected to be suitalbe for processing~and the annual final smoked production will be about 150 tons/year. g. The raw material cost assumed to be at LE 500/ton on average ( Table No. 4, Appendix I shows the list of hand line and gill nets fish prices in Hurghada from 1982 and Table No. 1, Page No.7 shows pelagic fish prices). h. The end smoked product from different fish species will average LE 2000/ton ( factory gate price). 5.4.1 Cost of raw material '!'.~!§!_;[~§~ LE All sharks at LE 0 .50 /kg gutted & headed ( 50 ton/yr) 25 OOO All Pelagic fish of L.E 0.50/kg (150 ton/year 75 OOO All large sized coral reef fish at L.E 0.60/kg(lOO ton/year 60 OOO ~66-E~~7~~~~----I~6~666 19 - 5.4.2 ~~~!~-~f_f~~~!_E£~~~~~~-E~£-~~~£{~~l!l a. Headed & gutted shark: (50 ton/yr) with 5 ton losses before processing) Body proportion 2/ Fresh Processing Final weight losses Product % % kg --~~------ Fins 9 4 050 64 (drying) 1 460 (dreid) (Hides 26 11 700 100) ( ) non valuable (Back ) II II (bone 7 3 150 100) Fillets 58 26 100 30 (smoking)18 300 (smoked) ------Total 100 45 OOO b. Smoking losses for pelagic species ( 150ton raw material with 15 ton losses before pr@cessing)estimated to be about 25%. This means that the annual final smoked product will be 100 ton per year. c. Losses during filleting and smoking for other large sized species ( mentioned previously in Table 4) averaged 65 - 70%. This means that the final smoked product of the 100 tons raw material with 10 tons losses before processing (30% of 90 tons raw material) will be 27 tons per yeRr). 1/ Assuming 10% losses in raw m~teriaJ beforP processing. (during fish sortin~ an~ select~ng the most suitalbe fresh fish to be processed). 2/ Estimated durL-1g Wadi Gimal experimental camp for complete shark utilization in the period from Feb. 15 to lvlar. 15 1982. The same figures will be utilized in the Study of Complete Shark Utilization under preparation. - 20 Therefore the expected annual yield of end products during the full capacity production year and their value could be smmuarized as follows: !'.:~s::!~::~ Total value ¥~!:: Price/ton ton L.E L.E Smoked shark fillets 18 2 OOO 36 OOO II pelagic species 100 1 500 150 OOO II large size coral sp. 27 2 500 67 500 Dried shark fins 1/ 1. 5 5 OOO 7 500 Dried fish meal 2/ 18 300 ------5 400 Total annual sales 266 400 The smoked fish ex-factory proposed prices are suitable for this type of product (LE 1.5 - 2.5/kg) and the consumer prices will be LE 2-3/kg which will be very competitive if compared with the similar imported commodity, LE 4.5-5.5/kg consumer price. 1/ for export 2/ 30 tons excluded fish before processing + 60 tons wet offal per yr sun dried to produce 18 ton/yr ( 80% drying losses). - 21 - 5 .5 2~~!-~!S~~!~~~-!-~~~~~~-~~~~-~~~!~-~!_E~~~~~!~~~-~~~~~~ ~~~~-~~E~~~!~-E~~~~~: Item L.E us $ Equipment & installation 53 OOO 64 fi 00 Civil works 40 OOO 48 800 93 OOO 113 400 ------Operating costs Raw material (fresh fish)l/ 160 OOO 195 OOO Processing materials 2/ 6 500 7 900 Packing material 3/ 10 OOO 12 200 Electricity 4/ 3 600 4 400 Water 5/ 1 200 1 500 Salaries & wages 6/ 33 OOO 40 200 Maintenance - Machinery 7/ 960 1 200 Buildings 400 500 Administrative costs & other expenditures 8/ ------2 500 ------3 OOO Sub total: 218 160 266 OOO Expected gross income: Sw.oked fish sales & 9/ other by- products 266 400 325 OOO Profit before depreciation 59 OOO & Interest 48 240 Depreciation 10/ 4 800 5 900 Interest on Loan 11/ 6 860 8 400 Net Profit 12/ 36 580 44 700 Production costs/ton 13/ 1 585 1·933 -22- Notes on Section 5.5 1/ 300 tons per year fresh fish costing LE 160 OOO mentioned previously on Page 18 . Requirements of raw material & evaluation of production. 2/ Annual requirements for processing materials assuming that all quantities of raw material.are suitalbe to be processed: Salt estimated 0.2 ton salt per ton raw material 300 ton raw fi~h x 0.2 salt = 60 ton/yr at LE 25 ton/salt LE 1 500 /yr * Sawdust: estimated 0.3 ton sawdust per ton raw material 90 tons/yr at LE 30/ton= LE ~ 700/yr ------Vinegar:. for shark fillet treatment before smoking at 2% 29 ton shark fillets x 40 kg/ton at LE 0.30 kg/ vinegar = LE ~~~/yr In addition, expendable handling utensils costs replaced each year LE 2 000/y~ Therefore, the cost of the processing ingrediants will be about LE 6 500 annually 3/ Packaging material increased by 10% reserve to pack 10% expected increase in production). a. Two plastic sealer machines to be replaced every year at local market price LE 200 ea. LE 400/yr b. One kg polyetheline roll at L.E 1.5 sufficient to pack 40 kg. smoked fish 1 kg package. The annual expected production 160 ton/yr will need 4000 kg polyeth line at L.E 1.5/kg Total annual costs LE 6 OOO c. It is estimated that the smoked fish will be packed in 20 kg cartons 0.8 x 0.4 x 0.16 m3 therefore 50 cartons at local market price LE 0.45 ea. sufficient to pack one ton plastic covered end products. Total annual carton costs= 160 ton end product x 50 cartons xLE 0.45 L.E 3 600 Total annual packing material costs: L~E16-666 * Transportation costs from Nile Valley Carpentery Workshops ta Hurghada included. - 23- 4/ Industrial electricity cost at Hurghada= up to 70 OOO kw/yr LE 0.0235/kw From 70 OOO to 100 OOO kw/yr = LE 0.0185/kw Over 100 OOO kw = LE 0.0175/kw. !~!~~-~~~~~~-~~~~~~~~~~!~ Kiln operations for one shift 1 ton capabity estimated from attached offer ( Model 120) will be 273 kw/shift ( 1.5 shift/day x 273 Kw/shift x 250 annual operating days= 102375 Kw/yr~) Other operations and lighting about 20 OOO kw/yr Refrigeration annual requirement = 60 OOO kw Total annual requirements 180 OOO kw costing 70 OOO x 0.0235· + 30 OOO x 0.0185 + 80 OOO x 0.0175 LE 3600/Yr. 5/ 8/ton day fresh water at LE 0.60 per ton x 250 annual operating days L.E 1200/Yr. 6/ Labour involvement 15 min/kg of final smoked and packed product one ton end product will need 250/hr~ Daily requirements of labour hours (0.6ton smoked end product per day) will be 150 hr. At 8 hr shift/day the daily labour requirements will be 19 labourers/day. At LE 3 labour wage per day and 250 annual operating days the annual labour costs will be 19 x 3 x 250 L.E 14 250 In addition One kiln operator at LE 1 800/yr - LE 150 month One electrici~n at LE 1 800/yr - LE 150 month One foreman at LE 2 400/yr - LE 200 month Two unskilled labourers at LE 1440/yrLE 60/month each Therefore total annual salaries & wages for one Bhift/ day ~ill be = L.E 21.690 * 7/ Maintenance costs estimated to be 2% of machinery costs and 1% building costs 8/ Insurance 2% of machinery and building costs in addition to administrative costs. 9/ Smoked fish sales during the full capacity years expected to be as follows: * The daily oper~tions will need 1.5 shifts per working day, i.e in such case the annual salaries & wages are expected to be L.E 33 OOO/yr. - 24 - Final product Qty Factory price/ton Total ton value L.E L.E Smoked Shark fillet 18 2 OOO 36 OOO 11 pelagic sp. 11 100 1 500 150 OOO 11 large size coral sp 27 2 500 67 500 Total 145 253 500 By- products value LE 12 900 10/ Machinery useful life 10 yrs & buildings 20 yrs Replacement costs=i~!~~~~!-~~~!~=-~~!~~~~-~~!~~ expected years of useful life - the salvage value assumed to be zero in all cases 11/ 75% from capital costs will be covered by Food Security Loan, 1 yr. grace period, 5 yrs loan repayment&,.:6% rate of interest for_local currency & 13% for foreign currency starting from lst yr grace period LE 6860(Table No.6) 12/ Net Profit = Profit before depreciation & interest - (Depreciation costs+ financial costs). 13/ Production costs/ ton= ~E~~~!~~~-~~~!~-~-~~E~-~~~!~~--~~~~~~-~~~!~ Total annual production 5.6 ~~~~~~!~-!~~-~~E~~!~~-~~~~~!-~~~!-~!-~~~~~~!~~~~ ~~~!~!~-~-~~~~~!~~~!!!~ After commencement of production, e number of problems may arise,such as:- The application of production techniques, operation of equipment or inadequate labour productivity as well as the lack of qualified staff and labour. Therefore, it is expected that the production during the first operating years will be 55% from full productive capacity and increases gradually to be 75% and 100% in the second and third productive year respec tively. The following table shows in detail the time schedule of the expected production and its value throughout the project's useful life. Table 7: Schedule for annual costs of production & profits(LE) Period Cons tru• ·· Start-up Fu 1 1 .Cap a c i t y t ion Year 1 2 --;-----1----~------[---~------~~~~- 0 55% ---~~~~~~!~~~-E~~~~~~~~----- ==z~~===J:==i~~;======i~~;====t==i~~;=== Q2~:::~!~~~-~'.?.~!~: Raw material 88 OOO 120 OOO 160 OOO 160 OOO 160 OOO Processing ingredients 3 570 4 870 6 500 6 500 6 500 Packing materials 5 500 7 500 10 OOO 10 OOO 10 OOO Electricity 3 600 3 600 3 600 3 600 3 600 Water 1 200 1 200 1 200 1 200 1 200 Salaries & wages * 22 OOO 22 OOO 33 OOO 33 OOO 33 OOO Maintenance : Machinery 960 960 960 960 960 Buildings 400 400 400 400 400 Administrativecos·cs & Other 2 500 2 500 2 500 2 500 2 500 TOTAL 127 730 163 OOO 218 160 218 160 218 160 N ()1 End product sales 146 520 199 800 266 400 266 400 266 400 Profit before depreciation & interest 18 790 36 800 48 240 48 240 48 240 Depreciation I I 4 800 4 800 I 4 800 4 800 4 800 5 488 4 116 __ f ~~~~~~~~-~~~~~-~-!~~~£~~~~-~~-~~Q~--~-~~Q_ 7 130 26 512 I 39 324 --~~!_E~~!~!-~~------Production costs/ton 2/ 1 742 1 590 I 1 566 ==;~=i!~===~=;~=;;~== ------~------~------J * One shift during the start-up period & 1.5 shifts during the full capacity period 1/ End product sales - ( operating, Depreciation & Fin~ncialcosts). 2/ Total Operating, Depreciation & Financial costs divided by the annual production of smoked fish which expected to be 80 tons in first start-up year, 109 tons in- the second and 145 tons there after. ' 26 At first glance at Table No. 7, one can observe that production costs in start-up years are higher than the following full capacity years. It is better from the investor's point of view to reduce the start up period and enter the full capacity production years as quickly as possible in order to reduce costs and increase profits. But attention should be paid to the start-up period not only to face the operational difficulties which may appear after the production commencement, but also the necessity to enter the local market with the new commodity gradually, especially where already existing imported smoked herring in the market which expected to be very competitive to the proposed new product. The situation could be analyzed as follows:- a. Price:- is the primary component of competing. The-proposed smoked fish prices are very competitive specially if compared with the similar imported commodity. b. Product quality: is a second parameter of competi tion~---yt-could not be possibly expected that the produced smoked fish will be very high quality product if compared with the imported one, at least during the start-up period, but if should be very acceptable quality during the full capacity period in which the end product will be very competitive to the imported one in quality. Price and quality theoretically yield consumer value. Consumer preference increases in proportion to the value. c. Service: this is the third parameter of competition In-this case, service will be the responsibility to the distributor which is propoied to be one of the Food Security Companies which exists in Egypt. The proposed marketing com.pany, should secure fast delivery, inventory supply and promotional informa tion in addition to its own marketing.channels. In most cases, new products go through product life cycle (PLC) during which their market experience changes. The modelJof t~e(PLC) is presented in the following figure. 1-larket entry Growth Maturity Decline Cl) al r-i ('j I\) (/) -...] Time Prodnct Life Cycle ( PLC ) Source: James E, Austin, Agroindustrial Project Analysis EDI Series in Economic Development. - 28 - Commenting on the above figure and the ensuing curve it should be noted that the managemePt of the prcduc ing unit as well as the management of the marketing and distribution must ensure that the years of product maturity must be prolonged as much as possible to avoid early decline in product acceptance. In doing so, continuous product development and promoting techniques must be carried out. Advertising, quality, packaging,etc. are such means to prolong product maturity years .. 5.7 Enterprise Financial Rate of Return The following Table No. 8 shows inflows, outflows and cash flow throughout the enterprise lifespan. The financial internal rate of return exceeds }0% and reflects the feasibility of project from the investors point of view, Also this rate surpasses the social rate of interest which is about 15%. Table No. 8 ·Financial Analysis of Proposed Fish Smoking Enterprise (L.E. 1 000 1 ) Analysis (It ems ~oject'slife 1 2 3 4 '.5 6 7 8 9 10-20 I. Inflows: ------l/ - Annual sales ""' - 147 200 266 266 26.6 266 266 266 266 2/ .:.~ - Long term loan value - 70 ------3/ - Short term loan value - - 21 27 ------ ml Tot inflows 70 ·168 22~ 266 266 266 266 266 266 266 [\) II. Outflows: (!) ------.•. 4/ - Capital costs 93 ------·- - Long term loan 5/ repayment - - 14 14 14 14 14 - - - - .. 5/ ..... Inter e s t· · on l.oan - 7 7 6 4 3 2 - - - - - Short term loan 5/ repayment & interest - - 24 31 ------Operating costs - 128 163 218 218 218 218 218 218 218 - Replacement costs - 5 5 5 5 5 5 5 5 5 .:... Total Outflows ioo 178 2 J, 9 241 '240 239 223 223 223 223 11 Net benefits (30) ( 10) 18 25 26 27 43 43 43 43 . Taxes 6/ ------17 17 17 Cash flow (30) ( 10) 8 25 2'6 27 43 26 2'6 ' 26 F.I.R.R. = 40% - 30 - Notes on Table No. 8 1/ Sales of smoked fish and by-products. 2/ Food Securi.ty long term loan 3/ Short term food security. loan, 1!:% rate of interest, to cover 2 months operating costs ( working capital) at the beginning of both start-up years 2nd &3rd years to be repayed at the end of the same years. 4/ 25% of the capital costs (L.E 23.000) should be self financing by Hurghada Project and balance available as a food security loan. 5/ The prevailing food security long and short term loan conditions are the basis for these calculations. 6/ 40% taxes on profits to be deducted from net profits, starting after 5th profitable year. 5.8 Table No. 9 shows that the Economical Internal Rate of return is 31% and reflects the feasibility of the project from the society's point of view. This.rate surpasses alternative opportunity cost in the society. In addition, the proposed enterprise will create about ~4 new job opportunities with gross annual income of about L.E 33,000. Furthermore, the results of the sensitivity analysis calculations on the assumptions of cost over-run by 10%, the E.R.R. will be 13% and on the assumption of shortfalls in benefits by 10% the E.R.R. will be 10% This means that the Project under various conditions will be-- feasible:. Table No. 9 Economical Analysis of Proposed Fish Smoking Enterprise (L.E. 'OOO') . Analysis (It ems ~oject'slife ' 1 2 ,3 4 5 6 7 8 9 10-20 I:. ------Inflows: - Annual Sales - :147 200 266 266 266 266 266 266 266 ' .147 .,, 200 266 266 266 266 266 266 Total inflows - 266 II. ------Outflows: - Capital costs 106 ------ 1 - Operating costs - 1:E8 163 218 z1 8 ~18 218 218 218 218 I Replacement costs - 6 6 6 6 6 6 6 6 6 - (,,) f-l Total outflows 106 134 169 224 224 224 224 224 224 224 Cash flow ( l 06) i:3 31 42 42 42 42 42 42 42 E • I •. R • R • = 3 1"% Note: Foreign exchange shadow price: (August 1982) U.S. $ 1 = L.E. 1.02 32 References 1. Austin, James E., ~~~z!~~~~!~!~~-~~Zi~~! ~~~~z~!~· EDI Series in Economic Development 2. Barrania, A.A. & Shennawi, M.A !~~-~~E~z~~!z~z-~z~!z ~~z~z~!~~~~~~z_z~-!~~ ~~ZE!!~~-~~~-~~~-~!~~~~!~~~ Report No. RAB/77/008/1, March 1979 3. Codex Alimentarius ALINORM 79/18~ Appendix VII Commission, " Recommended International Ffsh~~Step_Scode-of-Practice-for-smoked ______ 4. Eid, M.H 1982 A Survey System for Quick Estimates of some sectors of some sectors of the Fishing Industry ( Red Sea Fisheries) Part 1. 5. FAO, 1970 Smoke curing of fish FAO Fish. Rep., (88) : 43 p 6. FA0,1981 The prevention of losses in cured fish. FAO Fish Tech. pap., ( 219) ;-37-p------ 7. FAO, 1971 Equ{pment and methods for improved smoke-drying of fish in the tropics. FAO27_p Fish______Tech. Pap., _ (104): 8 . Feidi, I.H Project Proposals to Support ~~~!~~~~=~~~~~~~~~=~~~~~~E~~~! (Red Sea & Gulf of Aden) Report No. RAB/77/008/10, February 1981. 9 . Lisac, H., Fish-App1ica51e-rn-theSome Techniques of Smoking ___ _ ------Mediterranean-Area~-1970 10. Moharram, M.A - 33 - 11. Sanders, M.J & ~~~~~~~-~~~~~~-~~-~~~-~~~ Kedidi, S.M., Commercial Fisheries Catches 9nd ~tock Assessments, Report No~-RAB7777668719~-March 81 12 UNID0,1979 Manual for the Preparation of Industrial Feasibility Studies. - l - Appendix 1 Table 1 Total Egyptian Meat & Fish consumption 1973-1978 '(XX) tons Years Total meat % Total fish % Total CoriSurnption 1973 342 78 99 22 441 74 345 75 116 25 461 75 359 73 133 27 492 76 383 77 115 23 498 77 396 75 130 25 526 78 404 71 162 29 566 Average annual 371.5 125.8 497.3 consumption Percentage 75% 25% 10)% Source: Ministry of Agric., Agric. Econanics Institute Append:L"'i:1 Table 2 Fish landings at Hurghada landing site during 1981 (tons) Month Hook & gill nets Purse seiners Trawlers Total Fishenrens Private Hurghada Private Private Sector Per rronth Society sector Project sector Jan 5 14 69 78 55 221 Feb io 11 81 137 37 276 Mar 12 12 56 414 26 520 Apr 34 33 10 212 33 322 May 151 31 - 27 2 211 Jun 83 27 - - - 110 N Jul 68 14 - - - 82 Aug 15 18 - 2 16 51 Sep lkl 25 - 48. - 87 Oct 31 38 34 146 7 256 Nov 23 26 32 78 - 159 Dec 27 14 40 161 6 248 Total 473 263 322 1 303 182 2 543 Source: Departrrent of Agric. Red Sea Governorate - 3 - Appendix 1 Table 3 Recorded loss of weight and labour needed to process 1 CX::O kg live carp into snaked carp portions Operation Weight loss .Labour % (min) Killing & dressing 1 885 - heads 17.0 viscera ) 14.1 fins ) blood 4.9 others Brining, scrubbing, tentering 3.0 2 575 &no king 9.4 540 Packing 1 140 Loading 90 Cleaning working facilities 540 Other works 780 Total 48.4 7 550 Overall yield was 51.6 percent, offal for fish meal amounted to 31.3 percent, labour involved was 8 min/kg raw carp, or 15 min/kg of final sroked product. Source: Sane Techniques of snaking fish applicable in the Mediterranean Area, by H. Lisac, FAO Fishery Products & Marketing Branch. Append:ix 1 Table 4 List of fresh fish contrqlled prices in Red Sea Governorate Fran l2 October 1982 - .Prices : LE / Kg Producer price Selling price Rest- First Fish species Fisheries Dev.Project fran Fish.Dev.Proj Hurghada Quseir Safaga Ras aurant & class Hurghada to Marketing Co. city city Garib Clubs hotels Snappers - Seabream - .Golden Snapper - Spanish 0.670 0. 7.60 0.800 0.800 0.830 0.850 0.900 1.600 mackerel - Silver biddy Emperors.- Seabreams - 0.570 0.660 0.700 0.700 0.730 0.750 0.800 1.500 b Barracuda Groupers ; Greasy Grouper Rabbit Fish No.I 0.470 0.560 0.600 0.600 0.630 0.650 0.:700 1.400 Snappers - Grunts - Jacks Parrot fish - Needle fish 0.540 0 ..540 0.580 0.600 0.$40 1.350 Sea chubs 0.410 0.500 Seabream -Mackerel tuna 0.260 0.350 0.390 0.390 0.400 0.450 0.490 1.200 Rabbit Fish No.2 For fishmongers outside Hurghada prices are subject to supply and denand Source: Supply D3partITBnt, Red Sea Governorate - 5 - APPENDIX I FLOW DIAGRAM FOR SMOKED FISH PROCESSING OPERATION Receiving "' ------Raw material storage Raw material preparation Dressing J Waste material storage rl I ------.~ Sal ting Disposal ------Dripping, drying ------Sawdust, wood storage Smoking < ! I ,; Cooling ------PooQging material eto;ag, Pa.cka.ging < I J ,v Fi.n.&l product s"korage I Distribution" ea.le (a~lid linea denote physical sepa:M!.tion) - 1 - Appendix: II SOME USEFUL TABLES Brine strength measured at 16°c (60°F) Salinometer Speoifio Percent lb salt per gal of water salt by degrees gravity Yei.11.'ht lb lb - oz 0 1.00 o.ooo o.ooo 0 - 0 10 1. 019 2.640 0.271 o - 4Y2 20 1.038 5.279 0.557 0 - 9 30 1 .058 7.919 0.860 0 - 13~ 40 1 .078 10.558 1.180 1 - 3 50 1.098 13.198 1 .520 1 - 8Y2 55 1. 108 14.517 1 .699 1 - 11 60 1.118 15 .837 1.883 1 ·- 14 65 1 .128 17.157 2.071 2 - 1 70 1 .139 18.477 2.267 2 - 4y4 75 1 .149 19.796 2.468 80 1.160 31.116 2.677 ~: ;o~ 85 1 .171 22.436 2.895 90 1.182 23.755 3.115 ~ = ~~4 95 1.93 25.075 3.346 3 - 5f; 100 1.204 26 .395 3.587 3 - 9Y2 1 gal • 4.546 11 1 lb - 0.454 kg1 , oz • 28.35 g Loss in veight of fish in relation to temperature and processing time in an Alton& oven Temperature Processing Weight Average loae vithin the oven time of fiah of weight Measured Avera1 0 30 0 28 to 31 30 3 19.5 to 22.5 30 105 to 113 110 6 13.8 to 18.5 45 90 to 102 95 9 9.2 to 16.8 60 82 to 94 90 12. o.o to 12.0 69 75 to 98 85 15 6.6 to 7.8 78 79 to 91 85 The above figures are measured maximum and minimum values over averages calculated from five different tests. The relative humidity of the outside air during the tests vae between 40 and Bo percent, measured by vet and dry bulb . thermometers. - 2 -. APPENDIX II Pre arn.tion of Brine of Re uired StrEm h The B!!lOunt of salt to--bt; disso ved :i:n· water to obtain i-equired brine strengths.) Sp8cific % NaCl Ba.UJ!l6 degree B Salinomctc:r Kg NaCl to be dissolved gravi t~r by weight u.s. standard degrC.!cs in 100 1 water 1 .007 1 l.o 3.8 LO I 1 .014 2 2.0 7.6 2.0 1.022 3 3.1 11 .4 3 .1 1.029 4 4.,1 15.2 4.2 1.037 5 5.2 1.9. 0 5.3 1 .044 6 6.1 22.7 6.4 1 .051 7 7.0 26.5 7.5 1.058 8 7.9 30.3 8.7 1.066 9 8.9 34. 1 9.9 1 • 0'{.3 10 9.8 37.9 11 ~ 1 1 .081 11 10.9 41. 7 12.4 1.089 12 ll.9 45.5 13.6 1 .096 13 12.7 49.3 14.9 1 .104 14 13.7 53.1 16.3 1 • 112 15 14.6 ·56.8 17 .6 1.119 16 15.4 60.6 19.0. 1.127 17 16.3 64.6 20.5 1.135 18 17.2 68.2 22.0. 1.143 19 lt>.l 12.0 23.5 1.151 20 19•0 75.8 25.0 1. 159 21 19.9 79.6 26.6 1.160 22 20.9 83.4 28.2 1.176 23 21.7 87.2 29.9 1 .184 24 22.5 91.0 31.6 1.192 25 23.4 94.8 33.j 1. 201 26 24.3 98.5 35 .1 1. 204 26.4 24.6 100.0 35.9 - (Brine strength measured at 16oc (610F)) - 3 - Fish .11..smoJsing . in a . "Torry" type mechanical kiln Time Designed ';I'ype o! oure in Temperature No. of veight kiln !'ires loss' (h) oc OF ( Kippers 4 29.4 85 all 14 - 18 Kippers for canning 2Y2 29.4 85 all 12 - 14 Kipper fillets 2Y2 - 3 29.4 85 all 10 - 12 Cod and haddock fillets 3 - 5 26.7 80 ~ to a.ll 10 - 12 Finnan haddock 4 - 6 26.7 Bo ~ 12 - 14 Pale cured haddock 2 - 3 26.7 80 Y3 to o/J 8 - 12 "Golden outlet" haddock 2 - 3 26.7 80 213 10 - 12 Bloaters 3 32 90 Y3 14 - 16 Red herring 36 29.4 85 a.ll 20 - 25 intermittent Silver our• herring 8 29.4 85 Y3 5 Salmon 8 - 12 29.4 85 -Y3 10 Cod .roe 8 37.8 100 Y3 20 - 25 Bilckli,ng 2 - 3 26. 7 - 71 80 - 160 all 10 - 12 Sprats !or oannirig Y2 - 26.7-71 80 -· 160 Y3 10 - 12 Kieleraprotten 1 - *1Y2 26. 7 - 71 80 - 160 all 15 - 20 ., Smokies 2 26. 7 - 71 80 - 160 all .30 Trout 3 26. 7 - 71 80 - 160 all 10 - 12 Eels 2 26. 7 - 71 80 - 160 all 10 - 15 Source: Bureess ~ al., 1965. - 4 - Storage life of some species of smoked fish Stora,11e life 16°C (600F) o0c ( ~2°F) In first In firat Species Sm.bk,!}(!, product, clasa remaina remains edible class edible condition condition days day a days da:va Cod Single fillets, cold smoked 2-3 4-6 4-6 8- 10 Haddook Single fillets, cold smoked 2-3 4-6 4-6 8- 10 Blook fillets, cold smoked 1 - 2 2Y2- 3 4 6 (golden outlets) Finnans, cold smoked 2-3 4-6 4-6 10 - 14 Pales, cold smoked 1 - 2 2Y2- 3 4 6- 7 Smokies, hot smoked 1 - 2 2Y2- 3 3 -.4 5- 6 Herring Kippers and kipper fillets, cold smoked - unwrapped 2-3 5-6 4-6 10 - 14 cold smoked - 'W'r&pped 1 - 2 3 3 3- 44 Blos.tera, cold amoked ·1 - 2 2-3 3- 4 5- 6 :BUokling, hot amolced 1 - 2 2-3 3-4 5- 6 Salmon Fillets, cold smoked 2-3 4-5 .4 10 Trout Whole, gutted, hot amoked 3 7 6 10 Cold storage life of smoke cured products made from good quality rav material -9.5°c (15°F) -20°c (-5°F) -29°C (-20°F) Type of fish I Good Inedible Good Inedible Good Inedible Smoked 1 3 3Y2 10 7 more than white fish month months months months months 1 year Smoked 3 2 2 5 4Y2 more than fatty fish ·weeks months months months months 9 months - 1 - APPENDIX III ~~~~-~~~~!~~-~~~~-~~~~~~~-~~~~~~~~~!~ in the Mediterranean Sea 1/ 1.1 Sardinella: Sardinella ( Sardinella aurita) a~undant------in the southern part of the Mediterranean is a very suitalbe raw material for smoking. The fish are washed, eviscerated, washed again, brined in saturated brine for 2 to 3 hours, tentered on sticks and predried in air. Sardinella are then placed in smoking ovens, pre-dried in smoke of about 100° C for 10 min., subsequently cooked in hot smoke of about 135°C in order to eliminate some water and fat, smoked in a dense smoke for 12 to 16 hours and finally exposed to a rapid drying over a fire of vine branches for only a few minutes ( Dieuzeide and Novella, 1951). 1.2 Horse mackerel: Horse mackerel ( Trachurus trachurus) have-been-preserved as a smoke cured product for immediate consumption in Egypt on experimental basis~ Whole fresh or defrosted fish are brined in chilled brine until the salt content reaches 6 to 8 percent. Pre- drying of brined and washed fish hung by tails on small sticks can be carried out in a sheltered airy place for about 6 hours until the surface of the fish becomes dry. Pre-dried fish are placed in the smoke chamber and exposed to smoke of 25 to 30°C fr0m a separate smoke generator for 24 hours. It is further smoked at not more than 40°c for another 24 hours. The colour of smoke cured pro ducts should be golden brown. They can be stored for up to three months at 0 to 5°C. Mackerel ( Scomber scombrus) and large sized European pilchard ( Sardina Pilchardus) could be§rnoke cured in the same manner as horse mackerel. ( M.A.Hammam,General Egyptian Organization for Aquatic Resources - Nasr City- Egypt- Personal Communication, 1970). 1.3 Mackerel: Hot smoked mackerel ( Scomber Scombrus) Is-appreciated as a tasty product-In-some-European countries such as Holland, Denmark and Germany ( Dieuzeide and Novella, 1951). Mackerel are eviscerated, .. brined somewhat long.er than herrings of the same size, tentered throlffil-f:-eyes and then hot smoked in a similar way as herring for " Buckling" (Wille, 1949). Another method of smoking mackerel is to brine whole fish for about 12 hours before gutting, to smoke them in a relatively cold smoke for 4 to 5 hours and finally to cook in hot smoke during the next 2 hours. ( Dieuzeide and Novella, 1951). 11-s0urce:-R~-1rsac~f Ao-fishery-Products-&-Marketing-Branch~------~tudies &. Reviews N0.45/1970.Some Techniques of Smoking Fish Applicable in the Mediterranean Area. - 2 - APPENDIX III 1.4 and tuna Thunnus spp.)lo~rrs or chunks are either well boiled-or-steamed and laid on smoke frames to drip and dry in air for serveral hours. When sufficiently dry, they are hot smoked until acquir ing a deep chocolate- brown colour. The product is very firm; cut in tiny fragments it can serve as a basis for many culinary preparations, ( Dieuzeide & Novella, 1951). Another type of smoked tuna product, well accepted in Europe, is obtained from tuna chunks weighing 100 to 250 g. each, brined in 8 to 10 percent brine for 15 min. The brined chunks are wrapped with raffia, hung on small sticks and hot smoked. During smoking process excessive heat should be avoided ( Biegler, 1960). Supplies------& Equipment 2.1 Fuel Smoke for smoking fish is produced by burning slightly wet wood, wood chips o~ sawdust. In principle, any kind of non- resinous wood can be used as fuel for smoking. Where wood is scarce, dried leaves, turf, straw or maize cobs can be used, The most desir~ able types of wood are oak, beech, walnut, ash and elm; they are hard wood and they produce the best preservative effect. Soft wood such as willow, elder, birch and poplar are less frequently used. Dried leaves of oak and ash are used if wood is not available. A mixture of oak with wheat or barley straw is also used in some areas and a mixture of mahogany chips with elder in others. Aromatic plants such as sage, thyme, marjoram, vosema~y, juniper or laurel and their mixtures can be added to sawdust in order to obtain some that will give a particular flavour to the smoked fish. Vine branches are often added to other fuel during the last period of smoking ( Dieuzeide and Novella, 1951). 2.2 Smoking Ovens There are many variations of smoking oven,s, their main difference being the level of mechanization of the smoking operation. Two examples are described below: one is a non- mechanized smoking oven suitable for artisanal scale production and the other is a mechanized smoking kiln suitalbe for a larger scale industrial production. - 3 - APPENDIX III A need for proper operational skill is a common requiremen~ for all types of smoking ovens and in particular, a long practical experience is required to operate the non- mechanized types~ 2.2.1 Non- mechanized smoking oven Fig.1 shows-one-variation-of-a-non-mechanized smoking oven traditionally used in the Baltic Sea ( Chupakhin and Dormenko~ 1967). Basically, it is a simple chimney in which fish can be arranged and exposed to the smoke. The draught is controlled manually to a certain extent~ The oven is constructed of brick and angle iron with metal doors, and is very similar to to Altona-type smoking oven, Its capacity is about 150 kg. of fish per batch. 2.2.2 ~~~~~~~~~~-~~~~~~~-~~!~~· A variat~on of highly mechanized controlled smoking kilns widely used in the UK can be seen in Figs. 2 and 3 ( Cutting, 1950), Smoke for the kilns is produced from fires laid in special hearths outside the kiln. The smoke is led into the kiln by ducts and mixed with air. The temperature is maintained by either electric or steam heaters which are thermostatically controlled. The humidity of the warm smoke can be controlled by altering the amount of fresh air entering the kiln. The warm smoke is blown by a fan at an even speed through the trolleys of fish in a horizontal tunnel. A proportion of the smoke passes up the chimney but the majority is recirculated .. Kilns of various capacities from 50 to 1000 kg. of fish per batch are available. With increase of construction costs, the cost of brick ovens should be carefully comared with pre-fabricated mechanized ovens. of the same capacity ( burgess et al, 1965). 3. ------Layout Particular attention should be given to the layout of fish smoking operations in fish processing plants. In order to prevent bacterial contamina- tion between the raw fish and smoked product, the - 4 - APPENDIX III two operations must be kept separate (Dougherty and Seagran, 1967). Samller plants which manufacture a variety if speciality smoked product~ are often equipped with non- mechanized smoking ovens and therefore do not have a continuous flow operation (Fig~ 4). Larger plants are usually based on mechanized smoking kilns and should therefore attempt to maintain a continuous flow ( Fig. 5). Depending on climate and market demand, a refrigerated storage or frozen storage facilities should be provided for the smoked products. Standards of fire protection should be strictly observed· at the designing stage. - 5 APPENDEX I I I A E G E 0 0 I() E E 0 0 CD N I I L_ .J [ I~ 1400mm .! Fi~e 1 - Non-mechanized smoking oven 0£ Leningrad 'type (Courtesy: Chupal:hin and Dormenko, 1967) - 6 APP EN DEX I I I CIRCULATING FAN VERT l(AL f>ART IT I ONS ElECTR 1C MOTOR --.--._ '\'\ '\ '"----£-.- r-..i---...... ~-t-..;..;--"'r---""""~~--~"""'~~~--"--i..-~--, '' AIR FLOW RAIL GUIDE "".. D1FFUSER HEATERS Dl°F FUS ER WALL I WALL SMOKE SMOKE CURING llllET CHAMOER AHlOFOILS TAP~RING SMOKE DUCT OUTLET CIRCUlAT ING 'JERTICAL FAN PARTl1'10NS Figure 2 - Mechanized 650-kg capacity Torr§ Research Station smoking kiln (Courtesy: Cutting, 1950) - 7- APPENDEX Ill _ Figure 3 — A 6510...kg capacity mechanized Torry Research Station smoking kiln (Courtesy: Cutting, 1950) - 8 f\.PPENDEX I I I RA.w 11SH OP[l!ATIO' Figure 4 - LAYOUT OF A FISH SMOK1NG PLANT WITH A SET OF NON-MECHANIZED SMOKING OVENS OFFAL STOR£ SALT STOR£ SAw OUST l"ACKAC:IHCr OR( MATERIAL SANITARY Sl SANITARY STORE ROO~'S ROOMS ~ ! 1· ! IJ ;;; / 8r1n1 font& ... - - ~ ~ 0 E ~ ~ ... ·i:· "' . ~ RAW c SMOKED .> iu FISH ~ c PllOOUCTS . 0 ... STORE . u . STOllE 0°C ;; o•c . :!. "'2. ;;. -0 TroH•T o- e T rolle-y r .~"' - Co - .. 0 . ~ A . "0 ... c.. ,....c I -- RAW FIS'1 SMOKED / Yra1h1n9 OPERATIONS - rant SMOKING FISH OP(ll\ATIONS Figure 5 -J.AYOUT OF A FlSH SMOKING PLANT WITH 3 MECHANIZED SMOKING KILNS APPENDIX IV LIST OF ADDRESSES OF SMOKE KILN SUPPLIERS & OFFER BY AFOS LTD SELECTED LIST OF SMOKING KILN PRODUCERS 1) AFOS Telex: 527231 Manor Estate, Anlaby Phone: (0482) 52152 Hull HU 10 6RL Cable: APEX HULL England 2) Atlantic Bridge Co. Ltd. Telex: 019 21 654 P.O. Box 1120 Phone: (902) 634.8821 Lunenburg Nova Scotia BOJ 2CO 3) Atmos Lebensmitteltechnik GmbH Te 1 ex : 0 2 14 16 6 B.O. Box 800129 Phone: 040-72-701-1 D-2050 Glinde, Hamburg 80 Germany, Fed. Rep. 4) Kurtsiefer Maschinen und Apparatenbau Telex: 889412 JOKUL-D P.O. Box 1101 Phone: (02246) 4078 5204 Lohmar 1, Avelsweg Germany, Fed. Rep. 5) Mauer H. & Sohne GmbH & Co. KG Telex: 0733285 D-7752 Insel Reichenan 'Phone: (07534) 441 Germany, Fed. Rep._ and 446 6) NEFF-WERKE P.O. Box 96 7518 Bretten Germany, Fed. Rep. 7) PETERSEN Elix Rosenvaengets Side alle-1 DK 2100 Copenhagen Denmark 8) THIRODE Telex: 68230 88, rue Anatole France Phone: 8349354 93700 Draney 2840054 France 9) TECHMASHEXPORT Telex: 7560 35, Mosfilmovskaja ul. Phone: 143-87-51 Mosko~, V-330 143-86-60 U.S.S.R. 10) Ve~ag Verdener Maschinei1 und Telex: 024216 Apparatenbau, GmbH Phone: (04231) 171 P.O. Box 320 D-309 Verden (Aller) Germany, Fed. Rep. 527000 G 11) J.H Food Machinery Ltd Telex Phone 781208 921 Hedon Road Hull HU 9 5 QP United Kingdom 12) Stord Bartz As Telex 42051 P.O Box 777 Phone 00475 2110 30 5001 Bergen Norway Phone 45687 13) Fishkey Ltd CYGMARS Britannia Yard Penryn Cornwall England 14 ) Nord.en S e a F o o d Mach i n er y AB Arenco Fish Machines P.O Box 2041 S-421 02 V Frolunda Gothenburg Sweden Anlaby Hull England HUi06RL telephone Hull (0482) 52152 telex 527231 (ans back A1os) cables Apex Hull Mr. Ben Alaya, manuliicturer:, of Development of Fisheries in R·ed Sea & Gulf of Aden, ducled a11 heaters free-standing air heat'ers PO Box 2223, botler/burner units Cairo, de11osting plants Egypt. Torry 11sh and meat kilns Torry hot smoking kilns renewable tube heater batteries unit heaters (steam and wa,1er) mechanical air moving equipment quotation your reference our reference Jl'.B/F .G date 6th April 1982, Dear Sir, With reference to your telex enquiry, and our telex yesterday, we are pleased to enclose our catalogue and leaflets on the range of kilns with our current price lists giving the ex works prices. As we ·were uncertain to which port you required C and F prices, we thought it best to list the options open to you as follows: The capacity of a kiln varies according to the size ar.d v-;t.ight of the o oc• ·et bu~ v-1e would suggest either our No. 120 kiln or our No. 200 would be suitable. I Current delivery is 8 weeks .from receipt of 'an order, and payment is 30 %deposit with order, balance due on completion before despatch, by Irrevocable' letter of Credit. No. 120 kiln galvanised/painted ·finish complete with Automatic Smoke Producer, £17,000 Ex works ...- Trolley aluminium, suitable for trays, .. each .••• £ 240 Ex works Suggest minimum quantity 8 off £ 1,920 Ex works - Trays for trolleys nylon coated· (hot & cold smoking) each £ 7 Ex works For 8 trolleys you would require 400 •..••.•• £ 2,800 Ex works ..-- Kiln clean spray and fluid £ 90 Ex works ./ Drip trays· (s/s teel) for bottom of trolleys 16 off £ 320 Ex works _, Spares - allow £ 500 Ex works C and F costs using 4G' open top container A. To port of Hoddehah, North Yemen £ 3,636 C and F Insurance to be effected in Yemen B. To port of Aden, Southern Yemen £ 5,883 C and F These prices are valid for one month only, due to fluctuations in shipping costs...... /2 duecrors MG Hunter manag,ng J K Bellamy sales all contracts are entered EM Snelhng JM Sur"doe into subject to the Company's WF Hunte~ · Standard Terms and Conditions Afos limited .. /2 As regards the No. 200 unit prices are as follows: No. 200 kiln galvanised/painted finish complete with Automatic Smoke producers £23,000 Ex works Trolleys, aluminium suitable for trays each £ 320 Ex works We would suggest minimum of 8 off trolleys ..•••.• £ 2,560 Ex works Nylon covered trays for above (54 per trolley) each £ 9 Ex works For 8 trolleys you would require 432 £ 3,888 Ex werks Kiln clean spray and fluid £ 90 Ex works Drip trays (s/steel) for bottom of trolleys 16 off £ 320 Ex works Spares - allow £ 500 Ex works C and·F costs using 40' open top container A. To port of Hoddehah, North Yemen £ 3,697 Ex works B. To port of Aden; 6outhern Yemen) £ 7353 Ex works We trust for budget purposes the prices quoted will be sufficient, and obviously when you order, details of electrical voltages and cycles will be required, and also the "hand of the unit 11 will have to be decided i.e. whether the smoke producer ~) are on the left or the right of the kiln, when facing the front doors. If you require any further information please do not hesitate to contact us, Yours faithfully, Afos' limited \'\r \; : LI /\._,.J-' ~ .J. K. BELLAMY Sales Director t~ Enc. AFOS LIMITED QUESTIONNAIRE FOR All KILN ENQUIRIES Telephone 0482 52152 Telex.527231 AFOS G Contact J. K. Bellamy F. J. Grant Please fill in and return to Afos Limited 1. Size of kiln required if known, or througbput of product required. 2. Is the kiln required for hot, cold smoking or both? 3. What product is to be smoked? 4. Do you require trolleys, for speats, or trays - how many? 5. How many trays do you require? State whether plastic (cold smoking) or nylon coated or stainless steel (hot and cold smoking). 6. How many speats are required? Stainless steel only. (for hanging whole fish) 7. What precise electricity supply is available? State voltage, phases and cycles. Is there a neutral conductor available? 8. Is the kiln to be fitted with electric batteries, steam batteries or in the case of cold smoking only, water batteries? 9. Are the smoke producers required on the left hand side or the right hand side when facing the kiln doors. (No. 25 and No. 30 unit left hand side only). 10. Please confirm the following. The floor is flat and will withstand the weight of the kiln. There is sufficient access to install the kiln. Access of 12' x 9' width is desirable for delivery in one piece; please state restrictions and send in sketch if not. 11. Can you arrange for a site electrician to wire the kiln? 12. Can you arrange for a suitable flue to be made and fitted? .. 13. Will you require our engineer to commission the kiln? 14. These units are ex works; do you wish us to arrange delivery to site? Or do you require a FOB/CIF/Air Freight. price? If so please state port/destination. 15. Payment is usually 30% deposit with order, balance due on despatch, or by Irrevocable Letter of Credit; is this acceptable? 16. Have you checked if you will require an Import Licence? Please return this form to Atos Limited, Manor Estate, Anlaby, Hull, England, HU10 6RL. Please give your full name and address, telephone and telex numbers. ...... ~ ...... - ...... -- ...... ····· ··-~·- ...... ...... ··········································································································································································--····························································--···--······················· =mom.. gow■ 4.1.■ 111111■11M111111111111• SIMMS 1101■111. 110■•■••■ MOWN MOM 111■111 =OM NOM 1111111111■. EASY TO OPERATE MSS mirimmin MIES MIS NMI MOM INIIII■11 IMIEN SESIN .811110111110. LOW OPERATING COSTS Mir MEM NM 111111 NM NM UNIFORM CONTROLLED PROCE: MR Mali 'WV] NO PRODUCT WASTAGE LITTLE MAINTENANCE r No. 25 Smoking Kiln with Automatic Smoke Producer. Abs No. 60 Smoking Kiln in stainless steel with Automatic Smoke Producer. COLD SMOKING HOT SMOKING All White Fish Fillets Buckling Finnans Sprats Bloaters Smokies Kippers Sausages Salmon Fillets Chickens Oysters Turkeys Bacon,etc. Eels Trout, etc. 5411,7 !QV rViv: 1!!1(n nnu itzTkin-Amet AFOS lORRY SMOKING KILNS ARE IN ••••...• ••■■■• ...... ...... ■ *No 11.011011.2 111■141 mom moos mamma. 0mM OPERATION IN MORE THAN 70 COUNTRIES .111¢10011M.1101 1XIMMUMBI 100010.0Z WM. 11210=8219. IMEIt IM2111110 =ME NOZEIM... TECHNICAL BACK-UP AVAILABLE NORLDWIDE. WNW NM illaSOUNI Milt IIINIM '11153115& Irt= Mt A DESIGN AND CONSULTANCY SERVICE r7: r:17: FOR YOUR PROCESSING REQUIREMENTS -f- CAN BE SUPPLIED BY AFOS. LLr Control Box Main Heat Exchanger Smoke Discharge Pipe Motor Driven Fan Vertical Aerofoil Smoke Duct Aerofoil Inlet Plenum 0 0 Sawdust Feed 0 Hopper Inlet Diffuser Wa (2) i l i Automatic Smoke Producer R ecrcuaton Outlet Diffuser Wall Channels Booster 'Heat Exchanger Fish Trolleys Damper DESCRIPTION ECONOMIC SUITABILITY The range of lorry mechanical smoking kilns has been developed by Afos following research into food drying All products in the kiln are processed quickly and finished at the technology and aerodynamics. The kilns are designed for same lime, eliminating wastage. The cost of labour for mechanised hot and cold smoking, Crying and cooking of a operation is only a fraction of that for traditional methods. The variety of products and are manufactured in a range of sizes to automatic production of uniform smoke density combined with suit most requirements. the accurate control process temperature ensures constant production of the required quality with no unwanted side The kilns are self contained units Consisting of a basic cabinet with an air circulating fan, exhaust fan, heat exchangers and effects. The operation of the kiln is clean and hygienic. controls. The smoke producer(s) are connected with a rectangular duct to the main cabinet. All component parts are housed in a structural steel frame encased in sheet galvanized steel. The external panels are painted — the standard colour being blue/green. OPERATION CAPACITY The layout of the kiln is shown on the sectional diagram above. The capacity of the kilns vary from installation to installation Air is circulated round the kiln and conditioned to the correct depending on the size of fish and process required. The figures temperature using heal exchangers in the top section and below are'examples of loadings achieved with various types of when necessary in between the trollies of the bottom section. fish in commercially operating installations. In the case of These heat exchangers are controlled thermostatically and the kippers on trays, the fish had first been processed through an temperature of the air over the product can therefore be Abs Tumbler Drier— see separate leaflet. accurately controlled. In order to achieve the correct relative humidity in the kiln, air is taken in at high level through a controllable damper and a similar proportion taken out of the kiln through another controllable damper via the exhaust fan through the chimney to outside atmosphere. Adjusting the inlet and outlet dampers allows the required relative humidity to be attained. The required quantity of smoke is drawn into the kiln from the smoke producer through connecting ducts and is Kiln White Fish 'Trout Salmon Kippers Boneless Mackerel mixed with recirculating air and incoming fresh air before Fillets on on on Trays on Trays Herring Fillets passing through the lop heater battery. The air is circulated Banjoes Speats 650 gm 150 gm on Trays on Trays through the main section of the kiln with the belt-driven axial 450 gm 200 gm sides 100gm 100 gm flow fan in the top section. Air is distributed through the lower 200 900 kg 2000 kg 1700 kg 1300 kg 1200 kg 1750 kg section at even velocity using vertical splitters in the lop section, aerofoils and splitters in the end section and a diffuser 120 800 kg _1350 kg 1200 kg 840 kg 800 kg 1150 kg wall before the first trolley. Various methods of hanging and 60 400 kg 675 kg 600 kg 420 kg 400 kg 575 kc supporting the products within the kiln are used; details of these methods are shown on a separate leaflet. Details of the 30 200 kg 340 kg 300 kg 210 kg 200 kg 290 kg Automatic Smoke Producer are also shown on a separate 230 kg leaflet. 25 160 kg 280 kg 235 kg 170 kg 160 kg IN USE IN OVER 7n nellIKTMFP 1111■1■1t =Moat alumna some= mama, moss ■ ■ TORRY NN/If 1111••■ 111.1 •• OMNI sums. MIN IMO fil MOM OWN 111.1110Mk. MINI MOM 11111=111 MIN ■•111111114 MR MIR NMI MIMI 11•11 11111111 NMI SMOKING nOINNi INE Mi :Arai IN WIN NUR KILN patent number 118436. — The Afos Mini-Kiln is an extension of the range of Afos Torry The Mini-Kiln can be used for the following products:— Kilns that have been manufactured by us for over twenty years, and are used by leading Companies both in this country and COLD SMOKING HOT SMOKING abroad. All White Fish Fillets Buckling It is a self-contained unit capable of both hot and cold smoking Fin nans Sprats Smokies a wide range of products, and can be quickly adjusted to cure Bloaters Sausages the production required. Kippers Salmon Fillets Chickens The Mini-Kiln is simple to operate and drying and smoking is Oysters Turkeys carried out in a single operation. The control system has been Bacon, etc. Eels designed to simplify the kiln operation. A single damper lever Trout, etc. regulates the amount of air discharge up the chimney and an automatic stabilising damper fitted on the inlet maintains the correct volume of air passed into the fan. Automatic control of temperature is maintained by a pre-set thermostat and slide dampers regulate the smoke density required. anu IX 1`44_11N AFOS LID in the UK supply smoking kilns and thawing quantity of smoke is drawn into the kiln from the smoke plant worldwide and have recently obtained orders for producer and mixed with recirculating air and incoming their drying units in Nigeria and British Guyana where fresh air before passing through the top heater battery. there has been a considerable increase in interest in fish The capacity of the kilns varies from installation to drying. Afos Torry smoking kilns are designed for installation, depending upon the size of fish and process mechanised hot and cold smoking, drying and cooking required. An Afos No. 200 kiln, for example, will of a variety of products and manufactured in a range process 1700kg of salmon, 1300kg of kippers and 1200kg of sizes to suit most requirements. The kilns are self- of boneless herring. contained units of a basic cabinet with an air circulating A recent addition to the Afos range of fish processing fan, exhaust fan, heat exchangers and controls. The equipment is the Auto-briner 500, designed for the smoke producers are connected with a rectangular duct automatic brining of kippered herrings and boned fillets. to the main cabinet. However, mackerel and other fish may also be brined by The operation of the kiln is as follows: Air is circulated varying the procedure. Capacity of this machine is round the kiln and conditioned to the correct temperature 230kg/hr, although larger capacity models of a similar using heat exchangers which are thermostatically design can be tailor-made to suit a customer's require- controlled. In order to achieve the correct relative ments. The body and tanks are manufactured from a humidity in the kiln, air is taken in at a high level through special type of stainless steel to resist any chemical a damper and a similar proportion extracted through reaction from the highly saturated brine solution used another damper via the exhaust fan. The required in the process (95 per cent). Main Heat Exchanger Motor Driven Fan Smoke Discharge Pipe-C1 Vertical Aerofoil Smoke Duct Aerofoil Inlet Plenum El II:N1:1 ' . IPIPIIVI: MIP-11 Sawdust Feed CD E-MI11111 -. —0111 111 111.11 Hopper 0 -,.M -1111101111...... 611-1111 ~... -..111!.11-1111-1111 0..—.IIIII.- I .....1. 1 Inlet Diffuser Wall 0 Mg1111...._, _ 1111111I -1 RUH1.0 ...... ■ 1 51 3 'r 0 NFIIIIIIIIIP_ - --1111 M111- .. .-11 1111IX 0 MI.111111111..._ . . _ llJill .._. _1111 I D - .... -11111 -.....I. -111111 D ...-- 11 M—1 1111111!.._ ..1111.1.1 l Automatic Smoke Producer R ecircuation Outlet Diffuser Wall Channels Booster Heat Exchanger Fish Trolleys Damper The Afas Torry smoking kiln AFOS LTD. Manor Estate Anlaby Hull England HU10 6RL Telephone Hull (0482) 52152 Telex 527231 (ans back Afos) cilUb piuuuk_Ab - the most widely used in. -the world Length. X See table below Unit Construction The standard unit is designed forthe 107 cm x 53 cm x 10 cm Main frame constructed from rolled channel, hollow section, (42! x 21" x 4") block of frozen fish, weighing approximately angle section and galvanised sheet. The doors are fitted with "D• 45 kg (100 lbs.), which is the one most readily available. Section neophrene rubber seals giving a watertight joint between doors and main frame. Each tray is capable of accommodating two of these blocks and therefore each trolley will hold approximately 725 kg (1600 lbs.) Heater Batteries of frozen fish. On the standard thawer each door gives access to The heater batteries are positioned at either side of the fan in the two trolleys or 1450 kg (3200 lbs.) of fish (approximately top plenum chamber and consist of copper gilled tubes suitable 1-5 tons). for steam at 2 bars (30 p.s.i.), low pressure hot water at a mean temperature of 76-6'C (170'F) or electrical elements. Hourly throughput of the different size thawers are shown in the table below, the figures are approximate and will vary depending Humidifying Equipment on the condition of the fish on loading and the condition required Method of humidification is by injection of water at high pressure at unloading. through jets positioned along spray banks. Site Requirements Main Fan A flat level concrete floor should be provided for the thawer. A The main fan is an aerofoil unit mounted in a circular casing and cement seal will be necessary inside either end plenum chamber driven by a constantly rated T.E. motor. It is of a truly reversible and drainage to outside the unit will also be required. pattern capable of delivering the same volume in either direction and giving a velocity of approximately 6 metres per second (1,200 f.p.m.) over the fish blocks: A clean fresh mains water supply of approximately 540 litres/ hour (120 gallons/houry will be required for the water spray Trays and Trolleys banks. This should be separately supplied from adjacent taps The trolleys are supplied suitable for pallet loading, each trolley in order to avoid fluctuations in supply pressure. having eight fixed galvanised trays. Sufficienttrolleys are -normally supplied within the price to cover fully loading the The standard unit requires an electric supply of 380/440 volts, thawer. Additional trolleys are recommended and can be supplied 3.phase, 50 hertz with a total consumption of approximately 20 kw at an extra cost. and has a maximum starting current of approximately 60 amps. No. of Hourly No. of Trollies No. of Hourly No. of Trollies Doors Length Height Depth Throughput per Door Doors Length Height Depth Throughput per Door _ 2 4-8 metres 3-4 metres 2-74 metres 600 kg. 2 2 15 '-.8" 11 '-0" 9 '-0" 12 cwt. 2 • • •., . 6-24 metres 3.4 metres 2-74 metres 900 kg. 2 3 20 *-6" 11 '-0" 9'-0' 18 cwt. 4 7.7 metres 3.4 metres 2-74 metres 1200 kg. 2 4 25*-4 - 11 *-0- 9*-0" 1 Ton 4 cwt. 2 5 9•17 metres 3-4 metres 2-74 metres 1500 kg. 2 5 30"-2- I 1 -0 9-0" 1 Ton 10 cwt. 2 proceF.sinc; equiprunnl n --..1ntiLlc:iired by Atns includes: lorry ilist) Curing Kiln f--1.31 Drying Units Wastiers. Tumbler Dryers, Brining and 1 enicring Conveying Equipment, etc. Below qre cxzimplcs of various Afos products instaned in fish processing. laclories. We reserve the right to alter prices and specification without notice. L t -, •,-. _ ..? , .• i 1 e: . t i i _ -.:.-- i 1 , z , r - h ' , • f_, - r.i R , , i i t- . -V..,.. 1 _ . ---- , _ . Y . .. wait..- _ .,.. ,--rr - I , I . ------:---"-- , .,z- ..._.0 -•0 ,-- ii--1- --- C -• . - - ,— - - 1 _•...... • - • • „i • • i „ ■ 7i . . I ,. • ■ [ it . . , .1 ... ...... ,.. . .. ,..... '"- -- -1 t , ....1..P, r.-. i I i . . - - . 1 ... •, .. I t , :11 , - 1 . i .i .1 r. • ---"- ', - - -- . --- - .-:-. - _ --ik"" -- -,:... --_-';',.;:.-,-,_:,, ,..-.7': •-•-.;- - - 1.-. ..' - :;_ ' - -,,,. - _-, . . -. . • 11C...... , . ',...------'--::' _-_-:._:__. - _ - _. - , . ■ . , .. - -...-- . - - . Id • • .41'. d.:3. • I ,•• ' ..... I • T. • r...-.:.. _. . 4.:44a. - • ' 4.... — . _ . -. . _-- ..-. -- ,----;_. . ; . . .- _ . . _ _ t.,------,------•-• •', -- .;,-)+40-,-.. --1-.-4 ... s-7..... ,--- - . . -4- • ... -. _- _ _ ...... _ _ defrosts faster defrosts cheaper defrosts better ..,..,..... ,.., ' - - I ----,-,---.-., ' r .0-! •-...... ,,, 1 / I • - • i • _._ The introduction of freezertrawlers has made it necessary for the The defroster operation has been designed to fit into production fish trade to have available an economic, hygienic and compact lines used in other pans of the factory. mechanical defrosting plant. Such a unit is now available from Abs Ltd., manufacturers of the Torry Mechanical Curing Kiln. The doors of the defroster are not all loaded at once. They are loaded with a delay period between them calculated as follows. The Afos equipment is a combination of scientific and engineering application forthawina and is simple to operate with The delay period equals the length of time to defrost fish a minimum of labour and maintenance. (approximately 5 hours for 10 cm. thick), divided by the number of doors on the defrosting unit. (For example, the delay on a 5-door defroster would be 1 hour). The unit consists of an upper and lower chamber, the upper chamber housing the fan, heater batteries and banks of water sprays. The lower chamber comprises two diffuser walls with This means that after an initial period of 5 hours approximately compartments which house the fish blocks situated between one door will be unloaded each period (and reloaded), giving them. The fish are loaded on to special trolleys and positioned quantities of fish to the next stage of production at regular with a pallet truck into the compartments in the lower section, intervals, instead of the entire capacity of the defroster every where they remain until thawed. Air at a controlled temperature 5/6 hours, which would be the case if all doors were loaded and humidity is circulated over the fish, the direction of the air flow together. being reversed automatically every 30 minutes. The normal thawing time for a trolley loaded with 10 cm (4') thick blocks is Afosthawers are manufactured in a range of standard sizes shown approximately 5 hours. opposite. The thawers can also be modified to accommodate non- standard sized fish blocks if required. ..}0 automatic smoke producer TECHNICAL SPECIFICATION UNIT CONSTRUCTION Heavy mild steel drilled frame to withstand hard wear. Fitted with rustless panels totally enclosing machine. All components mounted inside the unit. HOPPER Integral fuel hopper, capacity approximately 100 lbs. (46 kilos) sawdust, giving a running time of approximately three hours on full output. Hopper .fitted with anti-cavitation paddle and mesh guard and sieve at the top. METERING VAVLE Rotary metering valve incorporated in the base of the hopper with four fuel speeds of approxi- mately 30 lbs. (15 kilos), 20 lbs. (10 kilos), 10 tbs. (5 kilos) and 5 lbs. (2-5 kilos) per hour. FIRE BOX The fire box incorporates a primary air fan providing combustion air to the underside of the grate. The perforated grate is fitted on a slide and is immediately removable for cleaning purposes when necessary. FEED RACK Simple type of reciprocating feed rack transmits the fuel along the fire bed, maintaining a constant thickness during burning. Firebed levelling bars in rack are made of stainless steel for long life. POWER DRIVE Heavy duty gear motor unit is incorporated in the base with primary chain drive to grate and hopper, the secondary drive being provided to the hopper agitator. All shafts run in ball bearings and all components are easily accessible for inspection and maintenance. SMOKE BOX The smoke box incorporates -a large access door for lighting and cleaning purposes and a smoke filter unit and flanged outlet for duct connection. ASH BOX Heavy gauge ash box is fitted at the front of the unit with quick removal front door incorporating inspection glass in the front. CONTROLS Two control dampers are provided, one for selecting the rate of fuel feed, the second one for adjusting the air to the fire bed. A rotary switch is also fitted to the front panel for 'Off', 'Lighting' and 'Running' control. ELECTRICS Units are normally supplied for 400 V, 3 phase siipplies, or 220 V. 3 phase, 60 cycles for export models. The unit is fully wired and main isolator, motor protection gear and safety stet are included. DIMENSIONS Length Width Height 4' 14" 2' 2+" 4'2 (1257mm) (473mm) . (1282) AF OS LIMITED MANOR ESTATE ANLABY HULL ENGLAND TELEPHONE 52152 (3 LINES) Leaflet No 9571. Patents Pending 1353/71. England a nd Other Countries. Printed by Fretwelts of Hull SfE3 (56) tr- S automatic smoke producer UDC for Fish, Bacon, Meat and all smoked products Ault:mit:tic Ignition Compact design Simple to operate Continuous smoking Constant density Integral smoke cooler Cuts fuel and labour costs Full output in minutes from lighti - Robust construction for long life Afos is a completely new system, a. ,Atomatic smoke producing for fisk a- bacon smokers, etc., one compact uniE replacing up to six traditional harlot fired hearths. It is very simple to operate, completely reliable and robustly constructed to give many years of trouble free operatior The unit burns any type of hard wood or soft wood sawdust, peat, etc., and uses less fuel than conventional meth Full smoke output is obtained in a few minutes from lighting and requires no other attention than keeping the hopp€ filled The unit incorporates a water circulating heat exchanger above the fire bed level which keeps the volatiles in the fu , below combustion temperature and any tendency to flare is eliminated. The smoke is also cooled before discharg into the kiln and surplus moisture is condensed minimising the heat gain and humidity from the producer. This important during summer months and in climates where ambient temperatures and humidities are high. The Afos unit not only simplifies smoking but ensures that the required amount c:4 smoke for the product is obtaine , an important factor for firms using strict quality control of products. The low initial cost- of the Afos smoke producer, with saving in both fuel and labour costs, makes consideration 1 conversion of any hand, fired- kiln a necessity and the unit is strongly recommended when it is necessary to repla( any mechanical smoke producing equipment. AFOS LID MANOR ESTATE ArILA3y HULL r TELEPHONE 52T 52 (3 LINE: ,1 AL EASY TO OPERATE 111••■■OF .0■■••■■••■• Mow* LOW OPERATING COSTS UNIFORM CONTROLLED CURE NO PRODUCT WAS T AGE LI II LE MAINTENANCE COMPACT UNIT CONSTRUCTION 7 —12t.7t Illustration showing the compact control arrangement with the temperature controller Tenter bars (not supplied with kiln) Approximate capacity 20k &indic....ator on the right hand side. used for hanging kippers using 175 gm product _ Method of hanging chickens & turkeys App oximate capacity 20 kg Operator removing smoked salmon from kiln Approximate capacity 25 kc us no 1 to 1.5 kg products using 700 gm product I L Metimd of hanging sausages in kiln Approximate capacity 15 kg Method of smoking boneless kipper fillets Approximate capacity 16 kc using 250 gm products using 100 gm product5. 18.2 1-..._119M11111,1111 , Method of hanging trout iitickling Approximate capacity 27 kg Banjoes used for hanging white fish fillets Approximate capacity 12 kg using 200 gm products using 250 gm products 00 09Q 0 127 mm (5") V - 0 000 0 CONSTRUCTION DIMENSIONS (See also above) The kiln is manufactured as a single unit in box section, and is 185 cm long x 66 cm wide x 96 cm high constructed from galvanised or stainless steel. Al! joints are 6ft lins long x 2ft 2ins wide x 3ft lins high sealed to eliminate leakage of smoke during operatic ,' Trolley access is provided by a double skinned door CRATED DIMENSIONS pivot type hinges. Sponge sealing strip gives a pc. 190 cm long x 71 cm wide x 94 cm high approx. under working conditions. 6ft 3ins long x 2ft 4ins wide x 3ft 1ins high approx. The smoke producers which are incorporated in the un it comprise three drawer type hearths, each incorporatinc a slide WEIGHT type air inlet control to provide setting for the amount of air Nett 155 Kg approx. passed over the fires. The smoke producers are easy to light Gross (crated for export) 225 Kg approx. and clean. ELECTRICITY SUPPLY AIR FAN 240 volts, 50 Hz, 15 amp. Air flow is provided by an integral, centrifugal fan to give an air velocity of approximately 1 m/sec (200 ft per minute) across OPTIONAL EXTRAS the working section of the kiln, and the fan is driven by a The following variations and additions to the standaru continuously rated motor. specification above are available, prices on application. HEATER BATTERY 1. Special voltage and frequency. The 4kw electrical heater battery is thermostatically cryitrQs 2. Wooden tenter bars. tz maintain the pre-set temperature required in the kiln 3. Export packing. 4. Delivery. -finerrn0SLatic controller incorporates a dial type indicato r o tittf the working temperature can immediately be seen by the operator. INSTALLATION & MAINTENANCE Kilns are supplied in unit form needing connection to the AIR CIRCULATION electricity supply and exhaust chimney. The air is drawn through a diffuser wall, which is of multi-plate Little maintenance is necessary other than periodic attention to construction to give an even air flow over the working section of the smoke producer and cleaning of the kiln. the kiln, and is passed through the fan and recirculated by the top duct section of the unit. Full installation, maintenance and operating instructions or. supplied with the kiln. Provision is made to control the amount of air flow by a single damper, which works in conjunction with an autorr ,tic inlet control, to ensure there is an even suction acros.'.- •e smoke SERVICES producers during operation. Technical and sales information can be obtained from Afos Ltd. at their head office in Hull, England. A consultancy service STANDARD ACCESSORIES covering kilns and the many associated pieces of equipment Multipurpose trolley. manufactured by Afos is available to assist in factory layout 7 trays. etc. The equipment supplied direct from the manufacturer and 12 banjoes - stainless steel. prices can be given covering delivery, site commissioning etc. 16 speals (56cm) - stainless steel. A separate standard price list is available giving ex works 1 drip tray - stainless steel. prices. speat carriers. All contracts are entered into subject to the Company's Plastic brine tub. Standard Terms and Conditions of Sale. The Company 1 container "Kiln Clean" reserves the right to change prices and specifications without Operating Instructions. notification. Afos Limited ■•■■•••■■•■ Manor Estate wormarrom ZnallEMINtlat Anlaby MUM IOW ME Hull MIR NM England HU10 6RL iMit telephone Hull (0482)52152 telex 527231 (ans back Afos) cables Apex Hull Manufacturers of - Ducted Air Heaters, Free Stan 6111r:- Air Heater, Boiler/Burner Units, Defrosting Plants, "Toffy" Fish &•Meat Kilns, "Torry" Hot Smoking Kilns, Renewable Tube•Heater Batteries, Unit Heaters (Steam & Water), Mechanical Air Moving Equipment. 1/3/81 Printed by Fretwells of Hull, England. ;()- core LE )-}- .,._ ____ SUPPLT P!OO"I SUPPLY SANITARY lllOOMS STORE STOl!E 0J5PATCH SHED )-~-• 0 0 SMOKED D 0 Trolle7 PRODUCTS >-:- Pock.091n9 toblaa - COOLING w- S'f ORE - - O"C D D ROOM PACl'\ING l!OOlol 0 0 \