TANG-8-93-002 C3
CICtlUIfHgggpy SeaQt'act pepository
Design,Operation and TrainingManual for an Intensive Culture
Granvil D. Treece Joe M. Fox
Texas ARM University Sea Grant College Program Design, Qperation and Training Manual for an Intensive Culture Shrimp Hatchery with emphasison Penaeusmonodon and Penaeusvannamei!
Granvil D. Treece SeaGrant College Program Texas A&M University
and
Joe lVl. Fox Pesca S.A. Guatemala, C.A.
TAMU-SG-93-505 July 1993
Publicationof this documentsupported in part by Institutional Grant NA16RG0457-01to TexasA&M University SeaGrant College Program by thc National ScaG rant Office, National Oceanic and Atmospheric Administration, US. Department of Commcrce, 0~1992. Copyright@1993 Texas A&M UniversitySea Grant College Program All rights reserved. Printed in the United States of America.
TexasA&M UniversitySea Grant College Program Publication TAMU-SG-93-505 ISBN 1-883550-02-5
For more information on Texas A&M SeaGrant publications,contact: SeaGrant Program Texas A &M University TAM U-SG-93-503 2nd Floor, Building 306 1 M July1993 4700 Avenue U NA16RG0457-01 Galveston, Texas 77551 A/F-1 Purpose of this Manual
In 1986there was a perceived need for more written information on intensive shrimp hatchery management, especially with P. monodomand P. vannmnei,and especially for training purposes, In compiling the information in this manual, the intent hasbeen to survey existing information abou t intensive penaeid shrimp hatcheries to develop the production procedures needed to maximize the efficiency of the hatchery and minimize the length of time that it takes to train personnel in the procedures. The underlying question is: what is presently known and what needs to be known to operate a commercial hatchery efficiently? This manual has been organized into three main parts Design, Operation and Training! within nine chapters, The designpart focuseson two hatcheries one for eachspecies! and givesdetailed plans of their constructionas well asother options. The operation portion of the manual details the procedures for most efficient operation of a specific hatchery. The training portion of the manual consists of compiled, presently known background or historical! information thought to be important for training new personnel.Hopefully this compiledmaterial will alsoserve as reference material if future problems are encountered, Having historical or background material as well as current or "state-of-the-art" technology availablemakes it easierto solveproblems. Each hatchery is unique with its own setof requirements,The nextbest thing to experience is having a broad-based reference collection or library at hand. It is the intent of this manual to provide a single publication that will cover most of the important steps in intensive larval shrimp culture, will act as a single reference to our present knowledge on the subject and/or will be a source of information. It is hoped that there is enough detail in this manual to provide the newcomer with an adequate amount of knowledge presentedin laymen's terms to run a hatcheryand, at the sametime, provide details and new technologyto assistthe experienced hatchery manager. Acknowledgements
In addition to those acknowledged at the end of each chapter and in the literature citations, the authors would like to thankthose "pioneers" in the shrimpaquaculture field who havepaved the road to penaeidshrimp larval culture those peoplewho havespent their livesdiscovering, testing, publishing and sharing results. These are the people who have discoveredand published the information through the years that has been compiled in this manual. It is also their discoveriesthat wereused as a basisforthcspccific procedures that worked to makethe Dian Desahatchery more efficient. Someof these"pioneers" are Fujinaga,Cook, Murphy, Mock, Motoh, Platon, Kittaka, Liao, Salser, Yang, Shigueno, Shokita,Tabb, and Villaluz, just to namea few. Someof themore recent workers in thisfield whoalso contributed significantly through their work and publications areJohns, McVey, Tseng, Howell, Simon, Wilkenfeld, Lightner, Johnson, Redman, Primavera, Quinitio, Laramore, Tang, and many morc. Specialthanks go out to the U S.Agency for InternationalDevelopment, Development Alternatives Inc., Central JAVA EnterpriseDevelopment Project, and the Indonesian Government. Members of theseagencies tha t deservean extra special thankyou areJim Boomgard, Anton Sudjarwo, Mumuk Soebagiyo and Pa Dibo for theirassistance and friendship. We alsowould like to thank the SEAFDECpeople for their cooperationin releasingcopyrights to someof the information presentedherein. Thanksgo to Sea Grant for providinga workingatmosphere that allowed this manual to becompleted, to Cindy Liles, Lynn P ropesand DebbieHermann for processingthe manuscript, Amy Broussard,Melissa Hightower and David O'Ncal for editingand to Drs.James McVcy, Robert Stickncy and Bart Baca for reviewingthe manuscript and offering valuable suggestions. Table of Contents
Hatchery Site Selection, Design Criteria, Engineering and Construction. .1 Introduction I B ackground. 1 Small Hatcheries 2 Big Hatcheries 3 Maturation Facilities. ....,., 3 The Hatchery Cycle 3 The Future .... 4 FreshwaterAvailability . Electrical Support ...,... 5 Market Considerations. Availability of SkiBed Labor ...... 5 Availability of Building Materials. ...5 Availability of Mated Females...... 6 Feed Distributors ...... 6 Extension Assistance .6 Competition with Other Operations. ,. ...6 Expansion Potential ...... 6 Evaluating the Site. ,6 Hatchery Site Evaluation/Selection...... 6 DesignCriteria, Engineeringand Construction. 11 Preliminary Considerations .. ,....11 Approach to Culture ll General Layout of the Hatchery . ,, 11 Modular Concept for Future Expansion, 11 Culture Tanks. 12 Sizing the Hatchery 12 Specific Hatchery Background. ...,.20 Central American Facility Hatchery Example! . 20 Maturation and Hatching . ...51 SpeciesMatured in Captivity. ....51 Maturation ...,.51 ResearchHistory. 51 Maturation-Hatchery ResearchHighlights in the United States 52 Important Parameters for Maturation ,. .,53 Other Parameters tc Consider . 54 Additional Considerationsfor Optimum Maturation . ....54 Sources of Broodstock ...,.....,...... 55 Sourcing P. monodonin Indonesia . .... 55 ExternalCharacteristics of Adult PenaeidShrimp . 55 General Reproducti ve Characteristics 55 Male Reproductive System ...... 55 Female Reproductive System. .,58 Size at First Maturity and Mating ...... 59 Ovarian Maturation/Staging Mature Shrimp. The Shrimp Egg Mating of Open-TheIycum Shrimp ...... 61 Ma ting of Closed-Thelycum Shrimp . 62 Spawningand Rematuration ..., ...,...... ,...... ,..... 62 Fecundity ...... 63 Hormonal Control ...... 63 Eyestalk Ablation Background and Research . Maturation Feeds B roodstock Operations . . .,65 Broodstock Receiving and Shipping .....65 Broodstock HoIding Ponds 65 Broodstock Distribution and Feeding,. Ablation af Female Broodstock at Dian Desa Hatchery Tank Volume Determination, .70 Record Keeping. 77 Spawningand Hatching . .78 Transferring Nauplii . .78 Disinfection Procedures. .78 Selected Maturation References. .78 Larval Rearing .83 Introduction and Background. Daily Larval and PostlarvalRearing Schedule .83 Larval-RearingTank PreparationBefore Use .84 Other EnvironmentalConditions of Importance. .87 Larval Staging, Feeding and Observations.. .89 Artemia Enrichment 92 Formula 92 For Use with Hatching Artemia 92 For Usewith HatchedSeparated Artemia in seawater!. 93 Algae Culture in Support of Larval Rearing! 93 Growth Medium, 93 CommercialApplication and Community Method of AlgaeProduction used by Continental Obtaining Cultures. 93 Fisheries, Ltd., Panama City, Florida. 95 Growth Characteristics 95 Culture Techniques .....,.... 95 Filtration, Sterilization, Disinfection, 96 Comparisonof Disinfection Methods.. 99 Other Disinfection Methods . 99 CentrifugationWashing, Antibiotics or other Chemicals. ,, 99 Counting Alagal Cells and DeterminingAmount to FeedLarvae 99 AlternateExplanation of AlgaeCell Counting and Determining Amount of Feed. . 100 The Use of the Hemacytometer . 100 Preparationof Sampleand Hemacytometer 100 How to CalculateAlgae Culture RequirementsBased on 60,000Liter Larviculture Capacity 101 Alternate Larval Diets 101 Egg Diet Preparationfor PenaeidLarvae Mysis I or older! 101 Cooking Directions 102 Feeding Directions and Application Rates 102 Microencapsulated Diets . 102 OmegaYeast 102 Signs of LarvalStress, Diseases and Treatmentsat Dian Desa 102 More Detail of Treatments . 103 Harvesting Larval-Rearing Tanks at Dian Desa 103 Selected References ...... ,.... . 103 Postlarval Holding and Rearing in Circular Raceways .107 Raceway Description 107 RacewayTank Preparatioonand Operation 107 Raceway Stocking. 108 Postlarval Feeding . 108 Daily Inspection . 109 Diseases and Treatments at Dian Desa. 110 Records 110 Identificationof Postlarvaeand RecognizingHealthy, Desirableor UndesirableLarvae 110 Harvesting Postlarvae 113 Alternate Production Strategiesfor the YayasanDian DesaHatchery 115 Maturation 115 Larva] Rearing 115 Postlarval Rearing . 115 Alternate Production Strategies .. t ~two oct 115 Shrimp Toxicology and Shrimp Diseases, 119 Shrimp Toxicology,. ~ 92tt++M II 0+i ~ +tttI~ It 119 Organic ChemicalsOther than Petroleum 119 Industrial Organic Chemicals 119 Polychlorinated Biphenyls . 119 Pesticidal Chemicals. 121 Organochlorines 121 Organophosphates and Carbamates.. 122 Petroleum . 122 Heavy Metals. 123 Cadmium Cd! . l23 Iron Fe! . 124 Copper Cu! 124 Mercury Hg! . 124 Zinc Zn! . 125 Lead Pb! 125 Nickel Ni!. 125 Maganese Mn!, 125 Magnesium Mg! 125 Aluminum Al!. 125 Treatment of Heavy Metals. 125 Biological Agents 126 Biochemical Agents . 126 Infectious Pathological Agents 126 Interactions of Pollutants, Pollutant Mixes and Other Factors in Penaeid Shrimp 127 Pollutant-SalinityStress Interactions 127 Pollutant-Temperature StressInteractions 127 Pollutant-Pollutant Interactions .... 127 Pollutant-Natural Disease Interaction 127 Larval Diseases Overview. 128 Larval and Juvenile Shrimp DiseasesDetail 131 Infectious Diseases...... , 1 31 Bacterial and Fungal Diseases 134 Fluorescent Bacteria . ,. 136 Luminous Bacteria . ... 136 Fungi...... I 37 Protozoan Parasi tic Diseases. 1 38 Noninfectious Diseases . 138 Bacterial epicommensals,. 1 38 Protozoan epicommensals...... I 39 Algae ...... 1 39 Nutritional, Toxic and Environmental Diseases Detail...... 139 Nutrihonal Diseases ...... 139 Toxic Diseases, ...... 1 39 Methods for Routine Examinationof Larval Shrimp ...... 1 41 Particular Examinations .. ...142 Methods for Routine Examination of Juvenile and Adult Size Shrimp 142 Particular Examinations .. 143 Media and test proceduresaf specialimportance inpresumptiv e edentification of bacteria . ..143 Virological...... ,...... ,...... ,...... 146 Rickettsia/Chlamidia detecation ..... 147 Fungal ...... 147 Protozoological ....147 Helminthological Flukes, Acanthocephalans, and Tapeworms! 147 Specific Pathogen Free SPF! Shrimp...... 148 Acknowledgments .....148 Selected Recent Shrimp Toxicology and Disease References...... 148 Drugs Used in Shrimp Hatcheries as Chemotherapeutartts 155 Necessityof Antibiotics Chamberlain,1988!. ,. ,155 Problems with Antibiotics . ,155 General Use of Antibiotics. ... 155 CommonDrugs Usedin World Hatcheriesas Chemotherapeutants and Applicable Dosages 155 Chernotherapeutants in United States Shrimp Hatcheries ...... ...156 Oxytetracycline 159 TrifluraIin Treflan! . 159 Compoundsto be Replaced. 159 Needed Chemotherapeutants. 160 Results of Larval Rearing and Postlarval Rearing Trial Runs at Yayasan Dian Desa Hatchery .161 Other Information about the Raceways 168 Recommendations . 168 The Hatchery As A 8usiness . ...169 Introduction 169 The Manager's Role. 169 Planning 169 Sample Annual BusinessPlan . 169 Accounting/Bookkeeping 170 Hatchery Capital Flow. 170 The Purpose of Accounting , 170 The Monthly Profit and Loss Statement. 170 Notes on Operating Expenses. , 170 The Yearly Profit and LossStatement 171 The Annual Balance Sheet. 171 Marketing, 171 Packaging . 171 Delivery. 173 Customer Relations . 173 When To Do Marketing 173 How Much Is Necessary 173 Types of Marketing, 173 Summary. 173 Hatchery Cash Flow Example . 174 Monthly Cash Flow ...... 176 Large U.S. Hatchery Description 179 Large Hatchery Postlar val Disposition 179 Large Hatchery Production Summary ...... .....,...... ,.....,...... ,...... ,...... 1 79 Large Hatchery Postlarvae Costs ...... I 80 Large Hatchery Postlarvae Production and Disposition by Month s! . ., 1 80 Actual and Projected Large Hatchery Operating Costs 1989-1995 ...... 1 81 1990-1991Equipment Price List for CentralAmerican Shrimp Hatchery in U.S.$! with a ProductionCapacity of 10 Million Postlarvae/Month. ,...,...... ,...... ,...... 182 Aquaculture Equipment Suppliers ...... 186 New ResearchDevelopments for 1993 ...... 186 Adding Enteromorpha to Broodstock Diet ,.... ... ..., .... ..... ...... '187 List of Figures
1 Location of Java. 21 Location of Hatchery on Java 22 Dian Desa Hatchery 23 Front and Side View with Elevations. 24 Front and Back View with Elevation 24 246 35ja 25 HatcheryOverview with Detail Original SeawaterSystems 26 7b Final Seawater System 27 Artemia Production Area. 29 810 9Laboratory and Algae Production in FiberglassPolytanks 29 LaboratoryWork Bench 30 11 Carboy Standfor Algae Production ...... 30 12 Various Maturation Systems ...... ,. 31 13 Maturation Tank Detail ...... 31 14 TypicalRaceway Design Postlarvae!. 32 15 SpawningTank Detail, 32 16 Larval Culture Area ... 33 17 Larval RearingApproach ¹2 ContinuousFeeding! ..... . 33 'l8 Various Larval RearingTanks 34 19 Larval Rearing Tank Detail. 34 20 RacewayTank Detail 35 20a Central American HatcheryFacility. 35 20b ConceptualDrawing of SeawaterIntake Central American Facility 36 20c Central American Hatchery Foundation/Levels 36 20d Central American HatcheryRooms and Dimensioning. 37 20e Central American Hatchery Tanks/Location 37 20f ConceptualDrawing of Central AmericanHatchery SeawaterTreatment . 38 20g Central AmericanHatchery Seawater Elevated Header Distribution System...... 38 20h Central AmericanHatchery Maturation Facility SeawaterDistribution ... 39 20i Central AmericanHatchery Blower Aeration System 39 20j Central AmericanMaturation Facility Aeration Distribution System .40 20k Central American Hatchery Drainage System. .40 201 Central American Facility Maturation Tank Design .41 20m Central American Hatchery Larval RearingTank ....41 21 Lateral View of Adult Female Penaeussetiferus 56 22 Dorsal View of Adult Shrimp. 56 23 Details of Male and Female Reproductive System. 57 24 Details of Male Shrimp ReproductiveSystem . 57 25 Male ReproductiveSystem 58 26 Details of Male and Female Reproductive System ...... 58 27 Quick Identification of SelectedSpecies . , 59 28 ExternalAppearance of theOvaries of P. monodonat DifferentStages of Maturity ...... 60 as SeenThrough the Dorsal Exoskeleton 29 Developmentof DifferentEgg Types of Penaeusmonodon , 61 30 Courtship and Mating of P. monodon 62 31 Peneausvannamei and monodonLength to Weight Conversion .66 32 Length and Weight Data Sheet .68 33 Feed Rate Determination, .69 34 Weekly Schedule of Maturation Activities 72 35 Maturation Tank Log. 73 36 Actual Egg-Nauplii Data Log. 74 37 Maturation/Hatchery Egg-Nauplii Data Log, 75 38 Larval-State of Health, 76 39 Larval Rearing Tank Data Log . 84 40 Shrimp Larval Stages...... -----"-.--.-"-""- -" -"-"-- ...... 86 41 Naupliar Substages ...... 88 42 Zoeal Substages...... "---"-.--"-"-"- "-" - " -"" - -" -" ""-" .,88 43a SomeCommonly Cultured Microalgae...... 88 43b Typical Phytoplankton Culture Growth ,88 44 Myses and Postlarval Substages ...... 89 45a Stagesof ArfemiaDevelopment ...... 90 45b ArtemiaHatching Cones...... 90 46 Counting Artemia When Concentrated and Hensen-Stemple Pipet 91 47 Typical Cycle Used in Algae Culture 92 48 Glass Carboy 96 49 Typical Algae Culture Rack 96 50 Recommended Ozone Levels and Formula for Checking Ozone Residual .... .98 51 Hemacytometer . .100 52 Chemicaland Antibiotic TreatmentsUsed in Philippine Hatcheries ,156 53 FormsUsed for the Calculationof Drug and ChemicalRequirements for EachTank, Morning and Evening. ....158 List of Tables
1 Suggested Larval-CultureSequences and Postlarval Feeding for Yayasan. 85 Dian DesaHatchery, Jepara, Indonesia 2 Classes and Speciesof MicroalgaePresently Under Culture 89 3a Guilllard's F/2 Algal Culture Medium . 94 3b The Philippines Method of Algae Culture 94 3c IndonesianMethod of Algae Culture . 94 4 Alternate PostlarvalFeeding Guideline/Feed Requirement/Feed Costs per Month,...... ...111 5 Postlarval Holding and RearingData Log . 112 6a PolychlorinatedBiphenyls and PenaeidShrimp. 120 6b OrganochlorinePesticides and PenaeidShrimp . 120 6c Petroleum and Penaeid Shrimp 122 7 Diseases Foundin theDevelopmental Stages of PenaeidLarvae and Their Control Meth ods ...... 1 29 8 Penaeid Virusesand Their Known Natural and ExperimentallyInfected Hosts 132 9 Routine ProphylacticTreatments for Shrimp Larvae 156 10 Alternate Method of Larval Culture Sequences,Postlarval Feeding Regime and Disease PreventiveSchedule Used by JoshVilkenfeld, Aquatic Farms,Ltd., 1989. 157 1 l Actual Larval RearingTank Log for Tank Number 1 162 12 Actual Larval RearingTank Data for Tank Number 2 164 13 Actual PostlarvalRearing Tank Log for RacewayNumber 7 .. 166 14 Actual PostlarvalHolding and RearingData for RacewayNumber 8 167
36. Broodshrimpsettling in and eating squid; someare more stressedthan othersupon arrival and appeared red in color and swim at the surface until they too settle in 37. Healthy Broodshrimpabout one week after stocking;ready for ablation and to be placedin production 38. Demonstratingproper ablation technique holding 450gram femaleBroodstock just under water surface with one hand and removing contents of one eye with the other hand. Contents have been removed in the right eye! 39. A soft nylon net is used to capturebrood from ablation or just for inspection 40. Constant water level maintained in maturation tank by this dual standpipe water being drawn from the bottom of the tank at this point, but by removing the outer standpipe water can be "skimmed" from the upper surface in case there is excessfood floating! 41. Effluent flow rate is checked daily at the maturation tank in order to maintain a constant, stable environment 42. Fresh molt on the bottom of maturation tank 43.. Salinity readings are taken routinely once a week unless during the rainy season then refractometer readings may be required more often! Molts are removed after they are no longer a good food source usually within 24 hours and they have turned yellow-gold! 45. Using inexpensive underwater light attached to PVC pole! to locate late stage female shrimp 46. Flashlight can be placed such that light beams shows through exoskeleton and stage of developing female is determined 47. Records are kept for the day on a formica board hung near each tank 48. The daily records from the formica boards are kept on a clipboard for easy reference in the event there is a problem 49. Late stage females are placed individually in a series of 800 liter spawning tanks, each equipped with water inflow and screen standpipe 50. Counting egg and nauplii out of a 100 ml beaker subsample taken from the spawning tank note inflow and effluent screen with air collar! 51. Larval rearing tank approximately one-half full micron filter cartridge on inflow; central, screen standpipe with air collar and 100,000cells/ml algae! Larval rearing area Seriesof larval rearing tanks;some covered with plastic during evening hours to keep temperature up 53. 4,000 liter Larval rearing tank filled to capacity 54. Siphoningoff freshly hatchedArtemia nauplii after settling note the stratified layers;the bright orange layer is nauplii! 55. Laboratory work bench with balance and chemical storage 56. Algae lab behind closed doors in air-conditioned room 57. Algae production in small flasks 58, Algae production in glassjars wide mouth allows easyaccess for cleaningjar! 59. Figure 50, typical algae room arrangement 60. Figure 50, typical algae room arrangement 61. Postlarval rearing and holding area 62, Postlarvalholding and rearing tank 5ft.-dia., ferro cement,circular, holding approximately 12 tons, airlifts and screen habitats! 63. Feedingpostlarvae a finely ground pellet 64. Siphonused to cleanPL holding tank when necessary 65. Postlarvalrearing and holding data board formica board locatednear the tank! 66. 1,000liter plastic containers used to transport postlarvae 67. Example of a fiberglass postlarval transport tank Glossary of Selected Terms ablation Extripation, removalor otherwisedamaging the eye in somemanner to promote maturation. Anemia Brine shrimp. aseptic Sterile. axenic Free from other living organisms. bacteria One-celledorganisms that canonly be seenwith a microscope.Compared to protozoans they are of less complex organization and are much smaller in size. broodstock Larger animalsthat are sourcedand expectedto produceoffspring in the maturation facility. carboy Glass bottle. cysts Eggs of Arternia that are in a dormant stage. de capsulation Removal of the thick outer layer on Artemia cysts. disinfection Reduction of bacterial numbers to a "safe" or "acceptable" level. exoskeleton Shell of the shrimp. grooves There are numerousgrooves on a shrimp.Some are usedas an aid in identifying the species. Examples: The "thumbnail" grooves on the last abdominal segment of tropical Atlantic brown shrimp distinguish them from similar white shrimp; Thelength of the rostral grooveis shorterin P. monodonthan in P. semisulcatusand canbe used asone way to distinguishthe two similar species.Other distinguishing characteristics can be seen in Figure 27. hemacytometer Device used for counting algae cells Figure 51!. hemoiymph Blood. Hensen-Stemple pipet Pipet used to take an objectivewater sample Figure 46!. hep atop ancreas Digestive gland. larvae Plural of larva and the stage in the development of a shrimp's life cycle between the egg and the juvenile. maturation The act of maturing In the caseof white shrimp, egg development, mating and then spawning; with brown shrimp, mating, egg development and spawning!. media Plural of medium and in this case refers to saltwater and nutrients or food added to promote proper growth either of algae,larvae, etc. For shrimp, sheddingof the exoskeleton. nauplii Plural of naupliusand the first of threemajorlarval stages.Itisa non-feeding stageand isthebest stage to transport the animals until they reach the postlarval stage. penaeid The family, superfamily and an infraorder of shrimp distinguished from the caridean shrimp by the shape of the second segment of the abdomen. The sides of the penaeid shrimp shell known as the pleura! overlap each segment that is behind it. In the caridean shrimp the pleurum of the secondsegment overlaps both the first segmentand the third, making the secondsegment look very large. There are 109 species of penaeid shrimp listed by the Food and Agriculture Organizationof the United Nations F.A.O.!. petasma Male shrimp reproductive structure. prawn According to Dore and Frimod t 987!, different people use this name to mean and to apply to quite different species. Examples: U.K.: larger than shrimp, U.S.: restaurants use it to mean large shrimp and other places mean small shrimp or freshwater shrimp Norway: producerspromote the northern shrimp Pandalusas a prawn, and the "Dublin Bay prawn" is evenused to describeNephrops, which is a langoustineor Norway lobster.
Xiv The OxfordDictionary defines prawn as '1argerthan shrimp" whereas Webster's Dictionary describesit as "a small, edible crustaceanof the shrimp family." SouthAfrica. larger animals are prawns; smaller animals are shrimp. F A O. attemptedto introduce a clearcutdefini tion as early as 1967, At theWorld Conference on thebiology and culture of shrimpsand prawns held in MexicoCity, it wasagreed that the term "prawn"was to be reserved for freshwater creatures only, while their marine/brackish water relativeswere to be called"shrimps."Unfortunately, despite all of theirefforts, the confusion continues.The only point on whicheveryone can surely agree is thatthe use of "prawn"in the Englishlanguage is confusingand unclear, and shouldbe avoided. protozoea New world term of zoea or the secondmajor larval stageof penaeid shrimp. raceway A smallpond or tank that is usually rectangular with a centerdivider or circulartank with a water flow that "races" around the tank. rostrum Thepointed prow that extends from the head of mostshrimp. setae Hair-likestructures that appear to branchoff of appendagesor legs. sourcing Obtaininganimals to be usedfor broodstock. spore A small cell that can develop into a new individual. spp. or sp. Plura]and singularabbreviations for species, respectively. sterilization Total inactivation of all microbial life. thelycuxn Femaleshrimp reproductive structure, Chapter 1 Hatchery Site Selection, Design Criteria, Engineering and Construction
Introduction There is a perceivedneed for more written information on intensive shrimp hatchery management, especially with P. manadanand P. vannamei,and especially for train- ing purposes. In compiling this manual, existing information on intensive penaeid shrimp hatcheries hasbeen surveyed to develop efficient production procedures and minimize personnel training time. The underlying question is what is presently known and what needs to be known to oper- ate a commercial hatchery efficiently? The manual is organized into three main parts design,operation and training in nine chapters.Design focuseson two hatcherics onefor eachspecies! and gives detailed plans for construction as well as selected equip- Photo1. Seasonal haruest of zoild postlarvae arith scissor nets from the ment options. The operation portion details the most Pacificbeach of Bahia,Ecuador. efficient procedures for a specific hatchery, and the train- ing portion consists of compilations of background or In the1990sthere willbe thousands of shrimp hatcher- historical information thought tobe important in training new personnel. ies of all sizesoperating worldwide, helping to supply "seed" or postlarvae to one of the most valuable industries Hopefully, this material will also provide a referenceif future problemsare encountered,since having historical in the world. In 1992, over 700,000 MTs of farm-raised orbackground inaterial as well as current or "state-of-the- shrimp wereharvested 50,000 MTs from Thailand alone!. art" technologyavailable makes it easierto solve prob- Shrimp farmersnow produceat least28 percent of the2 6 lerns.Each hatchery is unique with its own setof require- million metric tons of shrimp placedon world markets ments.The nextbest thing to experienceis having a broad- today,and this percentagehas risen steadily since1981. based referencecollection or library at hand. It is the intent These shrimp hatcheries help provide a more reliable of this manualto provide a singlepublication that covers supply of postlarvaefor pond culture, especiallysince most of the important steps in intensive larval shrimp wild populations fluctuate unpredictably and are pres- culture, acts as a singlereference to our presentknowl- ently being harvested at or beyond their maximum sus- edge on the subject and /or is a sourceof informa tion. It is tainable yields. As a result of this exploitation of wild hopedthat thereis enoughdetail in thismanual toprovide populations,many countrieshave placed restrictions on the newcomer with adequateknowledge in laymen's the collectionof wild shrimp populations seeharvesting termsto operatea hatcheryand, at the sametime, provide wild postlarvae,Photo 1!. Shrimp hatcheriesare helping details and new technology to assist the experienced to fill thedemand for postlarvaeand to relieve someof the hatchery manager. pressuresplaced on the wild stocks.Undoubtedly, the lackof a reliablesupply ofpostlarvaewas once among the biggestsources ofuncertainty, inefficiencyand economic Background lossesfacing shrimp farmersworldwide. As time passed Shrimp of the family Penaeidaeform thebasis for one and we havebecome more familiar with the technology of the most valuable fisheriesin the world. The highly involved in shrimp reproductionand growout in captiv- esteemedquality and edibility of theseshrimp, their rela- ity, these uncertainties do not seem so monumental, We tively large size and their worldwide distribution have still havea longway to go beforewe arc totally indepen- eliciteda largeinvestment of manpowerand funds in the dentof naturalstocks, but thegap is closingquickly with shrimp industry. Worldwide, thc pcnaeidshrimp fishery the rapid technologicaladvances that have occured in is an annual multibillion dollar enterprise.According to shrimp hatcheries since 1985. Rosenberry 992! the fishery is a 2 million metric ton To solvethe majorlimiting factorof insufficientavail- MT'! marketof which 28 percent or 700,000MT'! were ability of postlarvae,mass production in hatcherieshas farm-raised in 1992. receivedmuch a ttcntionfrom researchers.The techniques 2 ... Treeceand Fox are now well known, although the results are not always satisfactory.The following threemam znethodsare used: ~ TheJapanese method ischaracterized bylow densig of aroundten larvaeper liter, largetanks up to 200m, a need for nuznerous wild-caught gravid females, direct water fertilization by inorganic nutrients to promotealgal bloom,and production of 20to 30day- oId postlarvae.This method is well adaptedto tem- perateconditions when it is necessaryto producethe seedin a shortperiod of time.Hut theselarge-volume tanks are difficult to con tz'olin tropical conditions and resultsare dependenton variationsof water quality and light. If diseaseoccurs, a curative treatmentis almost impossiblewith suchlarge voluznes. ~ Incontrast, theintensive method ischaracterized b~ high density 00/I!, small tanksbetween 1 to 10m, Photo2, Exampleof a largehatchery in Ecuador. few gravid females,phytoplankton or Artemiapro- ductionin separateculture systems and productionof alreadyprofitable in someparts of the world under differ- one to five day-old postlarvae can be modified to ent socio-economic conditions. We can also look forward produceolder larvaeif necessary!.It allows accurate to majorimproveznents that will leadto increased produc- controlof rearingfor water quality, foodquantity and tivity with a paralleldecrease in costs,which, in turn, will quality, anddiseasesby preventive andcurative trea t- broaden the market, ment. It is important to analyze the reasonsnot only for ~ The intermediate method is a coznbination of the first successbut also for failure. Technology can succeedonly two methodswith zneandensity 0/I!, medium-size if applied under the right conditions.Many failureshave tanks 0 to 50 ms!, and use of fertilization in the tanks been due to introduction of technology inadequate for to bloom an algal inoculum cultured separately, specificsite constraints and logistic availability. Thesethree methods differ mainly in degreeof control The management of production units is also essential. and,when practiced by experiencedpersonnel, give good Too often investors have focused their attention on bio- results. However, it must be znentioncd that many exist- logicaland technologicalproblezns, forgetting theimpor- ing hatcheries su ffer from a lackof reliability in resultsdue tance of routine decisionsand proceduresnecessary for to siteconditions, inadequate control of algal quality and any business.Success depends on good managementand lack of knowledge of thc necessary sanitary procedures technological advancements. suchas regular dry-out to eliminate the resistantpatho- Shrimp hatchery activity is just emerging from its genic bacterial strain problem that is always the most infancy.The successof the broiler industry was achieved limiting factor in a hatchery operating year round in only after more than 20 yearsof intensivescientific and tropical conditions. In recently establishedhatcheries, commercial effort, and the shrimp industry will undoubt- these results have prompted physical separation of the edly follow the samepath. Therate of developznentwill .different steps of the system in roozns that have indepen- dependon how closely researcherswill work with pro- dent water pipes and nets,that can be closedand dried ducers to identify the constraints and to integrate avail- regularly.At the commerciallevel, the resulthas been the able techniques according to the socio-economic condi- developmentof large-capacityproduction hatcheries 0 tions of each country. to 20znillion PL/nonth! in Japan,Ecuador and Panamaas The accompanying schematic represents the different well as in small-scale hatcheries in Taiwan, Thailand and feeding regimes used worldwide for the developmental the Philippines.The presentchallenge is not to be ableto stagesof penaeid shrimp and related culture parameters: producepostlarvae, but to optimize the techniques. Hatcheriessell two products:nauplii tiny,newly hatched To reach the necessary reliability level and decrease larvae! and postlazvae juveniles that have passedthrough production costs,research priorities have been focused on three larval stages!.Postlarvae are stockedin nuzsezyponds the following: or directly into growout ponds, Nau plii aresold to specialists ~ Characteriza tion o f algal quality according to culture who grow them to the postlarvae stage or to farmers who techniques stock them in nursery ponds at high densities and later ~ Replacement of algae and Artemia by inert feeds transfer them to growout ponds at lower densities.Hatcher- microparticles, microcapsules! ies come in two sizes big and small. ~ Optimization and automationof the procedures re- circulation systems! Small Hatcheries ~ Development of strict sanitary procedures like those Sznall hatcheries are usually operated by a family routinely used for pig husbandry group on a small plot of land. Called "nom-and-pop" or ~ Cryopreservationof sperm, eggsand nauplii to be "backyard" hatcheries, they adopt a green thumb, non- able to run the hatcheries by sequential period, technical approach. Their chief advantages are low con- Shrimp-hatchery techniques are far from their opti- struction and opera ting costsand their ability to open and mum efficiencya ta timewhen commercial opera tions are close, depending on the season and the supply of wild Design, Operationand Training ... 3
Larval Rearing Techniques of Penaeids
I Decreased light intensity Zoea 1! Zoea stage larvae light-sensitive / 2! Permits uniform environmental conditions t
Defused light intensity Cultured zooplankton 1! Mysis stage no longer light-sensitive Mysis x/ 2! Conditions larvae to natural environment ! /x I V Artemia naupl i i
Thinning I/ Artificial feed f! increases living space Postlarvae 2! Enhances vigor, rapid growth 3! Avoids stunting, high mortality Chopped meat of clam or shrimp indicates most prominent feeding regime indicates occasional feeding regime
* indicates community culture method only seed.They usually concentrateon just one phaseof pro- marginally successful.Some species are very difficult to duction, suchas nauplii or postlarvacproduction. They mature in captivity. Other species, such as the western use low densities and untrea tcd water. Diseases and water white shrimp, will mature in captivity, but it is a tricky, quality problemsoften knock them out of production,but expensive proposition. The Chinese white shrimp, on thc they can quickly disinfect and restart operations.Small other hand, seemsto be especially well suited to matura- hatcheries have achieved great successin SoutheastAsia, tion facilities. Viral and bacterial diseases limit the devel- particularly in Thailand,Taiwan and the Philippines. opment of successful ma turation facilities, Big Hatcheries The Hatchery Cycle Bighatcheries are multi million dollar, high-techfacili- Whether pregnant shrimp are captured in the wild or ties that produce large quantitiesof seedstockin a con- matured in a hafchery, they invariably spawn at night. trolled environment. Requiring high-paid techniciansand Depending on a number of variables temperature, spe- scientists, they work with high densities and clean water, cies, size, wild/captive and number of times previously attemptingto takeadvantage of thc cconorniesof scaleby spawned!, they produce between 100,000and 1,000,000 producing seedstockthroughout the year. When wild eggs. The next day, thc eggs hatch into nauplii, the first females and juveniles are readily available, big hatcheries larval stage. Nauplii, looking nrorc like tiny aquatic spi- have a difficult time competing with small hatcheries and ders than shrimp, feed on their yoke sac for a couple of fishermenwho supply freshly spawnednauplii or wild days. Then they metamorphose into zoeae, which have postlarvaeto farms. In Ecuador,farmers considerwild featheryappendages and elongatedbodies but few adult postlarvae the "Cadillac" of seedstock. Big hatcheries shrimp characteristics.Zocac feed on algae for about five haveproblernswithdiseascandwaterquality,andit takes days and then metamorphose into rnyses.fvtyses, the last them a long time to recover from production failures, In larval stage, have many of the characteristics of adult thewesternhemisphcrc,particularlyin Ecuador,bighatch- shrimp, such as segmented bodies, bulging eyes and a eries are the trend. Big hatcheriesalso supply most of shrimp-like tail. They feed on algaeand zooplankton. This China's seedstock, and big hatcheries are established in stage lasts another three days and then the myses meta- most of the major shrimp-farming countries secexample morphose into postlarvac. Postlarvac, looking almost like of large hatchery in Ecuador, Photo 2!. adult shrimp, feed on zooplankton, detritus and commer- cial feeds. After one to four weeks and almost daily molts, Maturation Facilities the postlarvae arc stocked in nursery or growout ponds. Maturation facilities are big hatcheries that maintain The larval period lasts abou t two weeksand the posllarvae captive broodstock to produce seedstock. They represent period four weeks, so from spawning to stocking in the future of the industry but, thus far, have been only growout ponds takes abou t six weeks. 4 . T'reeee and Fox
The Future quality seawater, Most successful hatcheries obtain their scawatcr directly from thisbody of water with theunder- Hatcheries remain the weak link in the production standing that the ocean is a fairly stable water source.The cycle. Feeding the various life stagesof developing shrimp further a hatchery is located from thc ocean, the more takes a majoreffort. Hatcheries are plagued v ith manage- likelv the facility is to experience difficulties in terms of ment, disease and water-quality problems, yet they are pumping, water quality and accessto broodstock. constantly improving and constantly increasing produc- tion. Hundreds of rcscarchcrs in a dozen countries work Distance from Ponds/Access on unraveling thc mysteries of hatchery production, and There is no optimum distance between the hatchery thousands of hatchcrymenin all thc shrimp farming coun- and the pond market it supports; however, an optimum tries work with new techniques, designs and ideas to situation could be described as a hatchery centrally lo- improve hatchery production. When hatcheries become cated among thc ponds it supplies with postlarvae PLs!. more reliable, the production of farm-raised shrimp will This helps to reduce PL transport costs and transport take another leap forward Bob Rosenberry, Aquaculture morta1ity, and generally helps public relations with buy- Digest!, ers. In Indonesia, hatcheries have been known to sell PLs The svstcrn described in this manual is called the to ponds more than l,000 km from the hatchery, which intensive culture system and can be conducted in either requires air transport. This is also complicated by inter- small or large hatcheries. The advantages nf this system island licensing procedures. A morc practical situation include the following: would involve the majority of ponds being less than two ~ Low initial investment to threchours,by car, from the hatchery.If road conditions ~ Only a small number of' spawncrsrequired for onc are favorable paved, well-maintained, low traffic, etc.!, operation the rnaxirnum distance is primarily dependent upon qual- ~ Larvae can be reared at high densities ity of packaging. Some hatcheries in Ecuador transport ~ Ea sicr to control d isea ses PLs from the hatchery to the ponds by boat,but many are This manual presents information on the intensive sent by air freight using direct runways near the pond method first by introducing hatchery site sclcction and sites. design criteria, engineering and construction of two very similar hatcheries onc for P, rnnnodon and onc for P, Elevation and Topography r anrurnrei!to show the similarities of procedures and de- Thc chosen site should bc flat and elevated above the sign criteria as well as the subtle differences, Maturation, maximum high tide mark but within reasonablepumping hatching, larval rearing, postlarval hoIding and rearing, distance. A good rule of thumb is hatchery floor elevation d iscascs, chemo thcrapeu tan ts, and thc hatchery as a busi- of less than 3 to 4 meters above the maximum high tide ness is also discussed. The technologies discussed in this mark and an overall pumping head height! of less than 6 manual also can be modified slightly to include intensive meters. Pumping cost verses elevation appears to be a culture of all penacid species. fairly linear relationship up to a certainpoint. At times, the The hatchery site seIection, design criteria, engineer- pumping requirement for even a small hatchery is in ing and construction plans that follow are from two inten- excessof 600to 7001itersper minute, if operated properly. sive hatcheries one P. nronodonhatchery in Indonesia and If theland is not flat, the expenditureon sitedevelopment onc P, vannanreihatchery in Central America!. will increase due to increased excavation or filling. The site should be on fairly solid ground. A coral or stone base Site Selection may be difFicult to level, but will eventually mean a reduction in overall concrete required for the foundation. Because the shrimp hatchery is concerned with the In some cases, concrete may not even be required. A production of living animals that would otherwise be foundation that uses a sand base will have a tendency to found in a marine or brackish-v,ater situation, special settleand will require additional concretesupport. consideration must be given tow ard selection of its loca- tion. Theprimary concernin situatinga hatcheryis water Water Quality quality. Sinceshrimp spawn in the open oceanand larvae The primary water quality considerations are pollu- remain there until they become postlarvae, hatcheries tion and fluctuations in seawater components within an should be able to accessoceanic-quality seawaterdirectly optimum range.Very few bodiesof water are pollution and have a year-round, constant salinity. Proper site selec- free and caution should be exercisedwhen reading re- tion also rncans proximity to thc local market farmers, ports that make this claim. In choosinga hatcherysite, middlemen,buyers, etc,!, accessto support industries and locations adjacent to or within 30 km of a major river utilities, simplified engineeringand construction,and systemshould be avoided unlesscareful analysisof the integra tion with gro wout ponds. Another majorconsider- watershedhas been performed. This involves surveying ation for hatchery site location is accessto a disease-free all potentialsources of industrial, municipaland agricul- broodstrock supply. The folIowing are importantsite tural pollution that impact that particular river. Nearby sclcction criteria. factoryor plant personnel,farmers, etc., shouldbe inter- viewedto identi fy possiblepollutants. Most hydrocarbon, Distance from Ocean pesticide or heavy metal pollution is quite serious and As mentioned previously, hatcheries should be lo- should bc avoided at all costs.The extent to which organic cated on the coast adjacent to a large body of oceanic- poilu tion e.g.sewage ou tfalls! hasa ffecteda waterwayis Design, Operationand Training ....'>
somewhat morc difficult to assess due to the inherent ability of the waterway to absorb nutrient offloading. A useful index of organic pollution is biochemial oxygen demand BOD!,which isan indicatorof thebiomassbeing supported by a body of water and how much oxygen it requires over a given period of time. High nutrient loads will support a high biamass primary productivity, macrospecies,etc.! as Iong as oxygenis availabIe.If this nu trient load is releasedinto thc oceannear the hatchery, it could result in blooms of disease-causing microbial species and place an excessive load on filtration equip- rnent, Therefore, it is recommended that water chemistry sampling take place not only in wa ter ways impacting the hatchery's near-shore environment, but also in the area aroundthepotentialhatcheryintake. Thissarnplingshould occur during the rainy season, since runoff is greatest Photo 3, Generators during this time of the year. Water chemistry sampling should bc continued on a monthly basis once the hatchery generator sct large enough to run the entire hatchery is is in operation. also recommended. If no rural electricity is available, two Although watersalinity is fairly easyto determine,it is generatorsets should be purchased.Rural electricpower oneof the majorproblems encountered as a resultof poor can be distributed more easily and can accommodate a hatchery site selection. As a rule-of-thumb, all hatcheries larger demand than gcncrator power, but it often can be should use water taken directly from the ocean, and morc costly to run lines from the main power pole to the prospective sites should not be located within 30 km of a hatcherythan to purchasetwo generatars Photo3!. major river-mouth. Hatcheries in Indonesia are often situ- ateddnear rivcrmouths and, as a result,experience tremen- Market Considerations dousseasonal fluctuations in salinity.The optimum range Hatcheries often are built without consideration of in salinity for hatcheryculture of penaeidshrimp is about demandor markets.If the hatcheryis owned by a com- 26 to 32 parts per thousand ppt!. Mature adult and pany that alsoowns growout ponds,the market is fairly postlarval shrimp are naturally found in the ocean,where secure most of the fry will be stockedin company-owned the salinity is approximately35 ppt 5 gramsof salt per pond s!, If not, the best possible approach is to estimate the liter of water!. numberof pondsin the localarea that would be willing to Water pH is seldom a problem in hatcheries thatobtain buy PLs from a hatchery.This can be accomplishedby their water directly from the ocean, Thc pH of seawater visiting the local fisheriesrepresentatives or by talking should fluctuate around 8.0 or slightly higher unless the with local pond farmers. Many times the market demand body of water usedas a sourceis polluted or is receiving is basedon a seasonalstocking strategy. There also could a largeamount of freshwaterrunoff. Occasionally,algal be somereluctance on the part of thepond farmersto buy culture will be modified by enrichment with carbon diox- PLsthat havebeen produced in a hatchery.These factors ide resulting in lower pH, but this is not a characteristic must be determinedprior to siteselechon. required of the water source. A very thorough water analysisfor a potentialhatch- Availability of Skilled Labor ery site in SouthTexas can be scenin Appendix A, B and Sinceit is usually quiteexpensive to impo~tlabor from C of the Hatchery Site Evaluation/Selection section of this outside the pond site area,and sometimessocially unac- chapter. ceptable,most hatchery developers turn to thelocal labor forcefor hatcherypersonnel. It is highly unlikely thata FreshwaterAvailability hatchery manager can be found in most rural areas,but a Freshwatermust be availableat thehatchery site both substantialproportion of the remainingpersonnel can be for cleaningand for the workers. Also, many nutrient- hired locally. It helpsif this local group hasat leastsome enrichmentmedias require preparationin fresh or dis- familiarity with hatcheryconcepts. Otherwise, extensive tilled water. Often hatcheries are located in areas with training is necessary,which increaseshatchery start-up very little or no ground water, or with water that is not time and overalI s tar -up costs. potable and may fluctuate in its concentration af dis- solved solids. The extent of the water table mus t bc known Availabilityof BuildingMaterials beforea wellcan be considered. It is too expensiveto truck Availability of suitablebuilding materials concrete, water to a site for this to be considered a viable alternative. sand,gravel, wood, roofing material,paint, piping,etc,! at reasonablccostsisanother importantcansidera tion.Many Electrical Support times hatcheriesare built in areasthat possessexcellent Continuity is themost important criterion for electrical water quality yet are so far from material outlets that support. Electricity is used to power aeration devices, constructioncos ts double. Sometimes con tractors request seawater pumps, algal culture lights and heaters should specificmaterials in order to achievea certaindesign but theyberequired!,Ruralelectricityis certainly a bonus,but neglectto determine whether these materials canbebought should not be relied upon as the only sourceof power.A locally.The further one locates a hatcheryFrom a large 6 ... Treeeearid Fox metropolitan area, the higher the cost of the material if to receive some assistancein circumventing disease i.e. locally bought! or the higher the cost of transport. In remote identification, prevention, treatment! it would certainly areas,the quality of material can often suffer. Poor storage bc advantageous to have some research institution in the conditions can leave the contractor with lit tie to choose from. vicinity. Identifying a localfisheries department represen- An exainpleis the use of volcanicsand in foundationand tative in the areacould help the hatcheryowner/operator tank construction. This sand, if purchased in Indonesia keep abreast of industry or fisheries development. Yogyakarta area! would cost about Rp, 4,000 per cubic tneter U.S. $4.68!.In building a hatchery near Semarang, Competition with Other Operations Indonesia,the contractor rcquircdroughly 1~ cubic meters If the local market for postlarvae is quite large, then a of this sand.Instead of paying the Rp. 4 million U.S.$4,680! little competition could be quite healthy in terms of the heexpected to pay,he eventually spent Rp. 14 million U.S. developmentof a shrimp hatchery. Often one hatchery $16~!. The more remote areas of the world where hatch- mayencounterunfamiliarproblems tha tanadjacenthatch- ery site locations and water quality may be more desirable ery has already solved. If these two hatcheries have a may also cost the owner double to build. This must be history of information exchange,both wiII benefit. Inter- consideredduring the planning stage. action is something tha t could be beneficial for the entire industry.A clandestineapproach to assistancecould prove Availability of Mated Females dctr imcntal later, Some potential hatchery sites are located adjacent to Should the local PL market be so small that it can large spawning grounds and can easily obtain a ycar- support only one hatchcry, it may be best to go elsewhere round supply of mated females for production of eggs/ if such a hatchery already exists. larvae!. This enablessuch ha tchcrics to reduce their opcra- honal overhead since they do not need to support a large Expansion Potential maturation facility. This is also advantageousfor site One aspectof site selectionthat is seldom considered is investigators since it reduces capital outlay on construc- expansion potential should the market demand increase. tion smaller maturation facility containing only spawn- Sometimesthc site itself will not allow for expansion due to ing tanks!. Information on availability can best be ob- physical constraints or the area available for development. tained by visiting thelocal fisheries department represen- Evaluating The Site weighted ranking system! tativeeand/or a localfishingvillage. Since offshore ma ting ~ Most evaluations use this method is seasonal in nature one should also ascertain the extent of the spawning/fishing seasonsand to what extentac- ~ Assigns relative weight of iinportance to criteria cessto these grounds is limited by thc monsoon or rainy ~ Assigns a scoreto each measurement or observation season!,which usually affects the mating seasonin some ~ Resultis weighted scoreversus ideal man~er. A source ofbroodstock should be found within 100km of the proposed hatchery site, if possible, and the Hatchery Site Evaluation/Selection stock should be disease free. Site Evaluation Feed Distributors Scoring The availability of feed refers primarily to inert/for- Range of Scores %! Evaluation mulated feed and Arternia, Thc cost of these feed items will 100-80 Excellent site increasein relation to transport distance, Somehatcheries 79-60 Good to Fair bypass higher prices by buying Artemia direct from the 59-40 Marginal United States while pcllctcd fccds are purchasedfrom Less than 40 Avoid site large importer s in thc local area. However, should a local feed distributor stock the particular brand of Arterrtia or Site sclcc ionis perhapsthe most critical step in the feed to be used, that is only to the advantage of the development of a successfulhatchery business. Selection hatchcry owner, However, because of poor stockings trat- of a suitable site can have a significant impact on the cgics and supply, local distributors are sometimes found profitability of the business.Many unsuccessfulhatcher- to be without quali ty feeds. Thus, it is recommended tha t ies were troubled by site-relatedproblems that were too beforechoosingahatchery sitesomeidca of feedavailabil- d ifficult or expensive to correct. The ideal site for a hatch- iP from local distributors should be obtained, The more ery probably doesnot exist anywherein the world if all conscientious hatcheries choose to buy direct from im- site selection criteria arc considered. The decision to locate porters or manufacturers, This is not so much an attempt a shrimp hatcheryat a specificsite is usually basedon to savemoney but an cnsuranceof availability. whetherthe biological requirements of the shrimp canbe fulfillcd at a reasonablecost. Political stability and safety Extension Assistance of the investment,as well as potential difficulties in re- Hatcheries are intensive culture systems. Being such, couping profits, must also be considered before the site they are often plagued by various diseasesof a nutritional selection decision is made. Five to ten acres two to four and/or endemicnature. Furthermore, hatchery operators hcctarcs!is generallysufficient land to build a hatchery locatedin remote facilities sometimesfeel that they arc and accommodatefuture expansion. losing touch with current developmentsin the industry A list ofboth general and detailed information needed new innovations, enhanced availability of previously for proper evaluation of a site follows. limited supplies, government regulations, ctc.!. In order Design, Operatianand Troirung ... 7
General Information on Site
1. Location:
2. Map:
3. Access:
4. Wave Action:
5. Water Salinity:
6. Water pH:
7. Elevation Above Seawa ter Source:
8. Land Topography: 9, Benthic Topography/Description:
10. Seawater Inlet Distance From Site: ll. Type of Inlet Prescribed:
12. Water Depth at Inlet Site:
13. Pollution Potential:
14. Organics in Water?: 15, Turbidity:
16. Nearest River:
17. Source of Broodstock/Price/Conditions:
18. Electrical Power:
19. Freshwater Source:
20. Aquaculture Distributor:
21. Source of'Trained Workers:
22. Potential for Well: 8 ... Tnmeard Foz
Detailed Information on Site
Land Details
Total Land Available Expansion Potential? Current or Previous Use Owner Cost of Land Lease Terms Available? Topography Soil Details for constructionpurposes! 1. Soil Samples Taken by location! Map of Sample Area
Location1: Depths Location2: Depths Location 3: Depths Site Stability determined by soil type! SeawaterQuality Details at Site 1. Potential Source Distance from Site Color of Water Wave Action Storm Potential 6. BeachAppearance 7. Erosion
Accretion Freshwater Plume 10 Proximity of River 11 Salinity 12 Tidal Flux 13 Type of Tide: Diurna 1/Semi-Diurnal 14 Navigation Traffic 15 Industrial Activity On or Near Source? 16 Describe Nearest Port
17. Potential for Pollution
18. Bottom Topography Near Inlet '19. Water Depth Near Potential Inlet Design,Operation and Training ... 9
Freshwater Details at Site
1. Nearest River 2. Size of River 3. Other Sources of Freshwater
4. RainySeason River Depth/Width 5. Dry SeasonRiver Depth/Width 6. EstimatedHydraulic Flow During Seasons
7. Potentialfor Flooding 8. LastMajor Flood/Damage
9. Distance of Freshwater Source from Site 10. PotentialFor Well, Pipeline or Canal 11. Tidal Influence/Flux
12. Salinity at PotentialIntakes Low Tide! 13. Salinityat PotenhalIntakes High Tide! 14. Potential Sources of Effluent
15. Pollution Potential
16. Agricultural/FarmingPoilu tion
Meteorlogical Data at Site 1. Dry Season 2. Rainy Season 3. TemperatureVariance: Wet Season Dry Season
Flora and Fauna at Site 1. Describethe Marine Fisheries/ObtainAny RelevantData
2. Distance to BroadstockFishing Grounds 3. Typical Fishing Vessels
4. NearestFishing Port
Utilities/Resources at Site 1. ElectricalSupply 10 ... Tram and Fox
Nearest Transformer Type of Current Capacity Cost of Electricity Potentialfor PowerShortages Petroleum,Oil, Lubricant Availability
Building Materials
Equipment Laboratory Heavy Construction Computers
Socio/Economic Data at Site 1. NearestCity 2. Industries Labor Force Construction Contractors 5. Engineers 6. Aquaculturists 7. University/ResearchBackup 8. Business Education 9. Nearest Village/Town 10 Local Industries Local Government 12. Political Peaceand Tranquility/Unrest in non-U,S.locales! 13. Other AquacultureProjects 14. Extent of Government Assistance Design, Operationand Training ... 11 Design Criteria, Engineering and Construction the typeof cultureand cultuze techniques that willbe used to producenauplii, larval and postlarval shrimp, algae, If one were to travel around the world examining and Ar temia,etc. For example, some hatchery operators prefer analyzing various hatchery operations, one of the first to add water to their larval-rearing tanks on a continuous observations would be that all hatcheriesarebasically the basis.This implies the use of largeoutdoor or indooralgae same, in that there are certain areas within the overall culture tanks,an extensivedistribufion network of pipes, complex that servespecific functions. The functions, when precision valves, a mixing manifold, etc. Figure 17!. The coordinated, constitute a production system that operates engineering is somewhat simpler for batch larval culture similarly to any factozy. However, when hatcheries are Figure 16!.In someareas of the world wherethe diurnal compared at a more detailed level, they become very temperature variation can be quite extreme, the matura- dissimiliar, Design can be influencedby local tradition, tion facility must resort to the use of a heat exchanger or the availability of certainbuilding materials,desired pro- must recirculate its water througha largebiological fil tra- duction level, differences in culture of the speciestargeted tion systern. for production, a particular approach to strategy and /or These are just some of the many examples of how a the physical site. In this section, some general statements certainapproach to culture caninfluence the engineering are made about design that can be incorporated into of a hatchery. Other examples are summarized below. developingany shrimp hatchery. ~ Propagation of algal cultures as food within the larval Preliminary Considerations rearingtank can determine roof designand length-to- width orientation of the hatchery itself. Selectinga suitablehatchery design should be one of the ~ Use of microencapsulated diets can mean less space first steps in hatchery development and, for this reason,is made available for algal and Artenria culture areas. closely tied to site selection. ~ The duration that shrimp stay in the hatchery can The first question that usually coznesup after site selec- determine whether or not raceway tanks are used tion is how much capital outlay will be required for the some hatcheries keep postlarvae only until PL3-5 project; however, this question cannot be answered unless and, once harvested, they are transferred either di- somelevel of production hasbeen identified. In somecases rectly to the growout pond or to a nursery pond!, the order is reversed, but let us assume that investment will ~ If algal specieswith a wide temperature tolerance are be applied as needed.! For example, most hatcheries in not usedto feedlarval shrimp,it may notbe practical Indonesiawant to produce abou tone to two million post larvae to include a large outdoor algae culture area. PLI5-20! per month. This is a relatively small hatchery These are only a few examples and may only be rel- compared to other hatcheriesaround the world, but none- thelesswiII serveas our subsequentmodel. evant to specific situations. Thereare basicaIIy two hatchery designscurrently used General Layout of the Hatchery in Indonesia a high stocking density model intensive- Most hatcheries are contained within one building or type! andalowstockingdensitymadel extensive-type!. The perhapstwo the nurserysection sornetirnes is segregated high stockingdensity model is characterizedby thefollow- to a separatebuilding!. Hatcherydesigns usually a temptt ing: to integrate all systems under one roof with the basic ~ Optimization of space understanding that efficient use of space will lower the ~ Environmental control overall costof the hatchery.Most designscentralize one ~ Dynamic water exchange important aspectof larval culture and orient other sys- ~ System integration tems around this point. The most common strategy is to ~ A continuous and coordinated production strategy ~ High level filtra tion locate the larval culture area centrally and have support- ~ A higher level of automation ing systems algae culture, Artemiaculture, feed prepara- The basic intensive ha tchery design modeled a fterthe tion, maturationand postlarvalculture, etc.! surrounding "ladder system," Liao, 1984! was used for the Yayasan it. Noisy areas or supporting areas that need substantial Dian Desa hatchery located in Jepara, Central Java. A interaction with the rest of the operation are situa ted as far quick glanceat the designwill show that all production as possiblefrom the larviculture area i.e., the generator facilitiesare containedwithin the samebuilding. room would not be located adjacent to the maturation Thelow stockingdensity design, however, is most com- area, the algae culture area would not be located between mon in Indonesiaand zeflectsthe followingcharacteristics: the larval rearing area and the postlarval rearing area, ~ Largerrelative surfacearea based on lower stocking etc.!.This approach attempts to eliminatethe potential for cross-contamination,reduceunnecessary work,and rnain- densities tain quiet in areasdemanding quiet. The hatcheryover- ~ No accom mod a tions made for en vironmen ta1 con trol ~ Low or intermittent water exchange in culture tanks view Figure6! is that of theYayasan Dian Desa Hatchery ~ Batchproduction that is not necessarilycoordinated YDD! Unit 1! in Jepara,Indonesia; Figure 20E shows the with other systems layout of a CentralAmerican hatchery. Both figuresillus- ~ Simple, low-level filtration trate these points. ~ Low-level of automation Modular Concept for Future Expansion Many timeshatcheries are designedto accoznmodate Approach to Culture eventual expansion. Modular designs are helpful should Another factor impacting hatcherydesign relatesto a larger market for fry develop. They also lend theznselves 12 ... Tnmz and Fox to seasonal/traditional fluctuation in the market. The tankwith a surfacearea of 120square meters has a diameter YDD hatchery typically experiencedfluctuation in fry of about 12.4meters, A stockingrate of 4,NN per square demandat theonsetofthemonsoon stocking season when meter requires a tank diameter of 6.2 meters. production demand doubled. Hatcheries in the United Thenumber of tanksused directly depends on thenum- Stateswould experiencesimilardemands duringthe spring berof postlarvaetobe produced each month. A projectgoal and early summer months and demand would decrease of 2 znillion postlarvaePL20 per month meansonly 4.5 during winter. million naupliiare required each month 5 percentsurvival Culture Tanks from PL3to PL20,60 percent survival &om N6 to PL2!.This numberof nauplii .5 mNion! meansstocking about 11 The size of the tanks used in hatcheries is determined larval-rearingtanks each month 00@00per tank!.Larval- by severalfactors. Many hatcheriessize their tanks ac- rearingtanks should be startedevery two to threedays. cordingto the single-spawn principal that is, the larval- However,this doesnot mean11 tanks are actually needed. zearingtank canhold one averagespawn of nauplii. The Withan average mme of13 days to PL3 and with a staggered postlarval-rearingtank, in turn, can hold the average approachto stocking,only six to sevenlarval-rearing tanks number of postlarvaesurviving fmm that spawn. For are required.More postlarvaltanks aze needed since they example,if the averagespawn from the maturationfacil- willbeholdingpostlarvaefor17days rather than 13 days P. ity contains400,000 viable nauplii typical for P.monodon!. rnonodonsell at PL18or 1Mayold PLs!. If stockingis at a rateof 100nauplii per liter in the larval Thevariety of shapesand sizes of culturetanks, as well as rearing tank, this tank should contain 4,000liters of wa ter. materialsused in construction,isextensive. It is necessary to If you usuallyexperience 60 percent survival to thepost- classifythem accordingto their function.The list below lazvaltransfer stage, this meansthat 240,000PL3 to PL5 summarizesthe variety of tank typesand shapescurzently will be transferredto the postlarvalholding and rearing used in hatcheries. tank.Some postlarval-rearing tanks have been stocked to densitiesin excessof 5,000PL3 to PL5 per squaremeter Sizing the Hatchery using habita ts or screenedbarriers. A safer level would be Once a production level has been determined, the next somewherearound 2,000 per squazemeter, depending pri- stepin designcalls for proper sizing of tanks,estunating marily on how long theywill be kept beforetransfer to the the numberof tanksto bebuilt, and theoverall layout/ pondand the ability to maintainproper water quality. If this dimensionsof the building itself. According to Boucher stackingdensity is used,the postlarval-rearing tank needs a unpublished data, 1987!, these determinations can and surfaceareaofabout120squaremeters.Again, this will vary shouldbe madewith consideration givento a certainlevel accordingto expectations of survival, ability to stock at high of detail.A checklistof thesecriteria, as well as design densities,water exchange rate and quality of feed,A round calculations,are shown on worksheets1 through11. Hatchery Culture of Shrimp Shape Volume, MT or sq. m! Round 12 Round 12 Round 6 Round 12 Round 9-12 Square 40 Round 0.2 Round Cylindro-conicao 0.7 Round 0.5 Square 0.5 Rectangular 1.0 Cylindro-conical 2-20+ Cylindro-conical 2-5 Cylindro-conical 2-5 Half-barrel 5-15 Half-barrel 5-15 Rectangular 2-20 Rectangular 2-5 Oval raceway 5-100! Round 5-30! Rectangular 0 -100! Rectangular 00! Square -5! Design, Operationand Training . 'I3 Worksheet I - Postlarval PL! SectionDesign PostLarvalSection Design Assumptions Number of PLsrequired per month PL/month Proposed PL delivery schedule days/tank Initial stage of PLs when stocked days Final stage of PLs when delivered days Maximum density in PL tanks PL/liter Estimated PL survival rate Average water depth in PL tanks meters Minimum freeboard in PL tanks meters Distance between individual PL tanks meters Distance between PL tank and exterior wall meters PostLarvalSection Design Calculations Duration in PL tanks days Minimum total PL tank volume Minimum number of PLs tanks used PL tanks Actual number of PLs tanks used PL tanks Minimum diameter of individual PL tank meters Actual diameter of PL tank used meters Actual volume of individual PL tank ms tank Worksheet 2 - Larviculture LC! SectionDesign Larviculture Section.Design Assumptions: Duration of nauplii stocking period days Duration from nauplii to PL1 stage days Number of LC tanks to stock one PL tank tanks/tank Maximum density in LC tanks PL/liter Estimated LC survival rate % PL/naup Average water depth in LC tanks meters Minimum freeboard in LC tanks meters Distance between adjacent LC tanks meters Distance between LC tank and exterior wall meters Width of central walkway in LC section meters Larviculture SelectionDesign Calculations: Duration in LC tanks days Number of nauplii required per day naup/day Minimum volume of individual LC tank m Minirnurn diameter of individual LC tank meters Actual diameter of LC tank used meters Actual volume of individual LC tank used m Minimum number of LC tanks LC tanks Actual number of LC tanks used LC tanks 14 , Treeeearrd Fox Worksheet 3 - Maturation MT! SectionDesign Maturation SectionDesign Assumptions: Broodstock stocking density adult/m2 Femalesas a percentageof broodstock % fern/adult Expected nauplii production rate naup/fern/rno Diameter of one maturation tank meter Averagewater depth of maturationtank meter Expected duration of broodstock viability weeks Diameter of one spawning tank meters Average water depth of one SP tank meters Number of femalesper spawning SP!tank fern/tank Distance between adjacent MT tanks meters Distance between MT tank and exterior wall meters Width of central walkway in MT section meters Maturation SectionDesign Calculations: Total number of broodstock required adults Number of female broodstock females Number of male broodstock males Minimum number of MT tanks required MT tanks Actual number of MT tanks used MT tanks Volume of one MT tank rn Broodstock replacement rate adults/week Volume of one spawning tank rrr Minimum numberof SPtanks required SP tanks Actual number of SP tanks used SP tanks Worksheet 4 - Building Design Building Design Assumptions; Height of exterior walls meters Spacing of columns/trusscs meters Thickness of floor slab centimeters Cross-sectional area of columns rn Building Design Calculations: Minirnrrmlength of larviculturc section meters next higher multiple of column spacing! meters Minirnurn length of maturation section meters next higher multiple of column spacing! meters Length of center area meters Total length of main hatchery building meters Minimum width of larviculture section meters Width of main hatchery building next higher multiple of column spacing! meters Width of postlarval shed meters Nurnbcr of columns columns Total exterior wall area m Total interior wall area In Design, Operationand Training ... 15 Worksheet 5 - Pipe Sizing Pipe Sizing Design Assumptions: Water exchangerate in PL tanks %/day Water exchangerate in LC tanks %/day Waterexchange rate in MT tanks %/day Desired filling time for PL tanks hours Desired filling time for LC tanks hours Number of secondary PL feeder pipes pIpes Number of secondary LC feeder pipes pipes Number of secondary MT feeder pipes pipes Maximum velocity in pipes test/sec Estimated fraction factor Equivalent length of PL supply pipe, fittings and gate valve feet Equivalent length of LC supply pipe, fittings and gate valve feet Equivalent length of MT supply pipe, fittings and gate valve feet Pipe Sizing Design Calculations: Maxirnurn flow rate to one PL tank liters/sec f3/sec Average flow rate to one PL tank liters/sec f3/sec Maximum flow rate to one LC tank liters/sec f3/sec Average flow rate to one LC tank liters/sec f3/sec Averageflow rateto oneMT tank liters/sec f3/sec Minimum diameter of each PL supply pipe inches Next larger pipe size inches Minimum diameter of each LC supply pipe inches Next larger pipe size inches Minimum diameterof eachMT supply pipe inches Next larger pipe size inches Maximum flow rate of PL feeder pipes liters/sec f3/sec Minimum flow rate of PL feeder pipes inches Next larger pipe size inches Maximum flow rate of LC feederpipes liters/sec f3/sec Total length of LC supply pipe meters Total length of LC feeder pipe meters Total length of LC mainline meters Total length of MT supply pipe meters Total length of MT feederpipe meters Total length of MT mainline meters 'I6 ... Treeceand Fox Worksheet 6- Header Tank Sizing Header Tank Design Assumptions: Minimum detention time in header tank minutes Mirumum pressure of pipe at discharge psl Header Tank Design Calculations: Flow rate for PL tank water exchange ms/min Flow rate for PL tank filling ms/min Flow rate for LC tank water exchange ms/min Flow rate for MT tank water exchange ms/min Maximum total hatcheryflowrate ms/min Minimum volume of header tank m Actual volume of header tank used m Minimum elevationof header tank standpipe abovehatchery floor feet meters NOTE: If it is desiredto reduce the elevationof the headertank, try selectivelyusing largerpipe sizesin one or more of the above applications. Worksheet7- SeawaterReservoir SR! Tank Sizing SeawaterReservoir Design Assumptions: Miscellaneous seawater usage ms/day Average water depth on SR tank dieters Minimum freeboard in SR tank meters SeawaterReservoir Design Calculations: Water exchangerequirements for PL tanks ms/day Averagenumber of PL tanksfilled per day tanks/day rounded to next highest number! tanks/day Filling requirements for PL tanks ms/day Water exchangerequirements for LC tanks m3/day Averagenumber of LC tanksfilled per day tanks/day rounded to next highest number! tanks/day Filling requirements for LC tanks ms/day Waterexchange requirements for MT tanks ms/day Total volume of seawater reservoir ms/day Design, Operationand Training ... 17 Worksheet 8 - Algae Culture Algae Culture Design Assumptions: Water exchange rate in LC tanks %%uo/day Algae feeding density in LC tanks cells/rnl Estimated ratio or larval algae consumption to natural algaeproduction in LC tanks cells/cell Volume of algae mass-culture AMC! tank liters Harvest cell density in AMC tanks cells/cell Minimum detention time in AMC tanks days No. of AMC tanks stocked/harvested per day tanks/day Volume of algae intermediate-culture AIC! tank liters Harvest cell density in AIC tanks cells/ml Minimum detention time in AIC tanks days No. of AIC tanks stocked/harvested per day tanks/day Volume of algae carboy-culture ACC! tank liters Harvest cell density in ACC tanks cells/rnl Minimum detention time in ACC tanks days No. of ACC tanks stocked/harvested per day tanks/day Volume of algae flask-culture AFC! tanks liters Harvestcell density in AFC tanks cells/rnl Minimum detention time in AFC tanks days No, of AFC tanks stocked/harvested per day tanks/day Maximum water depth in algal culture area meters Algae Culture Design Calculations: Total volume of AMC required liters Number of AMC tanksrequired AMC tanks Stocking cell density in AMC tanks cells/ml Total volume of AIC required liters Number of A!C tanks required tanks Stocking cell density in AIC tanks cells/ml Total volume of AIC required liters Number of AIC tanks required AIC tanks Stocking cell density in AIC tanks cells/rnl Total volume of ACC required liters Number of ACC tanksrequired ACC tanks Stocked cell density in ACC tanks cells/ml Total volume of AFC required liters Number of AFC tanks required AFC tanks 18 ... Treeeeand Fox Worksheet 9 - Arterrtia Culture Artemia Culture Design Assumptions: Duration from Ml to M2 days Feting density FromMl to M2 Ar temia/1nl Duration from M3 to PL2 days Feeding density FromM3 to PL2 Ar temia/ml Duration from PL3 to harvest days Feeding density From PL3 to harvest Ar temia/ml Expected hatching rate of Artemia cysts Artemia/gm l lydration density of Artemia cysts gm/liter Duration of hydration period hours Volume of Artemi hatching tank AHT! liters Anemia Culture Design Calculations: Expected number of LC tanks tobe at Ml-M2 stage on any given day LC tanks Number of Artemia needed from Ml-M2 Artemia/day Expected number of LC tanks tobe at M3-PL2 stageson any given day LC tanks Number of Artemia needed from M3-PL2 A rtemia/d ay Expected number of LC tanks tobe at PL3-harvest stage on any given day LC tanks Number Of Artemia needed frOrn PL-3-harveSt A rtemia/d a y Maximum nurnbcr of Artemia needed pcr day Ar temia/day Minimum amount of Artemia cysts to be hydrated pcr day gra ms/day Total volume of AHT required liters Minimum number of AHT tanks required AHT tanks Worksheet 10 - Aeration System Aeration System Design Assumptions: Acra tion requiremen ts for PL tanks f'/min/ms Aeration rcquircrnents for LC tanks p/min/ms Aeration requirements for MT tanks f /min/res Aeration requirements for SP tanks f'/min/m-' Aeration requirements for algal culture p/min/ms Aeration requireme~ts for SR tank f'/min/ma Number of diffusers pcr PL tank dif/tank Number of diffusers per LC tank dif/tank Number of diffuscrs per MT tank dif/tank Number of diffusers per SP tank dif/tank Number of diffusersfor algal culturc diffusers Prcssure loss through diffuser PS1 Minimum air presssure at discharge psl Number of backup blowers per application blowers Aeration System Design Calculations: Total airflow to PL section f'/m Total airflow to LC section f'/rn Total airflow to MT section F'/m Total airflow to spawning tanks f'/m Total airflow to algal culture area f'/m Total pressure head in PL section PS1 Total pressure head in LC section PS1 Total pressure head in MT section psl Total pressure head to SP tanks PS1 Total prcssure head to algal culture area PS1 Capacity of main hatchery blower f3!rn Maximum prcssure head of main hatchery blower PS1 Capacity of seawater reservoir blower P/m Maximum prcssure head of SR blower PS1 Total number of diffuscrs diffusers Length of air supply pipe/tubing meters Length of'3" pvc Fccdcr pipe meters Length of 6" pvc air mainline meters Design, Operatiortartd Training ... 19 Worksheet 11 - Shrimp Hatchery Design - ConstructionCost Estimate Item Units Quantity Cost per Unit Total Clear and grade m~ Excavation Rough grading mm2 m Landscaping Footings rn' Columns Concrete block wall m m~ Bond beam ms Top plate LM Prefabricated trusses EA Purlins LM Corruga ted roofing m2 Exterior doors EA Interior doors EA Overhead doors EA Postlarval tanks EA Larviculture tanks EA Ma tura tion tanks EA Spawning tanks EA AMC tanks EA AIC tanks EA ACC tanks EA AHT ta~ks EA Header tanks EA Seawater reservoir tanks EA 1" PVC pipe LM 1.5" PVC pipe LM 2" PVC pipe LM 3" PVC pipe LM 4" PVC pipe LM 6" PVC pipe LM 1" gate valves EA 1,5" gate valves EA 2" gate valves EA 3" gate valves EA 4" gate valves EA 5" gate valves EA Concrete drainage channel LM G.I. grating SM Main seawater intake pump EA Secondary lift pumps EA Main hatchery blowers EA Seawater reservoir blowers EA Water heating system LS Electrical system LS Lab suppliesand equipment LS Misc, supplies and equipment LS SUBTOTAL 3.5%Contigency TOTAL Note: LM = Lengthin meters,EA = each,LS = Lump sum 20 ... Treeeearrd Foz Specific Hatchery Background Indonesian Hatchery Development Program In Bandengan Jepara, there are two hatch- The following abstract appeared in the Journal of the ery units referred to as Unit I and Unit II. Unit World AquacultureSociety, Aquaculture Communiques I is a model hatchery whose construction was Volume 18, Number 1, page 20A, Cornrnuniquc number 72, 1987!. partially funded by USAID and which has 72. The Establishment of a Successful Penaerrs received most of the CJEDP program support monodorrHatchery in Jepara,Java. for hatchery development. Unit II is also oper- ated by YayasanDian Desa YDD! and was TREECE, GRANVlL D., Texas Marine Ad- built without USAID support, based on the visory Service, Texas A&M University Sea design of Unit I. YDD thereby doubled its Grant College Program, CollegeStation, Texas operational capacity and also doubled its fa- 77843;FOX, JOE M., Central Java Enterprise cilities dedicated to the researchand develop- Development Project, Gedung BAPPEDA, Jl. ment of appropria te hatchery technology Pemuda 127,Scrnarang, Indonesia, In general, both Unit I and Unit II have been A short-term technical assistance and in for- performing as expected during the past quar- mation transfer subcontractbetween Develop- ter. Unit I wasres ta rted a fterbeing ternpor a rily rncnt Alternatives, Inc., Washington, D.C., the shut down for cleaning, If the water quality United StatesAgency for International Devel- holds into next quarter, it is hoped that the opment, the Central Java Enterprise Develop- hatchery will achieve a combined output of 4 ment Project and the TexasAgricultural Exten- million postlarvae per month. sion Service-SeaGrant Advisory Program re- sulted in the establishment of a successful Unit I was constructed in 1986by Yayasan Dian Desa Perraeusmoitodori hatchery in Jepara,Java. The for approximately$90,000 U.S.!, and had aii estimated ha tchcry is now opera ting as a "model" train- production capacity of 3 million postlarvae per morith. The hatchery is located on the island of Java in the Repub- ing facility for the country and is also produc- lic of Indonesia scc Figure 1!, A recent NASA satellite ing an average of one million nauplii per day survey has shown that Indonesia, also referred to as The with only two maturation tanks in use, East Indies, Malay Archipelago or The Spice Islands, is Shortly after construction of the state-of- madeup of nearly 20,000tropical isles instead of the 13,677 the-art hatchery was completed, an intensive isles which it was once thought to have. In the words of technical information transfer was initiated. one writer, these isles "gird the Equator like a string of Broodstock was purchased from local fisher- emeralds," and they comprise the most extraordinary rnen, female shrimp were ablated and produc- collection of places, peoples, sights, tastes and natural tion began in less than onc week. Twenty rnil- wonders on earth, The model hatchery project of Yayasan lion nauplii were produced in the first 15days Dian Desa is more specifically located on the north shore and someof thebroodstock had spawned three of Java near Bandengan Jepara see Figure 2!. times in two weeks. After a production strat- Thebasic layout anddesign of the hatcherywas rnod- egy was initiated, which took into consider- eled after the "ladder system"described by Liao 984!, ation the hatchery's larval production needs, taking advantage of water levels and gravity. Even with and a continuous scheme of production was "state-of-the-art"design, and a good location, success established, the hatchery staff members were dependson good managementpractices. Management is trained using techniques to sustain produc- the key to a successfulhatchery opera tion, and it should be tion. Three training sessionswere conducted stressedthat eachhatchery will haveits own procedures with neighboring hatcheries invited. Hatchery for optimum production. procedures were incorporated into a training Figures3 through 20 give details of the hatchery,its program for future traincesby documenting seawater system, tanks and production areas, as well as tanks and systems used in other hatcheries. activities specifically needed at that hatchery. Theprocedures were compiled into a training- CentralAmerican Facility HatcheryExample! operating manual, which can be used as a Figures 20A through 20M depict a Central American guide or tool in future training programs. hatchery that was designed to produce 10