June 6 -10, 2011NATAL CONVENTION CENTER

NATAL, BRAZIL

RE-DESIGING BLUE ARCHIPELAGO INTENSIVE SHRIMP FARM IN MALAYSIA

BIOSECURE MODULE SYSTEM COMBINED WITH BIOFLOC TECHNOLOGY

Nyan Taw*, Poh Yong Thong, Ling Teck Ming, Chatree Tanabatra, Kamel Zikry Sallah & Mohd Afiq Md Razi

Blue Archipelago BHDwww.bluearchipelago.com

Shrimp (L. vannamei) farming has become competitive and as such technology starting from biosecure farm design and operation system utilized is essential for sustainable production. This has been proven by re-engineering from pond base culture to module base biosecure system at a large shrimp farm in Indonesia (Nyan Taw et.al., 2007). The basic concept of biofloc technology was provided by Avnimelech (2000, 2005a&b). The system was successfully applied in commercial culture of shrimps by McIntosh (2000a, b & c, 2001), McNeil (2000), Nyan Taw (2004, 2005, 2008 & 2010). Smith et al (2007) successfully used biofloc technology on Penaeus monodon in earthen ponds in Australia. Shrimp farm biosecurity was given by Nyan Taw (2010). Successful redesigning and production using biosecurity and biofloc technology was also provided very recently by Nyan Taw (2011).

Blue Archipelago intensive shrimp farm, Arca Biru SDN, is located at Kedah, northwest of Kuala Lumpur. The farm was established in early 1990s for Penaeus monodon culture. However, the farm was faced with serious viral (WSSV) outbreaks. In early 2010, the farm was re-designed from pond base to biosecure module base system including two modules lined with HDPE. For the remaining modules, only pond dikes were lined. The farm was operated with minimum water exchange, semi-biofloc and biofloc technology. The main objective of the cycle was to have a bench-mark for future production cycles as such a number of commercial trials were tried.

BACKGROUND

Arca Biru (BAB) Shrimp Farm, MalaysiaSeawater source 2.4 KM

Farm Location West Malaysia

CPB LampungModules Earthen & HDPE lined ponds (0.5ha). Recirculation system

1999

NT Dec09

DipasenaPond base in rows changed to Module base operation system in 2006 – reservoirs and culture ponds

Pond Base in rows

Module Base systemDipasena WM

Module Base system

20061995

2000

Nyan Taw WAS 2005 Bali Farmer sessionNyan Taw, Shrimp Farm Indo GAA 2005

Nyan Taw et al Reengineering Dipasena GAA 2008

THE CHANGES

Before Re-designing – Module ? Biosecurity ?

Sub Inlet gate - leaks

SI Canal –cannot dry

Nets – 1000 micron

Out let gates - Leaks

Sludge center pond – not removed

Crab fence – not maintainted

Dead WSSV shrimps after harvest – not removed

Not used

Crabs

Out let leaks

Black sludge now removing

Bird scare lines

Fish

Nets – 1000 micron ?

Reservoir pond

Reservoir pond Reservoir pond

Reservoir pond

Nets – 1000 micron

What we are protecting from ?

Basic WSSV Characters

1. Mass mortality: DOC <45 days

2. Temperature >30 less prone; <29 more prone; <26 dangerous.

3. Onset of heavy rain (season) with low temperature trigger outbreaks.

Seasonal occurrence is well document.

4. Virus dies in free water in 72 hours

5. Crustacean are carrier (crabs) – lives with virus.

6. Virus lives in freshly dead, indefinitely in fresh processed frozen condition

7. Virus can live and a very few can survive after mass mortality

8. No evident of wind carrying WSSV from pond to pond

9. Bacteria white patch (spots) on carapace can be mistaken as WSSV spots.

BIOSECURITY

Arca Biru SDN BHD - Layout2 Module HDPE + 6.5 Module HDPE At Dyke + 0.5 Module LDPE At Dyke – 9 modulesOperated only 1 Module HDPE + 6 Modules HDPE at Dike – 7 modules

Bio-secure Module system – Arca Biru

Arca Biru, MalaysiaBiosecure module - after re-designed

250 & 1000 micron screen net

HDPE Lined secondary supply canal

Biosecurity – crab fence & bird scare lines

HDPE lined ponds with center drain, secured outlet gates & Main supply canal

Sub inlet

Pond out let gate

Physical barrier for viral carriers – use 250 micron screen net

Chemical application – kill viral carriers. Apply crusticides

Kill free water bore virus (aging) - dies in 72 hrs without host

Treated water ready for use for culture (apply same procedure)

Module Biosecurity – Water treatment system (Control WSSV)

Treatment Reservoirs ponds

Culture ponds

Basic (SOP) Procedure for Biosecurity (Summary) Parameters

Closed Water

Semi Closed Water

Open Water

Fill in Water

Treatment (unit 1 & 2) and Culture ponds (Max. level > 120 cm)

Started fill in to Treatment (unit 1 & 2) and Culture ponds (optimum level >100 cm)

Started fill in to Treatment (unit 1 & 2 and Culture ponds (Max level > 120 cm).

DOC (Day of Culture) 1 - 45 46 – 90 91 - harvest Apply Crustacide/chlorine To Kill WSSV Carrier

All ponds/ Crustacide 0.5 – 1.0 ppm Chlorine 25-50 ppm

Chlorine 25-50 ppm or whenever possible

Chlorine if possible

Bio assay Check toxicity

Yes - approximately 5–10 days

Yes – approximately 5-10 days

Check if required

Aging water To Kill WSSV in water

All ponds minimum 3 (72 hours) days

Minimum 3 days (72 hrs) Minimum 3 days (72 hrs)

Screening: 250 – 300 micron. Prevent carrier entering module

Yes – at all critical points: Main inlet, between TP units TP & Main TP or Supply canal. TP & CP

Yes – at all critical points: Main inlet, between TP units; TP & Main TP or Supply canal. TP & CP

Yes – at all critical points: Main inlet, between TP units; TP & Main TP or Supply canal. TP & CP

Water exchange No Minimum (topping up only) Maximum Water source Within module only Start open to outside Open to outside

Module Base Close Water System

Basic of BFT in Shrimp Farming 1. High stocking density - over 130 – 150 PL10/m22. High aeration – 28 to 32 HP/ha PWAs3. Paddle wheel position in ponds4. HDPE / Concrete lined ponds 5. Grain (pellet)6. Molasses 7 C&N ratio >158. Biofloc controled at <15 ml/L9. Expected production 20–25 MT/ha/crop

Bioflocs

High density

High aeration

Dark Vannamei Red VannameiGrain pellet

Feed & grain application and biofloc

Biofloc

PRODUCTION PERFORMANCE OF ARCA BIRU FARM

Biofloc 0.4 ha HDPE Semi-Biofloc 0.8 ha HDPE Conven 0.8 ha HDPE DykeNo of Ponds 2 19 119 PWA Energy (Hp) 14 24 20 Stocking Density 130 110 83 DOC (days) 90 101 111 SR (%) 89.16 81.35 83.19 MBW (gr) 18.78 18.31 17.80 FCR (x) 1.39 1.58 1.77 ADG (gr/day) 0.21 0.18 0.16 Avg Harvest tonnage (kg) 9,006 12,950 9,616 Production (Kg/Ha) 22,514 16,188 12,019 Prod per power input (Kg/Hp) 643 540 481

Production Parameter System/size/type

Growth

DoC

Arca Biru (BAB) farm performance

Grams

Nyan Taw, et.al. GAA March/April 2011

Biofloc in shrimp farming

Kg

Nyan Taw Shrimp farming Indonesia GAA Aug/Sep 2005

The authors would like to sincerely thank Mr. Abu Bakar Ibrahim (CEO), Dr. Shahridan Faiez (former CEO) and Mr. Christopher Lim (COO), Blue Archipelago for their interest and support .

The staff and members of Blue Archipelago, Malaysia for their diligence and hard work to make this work possible specially engineers Mr. Noorazam Ismail and Mr. Sukirno.

Acknowledgements

Thank You

Nyan Taw and Team 7 June 2011