masabni-commercial system

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Commercial SystemJoe MasabniOverton, TX

Topics

• Fish Selection (The Engine)

• Plant Selection (What can you grow?)

• System Start up

• Commercial system and Production

Fish Types of fish

• Tilapia•Hybrid Striped Bass• Koi (Carp)• Blue Gills• Catfish (Blue Nile)•Goldfish (Carp)• Trout• Bait fish and others

Adapted from Aquaponics: Fish Species Section,

Todd D. Sink, Ph.D. Assistant Professor & Extension Fisheries Specialist Texas A&M

Best Species

• Tilapia

• Hybrid Stripped Bass

• Koi

Tilapia

• One of most widely cultured foodfish worldwide• Market acceptability & recognition

• Also, low price & lots of competition

• Utilize niche marketing

• Reproduction can be a problem• Can over‐reproduce – may need to be thinned

• Mouth brooders – lost production

• Adapt very well to tanks• Tolerate high stocking densities (0.75 lb/gallon)

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Tilapia•Many species (>300)

• 3 legal in Texas: Mozambique, Nile, Blue

• Blue & Nile preferred due to market size of 1 lb• Both require TPWD exotic species culture permit

• Tolerant of poor/marginal water quality• pH 5‐10, 6‐9 optimal

• Tolerant of high water temp, low DO, high ammonia

• Most species tolerate 50‐55F for a few days

• Blue tilapia tolerates 48F

Tilapia

•Very good production characteristics• 6‐8 months crop

• Low protein requirement: 26‐32% protein, 4‐6% lipid

• Very good feed conversion: 1.3‐1.8 lbs feed/lb fish• Low production costs

• Ponds: ¢51‐60/lb• Tanks: $1.51‐1.79/lb – already priced out of market

• $4.57‐5.42/lb fillets – breakeven or niche markets

Hybrid Striped Bass

•Hybrid between striped bass & white bass• Best traits of parent species (SRAC No. 300)

• Improved water quality tolerance

• 39‐92 F acceptable (optimal 73‐81 F)

• Tolerate 1 ppm DO for short periods (>4 ppm)

• Alkalinity 20‐100 ppm (>100)

• Hardness 20‐100 ppm (minimum 40, >100)

• pH 2.5 short periods, 6 no problem (7‐8.5)

• Do not reproduce• Must buy new fingerlings: 3‐5” costs 65‐70¢

Hybrid Striped Bass

•Well adapted to tanks (0.33‐0.5 lb/gallon)• Grow to 1.5 lb in 150 gallons – flow through• ≥400 gallons recommended for aquaponics

•High market value species• $2.58‐3.02/lb whole fish in bulk

• Fillets $8.99‐9.99/lb• Niche markets $6‐8/whole fish

• Market not well defined – not much competition• 81% shipped whole on ice to East coast

• Not seen in Texas grocery stores

Hybrid Striped Bass

• Expensive to produce• Market size – 1.5‐2.5 lb

• 12‐14 month production

• Require 36‐40% protein, 10‐12% lipid• 70% of production cost is feed• Feed conversion 2.5‐2.8 lb/ 1 lb fish• Dress out 45%

• $4.66‐5.31/lb fillets (market $8.99‐9.99/lb)

Koi

•Non‐traditional – novel• Can be high value species – not world class• Sold as large individuals for ornamental ponds

• Small individuals are of little value

• Farmgate 20‐45¢ 1‐3” pond run

• Retail small $5.99 (Petsmart)

• Market size 1‐3 lb• Value $20‐65/fish, possibly more

• Poorly defined & highly variable market• Must wait for right buyer ‐marketing

• Typically only sell 1‐2 fish at a time

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Koi

• Tolerate poor water quality• Temperature 32‐95 F (65‐75 F)

• Tolerate DO 2 ppm short periods (≥5 ppm)

• pH tolerance 5‐9

• Cheap to produce• Grow rapidly• 28‐32% protein (finish diet with pigments)

• 1.8‐2.4 lb feed/lb fish• 53‐70¢ feed costs produce 1 lb fish (+$1.60 finish)

• Unlike goldfish can be sold at profit

What can you grow?

• Lettuce, kale, arugula, green onions, Swiss chard, Asian greens (bok choy, Mizuna, Tatsoi, etc.) broccoli raab, herbs (basil, cilantro, mint, etc.), water cress, strawberries, tomatoes, cucumbers, peppers, Napa cabbage, beets, spinach, celery, kohlrabi, fennel, radicchio

• In media beds: avocado, fig, papaya, mango, banana, tomatoes, cucumbers, eggplant, peppers, okra

• In wicking beds: all the above plus, carrots, beets, radish, sweet potatoes, turnips, parsnips

Romaine - DRAGOON

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14 days Sowing/Germinating/Initial

Seedling Growth+

20 days in the system=

34 day grow out from Seed to table

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Live Plants Farmer’s Market Lettuce

Leafy greens and herbs System Startup

• Install system• Fill with water•Balance the water (pH and chlorine)•Add fish or an ammonia source

• Inoculate with bacteria•Monitor ammonia, DO, pH, nitrites and nitrates

•Add plants when nitrates appear

Ammonia Startup• ammonia source (household non‐scented)

• Inoculate with bacteria (SafeStart)

• Monitor ammonia, pH, nitrites, and nitrates (API Freshwater Kit)

• Add plants when nitrates appear

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Nit

rate

(N

O3)

ppm

NO3

NH3

NO2

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Adding Fish

• Once the system has Nitrate production then add fish

• Finished stocking density can be in the 1 lb into 4‐10 gallons of fish tank size

‐ eg 100 gallon tank 10 – 25 lbs fish at HARVEST

• Do not feed fish for 7‐ 14 days or longer as the system balances with the new fish ammonia load (no more adding ammonia)

• Keep daily monitoring of system once ammonia is constantly around 1.0 then start feeding at ½ rate (1‐3% weight) and then after a week go to full rate (depends on time of year i.e., temps)

• Keep adding plants to system to fill up

(Conversion Factor: 1 kg/m3 = 0.0083454 lb/gal = 0.83454 lb/100 gal)

Recommendations My System (200 gal)

High Density 10‐20 kg/m3 8.3‐16.7 lb/100 gal 16.6‐33.4 lb

Low Density 1‐5 kg/m3 0.8‐4.2 lb/100 gal 1.6‐8.4 lb

My system feed amount (g/200 gal)

HD 15 kg/m3 25 lb/200 gal 170 (1.5%)

LD 3 kg/m3 5 lb/200 gal 34 (1.5%)

Theory

Reality

170 g and 34 g were too much. Not all the feed was used. Excess feed clogged filtration. Fish died.

Now I feed with 10 g per tank

How to get started?

• How much space do you have?

• Will this be a hobby or a commercial operation?

• Where will it be located? Indoors, outdoors, in a greenhouse?

• Choose a design

• Build it and the fish and produce will grow

Commercial Aquaponics

My Production Estimates

• How many holes per 2’ x 4’ raft? • 18, 34, 55 holes for production and 122 for nursery

• I am using 34 holes per raft

• How many rafts do I have?• 6 rafts

• What can I sell my lettuce for? $1.50/head

• How many cycles will I get? 3‐6 harvests/year • 612 ‐1,224 plants or $918‐1,836 (per system)

Holes per Raft

18

34

61

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Reality of Production

Example: Max production per harvest – 204 plants

204 plants x $1.50 x 6 harvest = $1,836

Reality:

• Production: 25‐85% of max: 45‐153 plants

• Price: $1‐4 per head, depending on location and quantities

• Harvest: 4‐6 per year

• Minimum: $180 (45 plants x $1 x 4 harvests)

• Maximum: $3,672 (153 plants x $4 x 6 harvests)

Getting more out of the same space

•A separate germination area watered with AP water (1 ‐ 2 weeks)

•Use 61‐hole rafts for seedlings nursery (2‐4 weeks)

•Grow‐out in 8” spacing (3‐10 weeks)

Production Program

• Example: 4’ x 20’ DWC, 6x 32‐hole rafts and 2x 122‐hole rafts• Seed 76 2” net pots (continue this cycle weekly or after each harvest)

• After 1‐2 weeks transfer to one 122‐hole raft (pick the best)

• After 2‐4 weeks transfer 68 to two 34‐hole rafts (pick the best again)

• Repeat until system is full

• This will give you a harvest from 1‐3 weeks apart (depending on time of year)

• Produces about 35 ‐ 40 harvests per year: 1890 ‐ 2160. vs 1080.

• Note these are examples at total production your mileage will vary!

Commercial-300

Sustainable HarvestersHockley, TX

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Assumptions:‐ You already have the land‐ Electrical/water costs are not included‐ You are doing all the labor

‐ Building System‐ Operating System‐ Selling Products

‐ 34 week grow‐out (0.3g – 450g)‐ Fish FCR: 1.7‐ ‐100% Fish Survival‐ Everything that can be produced is sold‐ Not including the 3‐month cycling phase‐ $1/head of lettuce‐ $3/lb of fish



‐ 34 week grow out (0.3g – 450g)‐ Fish FCR: 1.7‐ ‐100% Fish Survival‐ Everything that can be produced is sold‐ Not including the 3‐month cycling phase‐ $1/head of lettuce‐ $3/lb of fish










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BuildinganAquaponicsSystem

Dual Loop

Aquaculture

• 2 fish tank

• Radial filter

• Biofilter

• Sump tank 1

Hydroponics

• Sump tank 2

• Grow Bed

DualLoopSystem

• Ifyouweretoeliminatethedualloopportionofthedesign,youcouldeliminateonesumpandrunthewaterdirectlyfromthesumptankintothegrowbed.

• Oneadditionworthconsidering,notincludedinthissystem,isadegassingtank.Thepurposeofthedegassingtank,simplyanother30gallontankwithanairstoneinit,istoremovecertaingasses(carbondioxideandhydrogensulfide)beforethevegetabletroughs.

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GrowBedorTroughConstruction

• Theinsidedimensionsofthegrowbedsare49.25incheswidebyalittleover20ft long.

• Thefloatingboardsare4ft wide.• Theextra1.25“widthallowsforsomemovementoftheboards.Totalwidth(outside tooutside)is52.25”.

• Thissingletroughwasconstructedusing2x12pressuretreatedlumber.

• Treatedlumberisokaytousebecausethefoodgradelinerusedinthetroughprotectstheplantsfromanychemicalleachingfromthetreatedlumber.

• The2x12sectionswerejoinedtogetherontheinteriorcornersusinggalvanizedbracketsandontheexteriorbysplicingwith1x4treatedwood.

• Thecornerswerereinforcedusinggalvanizedcornerpiecesand11/4"deckscrews.

2” nails

1x4 wood splice bracketGrowBedorTroughConstruction

• Oncethelumberisassembled,laydownthelinerandcutittolength.

GrowBedorTroughConstruction• TheUltraScrimR20WWlinercomesasarollof6.167ft x100ft andisFDAapprovedasfoodsafe.

• Pondlinerworksjustaswellandischeaper,butisnotcertifiedasfoodgradesoitcannotbeusedifyouaresellingyourproduct.

• TheUltraScrimonlycomesintwowidths,6.167ft and12ft sothattendstodeterminethewidthofthegrowbeds.

• The6.167ft widthisperfectfor4ft widebedswithsidesthatareunderafoothighwith2x12woodboards.

Tipsonfoldingtheliner• Thecornerswerefoldedoveroneanother(thinkhospitalbed)insidethetankandthenthecornerlipswerecutalonga45degreediagonaltofacilitatestaplingtothetopoftheframe.

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Tipsonfoldingtheliner• Whenstapling,stapletheendsfirst,thenthemiddle,andthenstapleatthemiddleofthelasttwostaples.Theremaybesomebulgingofthelinerinsidethebed,inotherwordsthelinerdoesn’thavetobespreadtightinsidethetroughasthatwilldisappearoncethetroughisfilledwithwater.

EndFilter• Allfiltersareconstructedinthesamefashion.

• LaydownaPVCpipeandanendcap,spacedabout6"apart,androllthehardwarenettogettheappropriatesizeandcutit.

• Dothesamewiththeblackpetscreen• Jointhepiecestogetherwithclamps.• Trimexcessnetfromend.

RadialFilter• Thedesignofthisradialfilterisverysimple,consistingofa30galloncontainerwithaplasticlidanda5gallonpailwithalid.

• Thebottomofthe5gallonpailiscutoutusingaSawzall.

RadialFilter• Aholethatisthesamesizeasthepail(excludingthelip)isthencutinthetopofthe30galloncontainerusingajigsaw.

• Thepailisthenfittedintothehole,thelipoftheedgecatchingonthecoverofthe30galloncontainer.

RadialFilter• ThetopofthePVCpipeshouldbeatalevellittlebelowtheoutletline.

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RadialFilter• ThePVCpipefromtheinletpipeshouldalsocomeupinthemiddleofthepail.

• Theoutletpipeisoutsideofthepailsothatsolidsareforceddownbygravity.

Inlet Pipe

Bio-filter• Next,waterflowstothebio‐filter.• Itissimplya30galloncontainerwithalidthatcontainstwotothreepackagesofbirdnettingscrunchedupintothecontainer.

WickingBeds• Thissystemdoesn’tincludeawickingbednordoesthematerialslistincludewhatwouldbenecessarytodoso.

WickingBeds• Thewickingbedwallsneedtobehigherthanthewallsofagrowbedusingthedeepwaterculturemethodwithfloatingrafts.

• Itisrecommendedtousetwo2x10piecesoftreatedlumbertomakea3ft widebedifyouonlyhaveaccessfromonesideorupto6to7ft wideifyouhaveaccessfrombothsides.

WickingBeds

• Theconstructionisthesameasthegrowbeddescribedabove.Otheroptions,perhapscheaper,includetheuseofIBCtotes.

• Rememberthatwickingbedsarenotlimitedtoaquaponics,butcanbeanexcellent,stand‐alonemeansofconservingwater(thinkEarthboxes).

WickingBeds

• Ifyouwishtorecyclethewateraspartofyouraquaponicssystemthenyouwilllikelyneedtohaveadrainonthebottomthatreturnstheexcesswaterintothereservoirofwaterbeingreturnedtothefishtanks.

• Thismaylooklikephotos71and72showingthepreviouslyconstructeddemonstrationsystemthatincludedthewaterflowingfromthetanksandfiltersintoamediabed,thenoutthebottomintoaraftsystem.

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WickingBeds

• Oncetheframeiscreatedandproperlylined,youfillthefirst4‐6"withinertstones(necessaryifrecyclingthewateraspartofyouraquaponicssystemsothatyoudonotchangethepH),thenweedcloth/gardenfabricandcardboardfollowedbythewormcompostmixedwithaneutralplantingmix(coconutcoir).

WickingBeds

• Thecompostprovidesnutrientstheplantneedsandthewateriswickedupfrombelow.Thelandscapefabricandstonepreventsolids(forthemostpart)frompassingintothewaterthatwillreturntothefish.

Conclusion• Fromacommercialstandpoint,aquaponicsworksifyoucansellthefishtocoveryourcostsandyoucanminimizeyoursupplementalinputsandmaximizeyourincomebygrowinggreens(lettuces,microgreens,kale,etc.)andselltorestaurantsandfarmersmarkets.

• Plantsharvestedarestillalivesinceyouharvestthemrootsandallsotheirshelf‐lifeismuchlonger.

• Forexample,youcanharvestlettuce,keepingtherootballinabag,andreplantitaweeklateranditwillcontinuetogrow.

Conclusion• Generallyspeaking,youwillnotfinditprofitabletoproducetomatoesandotherfruitingplantsinafloating raftbed becausetheytakeuptoomuchspaceinyoursystem(e.g.onetomatoplanttakesup2sq.ft.vs.2lettucesin1sq.ft.)relativetotheirpriceandyoucannotsupplytheadditionalnutrients(potassiumandphosphorous)efficientlyincomparisontoothermethods.

Conclusion• Separatetheaquaculturesystemfromthegreenhousehydroponicssystemsothatyoudon’tusevaluablegreenhousespacetoraisefishthatpreferadarkenvironment.

• Thebiggestcosttothesystemwillbethegreenhouseandtheheating/coolingthereof.

Conclusion• Youneedtodecide,upfront,whetheryouneedcertificationofoursystemforthesaleoffishand/orvegetablesandbuildaccordinglyasitwillnotbeprofitabletotakethesystemapartandoutfititwithfoodsafematerialslater.

• Thefishsideoftheaquaponicssystemisnotveryprofitablesoyouneedtodeterminewhetherthecostofthefishharvestedforpersonaluseisatasatisfactorycost.

masabni-commercial system

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