Pelagic fish processing systems for fish processing vessels

Skaginn 3X has taken its groundbreaking onshore pelagic processing techniques and adapted them for onboard applications. Skaginn 3X technology like non-pressure horizontal freezing, comprehensive temperature regulation and precision automation have created a new standard in pelagic onboard processing, with vessels able to land high quality, fully palletized frozen product.

The methods of maximizing product quality in the Skaginn 3X onshore solution—keeping temperatures consistently low, minimizing processing times and employing non-pressure freezing methods—have been realized with equipment specially designed for operation at sea. Although the solution is optimized for onboard applications, the system maintains the same high standards of automation, energy efficiency and low maintenance requirements that Skaginn 3X is known for.

System Overview

The Skaginn 3X turnkey solution for pelagic processing at sea is highly customizable. Below is an example of a buildout, although the solution offers great flexibility and is invariably configured to meet each client’s particular needs by the Skaginn 3X team of engineers and designers in close collaboration with the client.

1. Product enters processing deck and sorted through Automatic Grading

Extra long grading channels allow for great accuracy
Fully automated ensures high throughput
Gentle handling: no squeezing or abrading
Each grade is buffered for better batching

2. Product chilled with Fluid Ice System at all buffering points

Consistent low temp shortens freezing time and prevents bacterial growth
Temp range of -5°C to 0°C
Slurry thickness adjustable 10% to 50%
Automatic delivery system throughout the process

3. Product enters QC-Vision Batcher™ for quality control and batch-weighing

Computerized vision system regulates tank levels, infeed, buffering and flow
System rapidly analyzes each unit from both sides to determine size, weight, species and any damage
Creates a record of each unit for full traceability
Rejected units rerouted for further processing
Up to 15 batches per minute with high weight-accuracy

4. Batches bagged, brine-injected and vacuum-sealed

Non-transparent polybags provide superior protection
260kg rolls last up to 12 hours in production
Low-cost PE film (50µm)

5. Automated loading in Onboard Automatic Contact Freezer

Specially designed for operation at sea
Non-pressure freezing preserves natural appearance
Eliminates vertical plate freezing and its crushing effects on product quality
Utilizes deck height to save floor space
Runs up to 7 days between defrosting

6. Final product enters onboard automated packing and palletizing hotel

Palletized very early in supply chain to reduce potential damage to high-value product and resulting customer claims
Eliminates heavy lifting for safer working conditions
Carton size optimized for palletizing leaving no wasted space on pallet
Loaded, wrapped, labeled pallet moved to cargo hold via elevator
When cargo hold is full palletizing hotel serves as cold storage
No sorting on land necessary—product emerges ready for transport

Specifications

System capacity

100 MT/24 hrs

Footprint

Energy use for chilling per 100 MT of finished product

Total energy use w/o chilling per 100 MT of finished product

180 m2

200 kWh

300 kWh

* These specifications are provided for reference only and do not reflect how all buildouts perform. As the Skaginn 3X solutions are highly customizable, results vary greatly depending on how each system is configured.

Specifications

System capacity

200 to 450 MT/24 hrs

Footprint

Employee hours per shift at 200 T capacity

Employee hours per shift at 450 T capacity

300-900 m2

10 hrs

30 hrs

Specifications

System capacity

1000 MT/24 hrs

Footprint

Employee hours per 1,000 kg of finished product**

Energy use for freezers per 1,000 kg of finished product

Total energy use for factory w/o freezing per 1,000 kg of finished product

3,000 m2

0.94 hrs

60 kWh

66 kWh

** Employee hours is based on all factory employees, including cleaning time and technical service. This is based on 750 metric tons/24 hours of mackerel production with a total of 30 employees.