Fully automated onshore pelagic fish processing systems

Skaginn 3X has developed the principal technologies that distinguish its turnkey solution for pelagic processing onshore, including automated fluid ice delivery, computer visioning and precision automation to ensure efficient yet gentle handling. However, our designers and engineers also have considerable experience when interfacing with existing platforms.

The Skaginn 3X process maximizes product quality by keeping temperatures consistently low, minimizing processing times and employing non-pressure freezing methods. Moreover, Skaginn 3X systems are all designed with automation, energy efficiency and low maintenance requirements in mind. The equipment is optimized for easy yet thorough cleaning to support industry standards for hygiene.

System Overview

The Skaginn 3X turnkey solution for land-based pelagic processing 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 facility, weighed in and sorted by mechanical grader for shape and size

Refrigeration from vessel maintained in receiving tank with RSW
Low temps prevent product from softening—firm product results in most accurate grading

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 into Automatic Contact Freezer in tray or carton

Non-pressure freezing preserves natural appearance
Fully frozen in 3-4 hours
Low yield loss
Each freezer handles up to 100 tons per 24 hours
Runs up to 10 days between defrosting

6. Fully automated packing and palletizing

Eliminates heavy lifting for safer working conditions
Wagon-on-rail transport eliminates forklifts on factory floor
Gentle handling maintains high product quality
Low total packaging costs per 1000 kg of finished product

7. Equipment designed for use with robust cleaning system without halting production

Centralized system with high and low pressure washes, detergent and disinfection in a single unit
Easy to operate and low maintenance requirements
Up to eight operators can work simultaneously

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.