Sector planning & Master Plans

Scope

Studies for National Food Departments or Ministries to evaluate the state of the food processing sector.

The studies to be used for identifying the needs of the sector, for developing a strategy for restructuring, including rehabilitation of the sector and to co-ordinate the given assistance in preparation to enter the EU.


Advantages

  • Independent evaluation of the food processing sector
  • Overview of the present situation (production facilities, economy, markets and products
  • Action plans for individual companies with recommendations on economy, markets, production equipment and facilities, products, education and training etc.
  • Strategy for restructuring the food processing sector


Study

  • To establish a platform for a restructuring of the fisheries sector by carrying out an analysis of the sector in order to assist the national authorities in evaluating the performances and the conditions of the food processing sector and in elaborating action plans for the parties involved.
  • A strategy for the fisheries sector and the needs for investments, improvements and rehabilitation of the food processing sector to fulfil the EU standards to be elaborated on basis of the study.


Extent of study

  • A survey including visits to a broad section of the sector involved
  • A questionnaire covering analyses of products, markets, production, economy, education, quality and hygienic issues in the companies  forms the basis for the survey
  • An evaluation of the performance of the sector
  • An overall action plan for the sector
  • Specific action plans for the companies involved


References

Norway –  Developing of the pelagic fish processing industry.                        Detailed planning and programming of the developing of the pelagic sector. Presented at a seminar in Bergen in January 2007 for the entire Norwegian Pelagic Industry. Elaboration of Benchmarking studies for 4 pelagic industries.


Norway – Developing of the Pelagic Sector.

Analyses and presentation of scenarios for the development of the pelagic fish sector.


Lithuania  - Ministry of Agriculture Lithuania, Fisheries Department - 
An analysis of the industry's condition and performance including a strategy for preparing the industry for the Lithuanian admission to the EU. Project manager and responsible for the technical evaluation of the processing plants. 

Mozambique -  Master Plan for the Fisheries Sector - 
Phase 1 of the elaboration of a master plan for the industrial and semi-industrial fisheries sectors of Mozambique including:

Identification of sector problems and development objectives in a logical framework approach (LFA). 


Germany – Production Master Plan for cutting and deboning plant for 10.000 pigs/day. Work included re-arrangement of lay-out, improvement of flow, introducing new technical solutions to problems on processing equipment.

Feasibility studies & Business Plans

Scope

Feasibility studies or Business plans for meat - and fish processing plants to provide a base - technical, economic and commercial - for an investment decision.  It defines and analyses the critical elements that relate to the production of a given product together with alternative approaches to such production. The study provides a project of a defined production capacity at a selected location, using a particular technology or technologies in relation to defined materials and inputs, at identified investment and production costs, and sales revenues yielding a defined return on investment.


Advantages

  • Analyse whether the project is viable or non-viable before further initiation of the project
  • Optimisation process covering possible alternative solutions for production programmes, locations, sites, technology, plant, mechanical, electrical and civil engineering  and organisational set-up that have to be harmonised in order to minimise investment and production costs.
  • If the resulting data show a non-viable project, several parameters and the production programme, material inputs or technology would be adjusted in an attempt to present a well-defined, viable project.


Study

  • The feasibility study will describe the above mentioned optimisation process, justify the assumptions made and the solutions selected and define the scope of the project as the integration of the selected partial alternatives.
  • If, however, the project is not viable despite all alternatives reviewed, this will be stated and justified in the study.
  • Final estimates on investment and production costs and the subsequent calculations of financial and economic profitability is based on a unequivocally defined scope of project in order not to omit any essential part and its pertaining cost.
  • The scope will be defined in drawings and schedules which could then serve as a supporting structure during further project work.
  • It will be clearly described in order to accurately forecast the investment and production costs.
  • Will embrace all activities scheduled to take place at the plant site; the auxiliary operations related to the production, extraction, off-site transport and storage of inputs and the off-site transport of outputs (e.g. final products, by-products, wastes and emissions); and such off-site ancillary activities as housing schemes and educational, training and recreational facilities.


Extent of study

  • Executive summary
  • Project background and history
  • Market and plant capacity
    • Demand and market study
    • Sales and marketing
    • Production programme
    • Plant capacity
  • Material inputs
    • Materials and inputs
    • Supply programme
  • Location and site
    • Location
    • Plant site and local conditions
    • Environmental impact
  • Project engineering
    • Layout and physical coverage of project
    • Technology and equipment
    • Civil engineering
  • Plant organisation and overhead costs
    • Plant organisation
    • Overhead costs
  • Manpower
    • Labour
    • Staff
  • Project implementation
  • Financial and economic evaluation
    • Total investment
    • Project financing
    • Production cost
    • Commercial profitability
    • Economic evaluation
  • Annexes


References

Denmark/Eastern Europe – Master Plan for new pig slaughterhouse and cutting/deboning plant. Planning for a new green-field slaughterhouse in Eastern Europe. Together with the client, the team reviewed the overall layout of the factory including definition of all product and production flows, staff requirements, material and waste handling and discussed hygienic principles and food safety. Other issues were the optimal temperature regimes for all the different production areas, refrigeration and process ventilation.


Senegal – Technical and commercial due diligence for a newly established fish processing complex with own vessel and new large processing plant including all facilities and utilities. Yearly production planned to be up to 90.000 tons of fish. Evaluation and verification of business plan and assessment of processing lines and building facilities.


Montenegro – Preparation of a Feasibility Study for the disposal of animal by-products in accordance with EU regulation 1069/2009 and 142/2011.


Denmark – Investment and development plan for production of spareribs and tenderloin. Detailed investment plan with layouts, production calculations and cost benefit analysis all presented in a complete investment prospect for the Board of management.


Egypt -Grand Lake, Co-operation project with Egyptian company Modern Structures and Equipment Ltd under the private sector development programme. The first phase of the project under the Start-Up facility includes: Technical draft project and business plan for processing facility in Abu Simbel of EU standard; Introduction of environmental friendly productions and cleaner technologies, Increase efficiency of fishery and improve raw material handling and storage onboard the fishing boats; Design of new fishing vessel or purchase of second hand vessel, Feasibility study for farming of Nile Perch and a market survey for the Egyptian freshwater fish on the EU market.


Sojusrybprom – Kaliningrad, Russia – Business plan for new frozen fish production plant including new chill and cold stores. The project consists of business plan with technical project including layout, flowcharts, description of processing, production capacities, technical specifications and investment budget.


Poland  -  Preparation of draft project including layout, new product assortment and business plan for a new canning plant to be build in connection to the existing plant in Karsin.

Latvia  - Preparation of complete business plan including technical draft  project with layout for a new canning plant to be build in existing facilities at the kombinat in Saldus. The business plan is a part of the application for SAPARD funds.


Latvia  -  Preparation of complete business plan including technical draft  project with layout for upgrading of existing facilities for production of semi-preserves in Lapmezciems. The business plan is a part of the application for SAPARD funds.


Latvia  -  Preparation of complete business plan including technical draft  project with layout for upgrading of existing facilities for production of semi-preserves in Daugavpils. The business plan is used as a part of the application for SAPARD funds.


Lithuania  -  Assistance to the fishing industry in Lithuania in preparation and presenting of rationalisation and modernisation plans (business plans) for companies seeking project financing through Western development banks, Governmental agencies or through participation of industrial partners.


Russia  -  Business plan for establishing of a modern fish processing plant and cold stores in Kaliningrad . The production is based on frozen raw material from the company’s high sea fleet. The project is prepared for stepwise extensions of the plant and for flexible production lines. The project includes implementation of energy saving thawing methods, management systems for quality assurance and construction of modern cold stores.


Latvia  - Pre-feasibility study for smoked sprat canning plant with a capacity of 3500 tons of raw material per year. The overall purpose of the project was to assist the Latvian fishing industry “Baka Ltd.” in their privatisation efforts through the elaboration of a definite project for a modern smoked sprat canning plant able to produce on market economy terms. Strategically, the plant must emphasise the production of canned smoked sprat of high and consistent quality for the export market. The “high quality” image will enable the plant to establish itself as a reliable supplier of products to quality-conscious segments with a great purchasing power. The study included description and definition of conditions, process-flow, layout, production control system, offal handling, technical installations, investment budgets, market survey and cost-benefit analysis.

       

      Laying of foundation stone for new Fisheries Inspection Office & Fish Quality Laboratory in Beira, Mozambique as part of the Implementation of the Master Plan for the Fisheries Sector.

       

      Semi-Industrial fishing vessel in Beira Fishing Harbour testing power of engine as aprt of training of fishing captains under the implementation of the Master Plan for the Fisheries Sector.

       

      Presentation of Sector Analysis of the Lithuanian Fish Processing Industry for all the relevant stakeholders by Mr. Johnny Haupt Larsen.

       

      Cutting out tenderloin on start of cutting and deboning lines.


      Layouts for new processing plants or processing lines

      Scope

      Layouts and design of food - and fish processing plants for all kinds of products. The optimum design and layouts are based on our comprehensive knowledge of production techniques, available equipment, all requirements by high price markets, authorities including EU regarding hygiene, health and consumer safety (HACCP). 


      Advantages

      Defined product flow from raw material reception to final product storage and dispatch.

      Balanced production lines in order to avoid bottlenecks along the lines.

      Separation of production areas into different hygienic zones with the products always moving towards a zone with higher hygienic standard.

      Well organised and suitable staff facilities.

      Waste - and wastewater treatment organised with full respect to hygiene and environment - based on Best Available Technology (BAT).

      Utilisation of waste and by-products for saleable products.

      Always including the highest degree of cleaner technologies all over the plant to make the plant environmental friendly and improve the economy of production.

      Including the newest methods and equipment - securing the best possible marginal return and the shortest pay-back period.

      Layout and design


      References

      Philippines  - Harini Fisheries -  Preparation of layout for high quality tuna processing plant in the Philippines including process flows and recommendation on construction materials and details in order to fulfil the highest demands for modern processing facilities.
      Client: Intertec A/S, Aarhus Denmark.

      Poland  - Karsin S.C. -  Preparation of draft project including layout, new product assortment and business plan for a new canning plant to be build in connection to the existing plant in Karsin.
      Client: Karsin S.C. by Mr. Jacek Schomburg.

      Poland  - Losos Sp. z.o.o. -  Preparation of draft project including layout, process description, capacity balances and investment budget for a new cannery with a capacity of 50 mio. cans per year.
      Client: Losos Sp. z.o.o. Ustka.

      Poland  - Superfish S.A. -  Preparation of layout and investment budget for a new preliminary processing plant.
      Client: Superfish S.A. Kukinia.

      Belarus  - Santa Impex -  Preparation of detailed draft design for new marinated herring processing plant in Brest . The project included detailed layout, investment budget, technical installations, raw material and final product balances, process flow and descriptions, recipees and production manual for new product types.
      Client: Santa Impex, Brest Belarus.

      Mozambique - Directorate Nacional de Pescas and the Provincial Department for Fisheries in Beira -  Preparation of layouts for more than 10 shrimp and fish processing plants in order to fulfil the demands for export to EU.
      Client: DANIDA.


      News and published articles.


      The latest news will be presented here. If you have been a visitor to our web-site before and want to learn about news and revisions, please look here first.

      Latest news:
      New brochure "ENVIRONMENTAL FRIENDLY AND SUSTAINABLE PRODUCTION" - Download in pdf format by clicking here.

      Implementation of the Grand Lake project in Abu Simbel, Egypt
      2nd generation Multipurpose Seafood Processing line for value added products at HAVICO in Vietnam (May 2004)

      Egypt PSD Programme - Technical assistance under the Start Up facility (February 2004).

      Multipurpose Seafood Processing at CASEAFOOD in Vietnam.
      New partner in Poland.
      Sojusrybprom, Kaliningrad - Business Plan.
      Koga Maris, Poland - Technical assistance for SAPARD application.
      Latvia - HACCP.
      Email service.
      Second hand equipment
      Superfish, Poland - Raw material handling and silage production.

      Articles - click here.


      Grand Lake, Egypt - Implementation of the project.

      “ Grand Lake ” is an Egyptian company having been established in 2004. The company is presently active in trading with fish being caught by artisan fishermen in Lake Nasser and landed in the fishing port of Abu Simbel . It is the company’s objective to increase its scope of business into fishing and processing of fish from Lake Nasser having been caught by artisan fishermen and being caught or farmed through the company’s own activities. The fish species are Nile tilapia, Nile perch and catfish. The fish will be marketed and sold on the national market as fresh, iced fish and on the export markets as processed fish fillets.  

      The company has entered into a license contract on a rundown fish processing plant in Abu Simbel and intends to restructure the buildings and install up-to-date processing equipment all to meet the demands for producing and placing of fish products on the market, as given in “Regulation (EC) No 852/2004 of the European Parliament and of the Council of 29 April 2004 on the hygiene on foodstuffs”.

      The company has furthermore obtained licenses for fishing in Lake Nasser and for establishing fish farming activities in four huge creeks on the east bank of Lake Nasser .  

      It is anticipated that complete implementation will take 12 months starting from 1 January 2005 and is financed by International Leasing & Investment Co, Kuwait.

      Raw material supply will build up gradually through the first year of operation after implementation has been completed and will reach a daily supply of 40 tonnes of fish of which 20 tonnes comes from artisan fishing, 10 tonnes from the company’s own fishing activities and 10 tonnes from the company’s fish farming activities.

      During the first year a total of 8.100 tonnes of fish will be supplied to the company of which 4.300 tonnes will be sold as fresh fish on the national market in Cairo and 3.800 tonnes will be processed into fresh, chilled and frozen fillets all to be sold on the export markets

      More about the project in Egypt - click here.                                                                          


      Processing plant in Abu Simbel.

      Development of 2nd generation Multipurpose Seafood Processing line for value-added products.

      During the design and tendering of the production control system for CASEAFOOD, SEAQIP has entered into cooperation with another Vietnamese seafood processor HAVICO in Vung Tau on the planning and assistance in manufacturing and delivery of the 2nd generation of the MSP lines as presented in Nha Trang last year in November.

      Based on the experiences gained on planning, manufacturing, implementation and testing of the MSP lines at CASEAFOOD it is evident that the planning and preparation of layouts with the new MSP lines is of outmost importance for a successful implementation without unnecessary delays and equipment costs.  

      HAVICO has expressed the need for specific adaptation of the presented model of the 2nd generation MSP lines for their value-added productions in the new factory under construction.

      2.         The objective of the work is to:

          To prepare layout and specifications for the MSP processing department at HAVICO

          To draft detailed large scale arrangement drawings of the MSP department

          To assist HAVICO in evaluating tenders for the new production lines

          To assist SEAQIP and HAVICO in commissioning and running in of the production lines

       

      The project is fulfilled by LarEll Associated Consultants for SEAQIP - DANIDA, Hanoi, Vietnam.