Abstract:
A Vertically Integrated Aquaculture System for producing high quality consumer seafood products at a significantly reduced cost. The Vertically Integrated Aquaculture System includes at least one aquaculture grow-out module for containing an aquaculture species, a feed handling system for distributing feed to the aquaculture species located in the aquaculture grow-out module(s), an aquaculture species moving system for routing the aquaculture species at least out of the aquaculture grow-out module(s), and a processing system for processing the aquaculture species after harvesting from the aquaculture grow-out module(s).

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to aquaculture and more particularly pertains to a new Vertically Integrated Aquaculture System for producing high quality consumer seafood products at a significantly reduced cost. 
     2. Description of the Prior Art 
     The use of aquaculture is known in the prior art. More specifically, aquaculture heretofore devised and utilized are known to consist basically of familiar, expected and obvious structural configurations, notwithstanding the myriad of designs encompassed by the crowded prior art which have been developed for the fulfillment of countless objectives and requirements. 
     In many instances, open ponds and flow-through systems are used limiting the geographic locations available for production, as well as placing the stock being raised at increase risk for health and environmental concerns. 
     In these respects, the Vertically Integrated Aquaculture System according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in so doing provides an apparatus primarily developed for the purpose of producing high quality consumer seafood products at a significantly reduced cost. 
     SUMMARY OF THE INVENTION 
     In view of the foregoing disadvantages inherent in the known types of aquaculture now present in the prior art, the present invention provides a new Vertically Integrated Aquaculture System construction wherein the same can be utilized for producing high quality consumer seafood products at a significantly reduced cost. 
     To attain this, the present invention generally comprises at least one aquaculture grow-out module for containing an aquaculture species, a feed handling system for distributing feed to the aquaculture species located in the aquaculture grow-out module(s), an aquaculture species moving system for routing the aquaculture species at least out of the aquaculture grow-out module(s), and a processing system for processing the aquaculture species after harvesting from the aquaculture grow-out module(s). 
     There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. 
     In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. 
     As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. 
     One significant advantage of the present invention is the degree of quality control available during the grow-out process due to the aquaculture grow-out modules being positioned inside a structure. Additionally, this configuration allows non-traditional aquaculture environments (plains, deserts, etc.) to be used in aquaculture production. 
     Another significant advantage of the present invention is the high utilization of traditional waste products as further value added products of the system. 
     Still another significant advantage is the on-site customization of feed for use in the grow-out process to accommodate the immediate needs of the aquaculture species throughout the grow-out process. 
     Yet another significant advantage is the significant reduction of food miles associated with the end product. 
     “Food Miles” is a term which generally refers to the distance food is transported from the time of its production until it reaches the consumer; sometimes referred to as “farm to plate”. This metric can be used as one dimension in assessing the environmental impact of food. Some estimates have placed the average food miles to be between 1500 and 2000 miles. It is easy to appreciate the miles travelled by a Washington state apple being delivered to Sioux Falls, S. Dak. (Approximately 1500 miles), or to Ft. Lauderdale, Fla. (Approximately 3300 miles). When a food is more complex, the miles traveled by the ingredients to the plant for processing and then to the consumer should be considered. 
     As an example, consider the production of livestock. The feed, often grains, is raised on a farm and harvested. It is not unusual, for the grain to be transported to a large market for sale, and then transported from the market to the livestock producers. The grain is then fed to the livestock which are then in turn transported to a stockyard and sold to a meat processor. The processor then processes the livestock into a food product which is then routed to a wholesaler and then to a retailer for purchase to the consumer. In this case it is not just the miles traveled by the finished food product, which should be included in the food miles metric, but also the miles travelled by the grain which went into producing the livestock, and the miles travelled by the livestock which went into producing the food product. 
     Another dimension in assessing the environmental impact of a food is the waste products created during the production of the food and how these waste products may be disposed. Ideally waste products could be returned to the environment without negative impact. 
     In at least one embodiment of the present invention, both the overall food miles and the environmental impact of the waste products are greatly reduced, and thus the negative environmental impact of the production process is also greatly reduced. 
     Further advantages of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be better understood and objects of the invention will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein: 
         FIG. 1  is a schematic functional block diagram of a new Vertically Integrated Aquaculture System according to an embodiment of the present invention. 
         FIG. 2  is a schematic block diagram of the aquaculture grow-out modules of a preferred embodiment of the present invention. 
         FIG. 3  is a schematic functional flow diagram of the primary processing facility of the present invention. 
         FIG. 4  is a schematic functional flow diagram of the secondary processing facility of the present invention. 
         FIG. 5  is a schematic functional flow diagram of the tertiary processing facility of the present invention. 
         FIG. 6  is a schematic block diagram of the feed handling system of the present invention. 
     
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
     With reference now to the drawings, and in particular to  FIGS. 1 through 6  thereof, a new Vertically Integrated Aquaculture System embodying the principles and concepts of the present invention and generally designated by the reference numeral  10  will be described. 
     The present invention may be described as a highly integrated aquaculture production system, as illustrated in  FIGS. 1 through 6 . In at least one embodiment, the system includes a collocated feed mill for storing and processing grains into feed, grow-out facilities for at least one aquaculture species, and a processing center for processing the aquaculture species into one or more final product, thereby significantly reducing the food miles associated with the final product. 
     At least one preferred embodiment of the present invention is disclosed in the following several paragraphs. It is to be understood that alternate embodiments may provide cost, speed, and/or environmental benefits in particular settings. Additionally, as each of the components of the present invention are described, it should not be assumed that specific limitations of other components are required, unless specifically stated. Further, reference to any particular aquaculture species should not be assumed to limit or restrict the system from applications with other aquaculture species. 
     In an embodiment each aquaculture grow-out module  20  further may include a plurality of holding tanks  22  and a treatment system  24 . Each one of the holding tanks  22  may hold between 50,000 and 800,000 gallons. The size of each one of the holding tanks  22  may be determined at least in part by the intended aquaculture species to be grown in the holding tank. As an illustrative example, in the case of raising tilapia, it is preferred, although not required, that each one of the holding tanks  22  holds approximately 200,000 gallons and has a diameter of approximately 60 feet and a depth of approximately 10 feet. As a further illustrative example, in the case of raising salmon, it is preferred, although not required that each one of the holding tanks  22  be approximately 80 to 85 feet in diameter and approximately 20 feet deep. Each one of the plurality of holding tanks  22  is for at least temporarily holding a quantity of production water and a quantity of the aquaculture species during the grow-out process. It is important to note, that during production the volume referenced for the holding tanks  22  includes both production water and the aquaculture species. 
     The treatment system  24  is operationally coupled to the plurality of holding tanks  22  and at least partially removes waste from the production water. The waste removal may be performed through settling, mechanical filtering, biological action, or a combination thereof. 
     In an embodiment the quantity of the aquaculture species may include a quantity of fish, and the quantity of fish held in at least one of the plurality of holding tanks  22  is between 0.3 pounds of fish per gallon of production water to 6 pounds of fish per gallon of water. As illustrative examples only, and not for purposes of limiting the number, type, or characteristics of the aquaculture species which may be produced it is anticipated that at the start of each stage of the grow-out process for tilapia, a density of between 0.25 and 1.0 pounds of fish per gallon of production water will be used with an end-of stage density of between 0.75 and 1.5 pounds of fish per gallon. More preferably for tilapia a start of stage density 0.5 pounds of fish per gallon of production water will be used with an end-of stage density target of 0.875 pounds of fish per gallon. By way of contrast, an end of stage density for an aquaculture species such as African catfish may be between 3.5 and 5 pounds of fish per gallon of production water. 
     In at least one embodiment the density of fish per gallon of water at least partially inhibits reproduction of the fish being held in the holding tanks  22  reducing or eliminating the requirement to use hormones to inhibit reproduction. The reduction or elimination of hormones during the production process has the additional advantage of providing a potentially more desirable product for the consumer. 
     The system may include an oxygen dissolving system  26  for at least partially controlling a level of oxygen in the quantity of production water. 
     In an embodiment each aquaculture grow-out module  20  further may include 2 to 10 holding tanks  22 . More preferably, each module includes six holding tanks  22 . 
     In at least one preferred embodiment, the system includes a heating system  28  operationally coupled to the aquaculture grow-out module  20   s . Some aquaculture species, such as by way of example and not limitation, tilapia require warm water for efficient grow-out and health of the species. Providing heat to the aquaculture grow-out module  20   s  allows for non-traditional climates to be used for aquaculture. In at least one embodiment, geothermal water is used as at least a portion of the heating system  28 . 
     In a further embodiment each one of the plurality of holding tanks  22  further includes a central drain assembly  30  positioned substantially in a center portion of each one of the holding tanks  22 . The central drain assembly  30  preferably has a first portion  32  designed for draining waste in a predominately liquid form for direction into the treatment system  24 . The central drain assembly  30  may also include a second portion  34  designed for removing waste solids from the holding tank for direction into the treatment system  24 , and alternately directly into the waste discharge pond of the treatment system  24 . 
     In a preferred embodiment the treatment system  24  directs waste from the plurality of holding tanks  22  to a first pond  36  which maybe held in substantially aerobic conditions for use in fertigation. 
     In a further preferred embodiment the treatment system  24  also screens out a portion of waste solids and directs the waste solids to a holding pond  38  to be used as fertilizer in a traditional land application. 
     In a typical embodiment the feed handling system  40  may include a feed pellet storage means  41  and a pellet delivery system  42 . The feed pellet storage means  41  is for temporarily storing feed pellets to be fed to the aquaculture species, and may take the form of a bin, silo, interior pile, or the like. The pellet delivery system  42  routes feed pellets from the feed pellet storage means  41  to the aquaculture grow-out module  20   s . This may be directed to a central location for each aquaculture grow-out module  20  or direct to each holding tank. 
     Preferably, the aquaculture system may include a grain storage means  43  and a grain processing facility  44 . The grains stored and processed may be soybean meal, whole soybeans, wheat, wheat midlings, corn, peas, canola meal, and dried distiller&#39;s grains (wet or dry). Kelp or other feed components may also be added to boost DHA (docosahexaenoic acid) content. 
     In an embodiment the grain processing facility  44  further may include a feed pellet extruder  45  for forming a quantity of feed pellets into a selected size and shape. The feed pellet extruder  45  selectively forms pellets with a diameter between 0.05 inches and 0.5 inches inclusive. For small fish a 1/16 th  inch diameter is preferred. As the fish reach the final stages of the grow-out process the preferred pellet size increases incrementally to larger diameters. Again as an illustrative example, in the case of raising tilapia, the larger diameter pellet size for the final stages of the grow-out may be approximately 3/16 th  inch diameter. 
     In at least one embodiment air is incorporated into the feed pellets after extrusion to improve the characteristic of the feed pellets to float. 
     In a further embodiment the feed pellets may be formulated to include between 5 and 25 percent fat, between 25 and 50% protein, and the remainder carbohydrate and minerals. Typically a higher protein formulation is desired for smaller fish, and a lower protein formulation is desired for larger fish. 
     Additionally, in at least one embodiment fish or vegetable oil is applied to the feed pellets after extrusion to enhance the taste of the pellets for the aquaculture species. Further, the application of fish or vegetable oil reduces dust created during pellet handling and transport. 
     In at least one embodiment, the grain processing facility  44  also includes a dryer  46  for drying a quantity of feed pellets after extrusion using thermal energy. Waste thermal energy from the dryer  46  is directed to the grow-out modules  20  for heating water used in the grow-out modules  20 , through the use of a conventional heat exchanger or other similar method. 
     The pellet delivery system  42  utilizes a transport means  47  such as wheeled transport, conveyor, pneumatic, cable, chain, and auger systems. 
     While the specific timing and number of stages during the grow-out process is species dependent, an illustrative example of the grow-out process for fish is as follows: A quantity of fingerlings are placed in a first one of the holding tanks  22 . The production water placed in the tank is at least periodically filtered and the fingerlings are at least periodically fed. As the fingerlings grow they are sized and when they have reached a target weight the quantity of fish is divided and placed in at least two holding tanks  22  to allow room for further grow-out. This process is repeated until the fish reach a production target weight, at which time they are then routed via the aquaculture species moving system  75  to the processing system  50 . The aquaculture species moving system  75  may also be used to route the species between tanks throughout the grow-out process. 
     After harvesting, the harvested species are directed alive to the processing system  50  via the aquaculture species moving system  75 . Preferably the processing system  50  includes a primary processing facility  51  and a secondary processing facility  58 . These facilities may be collocated. 
     Although many different embodiments and configurations of the processing system  50  are anticipated by the present invention, a typical facility is described in the next several paragraphs below for purposes of illustration. 
     Typically the live species are directed to a stunning means  52  for stunning the aquaculture species prior to further processing. The stunning means  52  may be an ice bath, electric shock, or other appropriate method. 
     After stunning the species are generally killed by being bled. This may be accomplished by a killing means  53 . The killing means  53  may be a knife cut across the bottom of the gill and downward. This may be done by machine or by hand. After being bled, the species is placed into a second ice bath. The blood is preferably collected for later processing into fish meal. 
     It is important to note that some aquaculture species, such as algae, do not need to be stunned or killed prior to processing. 
     The species are then preferably moved from the ice bath to be scaled. This may be accomplished via fish auger. The species is preferably scaled by machine, but can be hand scaled. The scales are preferably collected for later processing into fish meal or other commercial uses. 
     After scaling, the species is typically degutted. The degutting means  55  is preferably a machine, but the species can be gutted by hand. The guts pare preferably collected for later processing into fish meal. 
     After being degutted the species may be routed for packaging as a whole fish. If the species is selected for packaging as a whole fish, it is anticipated that the net weight of the processed whole fish will be greater than 80% of the total weight of the live fish. 
     Alternately, the species can be deheaded. Preferably the deheading means  56  is a machine, but the species can be deheaded by hand. Preferably the heads are collected for later processing into fish meal. 
     At this point the primary processing is substantially complete, with the primary output being a “clean fish” or species carcass, which is next routed to secondary processing. 
     The secondary processing facility  58  a backbone removal means  59  for removing the backbones of the aquaculture species. The removed backbones generally including some flesh, bones, and ribs. The backbones serving as an input to a fish meal processing facility  70 . The flesh from the removed backbones is collected as edible trim for tertiary processing. 
     After removal of the backbone, the species carcass may be routed to the skinning means  60  for selectively removing the skin. Preferably the skinning means  60  is a machine. The removed skins may be used as an input for the fish meal processing facility  70 , for making gelatin, or for making leather. 
     The species carcass is then directed to the filleting means  61  for cutting fillets from the preprocessed aquaculture species carcass. In an embodiment remaining flesh not part of the fillets is collected as edible trim for tertiary processing. The filleting means  61  may be a machine or by hand operation. 
     Preferably the processing system  50  also includes a tertiary processing facility  63  designed for processing edible trim collected from the secondary processing facility  58  into additional consumer products. 
     In an embodiment the tertiary processing facility  63  further may include a forming means  64  for chopping and forming the edible trim into patties, sticks or balls. 
     In a further embodiment the tertiary processing facility  63  further may include a dehydrating means  65  for dehydrating the edible trim. 
     In still a further embodiment the tertiary processing facility  63  further may include a jerking means  66  for converting edible trim, or processed fillets into jerky. The jerking means  66  may include brine tanks, smokers, or dryers for facilitating the jerking process. 
     Preferably the processing system  50  also includes a fish meal processing facility  70  designed for processing waste products collected from the primary processing facility  51  and the secondary facility into fish meal. 
     In an embodiment the fish meal processing facility  70  further may include a steam generation means  71  for generating steam. The steam is selectively directed into the waste product to separate fish oil from solids. The fish oil being collected as in input for animal feed or biodiesel. The solids being dehydrated and processed as fish meal. 
     The steam generation means  71  may be from the combustion or gasification of biomass, commercial or industrial wastes, or landfill wastes. The steam generation  71  means may be geothermal, or from conventional boilers. 
     In still a further embodiment waste heat from the stream generation means being directed to the at least one aquaculture grow-out module  20  for heating water used in the at least one grow-out module  20  through the use of a conventional heat exchanger or other similar method. 
     With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention. 
     Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.