# " **;" itf1** 
**�,""",,/**

**."; .**  

# HANDBOOK

**. '.**  

## ,for **Materials** 

# A

**cc o** **nntiD. g'.**  **A. udits**  **and**

**. !**  

# Bes**t**

**' Mana** **ge m** **�" n** **t Practices**  **Pla '** **n s** 

**'. � /**  **/**

**.�,**

**. '**  **. :**  **","**



### Prepared **by:**

**Peter M.**  **Nicklason Bottornline**  **Performance** 

### 6759 **21st Street**  **NW Seattle,**  **WA 98117"** 

**H. Burney**  **Hill**

**. ..**  **,**



### U.S. **Environmental** 

### Protection Agency

**Region** 

## 1 **0 '**  **, �". .'**  **.'** 

### 1200 **Sixth Avenue**  **(OW,,135)' Seattle,**  **WA** 

## 981Ot/ **> ',"** 
**,:' �**  **' ":**  **' "** 

**.• ..**  **'>**
**' . :**  **'**



### October **13,** 

### 1995,><**PREFACE**

**This document**  **is the**  **secon d**  **draft of**  **the Seafood**  **Processing Handbook**  **for Materials**  **Accountin g**  **Audits and**  **Best Managemen** **t Practices**  **Plans. The**  **handbook is**  **intended as**  **advisory guidance**  **to Alaska's seafood processing**  **industry in**  **developin g**  **approaches to**  **pollution prevention,**  **materials account**  **in g**  **audit, and**  **BMP plans.**  **Com pliance**  **with environmental**  **and occupational**  **safety and**  **health la** **ws is**  **the responsibility**  **of each**  **individual business**  **and is**  **not the**  **focus of**  **this document.**  **.**

**Peter M.**  **Nicklason, President**  **Bottoml�ne Performan**  **ce 6759**  **21st Street**  **NW Seattle,**  **WA 9811**  **telephone (206)**  **783-6719, is**  **the primary**  **author of**  **the handbook.**  **Pete received**  **undergraduate degrees**  **in both**  **microbiology and**  **engineering from**  **the University**  **of Washington.**  **He completed**  **a Masters**  **in Food**  **Science at**  **the University**  **of Washington**  **with studies**  **focused on**  **seafood and**  **surimi. Mr.**  **Nicklason has**  **been involved**  **with the**  **fisheries of**  **Washington, Alaska,**  **and Oregon**  **for 15**  **years, with the**  **pa,st l0**  **years committed**  **to surimi.** 

**H. Burney Hill,**  **Aquatic Environmental**  **scientist NPDES**  **Permits Unit**  **(OW-135) EPA**  **Region 10**  **1200 sixth**  **Avenue Seattle,**  **WA 98101**  **telephone (206)**  **553-1761, is**  **the second**  **author and**  **project officer**  **of the**  **handbook. Burney**  **received his**  **undergraduate degree**  **in biology**  **and psychology**  **from Harvard**  **College. He**  **completed his**  **masters degree**  **in marine**  **stUdies at**  **the University**  **of Hawaii**  **with stUdies**  **focused on**  **marine ecology**  **and SUbsistence**  **fisheries. Mr.**  **Hill has**  **been involved**  **in aquatic**  **ecology and**  **fisheries management**  **for 25**  **years ,**  **with the**  **past 3**  **'years committed**  **to Alaskan**  **seafood processors.** 

**The U.S.**  **Environmental Protection**  **Agency invites**  **your review**  **of this**  **h�ndbook. In**  **particular, the**  **Agency seeks**  **information which**  **will improve**  **the quality**  **of the**  **handbook and**  **make it**  **a more**  **useful resource**  **for the**  **public. Please**  **submit your**  **comments and**  **any sup** **porting documentation**  **to Burney**  **Hill at**  **the above**  **address.**

**i TABLE**  **OF CONTENTS** 

**INTRODU CT**  **I O N**  **1 MATER**  **I A LS**  **ACCO UN** **TING .**  

## . . . . . . . . . . **3 What**  **Is the**  **Law of**  **Cons erv**  **a tion**  **of Ma**  **ss** 

### 4 **How to**  **De fine**  **Proce ss**  **Bou nda**  **r ie**  **s and**  **Develop Flo**  **w Diagra** **ms .**  

### . . . . . **. . . ..**  **4 Whi**  **ch Infor** **mati on**  **Is Needed**  **. . . . . . 8**  **How to Take**  **Good Me**  **asure ment**  **s . .**  **....•** 

## 9 **A Summary**  **of Materials**  **Acc oun**  **ting Princ**  **iple s**  

## 10 **CONDU CTING**  **A MATER**  **IA LS**  **ACCOU NTIN**  **G AU** **DIT .**  

## . **. ..**  **11 How**  **to organ**  **iz e**  **and Ma**  **i nt**  **ain Goo**  **d Re**  **cords** 

## . **. .**  

## 11 **Wh at**  **Are Good**  **Record s**  **and Forms**  **. ...**  **. ..**  **12 Wh**  **i c h**  **Mat e r**  **ials and**  **Metho ds**  **Supp ort**  **Good Measure**  **ment s**  **13 A**  **Reca p**  **of II**  **How To"**  **. . ....**  **•....•.•. .**  

## 15 **What about**  **I n st**  **rume nts**  **and Comp**  **uter Data**  **C o lle**  **ction Sy**  **ste ms** 

**, MATER**  **I A LS**  **MANAGE MENT**  **PRAC TICE**  **S How**  **to Ach**  **i e ve**  **Water Cons**  **ervation How**  **to Con**  **tro l**  **and Reduc**  **e Was**  **te How**  **to Con**  **vey Was**  **te ....**  **How to**  **Cleanup Your**  **Fa ci**  **lity**
**DE VE**  **L OP**  **I N G A**  **B E ST**  **��ll�l\TAG EMENT**  **PR� CT**  **I C ES**  **PL..lLN' •**  **How to**  **I d enti**  **fy and**  **Eval u**  **at e**  **Po ll**  **utant Di**  **s c harges**  **Wh at**  **Is a**  **Mate r i**  **als Acc**  **ount ing**  **Au d i**  **t •**  **. . .**  **. . . How**  **to Rank**  **and Pr**  **iorit ize**  **Pr oce**  **ss Str**  **e a ms**  **• • . Why**  **Est ab**  **li sh**  **Prel im**  **i n ary**  **Im provement**  **G o al**  **s ..**  **. What**  **Is Meant**  **by Meth**  **ods of**  **Op era**  **tion ....** **. Comp**  **letion of**  **BMP Pl**  **an** 

## . **.. . .**  **• ..**  **. END**  **-OF-P I P**  **E TREATMENT**  **OPT I**  **ONS .**  **. ..**  **... Wh**  **i c h**  **Pol lut**  **an t s**  **Occur in**  **Seafood Pro**  **cesso r**  **Was tes**  **Hgw to**  **Me asure**  **Efflu ents**  **. .**  

## . **. •**  **.. . •**  **.. End**  **-af-Pip e**  **Treat me**  **nt Te**  **chn o l**  **og ie**  **s**

**ii** 

## 15
**16 17**  

## 18 **18 19**  **20 20**  **22 23**  **23 23**  **24**
**24 24**  **25 28** 

### INTRODUCTION 

### Th **is handb**  **oo k**  **is de**  **sig ned**  **to he**  **lp se**  **afo od**  **pro ce**  **sso rs**  **in c**  **rease prod** **uct i o**  **n and**  **red uce**  **wa ste**  **. The**  **goal is**  **in c**  **reas i n** **g prod** **uc t**  **reco very**  **and profits**  **wh ile**  **r e duc**  **ing po**  **llu tio**  **n and**  **water dis**  **cha rge.**  **Th is**  **handb oo** **k supp**  **orts gener**  **al Na**  **tio na**  **l Pol**  **lutant Dis**  **charge El**  **imina t**  **ion Sy**  **stem (NPD**  **ES )**  **permit no**  **. AK-G5**  **2 -0000,**  

### wh **i c h**  **auth or**  **ize s**  **sea food**  **proces s o**  **rs to**  **dis char**  **ge pol**  **lu tant**  **s to**  **the su**  **rfac e**  **wa ter**  **s of the**  **un ited**  **st ates**  **in and**  **con ti**  **nuou s**  **with the**  **state of**  **Ala ska.**  **The** 

### 1 9 **95 gener**  **al** 

### NPDES **p e rm**  **it for**  **s e afood**  **proces sors**  **in Alas** **ka requ**  **ir es**  **th e**  **manage men** **t and**  **acco unt**  **i n g**  **of wa**  **ste gener**  **ated in**  **sea food**  **proc ess**  **i n g**  **p l ants.**  **The un**  **ited st**  **ates Env**  **ir on** **me nta**  **l Protec** **tio n**  **Agency (EPA)**  **of fers**  **th is**  **handboo k**  **'a s**  **prac tical**  **gu idance**  **in meet**  **ing t**  **he re**  **qu ire** **ments for**  **a best**  **manage ment**  **pr ac**  **t i ces**  **( B MP)**  **pla n**  **su pp**  **orted by**  **an accur**  **ate materi**  **als account**  **ing aud**  **it .**  **An accounti**  **ng aud**  **it of**  **the in** **puts and out** **puts of**  **s e afo**  **od, se**  **afo od**  **was te,**  **wa ter,**  **and che** **mica l**  **co ntam**  **in ants**  **that are**  **NO'M.O"-::;::';+-- O�**  **;l""I !:l c!O::l**  **i='r\r*\** **�** **l"'\�r*\r"OC'C"'r\""'"** **-r"""....."IT\C'" !:l**  **'rrl'':l''r"'\ ....**  **;+-''='o+-..;�r� h�_": ....**  **�_ ...**  **4_�,"-'4 __** **"""'" ...**  **... &. '-4 .....**  **'-''-4 ..**  **....,'''' ....... ,..,.L....", ....... '-"..0,1"�'-'A.-**  **.&..'-'.r... ...**  **,\� \,,4**  **"'1""'\.4""'-".'-""'-'l'-..L.V� �Q**  **t.::t ..Lt=)**  

## � **or man**  **agin g**  **th e**  **mat er**  **i** 

## � **ls of**  **prod ucti**  **on .**  **- Tne**  **BMP** 

### p l **an is**  **an in**  **�p lant**  **progra m**  **that ha**  **s the**  **dua l**  **goa ls**  **of ma**  **xi mizing**  **prod uct**  **ion ef**  **fi ci**  **ency and**  **min im**  **iz ing**  **waste .**  **The ha**  **ndbook addres**  **ses thr**  **ee areas**  **of env**  **iron me**  **nta l**  **conce rn.**  **The first**  **concern is the**  **wa ste**  **fu l**  **use of**  **fr esh**  **wat er**  **in pr**  **oc ess**  **i n g**  **seafood .**  **Th is**  **co nce**  **rn is**  **a d dres**  **s e d**  **by** 

### manag **ing and**  **ac cou** **nting the**  **flo w**  **and use**  **o f**  

### wa**ter th** **roughout a**  **pla nt**  **. Th**  **e s e**  **con d**  **concern is**  **th e**  **ex cessi** **ve g e**  **ne rat**  **i o n**  **of suspen** **ded an**  **d soli**  **d wast**  **es. Th**  **is concern**  **is add** **resse d**  **by man**  **ag ing**  **and acco**  **unt ing**  **seaf ood**  **to maximize**  **th e**  **r e co** **very of**  **raw prod** **uct s**  **as marketab**  **le pr**  **imary pr**  **odu cts,**  **by- pr**  **oducts, and**  **sec ondar** **y prod** **uct s.**  **The th**  **ird concern**  **is th**  **e ex**  **cessi ve**  **gener ation**  **of dissol**  **ved wast**  **es .**  **Th is**  **concern is**  **ad d**  **res sed**  **by ma**  **nag i n**  **g and**  **acco un** **tin g**  **w�t er**  **and sea**  **food to**  **min imiz**  **e con** **ta ct**  **time wh**  **i c h**  **co nverts**  **s o li**  **d wast**  **es to**  **dis so**  **lv ed**  **wa stes**  **. EPA**  **ex pects**  **that the**  **t i me,**  **ener gy,**  **and ex** **pense of**  **co nducting**  **a mat**  **e ria**  **ls account**  **in g**  **audit and**  **deve l**  **opi ng**  **a BMP**  **p l an**  **wi ll**  **vary in**  **dire ct**  **proport ion**  **to th**  **e s i**  **ze and**  **co mpl**  **exit y**  **of a**  **sea fo**  **od process**  **ing fac**  **i l it**  **y. Re**  **lat ively**  **sm a l**  **ler ope**  **rati ons**  **may have a**  **mater ials**  **aud it**  **and BMP**  **plan of**  **as few**  **as th**  **ree pa**  **ges. Re**  **lat iv**  **ely l a**  **rger fa**  **c i li**  **ties may**  **have a**  **mat er**  **ials aud**  **it and**  **BMP pla**  **n of as**  **much as**  **twenty five**  **pag es.**  **The size**  **and co** **mp l**  **exity of**  **th e**  **mat eria**  **ls au** **dit and**  **BMP** 

### plan **wi ll**  **ref le**  **ct the**  **s i ze**  **and co** **mp le** **xity of**  **the se**  **afo od**  **pro c**  **ess i n** **g fa**  **cil it** **y. Ult**  **i mate**  **ly the**  **plan t**  **manager is**  **responsi ble**  **for ensur**  **ing an**  **accur ate**  **mat er**  **ials acco**  **u nting**  **aud it**  **and**

**1 establishing**  **an effective**  **BMP plan.**  **However, in**  **medium and** 

**large facilities**  **the plant**  **manager will**  **rely upon**  **quality control, production,**  **and engineering**  **personnel to**  **conduct the**  **audit and**  **assist in**  **developing the**  **plan. Ideally,**  **trained lead**  **people and**  **processors will**  **be included**  **in the**  **implementation phase.**  **The understanding,**  **participation, and**  **support of**  **these key**  **members of**  **the processing**  **team is**  **fundamental to**  **achieving the dual**  **goals of**  **increased production**  **and reduced**  **pollution.**

**since the**  **whole of**  **materials management**  **is a**  **measurement and**  **accounting exercise,**  **some algebra**  **and math**  **skills will**  **be needed**  **to calculate**  **flow rates**  **and concentrations**  **and to**  **convert measurement**  **units. There**  **will be**  **examples included**  **in the**  **handbook. Through**  **training programs,**  **each plant**  **manager can**  **develop good**  **support staff**  **who under**  **stand both**  **the objectives**  **and the**  **methods of**  **the materials audit**  **and BMP**  **plan. In**  **time personnel will**  **become comfortable**  **with taking**  **measurements, making**  **calculations, and**  **using that**  **information to**  **make decisions**  **which will**  **increase product**  **recovery and**  **income which**  **reducing pollution**  **and water**  **use;**

**Handbook sections**  **include** 

### (1) **materials accounting,**  **l�} conducting**  **a materials**  **accounting audit,**  

### (3) **materials management**  **practices,** 

### (4) **developing a**  **best management**  **practices** 

### (BMP) **plan, and**  

### (5) **end-of-pipe treatment**  **options.**

**Materials Accounting**  **� This**  **section portrays seafood**  **processing facilities**  **as model**  **syste ms**  **with boundaries**  **within which**  **material inputs,**  **flows and**  **uses, and**  **material outputs are governed**  **by the**  **law of**  **conservation of**  **mass. In**  **fact, "materials**  **accounting" is**  **also known**  **as "mass**  **balance!" The**  **handbook will**  **consider which**  **info rmation**  **is important**  **in materials**  **accounting and**  **describe how**  **to take**  **good measurements**  **to develop**  **this information.** 

**Conducting a**  **Materials Accounting Audit**  **- The**  **goal of**  **this section**  **will be**  **to show**  **you how**  **to measure the**  **parts of**  **the seafood**  **that aren't**  **making money. It**  **will also**  **address the**  **water wastage**  **which is**  **costing money.**  **Good materials**  **accounting audits**  **can guide**  **a processor**  **in ge**  **tting an**  **extra 1%**  **to 3%**  **increase in**  **product recovery**  **and a**  **10% to**  **30'% reduction**  **in-water use.**  **This means**  **increased revenues**  **and reduced**  **expenses.**

**Materials Management**  **Practices -**  **This sec**  **tion will**  **describe management**  **practices which**  **can increase production**  **and .decrease**  **waste ...**  **wasted product**  **and wasted**  **water. Management**  **practices considered**  **may be**  **a process**  **step, a**  **material stream,**  **or an**  **individual job**  **and responsibility.**  **The methods**  **and technologies**  **presented in**  **this section**  **have**

**2**

### pr **oven s u**  **cce s s**  **fu l**  **in r e**  **du cing**  **wast e and**  **wat er**  **in other** 

**se afood**  **proc es**  **sing pl**  **an t s**  **. D e** **ve lop**  **i n g a**  **BMP Plan**  **- Th**  **is s e**  **ction will**  **desc r i**  **be how**  **to mak**  **e a**  

### BMP **pla n**  **fo r a**  **seaf ood**  **pro ces**  **�ing fa**  **c i lit** **y. The**  **di ff**  **erent asp**  **ects of**  **a BMP**  **p l an**  **- wi**  **ll be**  **d i sc**  **us s e**  **d and**  **an example**  **of a**  **BMP p l**  **an w i**  **ll be**  **la id**  **out (A** **ppend ix**  **D) .**  **S a m** **ple l a**  **ngua ge**  **wi ll**  **be pro**  **vided which**  **may be**  **us ed**  **as ap**  **pro pr**  **i ate**  **. The**  **goa l**  **here is**  **to help**  **you dev**  **elop the**  **best BMP**  **plan for**  **your oper**  **at ion**  **wh ile**  **meet in**  **g the**  **requ ire** **ments for**  **au thori**  **zat i o**  **n to**  **disc harge proce**  **ss ing**  **wa ste**  **sol ids**  **and was**  **te wate**  **r . En**  **d-o f**  **-P ipe**  **Trea tme**  **nt Optio**  **ns -**  **Th is**  **fina l**  **s e ct**  **ion is**  **f o r**  **fa c i**  **l it**  **ie s**  **that ca**  **n di**  **rec t**  **wa stes**  **to tre**  **atment proc**  **esses above**  **and beyon**  **d grin** **d-an d**  **-d isc** **harge. The**  **goa l**  **of su**  **ch tre**  **atment is**  **to r e** **duce the orga**  **nic and**  **che mical**  **l o ad**  **in th**  **e di**  **s c harge**  **d wa**  **ste wat**  **er. Much**  **of the**  **i n for** **mat i o**  **n in**  **th is**  **sec t i**  **on wil**  **l c o**  **ver equ**  **i pmen**  **t and**  **techno l**  **og y**  **that can**  **c l ean**  **up wa**  **ste sol ids**  **and wa**  **ste wat**  **e r .**  **Descript i o**  **ns of**  **the dif**  **fer e n** **t major**  **pol lu** **tants wil**  **l be**  **inc luded**  **a l on** **g with**  **some si**  **mple tes**  **ts to**  **det erm**  **in e**  **the ir**  **amounts.**

**MATERIALS ACCOUNTING** 


### Ma **te ri**  **als ac**  **count i n**  **g is**  **use d**  **to trace**  **the inf**  **l o w**  **and outf**  **l o w**  **of** 

### c o**m ponen** **ts in**  **a** 

### pro **cess s t**  **r eam**  **and to es**  **ta b l**  **is h**  **the qu**  **a n tities**  **of th**  **ese com** **ponen ts**  **. Th**  **is in**  **form ation**  **can th**  **en be**  **use d**  **to eva**  **luat e**  **yields and**  **ef fic**  **iency of**  **th e**  **pro c**  **ess i n**  **g operat**  **ion as a**  **wh o**  **le and**  **as parts.**  **For hig**  **h value**  **or hig** **h vo**  **lu me**  **sea food**  **prod uct**  **s the**  **abili ty**  **to eff**  **ici en** **tly i n** **vent or** **y the**  **proc ess**  **ing ope** **ra t i**  **ons using**  **ma teri**  **als acco**  **unt i n**  **g pr**  **i nc**  **i ples**  **has hig**  **h payback**  **poten t i**  **al. The**  **thr ee**  **th i**  **ngs you**  **, as**  **a pla**  **nt man**  **ager, sh**  **ould ex** **pec t**  **from a good**  **mat erials**  **acc ount**  **in g**  **audit are**  **:** 

## 1) **a method**  **to deter** **mine proce**  **s sing**  **ef fici**  **enc y**  **and mat**  **er ials**  **use for**  **any t i** **me p e** **rio d**  **greater th**  **an two**  **hou rs,**  

## 2) **a method**  **to ident**  **ify areas that**  **f a ll**  **be l o** **w exp**  **ect ed**  **pe rformance**  **sta nda**  **rd s,**  **and** 

## 3) **co m** **p l iance**  **wit h**  **re port**  **i n g**  **req u**  **ire ment**  **s of**  **the dis**  **charge per** **mit .**  **De s c**  **r iptions**  **of the ba**  **sic pr**  **inci ple**  **s f o**  **r doin** **g mat**  **eria ls**  **ac count**  **i n g**  **aud it**  **s are**  **prese nt**  **ed bel**  **ow.**



## 3

### Wha **t Is the**  **Law of**  **Con servation**  **of Ma**  **ss In**  **a nu** **tshel l,**  **the l a**  **w of**  **conse rvat**  **ion of**  **ma ss**  **states that**  **ma ss**  **is neit** **her cre**  **ated or**  **destro yed.**  **Wh at**  **goes in**  **comes out**  **... s o** **mew here**  **! Mass**  **i s '**  **cons er**  **ved .**  **Th is**  **can be**  **ex p**  **resse d**  **in pr**  **etty s i** **mp le**  **ar it** **hm et**  **ic as**  **a su** **mm at**  **ion .**  **INFLOW =**  **OUTFLOW +**  **ACCUMULATION**


### Be **l o w**  **are two**  **exam ples**  **of ho** **w th**  **e above**  **equat i o**  **n may**  **apply to**  **a seafood**  **pr oces**  **s i ng**  **p l ant**  **. Th**  **ere are**  **other ways**  **to ass**  **ign mater**  **ials to**  **the flo** **ws, but**  **wh at**  **goes in**  **must a l** **ways e q** **ual wh**  **at comes**  **out .**  **Exam ple**  

## 1: **Ent ire**  **Pla nt** 

**n INFLOW**  **=** 

### Se **afo od**  **ca t6h,**  **fresh water,**  **sal t**  **wa ter,**  **cle an**  **ing chem**  

## i **cal s,**  **pr ocess**  **in g**  **ad dit**  **ives, bo**  **i l er**  **or coo** **k water.** 
**A CC** 

### UMULAT 

### I **ON =**  

### Pr **oduct**

**e OUTFLOW**  **= INFLOW**  

### mi **nus PRODUCT**  

### Exa**mple** 

## 2: **Process** 

### step **of He**  **ad-an d-Gut** 

**• INFLOW**  **=** 

### Wh **o l e**  **sea food**  **, cle**  **an ing**  **wat er** **• ACCUMULATION**  **=** 

### Headed **and gut**  **ted seaf**  **ood (t**  **o next**  **proc ess**  **ste p)** 

**• OUTFLOW**  **=** 

### He **a.gs ,**  **gut s ,**  **b l ood**  **, s l**  **ime, sca**  **l es,**  **tr im** **min gs,**  **un usab**  **le seaf**  **ood ,**  **wat er**  **As can**  **be s e**  **en f r**  **om the**  **above exam** **ples, the**  **flo ws**  **can be**  **broken down**  **in to**  **c o mp**  **onen ts**  **. Id**  **ent i f**  **ying and**  **me a s**  **ur i n** **g the**  **key co** **m ponents**  **fOr a**  **proc es**  **s is the**  **bas is**  **for do**  **in g**  **mat eria**  **ls acco** **unt i n** **g aU** **d i t s**  **. How**  **to De**  **f i ne**  **Pr oc**  **ess Boundar**  **ies an**  **d Deve**  **lo p**  **Flo w**  **Di agr**  **ams To**  **begin , a**  **pr ocess**  **f l ow**  **diag ra** **m is**  **needed to**  **de f i**  **ne what**  **pr ocess**  **and c o** **mp on**  **ent s**  **are to**  **be mea**  **su r**  **ed .**  **Belo w**  **are d i**  **agr ams**  **base d**  **on the**  **two ex**  **amp les**  **in the**  **pr e** **vio us**  **'se cti**  **on .**  **The def**  **in ing**  **pl an** **t bou** **n dary**  **in Fig** **ur e**  

## 1 **en com** **pa sses**  **a l l**  **the pr**  **ocess in** **g ste** **ps in**  **the butc** **hering opera** **tion .**  **Th e**  **mater i**  **als acc**  **ount ing**  **audit for**  **th is**  **flo w**  **di agr**  **am wou**  **ld only**  **de al**  **wi th**  **the t o**  **tal in**  **f l ow**  **, outf**  **l o w,**  **and ac**  **cum ula** **tion that**  **enter and**  **ex it**  **th is**  **de fining**  **box. Mea**  **su r**  **in g**  **th ese**  **major s t** **re ams**  **would gi**  **ve inf**  **orm atio**  **n on**  **ove r a**  **ll pr**  **od uct**  **recove ry**  **an d**  **water use**  **, but**  **wou ld**  **not gi**  **ve any**  **inf ormat**  **io n**  **on the**  **con tr**  **i b ut**  **i o n**  **fro m**  **the indivi**  **dua l**  **steps .**  **Id ent**  **i fy**  **ing and** 

**4 Ul**  

# Flow 

# Diagram **for Rocky'**  **Cove Processors** 

**Salt Water**  **Fresh Water**  

# t----------nj:-----.-- **,-----I**



## .- 

# -- **�**

**�**

**Fish, Ice**  **and Water** 

**Water &**  **Ice**

**Unusable Fish**  

## Fish **Pieces Blood**  **& Slime** 

**process** 

# / **Boundary** 

# ) **· ·** 

**·'** 

# �= **�-U**

**� r--,** 

**.... �.**  **--.,** 

# �



# �

**Holding Tank** 

# 1

**Drain '**  **Belt**

**.�.** 

## Water **Fish Pieces**  **Blood &**  **Slime 1�vater** 

**H[eads, Guts**  **Freezer**



# =dj��������t=ngs**,**



## ..J**� .**  **��**

**•. w .• .**  **· ;**  **:::** 

## �1

**Used Glaze** 

**u�--- -----** 

**------------------------------�**

# � **All Waste**  **to**

**' .**  **w ·**  **· .**  **w, .· .. ,., .··.·.·.··**  **.. ·w**  **. . •**  **, . ·**  

### . **. ·**  **· . ··**  **N·.·.·.· ,** 



# J.?� **Grind &**  **Discharge** 

## Product

**To Fresh**  

## Market

# Process **Flow Diagram**  **for a**  

# Unit **Step Operation**  **in a**  

# Fish **Butchering Plant** 

**Salt Fresh Water**  **Water**

**6 measuring**  **the individual**  **processin g steps**  **would define**  **and rank**  **their contribution**  **of product**  **and waste**  **to the total**  **processing operation.** 

**The process**  **step boundary**  **in Figure**  

## 2 **defines a**  **box around**  **just the**  **butchering step.**  **The measured**  **flows in**  **and out**  **of this box**  **can be**  **compared with**  **the overal**  **l flo** **ws from**  **Figure** 

### 1 **to determine their**  **contribution to**  **the total**  **out f**  **low. From**  **a production**  **point of**  **view the**  **effi ciency**  **of this**  **step translates**  **directly to**  **product and**  **money.**

**Thus, the**  **first step**  **in an**  **audit is**  **to draw**  **a flo** **w dia**  **gram of**  **the process**  **or process**  **step that is**  **to be**  **measured. Next, a**  **boundary box**  **needs to**  **be drawn**  **around each**  **process or**  **process step**  **that you**  **want to**  **measure. Having**  **done this,**  **you are**  **prepared to**  **identify the**  **flo ws**  **and components**  **that you**  **want to**  **measure entering**  **and leaving**  **the boundary**  **box. You**  **have a**  **non-quant itati**  **ve "mode**  **l" of your**  **processin g**  **operations which**  **can be**  **evaluated and**  **quantified.**

**Except for**  **very simple**  **processes, materials**  **accounting** 

### audits should **be planned**  **in s**  **teps. sta**  **rt with**  **the** 

### big **picture of**  **the entire**  **pla nt**  **and build good solid info**  **rmation of**  **the overall**  **process flow.**  **The initi**  **al overal**  **l measurement**  **will be**  **the foundation**  **f o r**  **a l l**  **of the**  **fo llowing**  **steps. A**  **materials accounting**  **audit step**  **is comp**  **l ete**  **when you**  **can measure**  **the inflow,**  **out f**  **low, and**  **accumu l a**  **tion for**  **a de**  **f i ned**  **box and**  **get them**  **all to**  **add up.**  **Inflow should**  **equal out**  **fl ow**  **plus accumulation.** 

**The goa**  **l of**  **a materials**  **accounting audit**  **is to**  **have a**  **basis fo**  **r reducing waste and wastewater.**  **For a producer**  **the components**  **of interest**  **are sea**  **f ood**  **in, accumulation**  **of product,**  **and water**  **use. For**  **authorization to**  **discharge the**  **components of**  **interest are**  **al l**  **waste and**  **wastewater streams.** 

**Once the**  **flows to**  **be measured**  **have been**  **se l**  **ected a**  **units system**  **and tie**  **material can**  **be decided.**  **The units**  **system is**  **probably best**  **decided by**  **whatever the**  **product is**  **weighed as.**  **The major**  **units used**  **wi ll**  **then be**  **either pounds,**  **feet, and**  **gallons, or**  **kilograms, meters,**  **and liters.**  **A con** **version table**  **for these**  **uni ts**  **and other**  **use fu**  **l measurement**  **units is**  **provided in**  **Appendix** 

### A.

**A tie**  **material is**  **a compo**  **nent used**  **to relate**  **the quantity**  **of one**  **process stream**  **to the quantity**  **of another.**  **A good**  **tie materia**  **l is**  **the amou**  **nt of**  **product produced**  **in a**  **given time**  **period. The**  **relation of**  **any other**  **component or**  **fl ow**  **to product**  

## is **a direct measure of**  **ef ficiency.** 



### 7**Which Information**  **Is Needed**  **The goal**  **of a**  **materials accounting**  **audit is**  **to develop**  **a good**  **set of**  **these relationships**  **and then**  **to control**  **them in**  **order to**  **increase efficiency.**  **Measurements taken during**  **steady production and**  **steady flow**  **can be**  **directl y**  **linked to**  **product output.**  **The information**  **needed is**  **the relation**  **of a**  **measured flow**  **stream or**  **component to**  **product recovery**  **for a**  **unit of**  **time. In**  **some situations**  **these relations will**  **help identify**  **and recover**  **significant losses.**  **In other**  **situations measuring**  **and minimizing**  **waste in**  **one process**  **step may**  **produce a**  **very small**  **improvement, but**  **when added**  **to other**  **steps the**  **total savings**  **can be**  **significant. Once**  **a measurement**  **program has**  **been set**  **up and**  **initial rela**  **tionships have**  **been establish**  **ed, goals**  **to improve**  **product recovery**  **and reduce**  **water use**  **can be**  **set and**  **production efficiency**  **can be-improved.** 

**A key**  **trait of**  **a good**  **measurement system**  **is that**  **it must**  **consist of**  **s imp**  **I'e ,**  **repeatable procedures.**  

### A **good example**  **is a**  **"qrab" sample**  **of a**  **materials stream,**  **one lite** 

## r **ally grab** 

## b **ed with**  

## a **hand, a**  **bucket or**  **a sho** 

## v**el. Being**  **able to**  **grab a**  **measurement easily**  **and accurately**  **has the**  **following advantages.**  

## 1) **The procedure**  **can be**  **taught to**  **other workers**  **so production**  **line efficiency**  **can be**  **checked regularly.**  

## 2) **There is**  **less chance**  **of error**  **and confusion.**  **If the**  **data measured**  **differs from**  **the typical**  **or standard**  **data then**  **it's much**  **easier to** 

**.. check**  **the collection**  **procedure. There's**  **always the**  **chance that**  **the data**  **which differs**  **significantly is**  **actually showing**  **an inefficient**  **process step.**  

## 3) **You' can**  **take more**  **measurements easily**  **and quickly.**  **It is**  **important to**  **take me**  **asurements under**  **steady flow**  **conditions to**  **establish relationships**  **between different**  **processing steps.**  **If you**  **can get**  **five or**  **six different**  **measurements quickly**  **then you**  **have information**  **to support**  **five or**  **six solid**  **processing relationships.**  **It is**  **also possible**  **to take**  **some measurements**  **simultaneously. Good**  **steady flow**  **is not**  **the rule**  **in m** **o st**  **oper a**  **t i**  

### o **ns so**  **ta k**  **i ng**  **lots of**  **measurements throughout**  **your l**  **i n**  **e** 

### or **system when**  **the steady**  **flow opportunity**  **arises is important.**  **Once relations**  **between processing**  **steps and**  **flow streams**  **have been**  **established at**  **a steady**  **flow, measurements**  **can be**  **taken at**  **any time**  **for comparison.** 



### 8**How to**  **Take Good**  **Me a s**  **ur ement**  **s Ev**  **en peo**  **ple who**  **ar e**  **ex per**  **ience d**  **wit h**  **conduc tin**  **g ma**  **te ri**  **al s**  **acc ounting**  **audit s**  **may co**  **me up**  **with unbe**  **li ev**  **ab le**  **or un**  **usa b**  **le data**  **wh en**  **they a**  **dd up**  **fl ow**  **str eam**  **measuremen t s**  **. The**  **end res**  **u lt**  **is con**  **fu sion**  **and wasted**  **time. The**  **s o lut**  **ion is**  **to kno** **w what**  **info rma**  **tion to**  **col lect**  **and wh**  **en to**  **meas ure**  **and to**  **use si**  **mple pr**  **o ced**  **ures to**  **col lect**  **th is**  **inf ormat**  **ion .** 

**A good**  **way to**  **s t art**  **is to**  **measure any**  **easi ly**  **acces s**  **i b le**  **str e a** **m or**  **com pone**  **nt and**  **calcul ate**  **the flow**  **rat e.** 

**When to**  **Me asur**  **e? The**  **be st**  **info rmat**  **ion is**  **ta ken**  **whe n**  **pro ces**  **sing is**  **at a**  **smo oth**  **con sistent**  **ra te**  **or flow**  **. These**  **s i tu**  **a t i**  **ons can**  **u s ually**  **be recog**  **nize d**  **by exper**  **ienced plant**  **p e rso**  **n ne**  **l. Most**  **oft en**  **s t eady**  **plant flo**  **w o c**  **cur s**  **wh en**  **oper ations**  **' ar**  **e running**  **at** 

## 10 **0% and**  **s t ead** **y feed**  **-in is**  **ke eping**  **the pl**  **ant humm**  **ing. It is**  **al so**  **im por**  **tant to**  **loo k**  **for opp**  **o r tun**  **it ies**  **to take**  **measu r**  **ements if**  **th ere**  **is a**  **s t eady**  **pace at**  

## 50 **% to**  

## 75% **cap acity**  **.! Thi**  **s is**  **how to**  **build good**  **rel a**  **t i ons**  **bet w e**  **en dif**  **feren t**  **flow stre**  **am s.** 

**Here is**  **�n exam** **ple of**  **how ste**  **ady s t**  **ate info**  **rmat ion**  **could be**  **us ed**  **.**

**On Mond**  **ay a**  **full load**  **of s e**  **af ood**  **c o mes**  **in' and**  **after two,**  **hours of pr**  **oces sing**  **the first**  **pr od**  **uct is**  **going in**  **the box**  **and the**  **cre w**  **and ma**  **chinery have**  **a goo**  **d pa**  **ce set**  **up. For**  **eman Bob**  **go es**  **down to**  **the pa**  **cking ta**  **ble and**  **se es**  **that they're**  **gett ing**  **a tw**  **e nty**  **pound case**  **out every**  

## 60-70 **sec ond**  **s over**  **the c o**  **urse of**  **abo ut**  **ten m i**  **nutes .**  **Bob grab**  **s a five**  **gallon bucket**  **and walk**  **s up**  **to where**  **the fr**  **esh wat**  **er spra** **y is**  **rin sing**  **the c l**  **eaned s e**  **afo od**  **on the**  **con vey**  **or .**  **He fi**  **lls the**  **bu cket**  **th ree**  **ti mes**  **in an**  **av era** **ge t i** **me of**  **28 seconds**  **per bucket.**  **Fro m**  **this he**  **ca lc** **ulat es**  **that he**  **�ses about**  

## 0. **6 gal**  **lons of**  **fresh wa**  **ter spray**  **for every**  **pound of**  **produ ct**  **. Th**  **is in**  **fo rmation**  **can n o** **w be**  **used to**  **contro l**  **wa ter**  **us e .**  **Fi rst**  **, water**  **flow can**  **be chec**  **ked dur**  **ing slo**  **wer prod**  **uction per**  **iods so**  **the ratio**  **of** 

## 0. **6 ga**  **llo ns**  **per pound**  **of prod** **uct is**  **not exce**  **eded .**  **S e cond**  **, a flo**  **w ratio**  **of** 

## 0.3 **or** 

## 0.4 **gal lons**  **per pound**  **of prod** **uct co**  **uld be**  **tried to**  **deter mi**  **ne what**  **the minimum**  **wat er**  **re quir**  **ement i s**  **. The**  **ex ampl**  **e above**  **is fa**  **i rl** **y s i**  **mple ,**  **but is**  **typica l**  **of many**  **me asur**  **eme nts**  **that can**  **be mad**  **e in**  **d i ff**  **er ent**  **proces sing**  **pl ants**  **. The**  **resu lt**  **of** 

## 0. **6 ga**  **llo ns**  **of fr**  **esh wat**  **er spray**  **per pound**  **of pr**  **oduct .is**  **now a**  **s o lid**  **num ber**  **and a**  **ref erence**  **st andard**  **for th**  **is one**  **step. Over**  **th e**  **c o urs**  **e of**  **t i me**  **more re**  **lat i o**  **n s h**  **ip s**  **can be**  **e s tab**  **li sh**  **ed .** 

**9 The ab**  **ove examp**  **le has**  **s o me**  **ele ments**  **wh i c**  **h you**  **may not** 

**h a ve**  **not i**  **ced but**  **wh i c**  **h ensure**  **the qua**  **l i ty**  **and va**  **l i d**  **ity of**  **the mea**  **sure men** **t s .**  **Fir st**  **, a s i**  **ng le**  **indi v**  **idua l**  **took the**  **me as**  **ure ment**  **s ...**  **thu s**  **avo idin**  **g diffe**  **rences wh**  **i c h**  **mi ght**  **ex ist**  **b e twe**  **en how**  **diffe rent**  **peo ple**  **would t a** **ke a**  **measur ement**  **. S e**  **cond, the**  **pe rso**  **n takin**  **g the**  **sa m** **ples was**  **Bob, a**  **kno wled**  **geab le**  **and tra**  **ine d**  **f o reman**  **... thus**  **avo idin** **g the**  **pro bl**  **ems of**  **s l oppy**  **s a m** **p l ing**  **tec hn**  **i q ues**  **and bad data**  **. Third**  **ly ,**  **Bob co**  **lle ct**  **ed Gat**  **l e ast**  **) three**  **sa m** **ples ...**  **thus ac** **hie vin** **g a l e**  **ve l**  **of re pli**  **catio n**  **wh i c**  **h shou**  **ld ensure**  **pr e c**  **ise dat**  **a . A**  **Su m** **mar y**  **of Mater**  **ials Accou**  **nting Pr**  **inc ip**  **le s** 

**Here is**  **a s u** **mm ary**  **of mate**  **rials acc**  **ount in**  **g ( a**  **.k.a. ma**  **ss ba**  **lance) .**  

## 1) **Law of**  **conser vat**  **ion of**  **ma ss**  **- Th**  **is refers**  **to the**  **imag i n**  **ary boundary**  **boxe s**  **that are drawn around**  **a pr**  **oces s i**  **ng p l**  **ant or**  **a proces**  **sing ste** **p . The**  **amount of**  **mater ial**  **that c r**  **os ses**  **over the**  **bou ndary**  **(w ater**  **and sea**  **food esp**  **eci al**  **ly) mu**  **st equ**  **al the**  **amount that**  **co mes**  **out .**  **In a**  **nutshe l l**  **: "What**  **goes in**  **mu st**  **come out**  **." You**  **can ac tua**  **l l y**  **mo de**  **l your**  **pla nt**  **and pr**  **ocess steps**  **and a c**  **co unt**  **for the**  **inp ut**  **, uti**  **li zati**  **on ,**  **an d**  **d i sc**  **harge of**  **both water**  **and sea**  **food .**  

## 2) **B o und**  **arv bo**  **xe s -**  **Draw a**  **boundary box**  **around the**  **pro cess**  **or proce**  **ss steps**  **that are**  **to be**  **me a s**  **ured .**  

## 3) **Flows to**  **be mea**  **sur ed**  **- Iden**  **tif y the**  **flows in**  **and out of**  **eac h**  **bound ary**  **box that**  **are to**  **be measu**  **red .**  **Start big**  **, wit** **h good**  **sol id**  **data for**  **ove r a**  **ll proc**  **ess and**  **reco very**  **for the**  **entir e**  **f a cil**  **ity .**  

## 4) **Flo w**  **d i agrams**  **- Thi**  **s refers**  **to flo**  **w me**  **a s ure** **men ts**  **of vo**  **lu me**  **or we**  **i g ht**  **wit hin**  **a proces**  **si ng**  **pla nt**  **or a**  **pro cess**  **i n g**  **st ep**  **. Dr**  **aw a**  **flo w**  **d i agr**  **am show**  **ing all**  **pro ces**  **s ing**  **steps and**  **all mater**  **ial flo** **w s t** **rea ms**  **in ______** **__ �**  **a.nd .out**  

## of---th�pr-OC-e**ss step** **�.----------------�** 

## 5) **Measure ment**  **sys tem**  **- Choo**  **se between**  **metric and**  **En glis**  **h un**  **its ba**  **sed up**  **on what**  **you c�s**  **to m**  **ar i l**  **y us**  **e in**  **me asu**  **r ing**  **product we**  **i g ht**  **. Ch**  **oose a**  **tie mat**  **er i a**  **l such**  **as product**  **ion rate**  **or prod** **uct reco**  **very to**  **com pare**  **all other**  **measure ments**  **to .**  

## 6) **T a kin**  **g good**  **measure men** **ts - Iden**  **tif y**  **and bu**  **ild a**  **set of**  **me a**  **surements and**  **r e lat**  **i o ns**  **that can**  **be u s**  **ed to**  **mo n i**  **tor and**  **ch ange**  **i n eff**  **icie ncy**  **and wa**  **ste .**  **Deve l o** **p s i**  **m p l**  **e meas**  **urement te**  **chn iq**  **ues to**  **get more**  **i n £orma**  **tion a n**  **d mo**  **re dep**  **enda ble**  **inf ormat**  **i o n .**  **Bu ild** 



## 10

### r e **lia ble**  **inf orm** **atio n**  **through pr**  **oc ed** **ures wh**  **i c h**  **a s sure**  **qua l i**  **ty . Tra**  **i ned**  **per s o**  **nne l**  **u s ing**  **de s c**  **r ibed**  **s a m** **pl ing**  **pr oced** **ures wit** **h adeq** **uate re** **pl icat**  **ion wi**  **ll prod** **uce inf**  **orma ti**  **on wh**  **i c h**  **is accu**  **rate and**  **pr ec**  **ise and**  **capa ble**  **of s a**  **vin g**  **you mo**  **ne y .** 

**CONDUCTING A**  **MATERIALS ACCOUNTING**  **AUDIT** 

### How to **Or ganize**  **and Ma**  **in tai**  **n Good**  **Records Deve**  **lopin g a**  **mater i a**  **ls acco**  **unt i n** **g aud**  **it pro** **gra m**  **in vo**  **lves two**  **sta ges**  **. Th**  **e f i**  **rst st**  **age is**  **l e arn**  **ing and**  **e xp**  **erim entat**  **io n.**  **The seco**  **nd stage**  **is def**  **in ing**  **a set**  **me a s**  **ure ment**  **rout ine**  **that is**  **eventua l l**  **y de**  **ter mined**  **to work**  **the best**  **for your**  **facil ity**  **and yo** **ur per**  **sonne l.**  **Hig h**  **va lue**  **shou ld**  **be placed**  **on a n** **y an** **d all**  **mea sur**  **ement s**  **and in**  **for mat**  **i o n .**  **Often a**  **rando m**  **me a s**  **ure ment**  **may not**  **s e em**  **im p o**  **rtant at**  **the tim**  **e, but**  **a mo**  **nth or**  **a year**  **l a ter**  **it may**  **show you**  **how f a**  **r you**  **have pr**  **ogr ess**  **ed. It is**  **im portant**  **to set**  **a** 

### s **id**

### e **sp ace**  **in** 

### your **office for**  **all work**  

### a **s** 

### s o **c** 

### i **a** 

### t **e**

### d **with** 

### doing **a mater**  **ials acc**  **ount i n** **g audit**  **so that**  **all rec**  **ords can** 

**. be**  **kep t**  **or ganiz**  **ed and**  **usab l e**  **. Do th**  **is rig** **ht aw** **�y. Ge**  **nerally you**  **wi ll**  **col le**  **ct four**  **type s**  **of infor** **mat ion**  **.** 

## 1) **Lea rnin** **g and ex** **per iment**  **ation -**  **Wh en**  **start i n**  **g ou**  **t the**  **va lue**  **and accu**  **ra cy**  **of ·m**  **e a su** **re me** **nts wil**  **l not**  **be obvi**  **ous .**  

### The **me asu**  **red stre**  **ams and**  **c o m** **pon ents**  **w i ll**  **also change**  **as part**  **of your**  **deve l**  **op ment**  **of th**  **e b�**  **st dail**  **y app**  **ro ach**  **'f or**  **you r**  **p l ant**  **. Save**  **all of**  **this infor** **mat ion**  **. It**  **wi ll**  **be very**  **use ful**  **in the f**  **u**

### tu **re.** 

## 2) **Set mea**  **sure men** **t r o** **ut ine**  **- Th**  **ese are**  **the meas** **urement s**  **th at**  **can be**  **ta ken**  **on a**  **regu l a**  **r ba**  **sis to**  **ch e**  **c**

### k **the eff**  **i c ie**  **ncy of**  **the pr**  **oc ess**  **ing o'**  **pe rat**  **io n .**  **A** 

### manager **may**

**. wa**  **nt this**  **infor mat**  **ion col**  **lec ted**  **f o ur**  **to s i**  **x t i** **me s a**  **day in**  **or der**  **to run**  **a t i**  **g ht**  **ope rat**  **ion . You**  **will need**  **to s e** **t up**  **a good**  **records syste** **m to**  **st op**  **th ese**  **records fro** **m beco** **ming 'a**  **us ele**  **ss paper**  **pile .**  

## 3 **) Ra**  **ndom ,me**  **asu re** **ment s -**  **Th ere**  **could be a**  **re lat**  **ions hip**  **between two**  **diff e r**  **ent ste** **ps th** **at, ar**  **e not**  **in a**  **fl ow**  **dia gram**  **. An**  **examp le**  **wou ld**  **be a**  **ma c** **hine speed**  **ver sus**  **a wat**  **er flow**  **rat e .**  **S o me** **ti me**  **s the**  **op portun**  **ity ar**  **i ses**  **to mea**  **sure a**  **dif f i**  **cult strea** **m at**  **a rar**  **e stead** **y flo** **w. Many**  **t i mes**  **the se**  **me asu** **r e ment**  **s are**  **not p l**  **an ned**  **and end**  **up wri**  **tten on**  **matc hbooks**  **or scraps**  **of cardboa**  **rd .**  **The inf**  **or mat**  **i o n**  **is sti**  **ll valua**  **ble and**  **sh ould**  **be ke** **pt and**  **or g** 

### a **n** 

### i **z** 

### ed.



## 11

### 4) **Calculations and**  **records -**  **These could**  **include a**  **large flow**  **diagram with**  **measured ratios**  **entered for**  **different streams**  **and the current**  **target goals**  **for those**  **streams. Also**  **included could**  **be the**  **calculation methods**  **for determining**  **different flows**  **and concentrations,**  **and up**  **to date graphs, totals,**  **or averages**  **of key**  **streams that would give**  **a measure**  **of efficiency.**  **communication is**  **much easier**  **with a**  **we ll-organized**  **system. In**  **larger operations measurement**  **responsibilities will**  **be part**  **of the**  **foreman's and**  **leads I**  **jobs. They**  **will need**  **to·understand the**  **goals and**  **results of**  **the input**  **they are**  **providing. If**  **a manager**  **sets up**  **a system**  **that only**  **he can**  **understand then.he cannot use**  **his hands-on**  **production staff**  **to full**  **advantage.** 

### A **well-organized system**  **with plant**  **floor inv**  **olvement. helps**  **�et measurable**  **goals for**  **the crew to**  **aim for.**  **There's nothing**  **better for**  **production than**  **two good**  **foreman trying**  **to outdo each**  **otherl What**  

### Are **Good Records**  **and Forms** 

**In order**  **to stay**  **organized a**  **standard measurement form**  **should be**  **developed and**  **used. If**  **information is**  **from the**  **experimental period**  **before a**  **form has**  **been developed**  **or is**  **a random**  **measurement then**  **the information should**  **be transferred**  **to a**  **regular** 

### 8.5" **by** 

### 11. 

### 0" **sheet of**  **paper. The**  **goal is**  **to be**  **able to·**  **arrange the**  **records in**  **order so**  **that you**  **can easily**  **flip through**  **them. It**  **is assumed**  **that a**  **regular form**  **would be**  **copied on**  **a standard sheet**  **size.**

**Don't limit**  **the space**  **for information**  **on a**  **form by**  **drawing too**  **many boxes**  **or lines.**  **Keep it**  **as simple**  **as possible.**  **Leave space**  **for making**  **notes on**  **what the**  **process or**  **seafood condition**  **is like**  **at the**  **time. Design**  **your form**  **so you**  **can locate**  **the numbers**  **and informa**  **tion you**  **want instantly.**  **If possible**  **use "write**  **in the**  **rain" waterproof**  **paper-and a**  **pencil.**

**Most importantly,**  **always have**  **a time**  **and date**  **associated with**  **every measurement**  **or note.**  **Placing the**  **date in**  **the upper**  **right hand corner**  **is easiest**  **for flipping**  **back to**  **check past**  **data. Time**  **should be**  **recorded in**  **24-hour mil**  **itary format**  **(e.g.,** 

### 1:30 **P.M. =**  

### 1330). **Most information**  **can be**  **recorded as**  **a shift total**  **so that**  **the time**  **would be**  **consi stent**  **with· shift**  **change. Some**  **information, such**  **as a**  **water side-stream**  **measurement, may**  **be checked**  **periodically so**  **the time**  **of the**  **measurement would**  **need to**  **be recorded.** 

**An example**  **of how**  **this works**  **refers back**  **to foreman**  **Bob who**  **wonders two**  **days after**  **making his initial measurement**  **what the**  **relation of**  **fresh water**  **spray to**  **whole seafood**  **is. His**  **notes say**  **that he**  **made his**  **measurements at**  **02:37 and** 



### 12

## 02:45 **(p re**  **tty e a**  **rly in**  **the morn**  **i n g!**  **), so**  **he ch**  **ecks the** 

**so rted**  **s e a**  **foo d**  **fee d**  **ta l l**  **y and**  **f i nds**  **that two**  

## 1,000 **p o und**  **tote s**  **were run that**  **hou r .**  **From th**  **is he**  **can fi**  **gure a**  **re co**  **ver y**  **and also**  **pred i c** **t how**  **to ad**  **ju st**  **his fresh**  **wate r**  **spray base**  **d on seaf**  **ood co** **ming in.**  **If a**  **good mate**  **rials acco**  **unt ing**  **aud it**  **prog ram**  **can be**  **de ve**  **loped fo**  **r a l a**  **rger fa**  **cil ity**  **it may have up to**  **ten poin** **ts that**  **can be**  **ea sil**  **y mea**  **su red**  **in order**  **to rout**  **inel y**  **chec k**  **e f ficie**  **ncy .**  **A co**  **mp uter**  **ru nnin**  **g a spre**  **adsheet pr**  **ogra m**  **is the**  **be st**  **way to**  **hand le**  **more than**  **f i ve**  **or si**  **x data**  **poin ts.**  **with a**  **go od**  **program set**  **up the**  **co m** **puter can**  **make all**  **ca l c**  **u l ati**  **ons of**  **i n te**  **re s t**  **, graph**  **the data**  **fo r**  **co m** **par i s**  **on to**  **prev i o**  **us pro**  **duct ion**  **periods, and even**  **g i ve**  **,a re**  **l a t i**  **ve p e**  **rfor m**  **ance rat**  **ing .**  **Th is**  **is a**  **litt le**  **s o p** **histi cated**  **fo r**  **mo st**  **faci lit**  **i e s**  **, but a**  **good com** **puter s e** **tup can**  **he lp**  **squee ze**  **the mo**  **st out**  **of an**  **operat ion**  **. Anothe** **r adv** **antage is**  **th at**  **all of**  **the infor** **ma tion**  **can be**  **s a ved**  **on a**  **flo ppy**  **dis k .**  **The infor** **mat ion**  **can then**  **be eas**  **i l y**  **copied, sto**  **red ,**  **or dis**  **t ri**  **but ed**  **to other**  **company off**  **icers.**
**v-l hic** **h Mat**  **eri al**  **s** 

### and **Methods Support**  **Goon Mea�11rpmAnt�** 


### A **good st**  **art f o**  **r a recor**  **din g**  **k i t**  **is the**  **a l um**  **i num**  **bi -fold**  **c l ipbo**  **ard that**  **s n aps**  **clo s e** **d and**  **is about**  **one inc** **h thi**  **ck .**  **In** 

### add **i t ion**  **to water** **pro of**  **pap er,**  **penc ils,**  **and a**  **watch ,**  **s o me**  **other us**  **eful ite** **ms to**  **inc lude**  **wo uld**  **be a plast**  **�c Eng**  **lis h**  **/m etr**  **ic ru**  **l e r ,**  **Eng l i**  **sh /**  **met ric**  **t a pe**  **mea su**  **re, s m** **all flas** **hli g** **ht, fo**  **ur fun**  **ction calc**  **u l at**  **or, and**  **wat erpro**  **of marker**  **. Near**  **ly al**  **l me**  **asu rement**  **s of**  **in t e**  **re st**  **w i ll**  **be eit** **her a**  **vo lu** **me or**  **we i g** **ht per**  **un it**  **t i me**  **. Mo**  **st of**  **the t i** **me you**  **wil l**  **be mea**  **surin g**  **how l o**  **ng it**  **takes to**  **fill a**  

### bucket **with so** **meth ing**  **. Ev**  **en thoug** **h th**  **is is**  **pretty ba**  **sic the**  **f i rst**  **st ep**  **is to**  **ass u**  **re that**  **good we**  **ig ht**  **s and**  **me a s**  **ure s**  **can be**  **made and**  **the pe**  **ople taki**  **ng" them**  **under stan** **d ex** **actly what**  **the proc**  **edu re**  **i s .**  **The a b**  **ility to**  **use the**  **to ols**  **at han** **d and**  **i n nov** **ate w i**  **th them**  **wi ll**  **s i m** **plif y**  **thi ngs**  **and in**  **cr ease**  **th e**  **chance f o**  **r su**  **cces s.**  **For wei** **g hing**  **, the**  **fi rst**  **ste p**  **is to**  **f i nd**  **the l o**  **c a tio**  **n and**  **c o ndit**  **ion of**  **al l**  **s c ale**  **s in the**  **pl ant**  **. The qua**  **l i ty**  **contro l**  **de par** **tment may**  **hav e a**  **good scale**  **tha t**  **is a c**  **cu rate**  **fo r**  **one pound**  **and belo** **w . There**  **may be**  **a s p**  **are pro**  **duct s c**  **ale th** **at can**  **be us**  **ed for**  **we ight**  **s in**  **the** 

## 10-50 **pou nd**  **range .**  **A** 

## 300 **po und**  **platfo rm**  **sca le**  **may be ha**  **ndy f o**  **r putt**  **ing a**  **larg e**  **box on**  **a n d**  **div ert**  **ing a**  **wh o**  **le strea** **m t o**  **. Che**  **cking the**  **wei ght**  **gain ev**  **ery f e** **w min** **utes wo**  **uld give**  **a ver** **y accu** **rate f l**  **ow mea**  **su rement**  **. Th�**  **nu mber**  **and type**  **of scales**  **'ava ilable**  **will det**  **er mine**  **wh at**  **measu reme** **nts can**  **be done**  **an d**  **if they**  **can be**  **done s i**  **mu ltaneo**  **usl y .**  **The nex** **t s t**  **ep is**  **to** 

### chec**k the**  **acc ur**  **acy of**  **the s c**  **ale s**  **and reca**  **l ib** **p ate**  **them if**  **ne ce**  **s s ar** **y. If**  **weig ht**  **sta ndar**  **ds are**  **not ava**  **ilable then**  **set vo**  **lu me**  **s of**  **water can**  **be**



## 13**used. (The**  **density of**  **water is**  **included in**  **Appendix A.)** 

**Finally, the**  **buck ets**  **or containers**  **to be**  **used can**  **be weighed**  **and the**  **net weight**  **written on**  **the side.** 

**For volume**  **measurements the**  **tool of**  **choice is**  **a five**  **gallon plastic**  **oil or**  **chemical bucket.**  **To calibrate**  **a bucket**  **pour in**  **a set**  **amount of**  **water and**  **draw a**  **line with**  **a waterproof**  **marker at**  **each fill**  **line. The**  **bucket can**  **be marked**  **off in**  **increments of**  **gallons, quarts,**  **or liters.**  **Measuring pitchers**  **will be**  **needed for**  **this. If**  **none are**  **available some**  **options are to**  **weigh out**  **the water,**  **borrow a**  **measuring pitcher**  **from the**  **cook, or**  **buy some**  **calibrated juice**  **pitchers from**  **the local**  **dry goods**  **store. The**  **volume can**  **also be**  **calculated by**  **measuring. the**  **bucket dimensions**  **and using**  **the formula**  **for a**  **cylinder volume**  **in Appendix**  

### B. **other volume**  **measurements may.be**  **a holding**  **tank, bin,**  **or forklift**  **tote and**  **timing how**  **long it**  **may take**  **to fill**  **or empty**  **them to**  **a certain**  **depth. Formulas**  **for different**  **tank geometries**  **are also**  **in Appendix**  

### B. **The dimensions**  **for tanks**  **and equipment**  **can be**  **gotten from**  **blueprint drawings.**  **These are**  **usually in**  **the plant**  **office or**  **with the**  **plant engineer.** 

**Some streams**  **of interest**  **can't be**  **easily measured**  **so a**  **best guess**  **or estimate**  **is the**  **only approach.**  **with a little**  

### planning **and practice**  **this technique**  **can be**  **very easy**  **and helpful.**  **Two examples**  **are provided**  **below. ..** 
**. Example**  

### 1: **Troughs or**  **flumes**
**An example**  **would be**  **a floo** **r drain carrying waste**  **and process water**  **to a**  **sump. There**  **are two**  **ways to**  **estimate the**  **flow rate.**  **The first**  **would involve measuring**  **the depth**  **of the**  **flow, the**  **cross section**  **of the**  **trough, and**  **the speed**  **of material**  **in the**  **trough. The**  **second method**  **would be**  **to measure**  **the volume**  **of the**  **flume, block**  **it off,**  **and time**  **how long**  **it takes**  **to fill.**  **Example** 

### 2: **Seafood washing**  **Another example**  **is from**  **a seafood**  **washing step**  **where all**  **wastewater was**  **collected in**  **catch-pans and**  **piped to**  **a sump.**  **The sump**  **had high**  **and low**  **level float**  **switches that**  **turned the**  **sump pump**  **on and**  **off.. The**  **sump was**  **square and**  **the depth**  **between the**  **high and**  **low marks**  **was consistent.**  **The fill**  **volume could**  **then be**  **calculated and**  **the time**  **to fill**  **the sump**  **between pumpings**  **could be**  **easily timed.**  **The flow**  **rate could**  **then be**  **calculated and**  **the time.between**  **pumpings was a**  **very easy**  **relation to**  **check'water use**  **at this**  **process stage.** 
**As shown**  **above there**  **are other**  **ways to**  **get useful**  **information than**  **by direct**  **volume or**  **weight measurement.**  **It**



### 14**, .** 



### may **be the**  **t i me**  **req uire**  **d to**  **fi ll**  **a tan** **k , bin**  **, or su** **mp. It** 

**may also**  **be an**  **equip ment**  **spee d**  **s e tt**  **i n g**  **such as**  **a wh**  **o le**  **s e afo**  **od pump**  **or a**  **meat**

**. pump.**  **The adv** **antage to**  **f i nd**  **in g**  **the se**  **ty pes**  **of mea**  **surements is**  **that they**  **are easy**  **, qu**  **i c k ,**  **dry ,**  **and can**  **be pe**  **rformed by**  **anyone wit** **h a wat**  **ch.**
**Deve l o** **pin g a**  **good mater**  **ials acco** **unt i n** **g au**  **dit and**  **the mea**  **su rement**  **tec hniq** **ue s**  **to inc**  **re ase**  **effic i e**  **ncy and**  **i n come**  **takes t i** **me. �xpe**  **r i mentat**  **ion and**  **in nov** **atio n**  **are both**  **key s**  **to your**  **su cc**  **ess .**  **It take**  **s pr**  **ac tice**  **to ident**  **i f y**  **wh at**  **,m ea**  **su r**  **em ents**  **and calc** **ulat ions**  **wi ll**  **work the**  **best .**  **star t**  **by mea**  **sur in**  **g the**  **s i mp**  **lest strea** **ms po**  **ssi ble**  **even if**  **they do**  **not s e**  **em impo**  **rta nt.**  **Th is**  **wi ll**  **g i ve**  **a way**  **to eva**  **luate the**  **ski ll**  **leve l**  **of the**  **peo ple**  **in vo**  **lved. The**  **goal is**  **to bui**  **ld con**  **fi de**  **nc e**  **and f a** **mi lia**  **r i ty**  **wi th**  **the pr**  **oce ss**  **and av** **oid .**  **co nf**  **usio n.**  **A Re**  **ca p**  **of "How**  **To" After**  **a flo** **w d i**  **ag ram**  **has been**  **made an** **d the**  **diffe ren** **t flo** **w strea** **ms id**  **ent ifi**  **ed, chec** **k the**  **fo l l**  **o win**  **g �ement**  **s of**  **your materials**  

### ac **count ing**  **before any**  **measurements** 

### are **takenQ** 

## 1) **Long t e**  **rm goa**  **ls -**  **start out**  **s i mpl**  **e and**  **bui ld**  **co nf**  **ide nce**  **and sk**  **il l.**  **Deve l**  **oping soli**  **d te**  **ch niq** **ues and**  **pro c e** **du res**  **wi ll**  **ens u**  **re pr**  **og res**  **s and**  **re su**  **lts ov** **er the**  **l o ng**  **te rm.**  

## 2) **P e r**  **so nne**  **l - I d**  **en tif** **y the**  **peo ple**  **who wi**  **ll be**  **i n vo**  **lv ed**  **and make**  **su re**  **that everyo**  **ne un** **der stands**  **the go**  **als ,'**  **measu re** **ment s,**  **and proc**  **edu res.**  

### 3) **Av a i**  **lable measu** **r e ment**  **too ls**  **an d**  **ca l i**  **b rat**  **io n -**  **Ho ld**  **a s c**  **avenge r**  **hunt to**  **f i nd**  **all vo**  **lu me**  **and we**  **i g ht**  **mea sur**  **ing ite** **ms th**  **at may be**  **us ed.**  **Cal ib**  **ra te**  **these it**  **ems and**  **f o rmu**  **lat� a**  **plan to**  **reg ularl**  **y check**  **th eir**  **c a l**  **ib rati**  **on.** 

## 4) **Or ga**  **n i zat**  **i o n -**  **Th i n** **k thr**  **ough a**  **sy ste** **m of**  **how to**  **keep measur**  **ement s**  **and reco**  **rds in**  **order .**  **Wh at**  **ab o'** **ut Ins**  **tru ment**  **s and**  **Com pu**  **ter Data**  **Co l l**  **e c tion**  **Sy ste** **ms The**  **eas iest**  **way to do**  **a job**  **is ha** **ve a**  **r e lia**  **ble inst**  **ru men** **t do**  **it !**  **Ins tru** **men t s or**  **me ters**  **insta ll**  **ed at**  **k ey**  

### measu**r ement**  **po in** **ts ofte** **n pay**  **for the** **ms e l**  **ves in**  **a ve** **ry short**  **ti me**  **by pro** **vid in** **g info**  **r mat**  **i o n**  **f o r**  **bett er**  **con tr**  **ol and**  **eff icie**  **ncy. Flo** **w met**  **ers in**  **major water**  **l i nes**  **wil l**  **help def**  **ine and**  **c o ntrpl**  **water use**  **very qu**  **ic kly**  **. Oth**  **er me** **ters c a** **n ind**  **ica te**  **equip men**  **t use**  **and speed**  **, or pr**  **oduct flow.**  **Th ere**  **are thr**  **ee ma**  **in bene**  **fit s**  **of havin** **g a key**  **in s t**  **ru ment**  **or met**  **er in**  **a vis**  **ibl e**  **l o cat**  **i o n.**  **F i rst**  **is the** 



## 15

### ab **ilit y to**  **ch ebk**  **a key**  **measure ment**  **and ma**  **inta in**  **the des**  **ired**

**s** 

### et **ti n** 

### g. **Second is**  **as sur**  **ing that**  **th ose**  **in ch**  **arge are**  **ma k**  

### i **n**

### g **use of**  **the in**  **form atio**  **n and**  **ma i n** **ta inin** **g the**  **de s i**  **red sett**  **ing or**  **rate .**  **Th ird**  **is a**  **method to se**  **t new**  **goa ls**  **and inc**  **ent ives**  **to ac**  **h i eve**  **the optim** **um op**  **erat i n**  **g rate**  **for th**  **at measured**  **quant ity**  **. Inst** **rum ents**  **and me**  **ters can**  **also be.**  **s e t**  **up to**  **ele ctron**  **i c all**  **y com** **mu n**  **icate the**  **me asu** **red values**  **to a**  **co mp** **u ter**  **. Th**  **ese syst**  **ems are**  **very us**  **efu l in**  **l a rge**  **seafo od**  **pro cess**  **ing fa**  **ci l**  **ities (e**  **.g., sur**  **imi p l**  **ants) wh**  **ere th**  **er** 

### e **are man** **y st** 

### r e **a**

### ms **and a**  **ver y**  **hig h**  **vo lume**  **of proc**  **esse d**  **s e a f**  **ood .**  **The c o** **mput er**  **can qu**  **i c kly**  **gra ph**  **all measu**  **re ment**  **s and**  **make it**  

### e 

### as **y** 

### to **p i np**  **o i nt**  **op erat**  **ions wh**  **ic h**  **are ou**  **t-of -l**  **ine. A**  **good** 

### real- **time ins**  **tru me**  **ntat ion**  **and data**  **ac qui**  **s i t i**  **on syste** **m can**  **outper for** **m any**  **hu man**  **and inc**  **rease pla** **nt op**  **erat ions**  **to a**  **maxim um**  **. (Exp**  **er i e**  

### nc **e** 

### in **the sur**  **imi indust** **ry has**  **sh own**  **th ese**  **inst ru** **me nt**  **and co** **m puter**  **sy ste** **ms to pa** **y for**  **th e** 

### ms **e l** 

## v **es in**  **l** 

### es **s** 

### th **an ten**  **days! )** 

**•** 

### ��TERIALS **��� AGEMENT**  **PRACTICES Ma**  **nagement and**  **st yl**  **e are**  **oft en**  

### li **nked together**  **be ca**  **use OI**  

### the **pers o**  **nal** 

## sty **l** 

### e **and ex** **perie nce**  **br ought**  **to t** **h** 

### e 

## j **o** 

### b **. The**  

### different 

### and 

## d **i** 

## f **fi c** 

## u l **t** 

## nature **of seafood**  **processing in**  **Alask a**  **make s a**  **manager' s**  

# f**ob** 

### pretty **har d**  **to def**  **ine .**  **Ho wev**  **er ,**  **the one**  

### th **i n g**  **that good**  **ma nager**  **s share**  **i n**  **any bu**  **sines s**  **is that**  **they make**  

### it look **easy wh**  **ile b**  

### e i **n** 

### g **s u cc**  **ess ful.**  **Th is**  **is** 

### due **in part**  

### to **mi n i**  **m** 

### i 

## z **i n** 

### g **e f fort**  **through good**  **or** 

### g **a**

### n i 

## z **a** 

### tio **n and**  

### pre**p** 

### a r **a**

### t i **on** 

### .

**The** 

### mo **st im** **port ant**  **bene fi**  **t of**  **orga n i**  

## z **at i**  

### o **n is**  **hav ing**  **a** 

### progr **am** 

### that **can be**  **ex pla**  **ined readi**  **ly to**  **a l l**  **s** 

### upar

## v **i s o**  **r** 

### s **and p**  **ers onn**  **e l .**  **Hav i n** **g a clea**  **r desc**  **r ipt**  **ion of**  **what i**  **s wa**  **nted and**  **e**

### xp **ec t**  

### e**d** 

### ma **kes it**  **easier to**  **in vo**  **lve mor**  **e** 

### peop **le and**  **d i stribute**  **ef for**  **t. Th**  **e goa**  **l is**  **to inc**  **rease** 

### e f **f i**  

### c **i** 

### enc**y by**  

## m**eas** 

### u **ri** 

### n **g a**  

### nd **c o**  

### ntro **l** 

### l **i** 

### ng **mor e**  **pr oce**  **ss po**  **i n ts.**  **Thi s**  **req uir**  **es** 

### goo**d communic**  **atio n so**  

### that **al l**  **pr** 

## o **d u**  

### cti 

## o **n perso**  **nne l**  **know wh**  **at is**  **go ing**  **on** 

### and **what th**  **eir res**  

### p 

## o **ns i b**  

### i **l i**  

### t **ies ar**  **e.**

**Us in** 

# g **ma ter**  **ials** 

### acc **o**

### u **n** 

### t **in**

### g **pr i n**  

### c i **p l e**  **s, key**  **pro ces**  **s ste** **ps can·**  **be** 

### def **ined in**  

### t **e** 

### r**m** 

## s **of the**  

### f **lo**

### w **of w**  **as** 

### t **e ,**  **wa ter**  **,** 

### an**d ·pr**  **odu c t**  **. On**  **ce th ese**  **h a ve**  **been def**  **i n ed**  **t**

### h **e** 

## j **ob re**  **sp o**  **nsi bi**  **li ty**  **of the**  **pe op**  **le** 

### in **thes e**  **areas should**  **inclu de**  **meeting** 

### the **go als**  **set by**  **manag ement.**  **This** 

### r **e** 

### q**u** 

### ire **s a c l**  **ear** 

### d 

### esc **r i**

### pt **io** 

### n **an d**  **co mmuni**  **cation of**  **the goa**  **ls .**  **Trained worke** **rs can**  **rec ogn**  **iz e**  **wh at**  **is rig** **ht** 

### a n**d act**  **to c o**  **rrect it**  **if ne**  **eded.**

**In a** 

### ddi**t i o**  

### n **to d e** **mand i n** **g mor**  **e respo**  **n s ibi**  **l i t** **y, in** **c ent**  **ives can**  **als o**  **be used**  

### e **f f e**  

### ct **iv ely**  **.** 

### If **sp eci**  **al tr**  **eat ment**  **or re** **wards b** 

### r 

## i **n** 

### g **hig her**  **e** 

### f f **i** 

### c **ien** 

### cy **, then**  **new pe** **r f ormance**  **benc hmark**  **s are**  **es** 

### t **ab** 

### l 

## i **s** 

### h **e**

### d **that ca**  **n be**  **use d**  **as**



### 16

### goa **ls .**  **Once e s**  **tab l i**  **sh ed**  **th ese**  **new l e** **ve ls**  **shou ld**  **be**

**ma in**  **ta i n**  **ed. Th**  **is is**  **wh ere**  **a s i**  **mp le**  **mea su**  **remen t**  **p r oce**  **dur e**  **is hel**  **pfu l**  **in ch**  **ec k**  **i n g**  **pe rfor** **mance both**  **by su**  **per visors**  **and work**  **er s.**  **Th e**  **best way**  **to crea**  **te an**  **efficie nt**  **pro c**  **ess in** **g ope**  **rat i o**  **n is**  **to e s**  **ta bl**  **i s h a**  **ste ady**  **rate of**  **ope r**  **ations so**  **that all**  **st rea** **ms an**  **d pro**  **c es**  **sin g**  **step s**  **can be**  **adju sted**  **to that**  **r a te.**  **This mu**  **st be**  **done f o**  **r lon**  **g eno**  **ugh so**  **th at**  **the s e**  **afood ca**  **tc h**  **en ter**  **ing th**  **e pr**  **ocess has**  **det er** **mine d**  **th e**  **ou tp** **ut at**  **th e**  **pa ck**  **ing tab**  **l e .**  **Once th**  **is pa**  **ce is**  **s e t**  **'up all**  **th e**  **steps in**  **be twe**  **en can**  **be adju**  **sted .**  **If th**  **ere is**  **an up**  **or down**  **pr odu**  **ctio n**  **chan ge**  **th en**  **all new**  **adju st** **men ts**  **can be**  **in pro** **portio n**  **to th**  **e chan**  **ge. .Ma**  **in ta**  **inin g**  **stead y**  **flow allo** **ws pr**  **oduct i o**  **n p e** **rs onne**  **l to**  **kno w**  **wh ere**  **th in**  **gs are at**  **an d**  **cont ro**  **l wh**  **ere they**  **are go**  **i n g.**  **How to**  **Ach ie**  **ve Wa**  **t e r**  **Co nse**  **rv at**  **ion Water**  **c o ns**  **erva tion**  **is ac**  **h i eve** **d by**  **peop l e**  **, mechan**  **ical mo**  **difi cat**  **i o ns,**  **an d**  **in stru** **ment s**  **or mete**  **r s .**  **Ult imat**  **ely it**  **is th**  **e pe**  **ople who**  **wil l**  **co nt** **rol th**  **e wa**  **ter use**  **. Manual**  **water adju**  **st ments**  **shou ld**  **be th**  **e respo**  **ns ib**  **il ity**  **of individuals**  

### who **are familiar**  

### wit**h wate**  **r-use go**  **als a**  **nd pr**  **op er**  **s e tt**  **i n gs**  **for p l**  **ant op**  **erati on.**  **Un au**  **t hor**  **ized pe**  **o ple**  **nee d**  **to know**  **tha t**  **th ey**  **�r e**  **not allo** **wed to**  **ad j**  **u�t water**  **us e.**  **Ho wever,**  **mec han**  **i ca**  **l modif**  **ic a** **tio ns**  **a�e g e** **neral ly**  **needed to**  **ac hi**  **eve wate**  **r cons**  **ervati on.**  **Be lo** **w are**  **s o me**  **s i m** **ple mechanic**  **al modif**  **ica tio** **ns th**  **at wil**  **l hel** **p min**  **imize water**  **use d**  **in a pr**  **ocess .**  

## 1) **T a nk**  **s - Float**  **va lves**  **wi ll**  **pre vent**  **ove rflo**  **ws in**  **hold in**  **g or**  **was hing**  **tan ks.**  

## 2) **Ho se**  **Nozz l e**  **s - Any**  **style of noz**  **zle that**  **r e quir**  **es han**  **d pre**  **s s ure**  **will pr**  **event wa**  **ste at**  **unat t**  **en ded**  **ho ses**  **. Th**  **is can**  **be pis**  **to l**  **gr ip**  **sty le**  **or the**  **more ru** **gge d**  **rub ber**  **ty pes**  **f o und**  **in the**  **dair y**  **i n dust**  **r y.** 

## 3) **Spr ay**  **Tips -**  **Spr ay**  **t i p**  **per for** **ma nce**  **is deter** **mined by**  **pres sure,**  **volu me,**  **and area.**  **Spr ay**  **t i ps**  **pr o**  **vide im** **pa ct**  **for c l**  **ean in**  **g wit** **h e i**  **th er**  **pr e s**  **sur e**  **or vo**  **lume. Th**  **e e f**  **fecti ve**  **di st**  **ance and**  **area of**  **spray on**  **a ta**  **rget also**  **deter mines**  **the effici**  **en cy.**  **Tech nical**  **sales peop**  **le can**  **grea tly**  **he lp**  **in providin**  **g th�**  **corr ect**  **app lica**  **t i on.**  

### 4) **Bru shes**  **- Good**  **de sig** **n an** **d ad**  **ju st** **ment of**  

### r o **tary bru**  **shes are**  **ve ry**  **e f fe**  **ctiv e**  **in red** **uc i n**  **g spray**  **cle a n**  **in g**  **water.**



### 17

## 5) **Ho ses**  **- Sm** **alle r**  **hoses wi**  **ll req** **uire lower**  **flows .**  

### 6) **Pressu re**  **Reg u l**  **atio n -**  **Lower pr**  **e s su**  **re pr**  **od uce**  **s l o** **wer flo**  **w.** 

## 7) **Ins tru** **ments and**  **Meters (a**  **tw o-sid**  **ed appl**  **icat i o**  **n) -**  **Th e**  **pr im**  **ary funct**  **i o n**  **here is**  **to pr**  **ovide a**  **too l**  **to g i** **ve pe**  **rso nne**  **l the**  **info rmat**  **i o n**  **to make**  **good a d**  **j ust**  **ments of**  **key flo** **ws or**  **equ ip** **ment in**  **th e**  **p l ant.**  **Th e**  **ot her**  **funct ion**  **is to**  **che ck**  **and ensu**  **re that**  **r e spon**  **s i ble**  **pe rs**  **on nel**  **are meet**  **i n g**  **the go**  **als se t.**  **How to**  **Cont rol**  **and Red** **uce Waste**  **Th is**  **sectio n**  **disc us**  **ses hand**  **lin g**  **methods fo** **r �a**  **ste that**  **is being**  **dis charged**  **or coll**  **ec ted**  **f o r**  **treat ment.**  **Th e**  **primary goal is**  **to e l**  **iminate lea**  **ks and**  **assu re**  **that all**  **waste is**  **d i spo**  **s e d**  **in the**  **manner cons**  **i st**  **ent wit** **h you**  **r perm**  **it .**  **The s e**  **condary goa**  **l is**  **to re**  **duce water**  **us e**  **in con**  **vey i n**  **g waste**  **mater ial**  **. Wher**  **e po**  **s s ib**  **le ,**  **cons oli**  **d atin**  **g wa**  **ste st**  **r eam**  **s reduces**  **the chanc**  **es f o**  **r spi**  **l l s**  **an d**  **ove rflo** **ws. For**  **f l u** **me con** **veya nce**  **the rat**  **io of**  **waste to**  **water can**  **be increased**  **wit h**  **the hig** **her flo** **w vo**  **lume of**  **com b i**  **ned str**  **� a** **� s.**  **Hav in**  **g a h i**  **gh er**  **wa ste**  **to water**  **r a tio**  **also dec**  **reases s e** **par at**  **i o n**  **of wa**  **ste in**  **ho l d**  **in g**  **ar eas.**  **Less s e** **pa r a**  **tio n**  **he lps**  **to con** **t rol**  **o i l**  **and fat**  **di spers**  **ion at**  **dis charge**  **po ints**  **and also**  **l i mits**  **the pos**  **sibil i t** **y of**  **cr eat**  **ing har**  **d-to -b** **rea k**  **foams. How**  **to C**  **on vey**  **Waste Th**  **e fo**  **l l o**  **win g**  **met hods**  **of mov**  **i n g**  **wa ste**  **are d i**  **rected at**  **re du**  **c ing**  **the use**  **of· hig** **h volu** **me ho ses**  **and flu** **me s.**  

## 1) **Soli d**  **Belt Co**  **nveyor s -**  **Th is**  **is ap**  **pl icable**  **to han** **d cle**  **a nin** **g l i**  **nes wh**  **ere wa**  **ste and**  **offal can**  **be pu**  **t on**  **the be**  **lt.** 

## 2) **Pump s -**  **Pr og** **ress in** **g ca** **vit y**  **or pi**  **s t on**  **type pu** **mp s**  **do not**  **need ad** **ded wa**  **ter and**  **can move**  **wa ste**  **with very**  **l i tt**  **le da** **mage. 'Unda** **maged wa**  **ste is**  **eas i e** **r to**  **han dle**  **and has**  **less chanc**  **e f o**  **r s e** **par at**  **ion an** **d foa** **min g**  **pr obl**  **ems.** 

## 3) **Va cuum**  **- Th**  **is is**  **the s a** **me as**  **a va**  **cuum c l**  **eaner exc**  **ept the**  **mate ria**  **l of**  **interest is seafo**  **od pr**  **oces si**  **ng wa**  **ste.** 

## 4) **Elb ow**  **Gr ease**  **- S c**  **oop it**  **up and**  **put it**  **in the**  **c o nvey**  **in g**  **sy ste** **m or**  **tote boxe**  **s for**  **wa ste.**  **Don't use**  **a hos**  **e to**  **wash it**  **away when**  **a litt**  **le elb**  **ow gr**  **ease wi**  **ll do**  **as we**  **l l !** 

**18 ·**  **.**

**How to**  **Cleanup Your**  **Facility The difficult**  **part of**  **cleanups is**  **motivating and**  **training people**  **to do**  **a good**  **job quickly.**  **There is**  **much information**  **available from**  **state and**  **federal agencies**  **on how**  **to conduct**  **a good**  **cleaning program.**  **The basic**  **steps of**  **a cleanup**  **are below.**  

### 1)



## 2)

**3 )** 
**4) Remove**  **all heavy**  **solids or**  **deposits. Doing**  **this** 

### by **hand, using**  **brushes or**  **scrapers, reduces water use.**  **High pressure**  **spray may**  **be needed**  **for some**  **deposits. Apply**  **cleaners where**  **necessary and**  **scrub with**  **scrub brushes and**  **other cleaning**  **tools. Rinse**  **and spray**  **off all**  **cleaned equipment**  **and surfaces.**  **Apply sanitizer.**  

### The **keys to**  **any good**  **c** 

### le **anup** 

### are **elbow g**  **r** 

### ea **se ,**  **a bucket**  **of cleaning**  **solution, a**  **scrub brush,**  **and specific**  **cleaning tasks**  **outlined for**  **individuals. water**  **sprays should**  **only** 

### be **used at**  

### the **beginning** 

### of **cleanups to**  

### remove **he avy**  **deposits and**  **to rinse**  **cleaning chemicals**  **from equipment.** 


### A **way to**  **decrease water**  **used for**  **cleaning and**  **increase production time**  **is to**  **clean as**  **much as**  **possible during production.**  **Identify areas**  **and procedures**  **for cleaning**  **during a**  **slowdown or**  **when other**  **opportunities arise.**  **This can**  **extend periods between**  **total stoppage**  **of the**  **plant for**  **a major**  **cleanup.**

**Cleanups are**  **the most**  **difficult part**  **of an**  **operation to**  **make efficient.**  **To reduce**  **water use**  **and cleanup**  **downtime the**  **first step**  **is to**  **define what**  **needs to**  **be cleaned, how**  **it will**  **be cleaned,**  **and who**  **will do**  **it. What:**  

### 1) **The processing**  **and contact surfaces**  **that determine** 

**°the health,**  **quality, and**  **nutritional value**  **of the**  **finished product**  **,** 

## 2) **Areas and**  **machinery that**  **are important**  **to safety,**  

## 3) **Buildup that**  **affects machinery**  **operation and**  **service f"**  **and** 

### 4) **Walls and**  **other surfaces.** 



### 19**D e pendin**  **g up**  **on the**  **opera t i**  **on ,**  **ite ms**  

## #3 **a nd**  

### #4 **may not** 

**nee d**  **to be**  **cle aned**  **every clean** **up .**  **They do**  **not contr**  **i b ut**  **e to**  **the inco** **me of**  **th e**  **pla nt**  **and are**  **usu all**  **y a dist** **rac tio**  **n , water**  **waste r ,**  **and labor**  **wa ster**  **. Tho**  **u s ands**  **of do**  **l l a**  **rs in**  **pote nt**  **ial r e** **venu e**  **ha ve**  **been lost**  **dur ing**  **good harve**  **st perio**  **ds fro** **m d o** **wnt ime**  **used dur**  **ing p o**  **or ly**  **p l anned**  **cle an** **ups .**  **How :**  

## 2) **Deter mine**  **the best**  **proc edure**  **f o r a**  **spe c i**  **fic j o**  **b,** 

## 2) **Deter mine**  **the t i**  **me nee**  **ded ,**  

## 3) **As s i**  **gn and**  **c o mmun**  **i c ate**  **steps** 

### 1 & 2 **to an**  **in divid** **ua l,**  **and** 

## 4) **Ins pe**  **ct and**  **check-o f f**  **. Who**  **: Spec**  **ific peo**  **p le**  **nee d**  **to be**  **respons ible**  **for the**  **areas or**  **equ i p** **ment associa**  **ted wit**  **h the**  **ir pr**  **o d uct**  **ion work**  **. Except**  **i o ns**  **wou ld**  **be ab**  **i l ity**  **to f i**  **nis h**  **qu ickly**  **and assist**  **in other**  **are a s**  **, uns**  **kille d**  

### with **eq uip** **men t**  

### or **proc edUr**  **e s ,**  **ad phys**  **ical l i**  **mitat i o**  **ns for the**  **def ine**  **d j o**  **b.**



### DEV**ELOP ING**  **A BEST**  **MANAG EMENT**  **PR A**  **CTICES PL** **AN Th**  **is section**  **will cover**  **inf ormat**  **i o n**  **and to** **pics that**  **will f o** **rm the**  **bas is**  **for Best**  **Man agement**  **Pract ices**  **( B MP**  **) pla**  **n s . The**  **goa l**  **here is**  **to descr**  **ibe wh**  **at s p**  **ecific infor** **m atio** 

**n will**  **be needed**  **and how**  **to pres**  **ent it**  **. Th**  **is will**  **hel p**  **you to**  **s a ve**  **t i me**  **and effo**  **rt in**  **de ve**  **l o p i**  **ng a BMP**  **p l an**  **and to d e** **ve l o** **p a BMP**  **p l an**  **that w i**  **ll l e**  **ad to**  **better wa**  **ste and**  **water hand**  **l i ng**  **practi ces**  **. S i**  **nce th**  **is is**  **a p l**  **an t-wide**  **e f fort**  **a cO** **mF,ittee of**  **key p**  **l a nt**  **pers on**  **nel should**  **be in** **vo lved**  **in the**  **d e ve**  **l opment**  **of th**  **e BMP**  **plan .** 

**The key words**  **are manage** **ment ,**  **p l ann**  **ing ,**  **and orga**  **niza tio**  **n . The**  **NPD ES pe**  **rm it**  **w i ll**  **req u i**  **re that**  **eac h**  **fa cil**  **i t y**  **do cument**  **the how**  **, wh**  **at ,**  **and why**  **of any**  **pro cess**  **st reams**  **that are**  **be ing**  **put bac** **k in**  **the en** **viron ment**  **. In**  **add it**  **ion ,**  **th ere**  **wi ll**  **also be**  **the need**  **to ident**  **i�y pot**  **ent ial**  **re duct**  **i o ns**  **in pol**  **lution and**  **pro pose**  **poss ible**  **s o lut**  **i o n s**  **.** 

### How **to Ide**  **nt i f**  **y and**  **Eva luate**  **Pol lutan**  **t Disc**  **harges**

**Th e**  **f i rst**  **ste p**  **is to**  **iden tif**  **y what**  **is be**  **ing disc**  **harged and**  **to rec**  **og nize**  **the effe**  **ct it**  **may have**  **on the**  **env i r**  **on ment**  **. B e**  **low is**  **a l i**  **st of**  **proces s**  **strea ms**  **that c o**  **ntr ib** **ut e**  **to disc** **harges and**  **th eir**  **poten tial**  **envir on** **ment al**  **im pact**  **s.**



## 20**Ground Seafood**  **waste :**  **Par ticle**  **s and**  **pie ces**  **- De**  **p ositio**  **n and**  **bur ial**  **of mar**  **ine l i**  **fe .**  **Red uct**  **ion of**  **dissol ved**  **o x ygen**  **in receivin**  **g water**  **s and**  **s e d**  **iments .**  **I n crea**  **se in**  **turb i d**  **ity and**  **color of**  **the water**  **colu mn**  **. Nutr**  **i e nt**  **enr i**  **chment of**  **rece ivin**  **g water**  **and s e**  **d iments**  **. S o**  **lub les**  **- Redu**  **ct i o**  **n of disso**  **lved ox** **ygen in**  **receivin g**  **wate rs**  **. Incre**  **ase in**  **turb i d**  **ity and**  **colo r**  **of the**  **water c o**  **lu mn**  **. Nutr**  **i e nt**  **enr i**  **chment of**  **rece ivin**  **g water**  **and sed**  **iments .**  **oil and**  **gr ease**  **- Effe**  **cts on**  **the a e**  **sthet ic**  **qua l i**  **ty of**  **s e a**  **sur fa**  **ce I**  **shore l i**  **ne ,**  **water colu** **mn and**  **sea f l**  **oor .**  **Redu ct**  **ion of**  **dissol ved**  **ox ygen**  **in receivin** **g water**  **and s e**  **d iment**  **. I n**  **crease in**  **tu rbid**  **ity and**  **co l o**  **r of**  **the wat**  **er c o**  **lu mn**  **. Nutr**  **i e nt**  **enr i c**  **h ment**  **of receivin**  **g water**  **and sed**  **iments .**  **Oil i n**  **g of**  **s e abirds**  **. Bone**  **and she**  **ll -**  **Dep o s**  **itio n**  **and bur**  **ial of**  **mar ine**  **l i f e**  **. n _**  **...:l � .. _ ",-**  **"; __ -..**  **.(: r=I ';**  **��_' -': T**  **�r:I: ""'V""t**  **TI""C' 'on**  **; '1""\ -v-o,-"o**  **; , T**  **i nrr**  **T�7 :1i**  **+- O ,..... C! .::t**  **nri L'l.c:UU.** **....... �..LU.11**  **V J... U .,.I,.. W .;;:::t V ..L**  **V 1; \.A,.**  **'-'4)..1. "::'J**  **¥� 1.**  **..Io.4.&. .. ...... ......**  **'- ..... V .....**  **4 4 ":J**  **'1''' ''''''' __**  **,",-_ """'**  **.A .A. '\aA.**  **sedi men**  **t s .**  **Increase in**  **turb idit** **y and**  **colo r of**  **th e**  **water colu** **mn .**  **Nu trie**  **nt enr**  **i chme**  **nt of**  **receivin g**  **water and**  **s e d i**  **men t s**  **: He**  **ate d**  **Process Wat**  **er:**

**Cook water -**  **Wide range**  **of soli**  **d par**  **tic les**  **and s o**  **lu ble**  **pro tein**  **depena lng**  **on sp**  **ecie s**  **and pr**  **oces s.**  **De pos**  **it i o**  **n and**  **bur ial**  **of mar**  **ine l i**  **fe .**  **Reduct ion**  **of dissol**  **ved oxyg**  **en in**  **rece ivin** **g waters**  **and sedi**  **men t s**  **. I n**  **crea se in**  **turb idit** **y and**  **colo r**  **of the**  **water colu** **mn .**  **Nu tri**  **e n t**  **enr i**  **ch ment**  **of recei**  **ving water**  **and s e** **d iments**  **. I n**  **crea se**  **in tem** **pe ratu** **r e .**  **Ret ort**  **con densate**  **and water**  **- Mod**  **erate pro**  **tein from**  **can nin**  **g proce**  **s s .**  **Red u**  **ctio n**  **of dissol** **ved oxygen**  **i n**  **receiv ing**  **water s**  **and sedi**  **men t s**  **. Inc**  **rease in**  **tu rbid**  **ity and**  **c o lor**  **of the**  **water colu** **mn .**  **Nutr i e**  **nt enr**  **i ch** **ment of**  **receiv ing**  **water and**  **sedi men**  **t s .**  **F i shm**  **eal stic**  **kw ate**  **r - Very**  **h i gh**  **in pro**  **tein and**  **oil .**  **Reduc t i**  **on of**  **dissol ved**  **ox ygen**  **in rec e**  **iving waters**  **and s e**  **d iments**  **. Inc**  **rease in**  **tu rbidi**  

## t**y and**  **colo r**  **of the**  **water c o**  **lu mn**  **. Nutr**  **i e nt**  **enr i c**  **hm ent**  **of receiv**  **i ng**  **water and**  **sed iment**  **s .'**  **Ot her**  **Proc ess**  **wa.t er** 

**Re frig**  **erated sea**  **water Moderate**  **sea food**  **pie ces**  **and s o**  **lub les**  **. Depos**  **it ion**  **and bu**  **rial of**  **mar ine**  **l i fe**  **.**

**21 Reduct**  **i o n**  **of dissol**  **ved ox**  **ygen in**  **rece iv**  **ing waters and**  **sed imen**  **t s .**  **Br i n**  **e f r**  **eeze r -**  **S o me**  **seafoo d**  **pieces and**  **s o lub**  **les**
**. S a**  **tu rated**  **salt s o**  **lut ion**  **. . Reduct**  **i o n**  **of disso**  **l v ed**  **oxyg en**  **in rece**  **iving wat**  **ers and**  **sed imen**  **ts .**  **Glaze water**  **- Moderate**  **seafo od**  **p i eces**  **. Glaze**  **ad dit**  **ive .**  **Reduct i o**  **n of**  **disso lved**  **oxygen in**  **rece ivin**  **g waters**  **a n d**  **s e d**  **imen t s**  **. Cle**  **an up**  **water -**  **Moderate to**  **h i gh**  **se�food pie**  **ces and**  **so l u**  **bles .**  **Clean ing**  **chem ica**  **ls .**  **D e p**  **o s i t**  **i o n**  **and bu**  **rial of**  **mar ine**  **lif e .**  **Reduct i o**  **n of**  **d i s**  **s o lved**  **ox ygen**  **in recei**  **vin g**  **waters and**  **sedi ments**  **. In**  **cr ease**  **in turb**  **i d ity**  **and co**  **lor of**  **the water**  **colu mn**  **. Nutr**  **ient enr**  **i ch** **ment of**  **rece ivin**  **g water**  **and sed**  **iments .**  **Che m i**  **c al**  **ha z**  **ard .**  **Seaf ood**  **Han d l**  **i n g**  **Water**

**Seafo od**  **hold and**  **pu mp**  **water -**  **Moderate to**  **hig h**  **s e a f**  **ood p i**  **eces and**  **s o lu**  **b l e s**  **. Depo**  **siti on**  **and bur**  **ial of**  **mar ine**  **lif e .**  **Redu ct**  **i o n**  **of dissol**  **ved oxygen**  **in rece**  **ivin g**  **wa ters**  **and sedi**  **me nts**  **. In**  **cr ease in** **· turb**  **id it**  **y and**  **c o lor**  **of the**  **water colu** **mn .**  **Nutr i e**  **nt enr**  **i chment**  **of receiv**  **i n g**  **water and**  **s e d**  **imen t s**  **. Ice**  **and s l**  **ush -**  **Low to**  **mod erate**  **seafo od**  **pieces and**  **s o lubl**  **e s .**  **Reduct io**  **n of**  **waters a�d**  **sed imen**  **t s .**  **rece lvl**  **ng**

**Sea food**  **wa sher**  **- Low**  **to moderate**  **s e afood**  **pie ces**  **and s o**  **lubl e s**  **. Reduct**  **i o n**  **of dissol** **ved oxygen**  **in rece**  **ivin g**  **waters and**  **sedi men**  **t s .**  **The st rea** **ms above**  **are gene**  **ral oper**  **ations that**  **can be**  **a part**  **of mo**  **st s e**  **afoo d**  **pr ocess**  **ing f a**  **c�l itie**  **s and**  **contr ib**  **ut e**  **eff luent**  **. The**  **r ema**  **i n in**  **g pr**  **oces s**  **strea ms**  **for a l**  **mo st**  **all pla**  **nts sho**  **uld only**  **in vo**  **lve fresh**  **water ,**  **salt wat**  **er ,**  **and seafood**  **wa ste**  **that are**  **u n ique**  **for each**  **pro cess**  **and con** **tr ibute**  **to the**  **gro und**  **seaf ood**  **wa ste**  **that is dis**  **charged .**  **Wh at**  **Is a**  **Ma ter**  **ials Acc**  **ount i n**  **g Aud**  **it**

**The init**  **ial mate**  **rials acco**  **unt ing**  **aud it**  **should inc**  **lude a**  **prod uct**  **reco very**  **r a te**  **on wh**  **i c h**  **to base**  **waste d i**  **s c har**  **ge esti** **ma tes**  **and an**  **overa ll**  **wa ter**  **use rate**  **est imate**  **. If**  **other che** **mi cals**  **and waste**  **co m** **pone n** **t s**  **can be**  **esti mated**  **then they**  **/ should**  **be inc**  **l u ded**  **. For**  **mater ials**  **acco unt**  **ing aud**  **its th**  **at are**  **not a c**  **cur ate**  **or req** **u i re**  **more inf**  **o r mat**  **ion on**  **ma j o**  **r proce**  **ss s t** **re ams**  **, a p l**  **an and**  **t i metab**  **le sho**  **uld be**  **inc l**  **u ded**  **on how th**  **is inf**  **o r mat**  **ion wi**  **ll be**  **gotten .** 



## 22

### How **to Ra**  **nk and**  **Pr iori**  **tize Proc**  **ess strea**  **ms As**  **s ign**  **eac h**  **and ever** **y pr**  **ocess strea** **m a ran** **k based**  **on co**  **ntr ib** **ut i o**  **n to**  **overa ll**  **disc harge**  **. If**  **a str**  **eam is**  **too diffic**  **ult to**  **measure or has**  **not been**  **f i ni**  **shed for**  **the mate**  **rials a c**  **count ing**  **aud it**  **then mak**  **e you�**  **best esti** **mat e**  **and ass**  **ig n**  **it a**  **ran k .**  **Why Estab**  **lis h**  **Pre l i**  **min ary**  **Im pr**  **ove ment**  **Goa ls**  **Th is**  **is the**  **ini tial**  **p l an**  **that ex** **p res**  **ses goa**  **ls and**  **im pro**  **vement of disc** **harge eff**  **luent ba**  **s e d**  **on ran** **k of**  **the str**  **ea m**  **and prac**  **tical mo**  **dif ication**  **of eq** **uip men** **t or** 

**. proce**  **du res**  **. Wh**  **at Is**  **Mean t**  **by Met** **hods of**  **Oper at**  **i o n**  **Th is**  **part of**  **the BMP**  **p l an**  **will inc**  **lude oper**  **ations po**  **licies that**  **cover da**  **i l y**  **or per**  **iodic pract**  **ices an**  **d do**  **cu ment**  **ation �o**  **s u pport**  **co ntr**  **ol of**  **eff luent**  **disc har**  **ge s.** 

**Good nQus**  **eke ep.ing**  **·**
**-** 

### Th **is is dir**  **ected at**  **ITta inta**  **inin g**  **an** 

### order **ly work**  **en viron** **ment in**  **rega rd**  **to che** **mic als**  **a n d**  **wa ste**  **that may**  **enter the**  **dis charge**  **strea m .**  **Use an**  **d st**  **orage of**  **che mica**  **l c l**  **eaners an** **d process**  **ad dit**  **ives should**  **be descr**  **ibed**

**. A**  **po lic** **y de**  **scri bin**  **g the**  **amou nt**  **s of**  **chemi ca**  **ls used**  **and the**  **ste ps**  **ta ken**  **to as** **sure the**  **prop er**  **use of**  **che mic**  **als shou**  **ld be**  **inc ludeq**  **. The**  **oth er**  **part of**  **goo d**  **house keep**  **in g**  **is eli**  **minat in**  **g sp**  **ills and**  **as sur**  **ing that**  **waste and**  **process strea** **ms follo** **w the**  **flo w**  **p a ths**  **ou t l**  **ined in the**  **p l an**  **t flo** **w d i**  **agram .**  **Exa m** **ples wou**  **ld be a**  **syste m**  **that ass**  **ur es**  **that a**  **proper numb**  **er of**  **wa ste**  **totes and**  **re mova**  **l t i**  **me are**  **ava i**  **lable ,**  **or per**  **iodic chec** **king of**  **areas where**  **waste flo** **w may bac** **k up**  **. Equ**  **ip ment**  **Ma i n**  **tenance and**  **Re pair**  **- Th**  **is part**  **of the**  **pla n**  **wou ld**  **de mons**  **trate that**  **respons ible**  **prod uct**  **ion and**  **en gineer**  **in g**  **person ne**  **l are**  **awa re**  **of the**  **proper operat**  **ion and**  **ma in**  **tenance of**  **key eq** **uip men** **t use**  **d for con** **vey ing**  **proces s i**  **ng wa**  **stes .**  **Proc ed** **ur es**  **for r e** **pa ir**  **of equ**  **ipme nt**  **and prepared**  **ness wou**  **ld a l**  **so be**  **inc luded**  **. I n**  **spec t**  **i o ns**  **and Records**  **- The**  **se records**  **wi ll**  **be of**  **the spe**  **cific mea**  **su rements**  **or esti**  **ma tes** 

**. that**  **track the**  **perf ormance**  **of di**  **s c harge**  **go als**  **. They**  **wi ll**  **cover set**  **prod uct**  **i o n**  **per iods**  **and de** **mon strate**  **the eff**  **ectiv eness**  **of the**  **BMP p l**  **an for**  **the facil**  **it y .**  **Th ey**  **wi ll**  **also descr**  **i b e**  **an y**  **impr ovements**  **or prob**  **le ms**  **associa ted**  **wit h**  **that pr**  **od uc**  **tion period**  **and any**  **act ion**  **taken .**  **Emp loyee**  **Tra in**  **ing -**  **Much of**  **th is**  **infor mat**  **ion wou**  **ld be**  **inc luded**  **in the**  **j o b**  **descri pt**  **ions and**  **safe ty**  **tra i n**  **ing f o**  **r the**  **maj or**  **ity of**  **the proces**  **s i ng**  **cre w .**  **The spec**  **ifi c**  **i n fo**  **rm ation**  **wa nted**  **here is**  **rel ated**  **to t** **ho se**  **respons ible**  **p e rson**  **ne l**  **that**



## 23**are tra**  **ine d**  **to recog**  **nize and**  **cont rol**  **gene rat**  **i o n**  **of wa**  **ste and** 

**water .**  **Th is**  **inf ormat**  **ion wou**  **ld desc**  **ribe the**  **key strea** **ms of**  **i n te**  **rest ,**  **the peo** **ple £ a** **milia r**  **wit h**  **th e**  **con tro**  **l of**  **tho se**  **s t rea** **m s ,**  **th e**  **methods to**  **con tro**  **l th**  **ose str**  **eams ,**  **and the**  **comm un**  **i c ation**  **of methods**  **and proce**  **dur es**  **to res**  **pons ible**  **person nel**  **. Th**  **is progra** **m shou**  **ld al so**  **a s sure**  **that the**  **se s e**  **lected p**  **eo ple**  **are fami**  **l i ar**  **with both**  **hands on**  **a n d**  **wr itten**  **proce du**  **res .**  **Com pletio**  **n of**  **BMP Pla**  **n**

**Up on**  **com pleti**  **on of**  **the BMP**  **p l an**  **it wi**  **ll be**  **r e vie** **wed** 

### by **the fa**  **cil i t** **y manager**  **and mem bers of**  **the co** **mmit tee**  **. The**  **facili ty**  **manager w i**  **ll s i**  **gn off**  **to ackno** **wl edge**  **that the**  **c o mmittee**  **of key**  **ex p e**  **r i enced**  **p l ant**  **perso nne**  **l an**  **d / or**  **tec h**  **nical peo**  **ple app**  **r ove**  **of the**  **BMP, .**  **Th is**  **ste p**  **is im** **por tant**  **to a s**  **sure th**  **at the**  **BMP pla**  **n is**  **r e ali�**  **tic and wit**  **hin the**  **capa bil**  **ities 6f the**  **peo ple**  **and phys**  **ical l a**  **yout of**  **the pla**  **nt .** 

**Refer to**  **the exa** **m ple**  **in Ap** **pe nd**  **ix D to**  **h e l** 

# p **f o rm**  **an appr**  **oac h**  

### to **mak ina**  **a ma**  **t� r i**  **rl l f':::**  **r1 r- r-n** **l lnt-**  **i n a**  **;:mn i t-** 

**.** 

### r\nn **'RMP**
**�.. ---**  **- - -** **--- J**  **-- ---**  **- ---**  **- ----**  **-- - -**  **- -**  **- - -**  **--- ;;;1**  **- - - -**  **- - --�**  **- - --**  **pla n .**  **Mu ch**  **of the**  **info rmat**  **ion in**  **th is**  **handboo k**  **w i ll**  **be ne** **w to**  **some operato**  **r s .**  **Ho pef**  **u l ly , it**  **wi ll**  **help make**  **the per** **mitt i n**  **g pr**  **ocess eas**  **ier .**  **Mu ch**  **of the**  **infor mat**  **ion and**  **pres en**  **t a t i**  **o n**  **us ed**  **in a**  **mater ials**  **ac co**  **unt in**  **g aud**  **it and**  

### BMP **pla n**  **w i ll**  **be usef**  **ul for**  **other government**  **pr ograms**  **. Fin**  **all y,**  **appr oac** **hin g**  **th is**  **j o b**  **wi th**  **the goal**  **of** 

### h **i g h**  **e r**  **re cover** **y , better**  **qua lit** **y , l o** **wer ov**  **e rh**  **e ad**  **, and**  **incre ased**  **i n**  **co me**  **in the**  **next one**  **to two**  **years w i**  **ll ma** 

### k **e the**  **e f fo**  **rt nlor**  **e wor**  **thw hile** 
**.**



### EN**D-O F-P**  **IPE TREA** **TMENT OPT**  **IO NS**  **Th is**  **s e ct**  **ion addres**  **ses the**  **treat ment**  **options wh**  **i c h**  **are a**  **v** 

### a **i l ab**  **le to**  **r e**  **d u**  **ce the**  **pol lutant**  **loadi n**  **g of**  **yo ur**  **eff luen**  **t . It**  **is s i**  **mp ly**  **an '**  **overv i e** **w of**  **th e**  **pol lutants**  **f o und**  **in seaf**  **o o d**  **pro cesso**  **r disc** **harge s**  **and s o** **me of**  **met hods**  **of** 

# � **rea t**  **ing the**  **se was**  **t es**  **Wh i c** **h Pol**  **lu tant**  **s O c**  **cur in**  **Seafo od Pr**  **ocessor Wa**  **stes**



### BOD **- Bioc** **hemi cal**  **Ox idat**  **i o n**  **Demand .**  **It is**  **the amount**  **of dis**  **s o lved**  **oxygen req** **uired i**  **n the**  **deco m** **positio n**  **of the**  **disc h**  **a r**  **g e d**  **e f**  

### f **l u en**  

### t **s . I**  **n disc**  **ha r**  **ge areas**  **wh ere**  **wa ste**  **i s**  **not we**  **ll** 

### d **i s**  **p e**  **r s e**  **d ,**  **the ox** **yg en**  **in the**  **wa ter**  **may be**  **used up**  **in the**  **deco m** **pos ition**  **of the**  **wa ste**  **strea m**  **and thu**  **s be**  **u n**  **a v** **a i l a**  **bl e**  **to aq** **uat ic**  **l ife**  **. Th**  **is wi**  **ll l e**  **ad to**  **a c cum** **ulatio n**  **of was**  **te and**  **also eli** **minate many**  **of the**  **pla nts**  **and a**  **n i**  **m a l**  **s that**  **r e**  **l y**  **on ox** **ygen .**  **The BOD**  **is th**  **e m a i**  **n in** **dica tor**  **of pol**  **lut ion**  **l e v** **els fro** **m s eafoo**  **d proce**  **s s ing**  **eff luents**  **.**



## 24

### TSS 

### - **T o ta**  **l Suspended**  **Sol ids**  **. Th**  **ese are**  **the par**  **t icles**  **,**

**such as**  **mu scle**  **f i be**  **rs an**  **d bone**  **frag men**  **ts ,**  **that are**  **susp ended**  **as sol**  **ids in**  **th e**  **l i qu**  **id eff**  **luen ts**  **. The**  **se su**  **sp end**  **ed solid**  **s are**  **th e**  **prod uct**  **of me**  **cha nical**  **gr in**  **din g**  **or shear**  **f o rces**  **br e a** **kin g**  **tiss ue**  **in to**  **fine p i**  **eces .**  **oil an** **d Grea**  **se -**  **Alt hou**  **gh th**  **is is**  **us u a**  **l l y a**  **min or**  **cons t i**  **t uen**  **t, its**  **che mical**  **nat ur**  **e make**  **it more**  **troub les**  **ome .**  **oil an**  **d gr**  **ease will**  **em uls**  **ify wit**  **h pro**  **te in**  **( m ak**  **ing s e** **p ara**  **tio n**  **very diffic** **u l t )**  **, cata**  **lyze r e**  **ac ti**  **ons th**  **at ca**  **use odor**  **and f o**  **rmat i o**  **n of**  **un wan** **ted bypr**  **od ucts**  **, an** **d for** **m vis**  **i ble**  **s c um**  **and fo**  **ams .**  **Solu bles**  **- Th**  **ese are**  **the water**  **-so lu** **bl e**  **pr ot**  **e ins**  **that** 

### are **con ta**  **ined in**  **th e**  **c e lls**  **and b l**  **oodstr ea**  **m of**  **the seafood**  **. Th**  **ese prote**  **ins grea**  **tly affe**  **ct th**  **e BOD**  

### s i **nce th**  **ey are**  **the f i**  **rst metab** **olize d**  **by micro-**  **o�gan i s**  **ms and**  **ca use**  **th e**  **greates t**  **dep l e** **tio n**  **of ox** **ygen .**  **TRC -**  **T o ta**  **l Res**  **id ua**  **l Chlo**  **r ine**  **. Th**  **is is th**  **e amount**  **of free**  **ch lor**  **ine in**  **the water**  **. S o**  **urces are**  **fro m**  **ch lorin**  **ato rs**  **fnr nn**  **��hl c**  **hl� � c**  **r � n**  **� � �**  **l� hl�**  **� c r**  **� n �**  **frn m**  **� l o �**  **n � "N**  **- - -**  **r - - -**  **--- ...**  **- - -**  **- _ ...**  **- --.-.**  **- ....**  **- ---**  **I _**  **.... -**  **- - - ... �, -**  **.... -_** **... .. .... .. ... ....,** 

### che**mic als**  **. Ch**  **lori ne**  **is a**  

### very **" r eac** **t i ve**  **" che** **mica l**  

# � **br eak**  **i n g**  

### do**wn mo**  **lec ul**  **es, which**  **is why it**  **is suc** **h an effe**  **ct i v** **e saniti**  **z e r.**  **It is also**  **why TRC is**  **hig h l**  **y tox**  **ic to**  **aq uat**  **ic life**  **. Ho** **w to**  **Measure Eff**  **luen ts** 

**Th is**  

### s e **ct i o**  **n ou**  **tl ines**  **s o me**  **met hods**  **to mea**  **su re**  **s o me**  **of** 

### the **abov e**  **disc harge**  **com pon**  **en ts**  **. The**  **inf or** **ma t i**  **on fro**  **m th**  **ese** 

### me **asu r**  **ements can**  **be co**  **m p a**  **red to**  **an y**  **l a boratory**  **an a l**  **ysis to**  

### co**m pare**  **th eir**  

### a c **cu racy**  **. These**  **mea sure** **men ts**  **can also**  **be used**  

### to **gain** 

### inf **orm at**  **i o n**  **th at**  

### can **used by**  **eng ineers**  **or t**  

### ech **n i** 

### cal **supp ort**  

### peo**ple to**  **make prel**  **iminary esti** **mates for**  

### any **se paration**  **eq uip** **m ent**  **that may**  **be cons**  **idered .**  **wit h**  **pr a**  **ct i c**  **e an** **d goo**  **d** 

### scie **nt i**  **f i c**  **techn ique**  **th ese**  **s i mp**  **le tests**  **c a n**  **ap proac**  **h the**  **ac curac** **y of**  **lab orator** **y tes**  **ts .**  **The prac**  **t ica**  **l use**  

### of **th ese**  **tests** 

### is **to esta**  **bl i s** **h a measured**  **poin t**  **and then**  **co m** **pare future tests to**  

### see **- if**  **th e**  **diffe re**  **nt co**  **m pone**  **nt s**  **are h i**  **gher or**  

### lo**wer than**  **the** 

### pre**vious test**  **. Th**  **is s e**  **ction** 

### may **be of**  **the** 

### most **use to**  **sur imi**  **prod uc**  **ers ,**  **but may**  **also be**  **ap plic** **ab le**  **to oth**  **er processes**  **and seaf**  **ood species**  **. Par**  **ticle S i**  **ze an**  **d Susp**  **en ded**  **Sol ids** 
**- Th**  **is is**  **s i mp**  **ly** 

### tak **i n g a**  **s e t**  

### vo **lu me**  **of wa**  **ste and**  **water ,**  **runn in**  **g it**  **throug h**  

### a **scree n ,**  

### an**d see**  **i n g**  **how much do**  **esn 't**  **go through**  **. st**  **art ing**  

### with **a large**  **me sh**  **an d**  **run nin** **g th**  **e f i**  **ltra te**  **thro ugh**  **su ccess**  **ive ly**  **sma + l**  **er mesh**  **size wi**  **ll g i**  **ve you**  **an idea**  **of the**  **part icle**  **size** 

### d i **st rib** **ut i o** **n. I d**  **eal ly**  **, havin** **g a set**  

### of **diff e r**  **ent** 

### mesh **s i z e**  **s of**  **sta in**  **less st**  **eel** 

### Sc **re ens**  **is** 

### the **be st**  **ap proa**  **ch. Rea**  **l i stic**  **all y,**  **th is**  **typ e**  **of** 

### measure**ment w i**  **ll prob** **ably be**  **do ne**  **wi th**  **wh atever**  **is at**  **h a nd**  **. Some**  **common**

**25 s o**  **ur ces of**  **me sh**  **a�e· exp**  **anded me**  **tal and**  **wire mesh**  **fro m**  **the**

**ma in**  **tenance depar**  **tment ,**  **an yth**  **ing the**  **coo k**  **is w i**  **lli ng**  **to loan**  **, and**  **anyth ing**  **that is**  **aV a i**  **lable fro** **m local**  **supp ly**  **hous es**  **or dry**  **goods stores**  **. ( For**  **exam ple**  **, wo** **men 's**  **ny l o**  **ns or**  **cotton ga**  **uze work**  **we ll**  **f o r**  **re mov**  **ing much**  **of the**  **fin est**  **sol ids**  **.) Th�**  **mesh size**  **w i ll**  **need to**  **be measur**  **ed or**  **esti ma**  **ted for**  **the f i**  **lter i n** **g steps**  **to aid**  **in an** **y pre**  **l i min**  **ary desig** **ns of**  **equ ipment**  **. other**  **info rmat**  **i o n**  **that can**  **be gotten**  **fro m**  **f i lte**  **rin g**  **tr ials**  **are obs**  **ervat ions**  **on dra**  **in t i**  **mes ,**  **clo gg**  **ing of**  **the dif**  **f e ren**  **t screens**  **, and**  **c l eanin** **g req** **uire men**  **t s .** 

**Tota l**  **Re s i**  **d ua**  **l Ch**  **lor ine**  **- I n**  **ex pens**  **ive and**  **s i mp**  **l� test**  **kits are**  **av aila**  **ble f r**  **om che** **mical and**  **scie n**  **tific su** **pp ly**  **hous es**  **to check**  **TRC .** 

**. Sol**  **ub le**  **Pro tein**  **Measu rement**  **- Bo**  **th of**  **the two**  **met hods**  **desc r**  **ibe d**  **be l o**  **w w i**  **ll wor**  **k for**  **m i xtur**  **es of**  **sol u**  **bles and**  **f i ne**  **suspended sol**  **ids if**  **the means to**  **re move**  **all the**  **par ticles**  **are not av**  **aila ble**  **. Th**  **ese mea**  **sure ments**  **are ba**  **s e d**  **on two**  **d** 

# � **�� e** **: e n** **t**

**_ treat** **ment s**  **f o r**  **mak ing**  **s o lu** **ble prote**  **in lose its**  **a r r**  **lnlt y**  **t o r**  **water a n** **d beco** **me insol**  **ub le**  **par ticle**  **s that**  **can be separate**  **d an** **d mea**  **sured .** 

**Heat Den**  **atur at**  **i o n**  **and Free**  **zei Tha** **w S e** **tt l i**  **ng is**  **most ap**  **p l icable**  **to sur**  **i mi**  **waste water**  **s i nce**  **stic kw**  **ater has**  **' alr**  **ead y**  **been c o**  **oked and**  **the sti**  **ckw ater**  **s o lu**  **bles may**  **not all**  **s e para**  **te out**  **. The**  **ite ms**  **ne eded**  **are so me**  **con tain**  **ers and**  **tUb i n**  **g . F i**  **ve gal**  **lon buc** **kets and**  **the l a**  **rge cle**  **ar two**  **l i ter**  **p l ast**  **ic be**  **ve rage**  **bott les**  **work we**  **l l .**  **_ Cut**  **the t o** **ps off**  **the p o**  **p bott**  **les and**  **s a ve**  **th e**  **l i ds**  **for the**  **bu cke**  **t s .**  **Belo w**  **is the**  **s e para**  **t ion**  **and mea sure** **ment proc**  **edu r e**  **.** 

## 1} **Take a**  **s a m** **ple of**  **waste wat**  **er in**  **the f i**  **ve gal**  **lon bu**  **cket or**  **s o me**  **of the**  **pop bot**  **tles .**  **Two to**  **f o ur**  **ga l l**  **o ns**  **is a**  **good sa** **mp le**  **s i z e**  **.** 

### 2) **The next**  **ste p**  **is to**  **heat the**  **was tewa**  **ter to**  **coo k**  **ou t**  **the prot**  **e i n .**  **" T his**  **is very**  **s i mi**  **l a r to**  **poac h**  **ing an**  **eg g .**  **" The**  **goa l**  **is to**  **heat the water**  **70 C.**  **to 80**  **C. as**  **qu i c** **k as**  **possi ble**  **to preven** **t enzy** **me bre**  **akd own**  **of the**  **prote i n**  **.** 

## 3) **After cook**  **i n g**  **put the**  **conta iner**  **(s) of**  **coo ked**  **wa s**  **tewater in**  **the cold**  **storage fre**  **eze r .**  

### 4 **) Th**  **e nex** **t day**  **put the s a**  **mp le**  **containers in**  **a warm**  **p l ace**  **to thaw**  **wh ere**  **they will**  **not be**  **moved or**  **dis t**  **urbed. Wh**  **en the**  **cooked waste** **water thaws**  **all of**  **the prote**  **in wi**  **ll be**  **s e tt**  **l e d**  **out on**  **the botto** **m . Be**  **care ful**  **not to**  **stir it**  **up .** 

**26 ,**  **,**



## 5) **Make ' a**  **mark sho** **wing the**  **de pth**  **of the**  **prote in**  **in the**  **co n**  

### ta **iner .**  **' T his**  **can be**  **used to**  **com pare**  **wit h**  **futur e**  **measu re** **men ts**  **. Now**  **th e**  **c l e a**  **r to** **p l i**  **qu id**  **can be**  **s i phoned**  **off wit** **h the**  **tUb ing**  **. 6)**  **The wat**  **ery protein**  **s l urry**  **th at**  **is lef**  **t can**  **be put**  **in a**  **sm alle**  **r co**  **nta iner**  **(s) and**  **th e**  **freez ing**  **, thaw**  **ing ,**  **and s i**  **ph on**  **steps can**  **be done**  **again to**  **' re** **move more**  **water .**  **The f i**  **nal vo**  **lu m**  

### e **here can**  **be mea**  **sured and**  **com pared**  **wit h**  **the beginn**  **i n g**  **vo lume**  **. It**  **may be**  **pos s i**  **b** 

### le **to do**  **a mo**  **ist ure**  **con tent**  **on th**  **is mate** **rial and**  **then calc**  **ula te**  **the a c**  **tu al**  **prot ein**  **content of**  **the beginnin** **g** 

### wa **ste water**  **. 7)**  **If the**  **prote in**  **is st**  **ill too**  **wet f o**  **r mo**  **i sture**  **me asu** **re ment**  **it shou**  **ld be**  **th i c** **k eno**  **ugh to**  **fil ter**  **out ,**  **wate r '**  **us ing**  **ny lons**  **or even**  **an old**  **tee shir**  **t . Gett**  **in g a**  **f i na**  **l wet**  **we ight**  **and mo**  **i s t**  **ure content wi**  **ll provide**  **the inf**  **or mat**  **i o n**  **f o r**  **ca l c** **ula t**  **ing a**  **wa ste** **water prote**  **in conc**  **entrat ion**  **. The**  **inf ormat**  **i o n**  

### fro**m the**  **abov e**  

### proce **d ur**  

### e 

### can **be ab**  **s o lut**  **e** 

### or **rela ti**  **ve .**  **If a**  **good f i**  **nal measure** **ment can**  **be made**  **thr ou** **gh to**  **step (7)**  **then it**  **shou ld**  **be rela**  **t** 

### ive **to the**  **mark made**  **in** 

### ste**p** 

## (5) **. T** 

### his **wi ll**  **g i ve**  **a good**  **e st**  **imat ion**  **te chn**  **iq ue**  **in th**  **e fut** **ure by**  **doin g**  **j u st**  **the f i**  **rst coo**  **k / fre**  **eze/t haw**  **cyc l �**  **. The**  **othe r**  **a l ternat**  **iv� is**  **to j u**  **st go**  **to st**  **e**

### p 

## (5) **and use**  **the mark**  **esta blis**  **h e** 

### d **th ere**  **to dete** **rm i n** **e if**  **the amount**  **of pro**  **tein is**  **inc reas**  **in g or**  **decre asin** **g . I�,**  **heat ing**  **is done**  **qu i c** **k ly**  **to l i**  **mit enzyme**  **breakdo wn**  **of pr**  **ote in**  

## � **n the**  **cooking ste** **p then**  **th is**  **tec h** **niq ue**  **wi ll**  **extrac t**  

## 90% **to** 

## 95% **of all**  **pr otein**  **in the**  **wa ste** **water .**  **Ac id/**  **Base S e** **pa rat**  **i ons**  **change the**  **pH of**  

### a **wa ste** **water so**  **l u t i**  **on and**  **cause s o**  **lu ble**  **pro tein**  **to s e** **parate out**  **. Th**  **e proce** **du re**  **desc r**  **ibed he**  **re covers**  **on ly**  **an acid**  **method that**  **us es**  **lo w**  **pH .**  **If strong**  **acid is**  **used then**  **proper safe**  **ty gear**  **and tra**  **i n ed**  **peo ple**  **should on**  **ly co**  **nduct th**  **is test**  **. Th**  **is test**  **c�n be**  **done wit**  **h appr**  **oxi ma**  **tely a**  **one ga**  **llo n**  **s a mp**  **le s i**  **ze. The**  **con ta**  **i n ers**  **to use**  **wou ld**  **be the**  **pop bot**  **tles or**  **s o met** **hin g**  **s i mila**  **r . 1)**  **D i str**  **i b ute**  **the wast**  **ewater sa** **m ple**  **to the**  **con ta**  **iners to**  **be use** **d . O**  

### n l**y fill**  

### t**h** 

### e **c o nta**  **iners 1/2**  **to 2/3**  **f u l l**  **.** 

### C l **ear con** **ta iners**  **are the**  **best to**  **use .**  **2) Ad**  **j u st**  **the pH**  

### to 

## 3 **.0 -**  **3 .5.**  **Vi negar**  **co nta**  **inin g**  **5%** 

### ace**tic acid**  **can be**  **use d .**  **It** 

### is **safer ,**  **eas i e**  **r to**  **get ,**  **but takes**  **more to**  **l o wer**  **the pH**  **. As**  **the pH drops**  **the s o**  **lu ble**  **protein will**  **turn wh**  **ite and**  **the mix**  **tur e**  **wi ll**  **loo k**  **mi lk** **y. Let**  **the mixture**  **s i t**  **f o r**  **f i ve**  **or ten**  **min utes**  **.**

**27 3)**  **Get a**  **stic k**  **that is**  **l o ng**  **enou gh**  **to r e**  **a c h**  **the bottom**  **of the**  **con t a**  **iner .**  **Wet the**  **s t i c**  **k wit**  **h water**  **and coat**  **it wit**  **h a thin**  **l a yer**  **of baki** **ng s o**  **d a .**  

### 4) **Put the**  **s t i c**  **k with**  **bak ing**  **s o da**  **in the**  **conta iner**  **all the**  **way to**  **the bot**  **tom ,**  **g i ve**  **it a**  **f e w**  **sw irls**  **, and**  **pu ll**  **it out**  **. The**  **ga s**  **generated fro**  **m the**  **reac tio**  **n w i**  **ll f l**  **oat all**  **the pro**  **tein to**  **the su**  **rface .**  **Don 't**  **breat h**  **th e**  **gas .**  **It may**  **conta in**  **irr ita** **tin g**  **su bstanc**  **e s .**  **5) After**  **a f e**  **w min** **utes the**  **foa m**  **can be**  **s c raped**  **off or**  **the l i**  **qu id**  **can be**  **s i phoned**  **off .**  **P r ime**  **the s i**  **ph on**  **tube by**  **filli ng**  **w i th wa**  **ter ,**  **not by**  **mo uth**  **suc tio**  **n.** 

### 6) **The s e**  **para ted**  **p r o**  **t ein**  **can be**  **measured at**  **th is**  **p o int**  **for a**  **r e**  **lati ve**  **mea sur**  **ement or**  **can be**  **conc entrated**  **further by**  **free ze/t**  **ha w**  **and f i**  **lt er**  **i n g**  **.** 

### D **e termi**  **nin**

### g **th e w**  **e i**  **g ht and**  **mo i**  **sture con** **ten t**  **of th**  **e s e**  **parated pro**  **tein can**  **th en**  **be use**  **d to**  **c a l**  **c u l**  **at e**  **the concen** **trat io**  **n in**  **the ori**  **g i na**  **l was**  **tewa t e**  **r.** 

### T**h** 

### i **s m**  **e t** 

### h **o d**  **s h**  

### ou **l** 

### d **ca use**  **about 95%**  **of the**  **protein to**  **s e parate**  **ou t.**  

### What **Are S o** **me of**  **the En**  **d-o t**  **- P i** **pe Treat** **ment Tec**  **h nolo** **gies**

**This se**  **ction covers**  **equipment and**  **treatment technolo**  **gies that**  **have p**  **o te**  **nt a**  **l u s**  **e fo**  **r r**  **e m**  **o v**  **i ng**  **p r**  **o t**  **ein, oil,**  **and grea**  **se from**  **se� food**  **proce ss**  **ing waste** **water .**  **The d**  **es c**  **ripti o**  **n s**  **will be**  **brief. More**  **deta i l**  **ed inf**  **orm atio**  **n has**  **been published**  **from other**  **st udies**  **th at**  **c a n**  **better des**  **cribe the**  **procedur es**  **and equipment. The**  **re feren**  **ce s**  **fo r**  **th ese**  **st udie**  **s are**  **co ntained**  **in Appendix**  

### c.

**Scree nin** **g - This**  **is a**  **si mple**  **an d**  **ver y**  **effe ct**  **ive way**  **to remove**  **in s o**  **luble meat**  **and protein**  **parti c l**  **es. Th**  **e e** 

### q**u i**  **pme n**  **t and**  **con cept**  **is si**  **mple, but**  **good de**  **sign is**  **di ff**  **icult. Very**  **good flow**  **and particle**  **size da**  **ta are**  **needed to**  **determine an**  **ef fective**  **des ign.** 

**Sedim e**  **ntation -**  **This is**  **colle cting**  **the waste**  **str eam**  **in a**  **tank or**  **pond and**  **letting mate** **ria l**  **se ttl**  **e ou** **t.**

**Centrifug ation**  **- Decanter**  **type centri**  **fu ges**  **are very**  **ef fective**  **at removing**  **particl es**  **.. Models'**  **are available that**  **can s e** **p arate**  **fine su**  **spend ed**  **particles. Centri**  **f u g**  **ati on**  **is al**  **so use**  **d to**  **separate oil and**  **water m**  **i x**  **t ure**  **s.**

**Heating and**  **Centrifu gation**  **- Thi**  **s uses**  **heat to**  **coagulate protein**  **and centri**  **fugation to**  **separate the**  **mixtur e.**  **The protein is**  **very high**  **quality and**  **the water**  **can be**  **recycled and**  **use d**  **in the**  **plant ..**  **Vi s c**  **o sit** **y and**  **flow**



### 28

### chara **cter i s**  **tic s**  **of th**  **e wa**  **ste str**  **eams o f**  **ten req** **uire s o** **me**

**eq u**  **ipmen t**  **mo dific**  **ati on**  **. Dis**  **sol ved**  **Air F l**  **oata tio**  **n - Th**  **is is**  **a com** **mon techn**  **iq ue**  **that is**  **us ed**  **in s o** **me seaf**  **ood pr**  **oc ess**  **ing p l**  **ants an**  **d ot** **her foo**  **d pro**  **c ess**  **in g**  **f a ci**  **l i ties**  **. Th** **e bas**  **ic mode**  **of opera**  **tion is**  **s i m i**  **lar to**  **th e**  **acid s e** **para tio**  **n de**  **scr i b**  **ed earl**  **ier .**  **There are**  **a numb**  **er of**  **var iatio**  **ns th**  **at use**  **di f f**  **e r ent**  **ch e** **mi cals**  **and wa**  **ys to**  **introduce ga**  **s bubbl**  **e s .**  **U l traf**  **i l trat**  **i o n -**  **Th is**  **uses very**  **fine fi**  **lt ers**  **th at**  **can be**  **s i zed**  **down to**  **r e move**  **many of th**  **e s o**  **lu ble**  **prote ins**  **. E l**  **ec t**  **rocoa gu**  **la tio**  **n - Th**  **is uses**  **an ele**  **ct ro-che** **mica l**  **reac t i**  **on to**  **start th**  **e co**  **ag ula**  **tion of**  **prote i n**  **. Ozon**  **at i o**  **n - Th**  **is pr**  **oc ess**  **generate s**  **o z one**  **wh i c**  **h acts**  **as th**  **e pro**  **te in**  **" coag** **ula tin**  **g a g**  **ent .**  **The cla**  **r i fie**  **d water**  **may be**  **r e cy**  **c l e** **d for**  **plan t**  **us e**  **depen din** **g on**  **its ch**  **emica l**  **con te**  **nt.**

**29 APPEND**  **IX A**  

### UN **ITS AND**  **CONV ERS**  **IO NS** 

**COMMON UN**  **ITS** 

### OF **ME ASU** **REMENT AND**  **EQUIV ALENTS** 

**1.0 kil**  **ogra m**  **= 1000**  **gra ms**  **=** 

### 2 . **2046 pounds** 
**1.0 pound**  **= 454**  **gra ms**  **= 0**  

### . **4 5** 

### 4 **ki l o**  **gra m**  **= 16**  **o un**  **c es**  

### 1.0 **ounce =**  **2 8 .3**  **gra ms**  

### 1.0 **metr ic**  **ton =**  **1000 kil**  **ogr ams**  

### 2204 **.6 lbs**  **.** 

### 1.0 **sh ort**  **ton =**  **2000 lbs**  **. =**  **9 0 7.2**  **kil ogra** **ms 1.0**  **l o ng**  **ton**



### 1.0 **meter =**  **100 centimeters**  **= 1 0**  

### 0 **0 mi**  **l l im** **eters =**  **3.2 8**  **feet**
**1.0 foo**  **t �**  **0 . 3048**  **meters =**  **3** 

### 0 **. 48**  **cent im**  **eters**


### 1.0 **inc h**  

### 2.5 **4 centim**  **eters**


### 1.0 **l i ter**  **= 1000**  **mi lli**  **lter s**  

### 1.0 **l i ter**  **1 . 0567**  **quar ts**  

### 1000 **cu bic**  **cent imet**  **ers**



### 1.0 **quart 0.9**  **46 l i**  **ter =**  

### 5 **7 .**  **7** 

### 5 **cu bic**  **i n che**  **s** 

### VOLUME **AND** 

### WE **I GHT**  **OF** 

### FRE **SH WAT**  **ER**
**1.0 cu** **bic centi** **meter** 

### H20 **=** 

### 1.0 **gra m**  

### 1.0 **l i ter**  

### H20 **= 1000**  **gr ams**  **= 1.0**  **ki l o**  **g ram**  **1.0 gal**  **l o n**  

### H20 **= 8**  

### . **34 pounds**  **1.0 qu**  **art** 

### H20 **=** 

### 2.0 **8 pound**  **s 1.0**  **cub ic**  **foot** 

### H20 **=** 

### 6 **2** 

### . **43 pounds** 
**1 . 0**  **short ton**  

### H20 **=** 

### 240 **ga llo**  **ns 1.0**  **l o ng**  **ton** 

### H20 **=** 

### 264 **g a llo** **ns**

### APPEND **IX B**  

### MENSURATION **FORMULAS FOR AREA**  **AN D**  **VOLUME**

**H**



### B **REC TAN** **GLE** 

# f\1

**I** 

# .l **I \** **__ �.lL-**  **_ B**  

### TRIANGLE **AREA BAS**  **E X**  

### HE **I GHT** 

**AREA =**  

### 1/2 **X** 

### H **X** 

### B .



## "IT **=** 

### 3 . **14159**

**AREA** 

## = **3 . 1 4**  **159 X**  

### R **X** 

### R

**CIR CLE**  

# L **71 AREA**  **"= B**  **X** 

### H

**B**
**PARALLELOGRAM**

**A**



### B

**TRAPE ZOID**  

# t 

# 1 **AREA =**  

### 1/2 **x** 

### H **x** 

## ( **A +** 

### B )**VOLUME L** 

**w** 

### RECTANGU**LAR** 

### SOLI **D**

**VO LUME**  **H H** 

**A** 

### CY**LI�DE R** 

**VOLUME 1/3**  **H**



### PY**RAMI D**  **OR C** 

### ON**E**

**PY R.A.M:ID**  **CAN HAVE**  **ANY NUM**  **B E R**  **OF SID**  **E S _**  **THE LEN** **GTH S OF THE**  **BOTTOM EDGE**  **9F EACH**  **SID E**  **MUST B**  **E EQUAL**  **_**

**AREA 1**  **w . :x**  **H**



### VOLUME **=** 

## 1/3 **X** 

### H **X** 

## ( **Al + A2 +** 

**AREA :2** 


### SEC**TIO N OF**  **PYRAMI D**  **OR CONE**  

# .J **Al X**  

## A2 )**H**



# t

**CIR CLE**  **SE CTIO**  **N**

**TABLE OF**  **RAT IOS**  **FOR CALCULAT**  **IN G**  **CI RCLE**  **SECTIO N**  **AREA RAT** **IO OF**  

## H/R
**0 . 008555**  **0 . 015**  **192 0 .**  **023704 0 .**  **034074 0 .**  **046283 0 .**  **060 307**  **0 . 0 7**  **6121 0 .**  **093 692**  **0 . 112**  **989 0 .**  **133 975**  **0 . 156**  **609 0 .**  **180848 0 .**  **206647 0 .**  **233956 0 .**  **2 6 2723**  **0 . 292893**  **0 . 324410**  **0 . 3 5**  **7212 0 .**  **391239 0 .**  **426424 0 .**  **4 6 2700**  **0 . 5 0**  **0000 0.5**  **38251 0.5**  **77382 0 .**  **617 317**  **0 . 657**  **980 0 .**  **699294 0.7**  **4118 1**  **0 . 7 8**  **3560 0 .**  **826352 0 .**  **869474 0 .**  **91284 4**  **0 . 9 5**  **6381 1 .**  **000000 RAT**  **IO OF**  

## AREAfRAD **IUS SQUARED** 
**0 . 0014901**  **0 . 003**  **5229 0 .**  **006 8570**  **0 . 0117993**  **0 . 0186444**  **0 . 0 2**  **76720 0 .**  **0391 456**  **0 . 053**  **3 100**  **0 . 0703895**  **0 . 0905860**  **0 . 1140780**  **0 . 1410188**  **0 . 1715355**  **0 . 2057277**  **0 . 243**  **6676 0 .**  **2853982 0 .**  **3 3 09339**  **0 . 3802606**  **0 . 4333**  **348 0 .**  **4900846 0 .**  **5 5 04103**  **0 . 614184**  **7 0 .**  **6812546 0 .**  **7514417 0 .**  **82454 37**  **0 . 9003667**  **0 . 9785754**  **1 . 0589969**  **1 . 1 4**  **13210 1 .**  **2252 533**  **1 . 3 1**  **04871 1 .**  **3967057 1 .**  **4835852 1 .**  **5 7 07963** 

### AP**PE ND**  **IX ·C**  **TEC HNI**  **CAL REFERE** **NCES**



### 197 **1 Ut**  **iliz a**  **t i 6n**  

### and **Dis po**  **sal of**  **Crab and**  **Shr im** **p Wa**  **s t e s**  **. Un**  **ive r s**  **i t y**  **of Alas**  **ka Mar**  **ine Ad** **viso ry**  **Bulletin** 

### No **. 2,**  **Fa ir**  **ban k s**  **, Alas**  **ka .**  

### 1979 **Re a s**  **sess men** **t** 

### of **Eff luen**  **t L i** **mit at**  **io ns**  **Gu ide**  **l i nes**  **and New**  **S o urce**  **Perf orman**  **ce Stan** **dard s**  **for the**  **Canned and**  **Pre ser** **ved Seaf**  **ood Proc**  **ess i n** **g Po**  **int S o** **ur ce**  **Cat egor** **y . Prep**  **ared for**  **the U .**  **S. En** **viron me**  **nta l**  **Protect ion**  **Agency by**  

### Edwa **rd C.**  **Jordan Co**  **. , Inc**  **. of**  

### Portl **and ,**  **Ma ine**  **.** 

### 1992 **Ways to**  **Redu ce**  **, Reu**  **s e ,**  **and Re**  **cyc le**  **Soli d**  **Wa ste**  **Generated by**  **S o u t** **hwe st**  **Alas ka**  **1s Fish**  **Pro cess**  **in g**  **Ind ustr** **y . S o** **uthwe st**  **Alas ka**  **Mu nici** **pa l**  **Confe rence**  **,** 

### 33� **0 Ar**  **ct ic**  **B l v** **d . ,**  **suite** 

### 2 0 **3, Anc** **hor age**  **, Ala**  **ska ,**  

### 99503 **. Tele** **phone** 

### ( 9 **0 7 )**  **562- 7 3**  **8 0 .**  **1993 Re**  **cov eries**  **and Yiel**  **ds fro** **m Pac**  **ific Fis** **h and**  **Sh ellfi**  **sh .**  **Chuck Crapo**  **, Brian**  **Paust ,**  **and Jerry Babbit**  **t ,** 

### Alas **ka Sea**  **Gran t**  **Co lle**  **ge Pr**  **ogra m ,**  **Un iver**  **s i ty**  **of Alas**  **ka ,**  **Fa i r** **ban ks**  **, Ala**  **ska ,**  

### 9 9 **775-5 0 4**  **0 . Te**  **l ephon**  **e** 

### (90 **7) 47**  **4 -67**  **0 7 i**  **FAX** 

### ( 9 **07) 474**  **-62 8 5**  **. 1993**  **Po l**  **lut io**  **n Pr**  **event ion**  **Op portun**  **ities in**  **the Fis**  **h Proce**  **s s in**  **g I n** **dust ry**  **. Pa**  **cific Nort** **hwe st**  **Po l**  **lut i o**  **n Prevent**  **ion Research**  **Cen ter**  **,** 

### 1 3 **26 Fi**  **fth Av** **en ue**  **, suite**  

### 650 **, S e**  **at t l**  **e , Wash**  **i n gton**  **,** 

### 981 **0 1 .**  **Tele phone**  

### (20 **6) 223-**  **l151 i**  **FAX** 

### ( 2 **0 6 )**  **223 -1165**  **. 1993**  **Wa ste** **water Han** **d l in** **g Prac**  **tices in**  **Sele ct**  **ed Fis** **h Pr**  **ocess in** **g P l**  **ants in**  **Northern Eu**  **ro pe**  **. Rep**  **ort to**  **the Fi**  **sher ies**  **Counc il**  **of British**  **Co l u** **mb i a**  **. Prepared**  **by NovaTec**  **Consultan ts**  **, I n**  **c . ,**  

### 224 **West Eig** **hth Aven** **u e ,**  **Vancouver ,**  **Britis h**  **Colu m** **bia ,**  

### V5 **Y 1 N5**  **. 1994**  **Proc eed**  **in gs**  **of the**  **Wa ste** **water Tech** **no l**  **ogy Confere**  **nce an** **d Ex** **h i bit**  **i o n .**  **Fisheries Co**  **unc il**  **of Br**  **itis h**  **Co lum** **bia ,**  

### 1188 **We st**  **Geor gia**  **street ,**  **Suite** 

### 14 **0 0 ,**  **Van co** **uver I**  

### British **Co lu** **m bia**  **,. V6E4A**  **2 . Tele** **ph one**  

### (60 **4) 6 8**  **6-64 5 4**  **; FAX**  

### ( 6 **0 4 )**  **684 -5109**  **. 1994**  **How to**  **Do a Seafoo**  **d Proces**  **s in** **g Pla**  **nt Wat**  **e r ,**  **Wa ste**  **, and**  **was tew** **ater Au** **dit .**  **Prepared by**  **Alan I s** **mond ,**  **Aqu a �** **Terra Consultan** **t s ,**  **Vanc ouver**  **, Br**  **itis h**  **Co lu** **m bia**  **for the**  **Province of**  **Brit i s** **h Co**  **lu m** **bia ,**  **Min ist** **ry of**  **Agr icult** **u re**  **, Fis** **heries and**  **Food ( A** **ttn :**  **John Wi**  **l low**  **, I n** **du stry**  **De ve**  **l opment**  **Office r )**  **,** 

### 808 **Doug las**  **street ,**  **Vi ctor**  **i a ,**  **Bri tis** **h Co**  **lu m** **bia ,**  

### V6A **2 Z 7 .**  **Tele phone**  

### ( 6 **0 4 )**  **3 5 6-2**  **167 ;**  **FAX** 

### (60 **4) 953**  **-5162 .** **"** 

### AP **PE ND**  **IX D** 

**EX AMP** **LE**
**OF BEST**  **MANAG EMENT**  **PRA CTIC**  **ES PLAN** **BEST MANAGEMENT**  **PRACT I**  **CES PLAN** 
**FOR ROCKY**  **COVE F**  **I SH**  **PR OCESSORS**  **, INC**  **.**

**SUB MIT** **TED TO**  **: UN**  **IT ED**  **ST AT**  **ES ENVI**  **RONMENTAL PR** **OTEC TIO**  **N AG**  **ENCY REGIO** **N X**

### TABLE **OF CONTENTS**  **PAGE**

**Ta ble**  **of** 

### c **on t**  

### en **t** 

### s **...... . .**  **........ ....**  **..... .......**  **1 s**  **i g** **n atur**  

### e **and Rev**  **i e w**  **P l ate**  **...... ...••..**  **..•. ...•**  **..** 

### 2 **BMP Cornrni** **tte Membe**  **rs .........**  **.... . .**  **..•. ...•**  **· • .••..**  

### 3 **Descrip tio**  **n of th**  **e Fa**  **cil ity**  **........ ...•.**  **. . .......**  

### 4 **Map** 

### of **Fa cil**  **ity and**  **Location** 

### ....**� .•••**  **•.. • •**  **•.•••..** 

### 5 **Proc ess**  **Flow Di**  **agram .•.••....•..**  **•.. .••**  **••• ...•.**  **•..** 

### 6 **Waste Disc**  **har ge**  **I d en**  **tific at**  **ion ..•..**  **.••.. . •**  **•.. G**  **•••** 

### 7 **Ma ss**  **Bal ance**  **Aud i t** 
**.... ..........**  **. . ...............**  

### 7 **P r** 

### o**ces** 

### s **Stre am**  **Risk . .**  **. . • • • .**  **. . • . . • . • • • . • • • • . • . • • •.**  

### 8 **Improveme nt**  **Goa l s**  **... ...**  **.......... .....**  **. . ...**  **.......** 

### 8 **Good Hous**  **e Ke** **eping Po**  **lic y**  **....•.... •••.•**  **•••..•••..** 

### 8 **Equip m** **e nt**  **Ma in** **tenance and**  

### R**e** 

### p**a ir**  **.•• .••**  **•••• ..•••..**  

### 8 **Ins pe**  **c tion**  **s and**  **Records •**  **. .**  **. .**  **• .**  **. . .**  **• • .**  **•••• .**  **. •••.•**  **. •**  

### 9 **Emp loyee**  **Tra inin** **g .•**  **, ....•••...•.** **0 • • • • • • • • • • • • • • • ••**  

### 9 **Spi ll**  **Prepare d** **nes s**  **......•.. .•••...**  **•••.. • •**  **•..•••..** 

### 10 **Sec ur**  

### i**ty . . . . • . . . . . . . . . . • . . . • • • . • •**  **. . . • • • •**  **. . •**  **. .**  **•••.** 

### 10

### The. **en clo** **s e d**  **Best Man** **agement Pract**  **ices Pla**  **n has**  **bee n** 

**revi ewe** **d and accepted**  **as r**  

### e **a son** 

### a**bl e**  

### by 

### co**mmi ttee**  **mem bers**  **of Rocky**  **Cove Fis**  **h Pro** **cesso rs**  **.**



### Da**te**

**____ ____**  **____ __** 



### Pl **ant Man**  **ager**

### BMF **COMMITTEE** 

### MEMBERS

**The fol**  **l o win**  **g peop**  **l e**  **have prov**  **i d ed**  **i n p**  **ut to**  **the** 

### BMP **p l an**  **for** 

### Rocky **Co ve**  **Fis h**  **Pro cess**  **ors and**  **agre e**  **that the**  **goa ls**  

### an**d conten** **t are**  **reas ona** **ble for**  **operat i o**  **n at th**  **is t i**  **me .** 

**NAME PO**  **SIT ION**  **EXPERI ENCE**  

### Factor**y Manag**  **er** 

### 7 **yr s .**  **Chi ef**  **Mechan ic**  

## 3 . **5 yrs**  **. F**  **o r**  **e m** **a**

### n 

## 3 . **0 yrs**  **. Foreman**  

## 2.5 **yrs .**  **Master Fi**  **sher man**  

### 2 1 **.0 yrs**  **.**

### DESCRIP**TIO N**  **OF THE FAC**  **ILI TY**  **�ock y**  **Co ve**  **Fish Pro**  **cessors is**  **loca ted**  **on the**  **S o ut** **hea st**  **s h ore**  **of Ro**  **ck y**  **Cove .**  **Ro cky**  **Cove , i**  **s a sm**  **all inle**  **t that**  **empt ies**  **dir e c**  **tly i n** **to Snively**  **Chann el**  **one m i**  **le from**  **the tow** **n of**  **Red bank**  **. T he**  **proces s i**  **ng p l**  **ant was**  **bui lt**  **in** 

### 1948 **and has**  **o p erated**  **ever y**  **year on**  **a seasonal**  **ba sis** 
**. The**  **f a cil**  **i t y**  **c o n**  **sis ts**  **of the**  **main proc**  **ess i n**  **g p l**  

### a**n**

### t, **a r**  

### ef **r i**  

### ge **r** 

### at **ion p l**  **ant and**  **ice room**  **,** 

### cold **sto r**  

### ag **e, storage**  **warehou s e**  **, phys**  **ical** 

### pl **ant and**  **erigineerin g ,**  **offi ces**  **, and**  **a l a** **rge doc** **k that**  **can** 

### ac**co mod**  **ate t** **hr** 

### ee **f i**  

### s **hin**

### g **v es**  

### se **l** 

### s **. F**  **or** 

### the **pas t**  

### eig**ht years**  **the main**  **p**

### r **o**

### du **c** 

### ts **ha ve**  

### been **fresh and fro**  **zen fis**  **h and**  **f i**  

### s **h** 

### fille**ts .**  **De p**  

### e **n**

### d **i n**

### g **on** 

### a**v**

### a **ila bi**  

### l **ity** 

### of **fish and**  **m**

### a **r**

### ket **demand pro** **duc ts**  **r** 

### ange **fro m**  **cuts of** 

### indivi **dua l**  **se rvi**  **ngs to**  **who le**  **fr oze**  **n fish**  **. Over**  **60% of**  

### all **fis h**  **pro cesse** **d is**  **usual ly**  **sal mon**  **. T h**  

### is **ta k** **e** 

### s **p** 

### la **c** 

### e **over a**  **t**

### w**o** 

### and **a ha**  **lf month**  **period wit** **h** 

### o

### ne **mo**

### nt**h b**

### e **in**

### g **the p** 

### e a**k o f**  **the** 

### sea **so**

### n. **Dur in** **g the r**  

### est **of** 

### the **year t**  **h**

### e **r**

### e **is s**  **o**

### m

### e **s t e**  **a**

### dy **and peri**  **o**

### dic **p r** 

### o **c** 

### e **s** 

### si**ng of**  **other** 

### f i **nfish and**  **f l atfish**  **depend ing**  **on fi**  **shing and**  **weather .**  **Th is**  **work is done**  **by em** **ployees that**  **l i ve**  **in th** 

### e **town of**  **Re� hank**  **. Th** **e fish**  **waste fr** **o m**  

### the **Rocky Cove**  **pla nt**  **cons is**  **ts of**  

### heads **, guts**  **, fra** **m es**  **, trimmi**  **ngs , and**  **unus ab** **le fis**  **h . Al**  **l t** **h** 

### is **waste is**  **fl u** **med or**  **conveyed to**  **a gr**  **inder and**  **pump .**  

### The **ground fis**  **h wa**  **ste is**  **p um** 

### ped **through 'a**  

### 400 **f o** 

### ot **pipe out**  **to Sniv** **e ly**  **Channe l wh** **ere the**  **dis char** **ge is**  **l oc**  

### ated **at the**  **ten fat** **hom m** 

### a**rk .** 

### OF**FI CES**  **W 0...**  **a:: w**  **l!> Ii::**  **« :r:**  **u (J)**  **o** 

# n **,.----h**



### I**Z ::::s::::**  **IA REHOUSE**  

# I **j ><** 

**: UTILIT** **I ES** 

# yS
**C O**  **Wl**

# \ **. STO**  **RAG E**  **I** 

### SNIV **E L Y**  **C H AN**  **N EL** 



# W **I** 

# S�

# \**\**

**N** 

# )

**ROC KY**  **C O VE** 

**U N O F**  **FI C I**  **AL LO**  **CA TI**  **ON MAP**  **FO R**  **ROCK Y**  **C O VE**  **PRO C E**  **SSORS OFF** **ICES w** **D c;:**  **w C>**  

### � **:z: u**  **!!! o**  **SNIVEL Y**  **C H AN**  **NEL**



# D **,------t,**



# ROC **KY C O**  **VE**

**UNO -FFI**  **CIAL LO**  **CATI ON**  **MAP FO**  **R ROCK**  **Y C O**  **VE P R**  **OCE SS**  **O R S** 

### FISH **, ICE**  **;0;.** 

### AN **D WAT**  **ER** 

# t

**co SC**  **A SO**  **RSE EEN**  **W RT**  

# 1 **�**

**WAT ER**  **AN D**  **ICE** 

### FLOW **D I AGRAM**  **FOR ROCKY**  **C O VE**  **PROC[ SSORS** 

**SAL T**  **WAT E** 

**�R** 

### FRESH **WA TER**  

# J

**HOL DING**  **� TAN**  **K** 

# l----,l 

# [DRAIN **'**

**BEL T**  

# -+ **--�r**



# CL� **�. �!**  **�G**

# I�**I**
**FREEZER**

# I
**�**

# I

**G L AZ**  **I**

**N G --""** **;::::- ....**  **PROD U**  **CT PORTI**  **ONING**



### WAT **ER fiSH**  **PIEC ES**  **BLOOD &:**  **SLIME**

# I **I I** 

**=- TO**  **F R ESH** 



### WAT **ER Kem!l.**  **C U TS.**  **fRAM ES,**  **TRIMMIN CS.**  

# + 

# 1 **-** 

### MAR **I< ET** 

**UNUS ABI.E**  **FISH**



# �I **BL OOD**  **&. SLIME** 

**.< __________________**  **U SED**  **G L AZ**  **E FI**  **SH. P I**  **ECES**
**BLOOD AND**  **SL lt.4E**  **-------:=:>""" ALL**  **WASTE TO**  **GRIND AND**  **DISCHARGE ,�**  **J J '11** 

**strea ms**  **. Al**  **l** 

### th **e** 

### s t **re ams**  **are acce**  **s s ible**  **.** 

### If **this does**  **not**

**g ive**  **good result**  **s the**  **inst alla**  **tio n**  **of a**  **f l ow**  **me ter**  **on the**  **sal t**  **w a** **t e r**  

### l i **ne wi**  **ll be**  **in ve**  **sti gated**  **. RI**  **SK OF**  

### PR**OCES S**  **STREAMS**

**Alm ost**  **a l l**  **of** 

### t**h e**  **fis h**  **wa ste**  **is** 

### from 

### the **area wh**  **ere the**  **fis h**  **are cut**  **and c l**  **e a ned**  **. Mo**  **st of**  **t h**  **e** 

### rema **ini ng**  **waste is**  **fro m**  **t**

### he **c** 

### o

### ur **s** 

### e s **c** 

### r **e** 

### en **i** 

### n**g step**  **.** 

### An**ything else**  **wo uld**  **be** 

### in **the dr**  **ain water**  **from t**  **he ho**  **ldin g**  **tan k .**  

### It **is esti** **mated that**  **the se**  **stre ams**  **accou nt**  **for 96%**  **,** 

### 3 % **, and**  **1% of**  **th** 

### e **f** 

### ish **was t** 

### e. **IM PROV** **EMENT GO** **ALS**


### In **o r der to**  **in crease**  **reco very**  **and r**  **ed u** 

### ce **waste the**  **nu mb** **er of**  **sa m** **ple we**  **ighings on**  **fis h**  **b** 

### e **i** 

### ng **pr ocesse**  **d wi**  **ll be**  **in cr** **eas ed**  **. T he**  **g oal**  **is to**  **try to**  **achi eve**  **and main** **ta in**  **a hi**  **ghe r**  **reco very rate**  **. GOOD**  **HOUS E**  **KEEP IN** **G POL**  **ICY** 

### Che**micals and**  **too ls**  **used for**  

### clefu **ling are**  **kept in**  **a se**  **parate st**  **orage area**  **away fr** **om** 

### the **proces s i**  **ng flo** **or .**  **Fore men**  **and sel**  **ected peop le**  **are tra**  **ined in**  **handl in** **g , us**  **e , and**  **proper di**  **lution of**  **chemi cals**  **during clea**  **nin g .**  **- T hey**  **are the**  **only ones**  **author i z**  **ed to**  **d o**  

### t**h** 

### is **. To ke**  **ep bui**  **ld up**  **of waste**  **on the**  **f l oors**  **and gratin** **g to a mini�**  **u.."U. th ere**  **is one**  **person from**  

### ea **ch pr** **o ·c**  **ess ing**  **area t** **hat is**  **ass igned**  **to regul arly**  **clea n**  **and assu** **re that**  **waste strea** **ms are**  **flo wing**  **. Al**  **l used**  **ice is**  **run thro** **u**

### gh **the sc** **reen i n** **g step**  **so it**  **is pa rt**  **of the**  **ov eral**  **l wa** **ste strea** **m . If**  **th is**  **is not**  **po ssi** **ble it**  **is set**  **as ide**  **in tote**  **box es**  **unti l**  **it can**  **be di**  **sp osed**  **of .**  **EQUIP MENT**  **MAIN T**  **EN ANCE**  **AND REPAIR**  

### All **fis h**  **and waste**  **are moved**  **by con** **veyo r**  **belts ,**  **water troughs**  **and flu** **mes ,**  **or** 

### by 

### hand **. Worn**  **or j a** **mmed con** **veyor be**  **lts are**  **usu all**  **y re**  **pa ir** **ed by**  **the shi**  **ft mechan**  **ic in**  **ten to**  **twe nty**  **mi nut** **es .**  **Repl ac**  **eme nt**  

### may **take up**  **to one**  **hou r**  **depen din** **g on the amount**  **of da** **m age**  **. Th**  **ese are**  **the only**  **me chan**  **ical de** **vices in**  **the pr** **oc ess**  **l i ne**  **that can**  **fa il**  **and cause**  **a backup**  **. Th is**  **is a**  **com mon**  **enough occu** **rance that**  **the** 

### pa**rts and**  **proc edur** **es for**  **repa ir**  **are we**  **ll known**  **.** 

### In the **event that**  **the main**  **grinder and**  **disc ha** **rge pump**  **ne eds**  **repair or**  **s e rvi**  **ce the**  

### follo**wing provi**  **s i on** **s have**  **be en**  **made .** 

**- Spare**  **parts and**  **a motor**  **are locat** **ed ne**  **arby in**  **a s**  

### t

### or**a**

### ge **loc ker**  **. .** 



### - **Lift poin**  **ts and**  **ho i s** **ts are**  **s e t**  **up to**  **remove the**  **en tire**  **mo tor**  **, gr**  **ind er**  **, and**  **pump .** **- To unc**  **log the**  **p u** **m p**  **r eq** **u i r**  **es approx**  **ima te**  **ly one**  **h o ur**  **.**

**- To replace**  **the grinder**  **and pump**  **impe l l**  **er req** **uires two**  **to th**  **ree hour**  **s .**

**- Rep**  **lac i n** **g the**  **en tire**  **un it**  **wo uld**  **req uire**  **f o ur**  **to f i**  **ve hours**  **.** 

### INSPECTIONS **AND RECORD**  **S A**  **ne w**  **dai ly**  **prod uct**  **ion report**  **is b e**  **ing dr**  **awn up**  **that wi**  **ll inclu** **de the**  **fol l o** **wing infor** **ma tion**  **. .** 

**- Wei**  **ght of**  **f i sh**  **proc essed**  **, we**  **i g ht**  **of prod** **uct ,**  **amou nt**  **of f i**  **sh waste**  **, and**  **re co** **ver y**  **rate .** 

**- Wa**  **te r**  **use based** 

**. on**  **me asu** **rements or**  **best esti**  **m a** **t e**  **. - Any**  **clea nups**  **and amount**  **of chemi**  **ca ls**  **used .** 

**- Mechani**  **cal fai**  **lures ,**  **repa irs**  **, and**  **mo dif**  **icatio ns**  **. The**  **esti mated**  **e f**  **fe c** **t on**  **pla nt**  **�ffici enc** **y and**  **waste strea** **ms .**  **EMPLO YEE**  **TRAI NING** 

**The are**  

### resp**ons ible**  **for overs**  **e e 1ng**  **training sel**  **ected pro**  **cess i n**  **g per** **s o nn**  **el in**  **the proper**  **ope ration**  **and go**  **als set**  **for di**  **f f er**  **en t**  **proce ss**  **f l ow st** **re ams**  **. Th**  **e contr**  **ol po**  **in ts**  **and pro**  **ced u** **res ar**  **e covered**  **belo w.** 

**SC REEN**  

### AND **S** 

### O**RT -**  **Salt wa** **ter spray**  **sho uld**  **be s e** **t to**  **a l e** **ve l**  **to c l**  **e a n the**  **f i sh**  **be ing**  **run .**  **Red uc**  **e the**  **flo w**  **rate if**  **there is**  **over sp** **ray or**  **wa ste**  **th at**  **is not**  **entering the**  **cat ch**  **pan .**  **The water sho** **uld be**  **s h ut**  **off wh** **en no**  **f i sh are**  **be ing**  **wa s h**  **ed and**  **sor te** **d . If**  **used ice**  **is be**  **ing discar** **ded en** **ough w** **ater flo** **w mus**  **t be**  **provided to**  **prevent bloc** **kage of**  **the was**  **te flum** **e . Large**  **unus ab** **le fis h**  **may need**  **to be**  **cut up**  **be fore**  **en terin**  **g the waste**  **f l ume**  **to preven** **t bl**  **ockage .** 



### HOLD **ING TANK**  **- The**  **ra tio**  **of wate**  **r or**  **s l ush**  **to fis**  **h should**  **be about**  **one to**  **one .**  

## A **hig h**  **l e ve**  **l mark**  **one foot be**  **l o w**  **the top**  **of the**  **t a nk**  **is not**  **to be**  **exceeded .**  **Th is**  **hig h**  **le v** **el mark**  **wou ld**  **indi cate**  **a vo**  **lu me**  **of abou** **t twe**  **nty tons**  **of fis**  **h and**  **water .** 



### DRAIN **BELT -**  **The spray**  **here sh** **ou ld**  **be adj**  **usted to**  **rin se**  **the fis**  **h cle** **an and**  **also keep**  **the be**  **lt clea** **n . If**  **the be**  **lt becomes**  **c l og** **ged an** **d dir** **ty th**  **e spra** **y may**  **need to**  **be tu** **rn ed**  

### up **or the**  **be lt**  **st opped**  **and hand**  **clea ned**  **. A clea** **n be**  **lt is**  **needed to**  **ke ep**  **waste fr** **om be**  **ing carr**  **i e d**  **to other**  **proc ess**  **i n g**  **steps or**  **outs i d**  **e the** 

## 4ra **in syste** **m at th**  **is step**  **.**

**FIS H**  **CLEAN IN** **G,** 

### AND **POR TI**  **ONING -**  **Th ere**  **are a**  **numbe r**  **of di**  **f f er** **ent stat**  **i o ns**  **and in** **divid ua**  **ls that**  **han d l**  **e cutt**  **ing ,**  **cle an**  **i n g ,**  **and trimming**  **ta sks**  **. Al**  **l em** **p l oye**  **es have**  **be en**  **s h own**  **the wa**  **ter shuto**  **ffs for**  **the hos**  **es supp**  **lyi ng**  **the ir**  **s t at**  **ion and**  **have be**  **en ins**  **tr ucted**  **to sh** **ut off**  **any water**  **that is**  **not bein** **g us**  **ed in**  **the pro**  **ce ssin** **g steps**  **or wh**  **en there**  

### is **a brea** **k or**  **st oppage**  **. As**  **ou t l**  **ined in**  **the goo** **d hous**  **ekeep ing**  **sec tion**  **a person**  **h as**  **be en**  **assig ned**  **the duty**  **of reg** **ula rly**  **pO l i**  **ci ng**  **th is** 

**area to**  **clea nup**  **sm all**  **s p ills**  **and bui**  **l d up**  **, and**  **make s u** **re wa**  **s t e**  **is f l**  **o win** **g in proper**  **channe l s** 
**. Th**  **is person**  **also mo**  **n i tors**  **the use**  **of water**  **. S P**  **ILL PRE**  **PAR EDNESS** 

**Dur i n** **g ve**  **ry hea** **vy f**  **i s**  **h i n** **g periods**  **there is**  **too mu**  **ch i c**  **e to**  **d i spos**  **e o f**  **. Thi**  **s ice**  **wi ll**  **be d i**  **�po s**  **ed of**  **by dump**  **ing off**  **the West**  **end of**  **the d** **o c** **k on**  **outgo in** **g tides**  **. The**  **amount of**  **dump ed**  **ice wi**  **ll be**  **recor ded**  **. In**  **the event**  **that the**  **main gr**  **inder and**  **dis charge**  **pump is**  **down ,**  **was te**  **wi ll**  **be dump**  **ed down**  **the old**  **flum e**  **that em** **p ties**  **di rectly**  **into Rock** **y Cove**  **. Past**  **expe r i**  **ence h** **as shown**  **that th**  **is can**  **be done**  **for up**  **to twe**  **lve hours**  **w i**  **th no**  **v i**  **s i**  **b l**  **e ma**  **teria l**  **dep osit**  **ed or**  **left onsh**  **ore after**  **one da**  **ily cyc**  **le of**  **tides .**  **The amo**  **unt of**  **wast e**  **diverted wi**  **ll be**  **recor ded**  **alo ng**  **wit h**  **notes on**  **any effe**  **ct on**  **beaches and**  **w i**  **l d**  **l i**  **f e**  **. SEC**  **URITY**

**The entire**  **wa ste**  **s y stem**  **inclu din** **g coll**  **ection in**  **the pl**  **ant I**  **gr i n** **der ,**  **pump ,**  **and di**  **sharge pip** **e are**  **a l l**  **ver y**  **vi s i**  **b l e**  **. Any**  **oper at**  **ion or**  **tam perin** **g by**  **unau th** **or ize**  **d peo**  **ple could**  **be s e**  **en by**  **fo remen**  **and other**  **wor kers**  **. The**  **pipe l i**  **ne is**  **above the**  **ground and**  **par allels**  **a we**  **ll trave**  **led pat** **h to**  **the beach**  **. Any**  **lea ks**  **or damage**  **to the**  **pip e**  **can be eas**  **i ly**  **det ected**  **.**

### APPE**NDIX E**  **AGE NCIES**  **AN D**  **ORGA N I**  **ZA TIO** **NS**

**Pa cific**  **North west**  **Po l l**  **uti on**  **Prev ent**  **i o n**  

### Re **sea rch**  **C e**  

### n **t** 

### e **r** 

### 1326 **F i fth**  **Ave .**  **su** 

### i **t e**  

### 650 **Seat tle**  **, WA**  

### 98101 **Uni ted**  **states Environ**  **men ta**  **l** 

### P **r o**  

### t **e** 

### cti **o n**  

### Ag **ency 1200**  

### six**th Ave**  **. Sea** **t tle**  **,** 

### WA **98101 Natio**  **na l**  **Ma r i**  **ne Fi**  **sh eries**  **Ser vi**  **ce Northwe**  **st Fi**  **sher ies**  **Sci ence**  **C** 

### e **n** 

### t **e r**  

### 2 7 **25 �o**  **nt l**  **ake Blv** **d .** 

### E. **Se a** **tt l**  **e ,**  **WA** 

### 98112 **Mi ni**  **stry** 

### of **Agr icult** **ure ,**  **Fi sher**  **ies ,**  **and Food** **" Aqu**  **ac u**  **l t u** **r e**  **an d**  **Commer cial**  **F i s**  **h** 

### e **r** 

### i e **s Branch**  **808** 

### Dou**g l a**  **s stree** **t Victori**  **a, B.C.**  

### V8W**2Z7 Fi**  **sheries Counc**  **il of**  

### B.C. **1188 We**  **st** 

### G**e o**  **r g**  

### i **a** 

### street **s u**  **it** 

### e 

### 1 4 **00 Vancov**  **er ,**  **B.C.** 

### V6E4 **AZ Wa**  **shin gton**  

### Dept **. of**  **Ecol ogy**  

### POB **47696 Lac**  **ey ,**  **WA** 

### 98504- **7696 Indus**  **try Canada**  **9 0 0-650**  **West** 

### Ge **o r** 

### g **ia** 

### Street **Vanco v** **er ,**  **B.C.** 

### V6B5H8 **B�C. E** **n v**  **i r** **o n** 

### m**en**

### t **1106-1175** 

### D **o u** **gl a**  **s St**  **reet Vi**  **cto ria**  **, B.C.**  

### V8V1 **X4**
**En vi**  **ronment Can**  **ada** 

### 224 **West Espa**  **lnade "N** **orth Vancov** **er ,**  **B.C. V7**  **M3H7 un**  **iv ers**  **it y**  **of Alaska**  **Fi sher** **y** 

### In**du st** **rial Te**  **chno log** **y C e**  **n ter**  **Kodi ak**  **, Al**  **ask a**  

### 99615 **Instit ute**  

### for **Fo o** **d Sci**  **ence and**  **Tech nolo**  **gy Co**  **l l ege**  

### of **Oc e**  **a n and**  **Fi shery**  

### Sci **ences Un**  **iv ersit** **y of**  **Wa shi**  **ngton** 

### HF- **IO Sea** **t tle**  **, WA**  

### 981 **95 oregon**  **State U** **n i**  **v e**  **rs i**  

### t**y Seafoo** **d Laboratory**  

### 250 **3 6**  **t h**  **St reet**  **As tor**  **i a ,**  

### OR **97103**