Weighing up costs and benefits in fish factories |
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| Cleanse-IT, Ice-IT, Log-IT | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
Simple software helps managers in fish factories in developing countries record and analyse data. Collecting data is the first step towards weighing up costs and benefits. Using ice, disinfecting machinery and constructing better containers all cost money. The software helps managers decide the most cost-effective ways to improve production. Tested in Uganda and Ghana, the software has helped cost the benefits of using ice, and provides information for a booklet on sanitation in factories and for designing fish containers and holds. A prototype hold improved returns by at least 15%. Use of the software is spreading to Pakistan and Morocco, and there is already interest in Namibia, Denmark and India. Project Ref: PHF13:
Research Programmes: Post Harvest Fisheries Research Programme Relevant Research Projects: R6959, R5027, R6817, R7008 Main contact - Dr Mike Dillon, Manufacturing Improvement International Ltd (formerly Mike Dillon Associates Ltd), Unit 20, Business Science Park, Nuns Corner, Grimsby, N E Lincolnshire, DN34 5FQ, Tel. 01472 277007 Research Outputs, Problems and Solutions: The main part of this project work has focused on investigating and costing control measures from 1998 - 2000. Quantitative and qualitative survey methods were developed and used with the subsequent production of a considerable amount of technical and economic data. This enabled modelling of the cost of intervention to provide advisory agencies, industry and government policy makers with a tool to allow a prediction, at the macro and micro- level, of cost interventions in the chain. The project therefore developed methods to identify, document and cost appropriate control methods within the fisheries chain. The first phase of the project was planned to investigate, document and cost sanitation control systems in fish processing plants in Uganda. Previous work had been completed in this area and the related loss prediction area by NRI under project no. R5027. This project built on the losses work, which demonstrated a need for effective control systems. The economic engineering team based at FAO in the Department for Fisheries had also completed significant investigations over 20 years and collaborated with the project team (Lupin et al Technical Manual 351). The icing work in Uganda and Ghana continued to promote the use of cost-effective practices. Software tools were developed to manage and capture information from the icing trials and cost the benefits. The Ugandan team completed the documentation of the factory cleaning controls and published a booklet to support industry in building better controls. The project aimed to assist to resolve the problem of losses of fish and fish quality in Ghana and Uganda. This was shown to directly benefit the fisherfolk and the processors through better yields, so making better usage of resources available. FAO had estimated that a significant shortfall (19 million tonnes) in fish protein by the millennium, with low income groups facing the severest deficit.
These outputs were developed for the fisheries sector, but some of the tools could be applied to different food sectors. The outputs on cleaning methods and costing systems could be used in any food-manufacturing factory.
How the outputs were validated: The economic engineering team based at FAO in the Department for Fisheries assisted in the design and testing of the models and the validation of the field -work. Protocols were developed and published with the software, so that the methodologies could be replicated. The project outputs provided the participating factories with formally documented cleaning controls and a cost estimate for their revised cleaning programme. The advisory service (NARO) have designed procedures for validation of cleaning controls and produced a national guidance document on best practice for food factory cleaning. The modified Ugandan icing and sanitation controls have been evaluated by the EU and found to meet their international export requirements thus enabling re-entry into the market. The handling, icing and cleaning controls were reported to have significantly improved since 1997. The Ghanaian team leader visited Uganda to review the approach in 1999. The approach to auditing factory-cleaning control was then successfully undertaken and tested at Divine Seafood in Ghana. The existing protocols for undertaking technical audit, trials and cost calculations were repeated and modified. The Ghanaian team focused on the icing work, which had begun in Uganda. They then reviewed the existing controls present in their fisheries chain and selected handling, better insulation, and improved icing as a focus of their intervention work. Where the Outputs were Validated: Full-scale sea trials in Ghana and the installation of software in three operational factories in Uganda provided positive feedback. Further factories in Uganda have requested software tools and fishermen in Ghana are now asking for lined holds. Subsequent trials have been designed to offer the level of validation necessary for technical publication. This trial data and other feedback from users has therefore enabled the final refinement of the software products to be undertaken prior to the closing meeting which took place in Ghana in September 2000. The prototype hold was found to be subject to rusting and the metal lining became separated from the wooden base. The next version was of a better construction and has been welcomed by the local fishermen. The economic benefits of the lined holds has been demonstrated in trials with gains of at least 15% being recorded (Akrofi and Sanchez, 2000)5. The Ghana team also documented the controls in fish handling and icing activities through an extensive technical survey executed throughout Ghana based on the Uganda approach. This project was linked through associated research to other activities. The Director of Fish Inspection (Tangiers) has been closely involved in the approach and has employed the tools and techniques to significant effect in Morocco. The methodology has also been demonstrated to target groups in 1998 (Namibia), 1999 (Denmark) and 2000 (Ghana, India) at a series of practical workshops. Who are the Users? The Ice-IT software is currently being used to analyse the fisheries sector and value added in Pakistan. Problems with IT infrastructure have meant that the IT tools are no longer being used in Uganda and Ghana. Where the outputs have been used: The Ice-IT software is currently being used to analyse the fisheries sector and value added in Pakistan. Problems with IT infrastructure have meant that the IT tools are no longer being used in Uganda and Ghana. Scale of current use: Current use of the IT tools is very low, and as far as is known the usage did not spread any further than the initial project scope. The use of ice for preserving fish however, has increased, but studies have not been conducted to asses this. Lessons Learned and Uptake Pathways Promotion of Outputs: The IT tools are currently being promoted on a small scale by Grimsby Instutute of Further and Higher Education who are working with the fisheries sector in Thailand. Potential Barriers Preventing Adoption of Outputs: The outputs of these projects was a group of IT tools, and so consequently access to IT equipment and its reliability is a major barrier. How to Overcome Barriers to Adoption of Outputs: Greater access to and reliability of IT systems. No formal poverty impact studies have been undertaken in connection with this project. At the outset of the project, average reject rates recorded at Ugandan landing sites were between 9 to 12% for Nile Perch. The adoption of icing and better handling practices in earlier stages of the chain has subsequently reduced this reject rate to below 5% and often nearer 3%. A 9% increase in quality material for export on the annual 100,000 ton fishery industry added $2.7 million dollars to the country revenue with fish valued at $3/kilo. The cost impact of the closure of the fisheries in 1998 (Bagumuire 2000) was estimated to be $30 million per annum. The export association (UFPEA) reported a major impact on the fisheries livelihoods of 500,000 dependants throughout the chain as fish prices were reduced by 70% when fishery was denied access to major market. The re-opening of the market was based upon demonstratable effective control within the primary and factory segments of the chain, which were supported by this project and recognised by the sector. Factory gate prices have now been seen to rise by 50% as the market has re-opened The usefulness of the approach is demonstrated by the application of the tools in further projects supported by UNIDO and incorporated into the policy and planning process in country e.g. the Ugandan 5 year medium term research plan. The work in Ghana resulted in economic gains for the fishermen, fishing mummies and the captains as the quality was seen to rise. In India, what was more important was that participants in the workshop were exposed to issues concerning the use of ice in post-harvest contexts. This had increased awareness amongst Fisheries Development Officers who attended the workshop and that this awareness had been fed into the fishing villages. The result was the rapid adoption of ice and ice-boxes to preserve fish on land and at sea. Indeed, some of those present went so far as to claim that the workshop had been instrumental in the shift towards the use of ice in Tamil Nadu fisheries. The result, it was reported, was a rapid increase in the demand for ice-boxes which at present the Directorate of Fisheries can not meet. It is presently seeking funds to subsidise distribution of ice-boxes. Direct and Indirect Environmental Benefits: None Adverse Environmental Impacts: None Coping with the Effects of Climate Change, or Risk from Natural Disasters: No impacts Relevant Research Projects,
with links to the
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For relevant research projects, with links to further information  Geographical regions included: Ghana, Pakistan, Uganda,  Target Audiences for this content:Fishers, Processors, Consumers, |
