The expertise built up by Danish company Carsoe in supplying complete factory decks with all the capacity needed to produce surimi on board led to the order for the Russian Fishery Company’s new Vladimir Limanov and its sister vessels.
The processing layout on board the new trawler is a significant leap forward in terms of processing value-added products at sea, ranging from shatterpacked pollock fillets to butterfly-cut herring and surimi. It’s a huge step up from the older factory trawlers producing largely wholefrozen and H&G pollock and herring.
Overall production capacity through the horizontal plate freezers is +200 tonnes per day, depending on the production mode and species, and Vladimir Limanov’s factory deck offers a range of options, from conventional H&G and wholefreezing, to the main focus on a value-added production, underscoring RFC’s commitment to reducing by 50% its fuel consumption and emissions per kilo of finished product.
“Producing H/G or whole round fish, we expect they will be utilising full freezing capacity,” said Carsoe’s sales and business manager Jeppe Christensen.
“Producing pollock fillets or surimi will be around half of that per day of finished product.”
Carsoe acted as the primary contractor, developing the layout to suit RFC’s requirements, producing the entire installation at its workshops in Aalborg, which includes liaising with a number of specialist sub-contractors to incorporate their equipment – and finally shipping the complete factory deck to the Tersan yard in Turkey, installing and commissioning it, all of which had to be done within the constraints of coping with Covid-19.
The processing line for pollock takes fish from the reception bunkers, feeding these to a suite of Baader processing machines that includes six Baader 212 filleting machines, from which fillets can be used to produce shatterpacks or fillet block, or can be routed to surimi production.
Carsoe’s engineers have plenty of experience in surimi production equipment, having delivered factory decks to US trawlers fishing in the Pacific, and RFC were looking to operate Vladimir Limanov and its new sister vessels on a similar pattern.
“Our team have been active in Seattle for more than twenty years with these installations and there’s a lot of experience with in the company from working with the Alaska fleet,” he said.
“So what we have done here is to combine the experience from Seattle and production capacity at Carsoe’s factory in Denmark to produce these factory deck for RFC. At the moment, only the Russian Fishery Company and Arctic Storm Management Group, Seattle are building new surimi vessels, and we are currently the main supplier producing these factory decks.”
Producing surimi at sea is a demanding process, with the fillets minced and mixed with fresh water before being cleaned in a system of rotary screens and refiners, after which the fish is dried in decanters for the final mixing to produce surimi paste to be frozen and stored in the refrigerated cargo holds.
Herring fillet production routes fish through a single high-capacity Baader 221 filleting machine to produce butterfly fillets that are then packed and frozen.
Vladimir Limanov’s factory deck can also produce fishmeal and fish oil, so that raw material is fully utilised, and nothing goes over the side.
Alongside the frozen production, pollock roe and milt are also extracted and utilised, as was also done on the older vessels, and these are products that are in demand on the Russian domestic market.