SHRIMP FARMING: BIOFLOC AS BIOSECURTY ?

Nyan Taw, Ph.D.

Technical Consultant

Blue Archipelago BHD

MALAYSIA

nyan.taw@bluearchipelago.com; nyan.taw@gmail.com

Biofloc, a very recent technology seem a very promising for stable and sustainable production

as the system has self nitrification process within culture ponds with zero water exchange

(Yoram, 2000, 2005a&b & Yoram, et at 2012). The technology has been successfully applied

commercially in Belize by Belize aquaculture (McIntosh, 2000a, b & c, 2001). It also has been

applied with success in shrimp farming in Indonesia, Malaysia (Nyan Taw 2004, 2005, 2008,

2010, 2011 &, 2012) and recently successfully commercialized in Malaysia (Nyan Taw, et.at

2013). The combination of two technologies, partial harvesting and biofloc, has been studied in

northern Sumatra, Indonesia (Nyan Taw 2008 et. al). Recently, a semi-biolfoc applied in

earthen ponds in Myanmar was published (Taw & Tun, 2013) and biofloc technology used

successfully in small family own farm in Bali, Indonesia will be published in early 2014 (Taw &

Setio, 2014)

With emerging viral problems and rising costs for energy, biosecure farm design with biofloc

technology appears to be an answer for sustainable production.

INTRODUCTION

FLOC COMMUNITIES AND SIZE

The biofloc Defined as macroaggregates – diatoms,

macroalgae, fecal pellets, exoskeleton,

remains of dead organisms, bacteria,

protest and invertebrates.

(Decamp, O., et al 2002)

100 µ

BIOFLOC

As Natural Feed (filter feeders – L. vannamie & Tilapia) : It is possible that microbial protein has a higher availability than feed protein (Yoram, 2005)

Brown Green

BIOFLOC

Biofloc color in pond & under microscope

Green Color

Brown Color

Biofloc technology is a system that has a self-nutrification process

within culture pond water with zero water exchange (Yoram, 2012)

BIOFLOC TECHNOLOGY CONCEPT

SHRIMP FARMING IN BIOFLOC

SUMMARY 1. High stocking density - over 130 – 150 PL10/m2 2. High aeration – 28 to 32 HP/ha PWAs 3. Paddle wheel position in ponds (control biofloc & sludge by siphoning) 4. Biofloc control at <15 ml/L 5. HDPE / Concrete lined ponds 6. Grain (pellet) 7. Molasses 8 C&N ratio >15 9. Expected production 20–25 MT/ha/crop with 18-20 gms shrimp

Bioflocs

High density

High aeration & PWAs position

Dark Vannamei Red Vannamei Grain pellet

Feed & grain application & Growth

Biofloc

Avg. F/D, GP Consumption & Growth Performance

0

20

40

60

80

100

120

140

160

1 8 15 22 29 36 43 50 57 64 71 78 85 92 99 106 113 120 127 134

DOC (days)

GP (kg), F/D (kg)

0

2

4

6

8

10

12

14

16

18

20

MBW (g)

F/D GP MBW

Paddle Wheels Aerator – Efficiency

Standard with 2 paddle wheel set – 1 HP

Model NAN RONG – High efficiency NR-A135

Specification: Horse power 1 HP

Standard O2 transfer rate 4.99 kgs O2/hr

DO 4.0 to 8.0 ppm

Effective horizontal disturbance of water 53.2 to 63.84 meters

Effective vertical disturbance of water 1.1 to 1.4 meter

Carrying capacity: Optimum efficiency (P. monodon)- 250 to 350 Kgs/HP.

Carrying Capacity – Vannamei

(Kopot & Taw GAA 2004)

Paddle Wheels Aerator – Efficiency

Standard with 2 paddle wheel set – 1 HP

Model NAN RONG – High efficiency NR-A135

Specification: Horse power 1 HP

Standard O2 transfer rate 4.99 kgs O2/hr

DO 4.0 to 8.0 ppm

Effective horizontal disturbance of water 53.2 to 63.84 meters

Effective vertical disturbance of water 1.1 to 1.4 meter

Carrying capacity: Optimum efficiency (P. monodon)- 250 to 350 Kgs/HP.

Carrying Capacity – Vannamei

(Kopot & Taw GAA 2004)

Physical barrier for viral carriers – use 250 micron screen net

Chemical application – kill viral carriers. Apply crusticides

Kill free water bore virus (aging) - dies in 72 hrs without host

Treated water ready for use for culture (apply same procedure)

MODULE OPERATION Water treatment system (Control WSSV)

Treatment Reservoirs ponds

Culture ponds Clean animals – SPF or SPR or PCR check Clean Ponds–clean or oxidized pond bottom Clean Water– treated water & nets (250 micron) Prevent carriers (fence) Strict security to avoid biosecurity breaches

Basic Procedure (Summary) Parameters Closed Water Semi Closed Water Open Water

Fill in Water Quarantine, Treatment

and Culture ponds (Max.

level > 120 cm)

Started fill in to Quarantine,

Treatment and Culture

ponds (optimum level >100

cm)

Started fill in to Quarantine,

Treatment and Culture ponds

(Max level > 120 cm).

DOC ( 1 - 45 46 – 90 91 - harvest

Apply Crustacide

To Kill WSSV Carrier

All ponds/0.5 – 1.0 ppm Use whenever possible No use

Bio assay

Check toxicity

Yes - approximately 5–10

days

Yes – approximately 5-10

days

No need

Aging water

To Kill WSSV in water

All ponds minimum 3

days

Minimum 3 days Minimum 3 days

Screening: 250 – 300

micron. Prevent carrier

entering module

Yes – at all critical points:

Main inlet, between QP &

TP; TP & Main TP or

Supply canal. TP & CP

Yes – at all critical points:

Main inlet, between QP &

TP; TP & Main TP or

Supply canal. TP & CP

Yes – at all critical points:

Main inlet, between QP & TP;

TP & Main TP or Supply

canal. TP & CP

Water exchange No Minimum (topping up only) Maximum

Water source Within module only Start open to outside Open to outside

BASIC OPERATION PROCEDURE (SUMMARY)

POND WATER PREPARATION For already treated water initially in culture ponds and series of

treatment reservoirs for later use>

Day Activity

1 Urea 8 kg & TSP 1 kg

Grain pellet 30 kg & Dolomite 50 kg

2 Tea seed cake 15 ppm

4 Grain pellet 30 kg & Dolomite 50 kg

6 Grain pellet 30 kg & Dolomite 50 kg

8 Grain pellet 50 kg, Molasses 8 kg & Kaolin 50 kg

10 Grain pellet 50 kg

12 Kaolin 50 kg

Nyan Taw AA 2006, LV

Shrimp will be cultured in less or no water exchange system. Water will be added only

to replace the loose water by siphon or evaporation. Water level starts with maximum

and maintain at optimum level. The system is to promote and switch from autotrophic

to heterotrophic condition. Water quality management during culture operation

Culture System (for 0.5 ha HDPE lined pond)

1. Dissolved Oxygen: Maintained at level >4 ppm.

2. Alkalinity: Maintained at level > 70 ppm by applied 50 kg/pond

Hydrated lime (Ca(OH)2) every week.

3. Kaolin: Apply 50 kg/pond once every three week.

4. Molasses: Apply 8.0 kg/pond three times a week

5. Grain Pellet: Apply together with feed from 10-20% during earlier

stage and increase to 20-50 % during late stage (see standard).

6. Sludge: Sludge accumulation in pond bottom need to be

removed periodically by siphoning.

7. Management: All applications need to be adjusted by Shrimp growth,

Biomass, Feed per day and Biofloc volume.

POND WATER MANAGEMENT

DURING OPERATION

Culture System (for 0.5 ha HDPE lined pond)

SIPHONING PONDS BY GRAVITY OR PUMPS

Water pump on float

Siphon tip

Gravity - central drain

FEED AND GRAIN PELLET USED (KG /DAY)

Full Biofloc Stock - 130 PL10/m2; 15 HP/0.5 ha; DoC 90-110 Production - 10-12 MT/0.5 ha; MBW 18-20 gram SR 80%; FCR 1.2 (feed ); Carrying Capacity - 650-750 kg/HP

SHRIMP FARM, INDONESIA BIOFLOC TECHNOLOGY APPLIED

IN COMPANY ASSET PONDS

Floc System Production R&D, Trial and Company Commercial Ponds

Period 2003 - 2005

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

< 2,0 2,0-

2,4

2,5-

3,0

3,0-

3,5

3,5-

4,0

4,0-

4,9

5,0-

5,9

6,0-

6,9

7,0-

7,9

8,0-

8,9

9,0-

9,9

10,0-

10,9

11,0-

11,9

>12.0

Production range (kg/5000m2)

Nu

mb

er

of

po

nd

R&D. Density 100-200 pcs/m2, M BW 16.41 g, Biomass 9.905 kg, SR 81.7 %, FCR 1.29 (number of ponds = 46)

TRIAL. Density 140 pcs/m2 , M BW 16.56 g, Biomass 10.082 kg, SR 87.0 %, FCR 1.42 (number of ponds = 13)

CCP. Density 130 pcs/m2 (standard), M BW 16.99 g, Biomass 9.557 kg, SR 85.5 %, FCR 1.21 (number of ponds = 131)

NO VIRAL (WSSV) OUTBREAKS: 2003-2005

From:

David M. Smith, et al, 2008 Development of protocols for the culture of black tiger shrimp, Penaeus monodon,in “zero”water exchange production ponds

P. monodon CULTURED IN BIOFLOC

0

5

10

15

20

40 50 60 70 80 90 100 110Density 80 (Dike)Density 110 (Full)Density 130 Biofloc

PRODUCTION PERFORMANCE OF ARCA BIRU FARM

Biofloc 0.4 ha HDPE Semi-Biofloc 0.8 ha HDPE Conven 0.8 ha HDPE Dyke

No of Ponds 2 19 119

PWA Energy (Hp) 14 24 20

Stocking Density 130 110 83

DOC (days) 90 101 111

SR (%) 89.16 81.35 83.19

MBW (gr) 18.78 18.31 17.80

FCR (x) 1.39 1.58 1.77

ADG (gr/day) 0.21 0.18 0.16

Avg Harvest tonnage (kg) 9,006 12,950 9,616

Production (Kg/Ha) 22,514 16,188 12,019

Prod per power input (Kg/Hp) 643 540 481

Production ParameterSystem/size/type

Growth

DoC

PERFORMANCE –BIOFLOC & SEMI BIOFLOC Acar Beru, Blue Archipelago, Malaysia

Grams

Nyan Taw, et.al. GAA March/April 2011

No Viral (WSSV) outbreaks

i-SHARP SHRIMP FARM PROJECT

Malaysia - Semi and Full biofloc

Phase one

Paddle wheel aerators position

HDPE Lined modules

Modules in operation

Production Performance CYCLE Trial & 1 for Modules 1 & 2

Density 40/m2 Density 60/m2 Density 80/m2 Density 130/m2 Density 100/m2 Density 100/m2

No of ponds 20 16 8 BFT 4 BFT* 24 BFT 24 BFT

Paddle Wheels Aerators (HP) 12 12 12 16 12 12

Days of Culture (DoC) 113 108 94 88 100 99

Survival Rate (%) 112.23 101.22 106.05 69.56 97.30 104.92

MBW (grams) 21.65 17.41 13.86 12.56 16.05 16.31

FCR 1.34 1.47 1.32 1.74 1.39 1.26

Average Production (kg/pond) 4,875 5,294 5,828 5,677 7,714 8,547

Average Production (kg/ha) 9,749 10,587 11,655 11,354 15,428 17,093

Prod per power Input (Kg/Hp) 406 441 486 355 643 712

CYCLE 1 -Modules 1 & 2 Production Parameter

CYCLE Trial - Modules 1 & 2

ISHARP BLUE ARCHIPELAGO, MALAYSIA SEMI-BIOFLOC PERFORMANCE

Nyan Taw et. al. GAA Jan/Feb 2013

No EMS or WSSV outbreaks –

October 2011-July 2013

-

10.00

20.00

30.00

40.00

50.00

60.00

41 42 43 44 45 46 47 48 49 50 51 52 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

Oct-11 Nov-11 Dec-11 Jan-12 Feb-12 Mar-12 Apr-12 May-12 Jun-12 Jul-12 Aug-12

Rai

n (

mm

),Sa

linit

y (p

pt)

& T

emp

erat

ure

(C

)

Month/ Week

Rain water Salinity Temperature

CYCLE Trial - Modules 1 & 2 CYCLE 1 - Modules 1 & 2

iSHARP Project, Malaysia

BIOSECURITY & BIOFLOC

MANAGED TO PASS THROUGH MONSOON ?

Nyan Taw et. al. GAA Jan/Feb 2013

BIOFLOC IN BALI, INDONESIA Family Owned Farm

0

5

10

15

20

42 50 58 64 72 79 86 93 97

Normal…Intense…g

Days of Culture

NO VIRAL (IMNV

or WSSV)

OUTBREAKS

2009-2013

Northern Coast of Bali, Indonesia

SHRIMP FARM BALI - Biofloc technology

Culture period August- November 2012

Pond A2 A3 F1 F2 E1 E2* B1 B2 B3 C1 C2 C3

Pond Size (M2) 2,400 2,600 2,800 2,800 1,000 750 2,000 2,000 2,000 600 600 600

PL Stocking Density (No/m2) 170 148 150 145 150 180 155 155 155 175 175 175

Aeration (hp) 18 18 16 18 6 4 12 12 12 12 6 4

Days of Culture 97 97 97 95 95 45 82 82 81 82 82 81

Body weight (gm) 18.4 18.12 15.32 17.3 16.48 4 19.5 18.5 16 14.68 19.72 18.48

Feed Conversion ratio 1.26 1.35 1.49 1.29 1.46 1.2 1.4 1.25 1.35 1.1 1.14

Survival (%) 105.8 104 101 106 94.7 103.9 94 92.9 97.4 98.5 101.9

Production (kg)/pond 7,914 7,281 6,388 7,682 2,345 6,307 5,399 4,622 1,503 2,050 1,981

Production (kg/ha) 32,976 28,004 22,814 27,436 23,450 31,535 26,995 23,110 25,050 34,167 33,017

Production/power input (kg/hp) 440 405 399 427 391 526 450 385 376 342 495

* Aeration problem - DO dropped <1.0ppm

Farm total Production: 53,472 kg (26,736 kg/ha)

In this cycle ponds B1,B2, B3,C1,C2 & C3 intense control less DOC to just over 80 days- more cycles/yearTaw & Setio, 2014 (to be published in Jan-Feb GAA 2014)

SHRIMP CULTURE - SEMI-BIOFLOC IN MYANMAR

Earthen pond bedside Soft Shell Crab Farm

Soft Shell Crab Farm Shrimp Ponds

L. vanamei Post Larvae imported from Thailand by Air

No viral outbreaks

Two modules-earthen ponds:

one module consisted of 1

reservoir and 3 production

ponds

STOCK VANNAMEI PL IN MARCH 2013

Taw & Tun, 2013

Shrimp sampling

0

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

45,000

50,000

Belize, CAmerica 2000

Lampung Indo2003-05

Medan, Indo2008

Java, Indo2008

N Bali, Indo2009

BAB Malaysia2010

BAB Malaysia2010 Trial

Commercial Kg/ha Max Record Kg/ha

BIOFLOC IN SHRIMP FARMING Production Performance

Kg

NITRIFICATION SEQUENCE

Avnimelech et. at, 2012 (data from experimental pond Dor, Israel)

Avnimelech et al 2012

ALGAE & BIOFLOC

Algae and Biofloc in Pond Water

Un

its-

ml/

L

25

Pond

Environment

( DO , pH , Temp , Trans , PO4-P ,

CO2 , TAN , NH3-N , NO2-N , NO3-N ,

Sal , Alk , Chlor-a , Floc , Bact , etc. )

WATER PARAMETER

72.01.10

-

1

2

3

4

5

6

7

8

9

10

1 11 21 31 41 51 61 71 81 91 101 111

DOC (DAYS)

DO, pH, TRANSPARENCY

( X 10 )

-

5

10

15

20

25

30

35

40

45

50TEMP

DO( am) pH (am) pH (pm) DO (pm)

Trans (cm) Temp(am) Temp (pm)

Vannamei STD 131 pcs./m2

Production : 8,971.8 kg; MBW

: 16.36 g SR: 83.9 %

FCR: 1.0 ADG: 0.14 DOC:

113

WATER PARAMETER

72.01.10

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

1 11 21 31 41 51 61 71 81 91 101 111

DOC (DAYS)

PO4-P, TAN, CO2

NO2-N, SALINITY(X10)

025

5075100125

150175200

225250275

300325350

375400425450

475500

ALKALINITY,

Chlorophyl a (ug/l)

PO4-P (ppm) Sal (ppt) TAN (ppm)NO2-N (ppm) CO2 (ppm) Total Alk (ppm)Chlorophyl a (µg/l)

Vannamei STD 131 pcs./ m2

Product ion : 8,971.8 kg; MBW : 16.36 g SR: 83.9 %

FCR: 1.0ADG: 0.14 DOC: 113

SHRIMP PERFORMANCE

72.01.10

0

2

4

6

8

10

12

14

16

18

20

1 11 21 31 41 51 61 71 81 91 101 111

DOC (DAYS)

MBW (g), Floc (ml/1L)

0

20

40

60

80

100

120

140

160

180

200

F/D (kg), Grain Pellet (kg),

Floc (ml/1L) MBW (g) Feed/day (kg) Grain Pellet (kg)

Van n amei STD 13 1 pcs. / m2

Pr oduct ion : 8 , 9 7 1. 8 kg; M BW : 16 . 3 6 g SR: 8 3 . 9 %

FCR: 1. 0 ADG: 0 . 14 DOC: 113

WATER PARAMETER

72.01.10

-

1

2

3

4

5

6

7

8

9

10

1 11 21 31 41 51 61 71 81 91 101 111

DOC (DAYS)

DO, pH, TRANSPARENCY

( X 10 )

-

5

10

15

20

25

30

35

40

45

50TEMP

DO( am) pH (am) pH (pm) DO (pm)

Trans (cm) Temp(am) Temp (pm)

Vannamei STD 131 pcs./m2

Production : 8,971.8 kg; MBW

: 16.36 g SR: 83.9 %

FCR: 1.0 ADG: 0.14 DOC:

113

WATER PARAMETER

72.01.10

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

1 11 21 31 41 51 61 71 81 91 101 111

DOC (DAYS)

PO4-P, TAN, CO2

NO2-N, SALINITY(X10)

025

5075100125

150175200

225250275

300325350

375400425450

475500

ALKALINITY,

Chlorophyl a (ug/l)

PO4-P (ppm) Sal (ppt) TAN (ppm)NO2-N (ppm) CO2 (ppm) Total Alk (ppm)Chlorophyl a (µg/l)

Vannamei STD 131 pcs./ m2

Product ion : 8,971.8 kg; MBW : 16.36 g SR: 83.9 %

FCR: 1.0ADG: 0.14 DOC: 113

SHRIMP PERFORMANCE

72.01.10

0

2

4

6

8

10

12

14

16

18

20

1 11 21 31 41 51 61 71 81 91 101 111

DOC (DAYS)

MBW (g), Floc (ml/1L)

0

20

40

60

80

100

120

140

160

180

200

F/D (kg), Grain Pellet (kg),

Floc (ml/1L) MBW (g) Feed/day (kg) Grain Pellet (kg)

Van n amei STD 13 1 pcs. / m2

Pr oduct ion : 8 , 9 7 1. 8 kg; M BW : 16 . 3 6 g SR: 8 3 . 9 %

FCR: 1. 0 ADG: 0 . 14 DOC: 113

Pond

Environment

( DO , pH , Temp , Trans , PO4-P ,

CO2 , TAN , NH3-N , NO2-N , NO3-N ,

Sal , Alk , Chlor-a , Floc , Bact , etc. )

0

20

40

60

80

100

120

140

160

7 14 21 28 35 42 49 56 63 70 77 84 91 98 105 112 119 126 133

DOC (day)

ppm

Heterotrophic Autotrophic

PH comparison between Autotrophic and Heterotrophic System

6

7

8

9

10

1 7

13

19

25

31

37

43

49

55

61

67

73

79

85

91

97

10

3

10

9

11

5

DOC (day)

(pp

m)

pH Autotrop am pH Autotrop pm

PH Heterotrop am PH Heterotrop pm

Dissolved Oxygen Comparison between Autotrophic and

Heterotrophic System

0

2

4

6

8

10

12

14

1 9 17 25 33 41 49 57 65 73 81 89 97 105 113 121

DOC ( day )

( ppm )

DO Autotrophic AM DO Autotrophic PM

DO Heterotrophic AM DO Heterotrophic PM

Alkalinity – Algae & Biofloc

pH – Algae & Biofloc

DO – Algae & Biofloc

POND WATER ENVIRONMENT

Chandaeng, S. et al.(2005): Taw, N (2006)

More than 2,000 bacterial species were found in well-developed biofloc water Biolfocs may enhance immune activity, based on mRNA expression of six immune-related genes.

ProPO1, proPO2, PPAE, ran, mas and SP1

BIOFLOC MAY ENHANCE IMMUNE ACTIVITY

From – In-Kwon Jang, IWA International Water Congress, 2012, Busan, Korea

SHRIMP DISEASES & BIOFLOC

EMS/AHPNS

Dr. Lightner, GOAL 2012

EMS (Early Mortality Syndrome)/ AHPNS (Acute Hepatopancreatic Necrosis Syndrome)

SOME ARTICLES ON EMS/AHPNS

EMS/AHPNS Spreading in Asia & SE Asia

Dr. Lim, GOAL 2012

PROPOSED ACTIONS FOR EMS

DOF Malaysia EMS Seminar KL, Malaysia March2013

BIOFLOC as possible solution for

EMS/AHPNS control at farm level

POSSIBLE SOLUTION FOR EMS/AHPNS AT

FARM LEVEL

(EMS Panel GOAL 2012 Bangkok)

PCR for EMS/AHPND

RECENT DEVELOPMENTS

BIOFLOC BASIC MANAGEMENT CONCEPTS

FOR SHRIMP CULTURE

1 Semi-biofloc to Full biofloc system feasible

2 Use treated water only

3 Zero water exchange (only topping up)

4 Earthen to HDPE full or semi-lined ponds

5 Aerators to have pond water (biofloc) in suspension (22-24 hrs)

6 Correct aerators’ position and number very important

7 Excess sludge need to be removed –specially for full biofloc

8 Biofloc volume control (<15 ml/L)

9 Control C/N ratio to above >15

10 Molasses & Grain pellet required (Carbon source)

11 Operate in accordance with Carrying capacity of pond essential

(species/stocking density/pond type/operating system)

WHY BIOFLOC AS BIOSECURITY BIOFLOC SYSTEM BIOSECURITY

1. Zero water exchange (topping up only for water

lost due to siphoning & evaporation)

Low risk of virus entering culture ponds

through water source

2. Use treated water only – through reservoirs Modular system

3. Aeration full 22-24 hours in accordance with

pond carry capacity (full or semi-biofloc) to have

biofloc suspended in pond water.

Stable dissolved Oxygen (DO). Healthier

shrimps

4. Phytoplankton (algae) bloom & crash non-

existent as biofloc does not depend on sun light

for photosynthesis.

Stable environment. Low stress for

shrimps – healthier shrimps

5. Stable culture water environment –

DO and pH.

Stable environment. Low stress for

shrimps – healthier shrimps

6. Extra natural live feed – biofloc with unicellular

protein (protein 30 -50%)

Extra nutritious natural feed

7. More than 2,000 bacterial species were found in

well-developed biofloc water

Possibly a probiotic affect

8. Biofloc contains six immune related genes May enhance immune activity in shrimps

Vietnam

Malaysia

Myanmar

Guatemala Beliz Nicaragua

Israel

New Caleonia

BIOFLOC TECHNOLOGY WORLD WIDE

THANK YOU

The author would like to sincerely thank the following:

Mr. Abu Bakar Ibrahim (CEO) and Mr. Christopher Lim (COO), Blue Archipelago for their interest and support. The staff and members of Blue Archipelago, Malaysia for their support.

ACKNOWLEDGEMENTS