UniSea, Inc. Dutch Harbor, AK - Aleutian Islands Risk Assessment

Transcription

UniSea, Inc. Dutch Harbor, AK
AIRA, September 01, 2009
Early History
•  UniSea was founded in 1974 as Universal Seafoods processing primarily
Red King Crab and shrimp.
•  The Viceroy ship and Vita Barge started processing Salmon, crab, Herring
& Cod in 1978.
•  Universal Seafoods was purchased by Nippon Suisan Kaisha in 1979.
•  Started processing Pollock surimi in one of the first on-shore facilities in
1987 in our “G1” facility. This was on the site of the old Pacific Pearl
Seafoods plant. Processing Pollock surimi was new to UniSea, we
continued to process Opilio & Red King Crab.
•  Started processing surimi in a new, highly-efficient facility – “G2” – in
1990. Originally built as a surimi plant, we now process a significant
volume of fillet block. This facility continues to be one of the most
efficient, highest volume Pollock processing facilities in the world.
People
•  UniSea employs between 800 – 1,200 people
•  Our diverse work force represents 43 different ethnic backgrounds &
languages
•  UniSea provides employees’ round trip transportation from Seattle, all
housing and meals, all necessary work clothing, laundry service, insurance
benefits and a 401K plan.
•  Our priority is to provide a safe workplace for all of our people.
•  Very high return rate: this season, we had 89% returning employees.
•  Many employees have been with us for 10 or more years; some as long
as 28 years.
•  We maintain a very high safety standard, awarded OSHA’s Star VPP
award in 2002.
Products
Products
•  UniSea processes about 11% of the Total Allowable Catch of Pollock from
the Bering Sea. 13 vessels that fish in rotation using a Cooperative system.
All boats are independently owned.
•  Pollock fillet block & surimi are our primary products.
Products
Pollock Surimi
Products
Pollock Surimi
Finished
Products
Products
Pollock
Fillet
Block
Products
Pollock Fillet
Block
Finished
Products
We are
currently
McDonald’s
largest
provider for
Fillet-O-Fish
product.
Products
UniSea continues to process significant amounts of Red King, Brown King
and Opilio Crab.
Products
Other major products include Pollock roe, Halibut, Pacific (Gray) Cod,
Black Cod & other flatfish & rockfish species.
Products
Products
Products
Production Process
Production Process - Pollock
UniSea has the capacity to process 1,200 metric tons (2 ½ million
pounds) of Pollock per day in 3 processing facilities. Our plants operate
24 hours a day during peak processing season. It can take up to 350
people per shift, working 12 hour shifts, to process during peak seasons.
We use about 4 million gallons of water per day: 3 million gallons of SW
and 1 million FW.
Equipment:
•  8 Baader 212 fillet machines and skinners for fillet block
•  5 Toyo filleting machines for surimi production
•  Baader 182, 192, 99 & 200 machines for other fillet production.
Plate Freezers have the capacity to freeze 150 MT of finished product
daily.
We can produce 375 MT (827,000 lbs) of frozen product per day.
Production Process – Pollock
All Pollock are
offloaded from
the boats
using a wet
vacuum
system.
Fish are sorted
& weighed
Pollock fillets
are minced for
surimi
production.
Minced meat
is washed &
pressed
before mixing
with dry
ingredients.
Pans with 10
Kg blocks of
surimi meat
are frozen in
plate freezers.
Blocks are
cased into
master
cartons for
shipping.
German-made
Baader
equipment
produces
skinless,
boneless
fillets.
Inspection by
the Candling
Crew to
remove
defective
fillets.
Finished,
frozen fillet
blocks.
Our combined
Cold Storage
capacity is
over 3,000 MT
Production Process - Crab
UniSea has the capacity to process 450,000 lbs of Red King crab per day.
Crab sections can be frozen in brine or blast frozen – depending on
customer’s requests.
It can take as many as 120 people per shift to process our crab.
Crab processing can use up to 300,000 gallons of water per day
depending on customer’s orders.
Crab are
offloaded by
hand using
large bags
called “brailers”.
Only male crab
are processed.
Only crab that
are alive can be
processed.
Crab
production
requires lots
of labor and
lots of water
– both fresh
water and
salt water.
Production Process – Meal Plant
Our Meal Plant is an integral part of our processing plan, utilizing all parts
of the fish not packed for food.
The Meal Plant can produce 110 MT of meal & bone per day.
Fish meal in
35 Kg bags
ready for
shipment.
We can produce 15,000 – 20,000 gallons of fish oil per day during peak
seasons.
The fish oil
that we
produce is
burned in our
boilers & our
Power House
for electric
generation.
Production Process – Power House
Our Power House has the capacity to generate 16 megawatts using 6
Fairbanks Morse gensets. We use a blend of diesel fuel and our own fish
oil to run the engines.
Effects of the Spill
Effects of the Spill
Major concerns were for our most valuable resources:
WATER
FISH & CRAB
MARKET REPUTATION
TIME
PEOPLE
Effects of the Spill - Water
Overall, communication by all agencies with the processors was good.
Local ADEC agent Becky Sheffield was key in managing communications,
along with Elise DeCola and others.
The town meetings at City Hall, “Reports to Processors” and updates were
helpful and informative.
Reports from Beach Walks & Sample Towing were also helpful &
informative.
Many questions regarding how this oil ‘behaved’ – Floats? Sinks? Moves
with currents?
We can use more fresh water instead of using potentially-contaminated
sea water; does the City have the ability to to match demand?
We had over 60 facility & vessel inspections by various ADEC agents.
There were also several other visits by Coast Guard, Unified Command
How can we best manage these risks?
We can use 3
million gallons of
sea water a day
for many
different aspects
of the
production
process.
Between
January 16 and
May 20, 2005,
we had over 60
inspections by
ADEC agents.
“Spill Watch
Procedures”
were
immediately
put into
place.
Booms were
placed
around our
sea water
intake areas.
“Silt
Screens”
were ordered
and installed
around the
perimeter of
the sea
water
intakes.
Effects of the Spill – Fish & Crab
Routine
inspections
of fish &
crab for oil
residues &
odors.
Routine
inspections of
fish & crab
vessels –
inside the
holds …..
And with the
vessel
skippers &
crew.
Effects of the Spill – Market Reputation
Our Sales Department fielded many calls from customers all over the
world who were concerned about product safety.
We had several visitors here during A Season (Cod buyers from
Massachusetts, fillet customers from France, Surimi sales groups
from Japan, Baader machine technicians from Germany)
Numerous discussions were held between our Production & QA
groups and Sales Groups for block, surimi and our parent company
in Tokyo.
The potential stigma of any processor actually finding oil in their
processing lines. Witness the examples with media coverage of
farmed salmon and heavy metals.
Effects of the Spill – Time
Oil spill related efforts demanded tremendous amounts of time by every
department:
•  Production Groups – inspecting fish & crab boats during offload; Sorters
looking for contamination; plant inspections for oil during clean-ups.
•  QA Group – water sampling; pom-pom inspections; numerous inspections;
extensive documentation.
•  Maintenance Groups – re-plumbing machines to operate on fresh water;
inspection of filters & strainers; inspection of open pumps & piping.
•  Environmental Compliance Department – inspection of docks & sumps;
water sampling; extensive documentation.
•  Management – meetings, research & decision making.
Effects of the Spill – People
We had 1,200 employees wondering if they were going to have jobs for A
Season.
We had 22 employees quit UniSea and start work with oil spill-related work.
•  These are employees that had to be replaced – some left during our
peak production during A Season.
•  Costs would include hiring (recruiting, drug testing, processing), air
fare from Seattle, orientation & training expenses.
With limited hospitality services available, it was challenging to accommodate
visiting customers, vendors, technicians, etc. for work-related stays.
Hindsight is 20/20……
Here at UniSea:
•  Ultimately, we were fortunate that no oil contamination was found on
delivering vessels, in process water, or on products.
•  We now have some procedures in place that would help us if this happened
again.
•  There are still some items we need to research for future incidents.
Hindsight is 20/20……
Some other items that might be helpful:
•  The ‘Unified Command’ might include one designated representative from
the local on-shore fish processors.
•  More ‘one-on-one’ conversations with the processing plants.
•  Routine ‘Beach Walks’ that are organized to include more of the community
and processors.

UniSea, Inc. Dutch Harbor, AK - Aleutian Islands Risk Assessment

Transcription

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