Closed fish pen project brings shuttered shipyard back to life
The world's first closed steel cage is being built outside Molde in Norway. It has reinvigorated the yard and offers fish farmers the chance to try closed containment by renting the pen.
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In the small coastal municipality of Aukra, Norway, activity has returned to a former shipyard that has been idle for several years. This time, it involves the construction of what is described as the world’s first enclosed steel cage for fish farming.
Inside the huge construction shed, the sounds of hammering, milling, and welding can also be heard. Steel plates are being shaped, sections are being hoisted into place, and the construction of what will become Varig 001 is taking shape.
“This is the beginning of something new. We believe that much of the future growth in aquaculture will take place in closed, floating facilities,” Bauta Fishfarms chief executive Gjermund Kvernmo Langset tells Fish Farming Expert’s Norwegian sister site, Kyst.no.
Advantages of the material
Production is taking place at the Vard shipyard in Aukra, Møre og Romsdal, which has not carried out shipbuilding work since 2019. Now, the facilities are being brought back to life.
Bauta Maritime is responsible for the steel work, and the ambition is that the production of the cages will generate more activity and more jobs in the region.
“We have both the expertise and the capability to build in steel. It is a material we know very well and that provides robust and stable structures at sea,” Langset says.
He points out several advantages of the material choice and states that there is a reason why ships are built from steel.
“Steel is easy to calculate, easy to industrialise, and we have good solutions for its maintenance and recycling. Furthermore, its weight provides a stable platform that sits well at sea and withstands harsh weather conditions.”
Believes in great growth
The design suggests a lifespan of around 40 years, but according to Langset, in practice it can be even longer with proper maintenance. Furthermore, the material is 100% recyclable.
The first cage has already been sold to Oceandock, which will rent it out to fish farmers. This also introduces a new model to the market.
Going forward, the plan is to both rent out cages through Oceandock and sell them to fish farmers.
Behind both Bauta Fishfarms and Oceandock stands a cluster with experience from both the maritime and marine industries, in the form of the industrial group Bauta Group, the wellboat operator Rostein, and the fish farming company Prophylaxia.
The group has a clear ambition to scale up the production of closed cages.
Today there are around 6,000 cages in Norway, and a doubling of the industry has been predicted by 2040. It is quite obvious that this doubling will not come exclusively from open cages. That is not possible, says Langset.
The company believes it can deliver up to 30 such plants a year, manufactured in Norway, with a construction time of 6–8 months per unit.
New business model
The first tenant is Prophylaxia, which will use it at its facility at Gjermundnes in the Romsdalsfjord.
“Not all farmers have the opportunity to make such investments alone. Leasing makes the technology available to more people,” says Rostein chairman Glen Bradley.
For Prophylaxia, this was crucial in order to be able to use a closed facility of this size.
“We would hardly have had the opportunity to enter this without such a model,” says chairman Bjørn-Vegard Løvik.
Betting on biological gains
The company already has experience with closed facilities through two smaller pilot versions of the Egg floating closed containment facility, produced by Ovum, and the results are promising.
“We have seen very good growth and low mortality. If we can recreate that on a larger scale, it will be a success,” he tells Kyst.no.
The small fish farming company has had several stockings in its two closed facilities, where they have taken the fish from 100 grams to around one kilogram, before transferring them to open cages.
The company's experience in this phase shows, among other things, 35% faster growth than in traditional cages, mortality of around 1%, and better feed utilisation rate (approximately 0.84).
The plan is to stock around 200,000 fish initially, starting towards the end of the year.
“When the fish grow faster, you can get started on fallowing and the next production cycle sooner. Over time, that can mean increased production without necessarily having to obtain new licences,” says Bradley.
Launching in October
The closed cage is 32 metres in diameter, holds 10,000 cubic metres of water and has a centre column that, among other things, contributes to controlled water flow. Bauta Fishfarm says that the systems have been developed to provide optimal control of the production environment.
“We will control everything from water intake and flow to oxygen levels, light, and sludge collection. There are many parameters that must work together,” says Langset.
The full water volume can be changed up to twice an hour, and the water intake depth can be adjusted and filtered. Sludge is collected and pumped out, allowing for reduced emissions.
“It’s about reducing risk while simultaneously improving both fish welfare and environmental impact.”
The cage is designed to also be connected to existing infrastructure.
“If you already have a feed barge and systems on site, this can be largely integrated. This makes the solution flexible.”
Must be seen to work
In addition to salmonids, the group sees cod farming as an exciting future opportunity for closed facilities.
At the same time, plans are being worked on for production outside Norway, near other markets.
“The need for seafood is increasing globally. We must be able to deliver solutions where the need is.”
The plan is for the first cage to be launched in October. Extensive testing will then take place before the planned stocking of fish into the facility before the New Year.
“Now it’s about getting it into the water and showing that it works in practice,” says Langset.
