Guide for the construction of improved FTT smoker in Myanmar Introducing improved FTT smoking technology for rohu fish smoking, Kale Township, Sagaing Region, Myanmar Guide for the construction of improved FTT smoker in Myanmar Myanmar Sustainable Aquaculture Programme (MYSAP) Bandara Rotawewa, International Consultant Don Griffiths, Yu Maung, Khaing Kyaw Htoo, Silvia Kaufmann, Florian Muehlbauer and Zin Win Htwe 2021 Table of Contents ACKNOWLEDGEMENTS ....................................................................................................................... 1 1. INTRODUCTION - FAO THIAROYE SMOKING TECHNOLOGY ......................................... 2 2. CONSTRUCTION OF THE FTT KILN .............................................................................................. 2 2.1 MATERIAL SELECTION FOR THE KILN .............................................................................. 4 3. FABRICATION OF METAL PARTS ................................................................................................ 12 3.1 GUIDE FOR METAL WORK MATERIAL SELECTION ..................................................... 13 3.2 LID FABRICATION.................................................................................................................... 16 3.3 SMOKING RACK – STEEL ....................................................................................................... 18 3.4 SMOKING RACK – WOODEN ................................................................................................. 20 3.5 FAT COLLECTION TRAY ........................................................................................................ 23 3.6 FURNACE BOX ........................................................................................................................... 27 4. REFERENCES ...................................................................................................................................... 36 1 ACKNOWLEDGEMENTS The international consultancy input for this document was funded by the Myanmar Sustainable Aquaculture Programme (MYSAP). The Myanmar Sustainable Aquaculture Program (MYSAP), funded by the European Union (EU) and the German Federal Ministry for Economic Development and Cooperation (BMZ) and implemented by Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH has the following objective: Support the sustainable intensification of the aquaculture sector, thereby realizing its potential for food security, nutrition and sustainable livelihoods. MYSAP is promoting small-scale aquaculture and improved human nutrition in three townships in Shan State and the Sagaing Region of Myanmar through its inland component MYSAP Inland which is being realized by WorldFish under a GIZ grant agreement. The two improved FAO FTT Thiaroye smokers constructed and tested with smokers in Kale Township, Sagaing Region, Myanmar were funded by the inland component of MYSAP. The authors wishes to express their thanks to the staff of MYSAP Inland and of the NGO Ar Yone Oo for their support in the field and for enthusiasm of the collaborating rohu smokers Daw Vuli from Pyin Khone Lay Village and U Lala from Nat Gyi Kone Village without whom this document could not have been produced. Photos © WorldFish/Y. Maung 3D graphics © B. Rotawewa 2 GUIDE FOR THE CONSTRUCTION AN FTT IMPROVED SMOKER IN MYANMAR 1. INTRODUCTION - FAO THIAROYE SMOKING TECHNOLOGY The FAO-Thiaroye Processing Technique (FTT) is a proven fish smoking technology that originated in Africa and was later introduced to Asia and the Pacific. The FTT was developed by Food and Agriculture Organization (FAO) and the National Training Centre for Fisheries and Aquaculture Technicians (CNFTPA) in Senegal to address identified shortcomings of existing African fish smoking kilns (FAO, 2017). The technology has gained popularity as a proven technology and has been disseminated to Asian and Pacific countries. The introduction of FTT to smokers of the Indian major carp species rohu (Labeo rohita) in Kale Township of the Sagaing Region of Myanmar has been adapted to suit specific local conditions. • The kiln was comprised of two identical compartments, but without the indirect smoke generator of the original design. All other components like the smoking racks and the fat collection trays were the same as the original design (Ndiaye et al, 2014). The kiln walls were constructed with two rows of clay bricks that retain heat inside the kiln chamber. • The furnace was slightly modified with the insertion of a tin sheet on the wire mesh to retain the wood embers longer. This was done because the rohu smokers in Kale Township of Myanmar, burn a unique combination of fuel wood and sawdust, which are predominately Dipterocarpus turbinatus. The tin sheet was used to prevent sawdust from falling through to the bed of the furnace. • The drawings were changed from metric to imperial units, with which the people in Myanmar were more familiar. • Additional wooden trays were also added to give extra processing capacity to suit daily processing demand. This construction guide outlines the construction steps specific to Myanmar. As part of the same international consultancy, a separate guide for the operation and testing of the FTT smoker was also produced entitled, FTT smoker operation and testing protocol guidelines. 2. CONSTRUCTION OF THE FTT KILN The housing component of the FTT consists of two identical compartments with smoking racks at the top and oil trays positioned in the middle. The kiln was constructed with clay bricks which were locally available. Ideally the kiln should be built with a roof to provide shade and to allow operation during rain and bad weather. A reinforced 3 inch thick concrete layer floor should be constructed as the base for the kiln. The kiln construction also requires the fabrication of metal parts as well. 3 Figure 1: 3D image of the FTT kiln (front view) Figure 2: 3D image of the FTT kiln (side top view) 4 Table 1: Material list for a two-compartment FTT kiln Material Specifications Unit Unit cost (MMK) Required quantity Cost (MMK) Rebar # 3 size Each 5,800 2 11,600 River Sand Masonry grade clean Cubic feet 800 23 18,400 Clay fired bricks 9" length x 3" height x 4.5" width Each 130 620 80,600 Plywood sheet 4 feet x 8 feet Sheet 12,000 1 12,000 Cement 50 kg Bag 6,000 7 42000 Iron pipe 1/2-inch tube Feet 8,000 8 64,000 Total (MMK) 228,600 Total (USD) 173 Table 2: Labor requirement (For a two-compartment kiln) Type of labor Number of days Remarks Skilled mason 04 The first day- brickworks up to the concrete layer. Second day up to 3' .3" height. On the third and fourth day, complete the plastering and finishing works. Helper 04 2.1 MATERIAL SELECTION FOR THE KILN It is always advisable to use locally available building materials. Clay bricks: 9" length x 3" height x 4.5" width. Well fired and solid. Cement: Cements with strength class 52.5 or 42.5 is recommended. 50 kg bags were available in the market Sand: Masonry grade river sand, free from dust, clay and debris. 5 Figure 3: Bricks in Myanmar ( https://avax.news/fact/A_Brick_Factory_in_Myanmar.html ) Figure 4: Laying a 3-inch thick reinforced concrete base as the base for the kiln 6 Figure 5: Precise brick work according to the measurements is important from the beginning Figure 6: Formwork mould for pouring the concrete mix into 7 Figure 7: Continue the brick works on top of the concrete reinforced beam Figure 8: Proper brickwork is important for better finishing 8 Figure 9: Plastering the walls of the kilns Figure 10: Place 4 pieces of rebar on the sides of the kiln wall to hold the fat collection tray in position inside the kiln chamber 9 Figure 11: Confirm that the oil tray can be moved smoothly lowered into position inside the kiln chamber Figure 12: Check that there is enough space between the kiln chamber wall and the smoking racks / fat collection tray 10 Figure 13: The position of the smoking racks can be easily adjusted by having iron rebar or iron bolts inserted at different heights in the kiln wall Figure 14: Fat collection tray under the smoking rack inside the kiln chamber 11 Figure 15: A piece of rebar or iron bolt can be used to fix the position of the smoking racks Figure 16: A smoking rack positioned on the upper level of the chamber 12 Figure 17: The kiln chambers are covered with metal lids 3. FABRICATION OF METAL PARTS The FTT has four main different metal parts. a. Lid: used to cover the top of the FTT kiln b. Smoking racks: used to place fish for smoking c. Fat collection tray: serve as collecting fat/ oil while cooking the fish and preventing direct flames and work as a heat distribution devise d. Furnace: holds firewood, sawdust and embers that generates heat for cooking and smoking of the fish. 13 3.1 GUIDE FOR METAL WORK MATERIAL SELECTION Each material is recommended based on its use and durability.  Angle iron - 1/8" x 11/4 inch x 11/4 inch: Used for making frames of the lid, smoking rack, and furnace.  Flat tin sheet - Used for lid, fat collection tray and furnace. The following guide is provided for the easy selection of tin sheets.  Lid = 20 or 22 gauge (0.7 – 0.9 mm) this is suitable because thicker guage tin sheet will make the lid heavy and difficult to lift or move.  Fat collection tray = 14 gauge (2.3 mm) tin sheet should be used. The fat collection tray is placed just above the furnace. If the tin sheet to too thin, it will be damaged by the flames over time.  Furnace: 14 or 16 gauge (1.8 mm) is recommended. Figure 18: Tin sheets 14 Figure 19: Caster wheels Figure 20: Stainless steel mesh 15 Figure 21: Iron tubes Figure 22: Galvanized steel mesh 16 3.2 LID FABRICATION Guide for material selection Frame: Use angle iron 1/8 inch x 1 1/4 inch x 1 1/4 inch Cover: Use 20 or 22 gauge (0.7 – 0.9 mm) tin sheet Handles: Weld two handles onto the lid cover for raising and lowering the lid. Construction Steps:  First, make the frame using angle iron (see Figure 23 and Figure 24).  Then fix the tin sheet onto the iron frame. Weld two handles on opposite sides of the lid for opening and closing.  Cut open 5" x 5" square holes as shown in the illustration and fix a 6”x 6" foldable cover sheet using a small hinge.  The edges should be rounded to avoid injuries while handling. Table 3: Material requirement for one unit of the lid Material Specifications Unit Unit cost (MMK) Quantity required Cost (MMK) Angle iron 1/8 inch x 1 1/4 inch x 1 1/4 inch Feet 450 24 10,800 Flat tin sheet 20 or 22 gauge (0.7 – 0.9 mm) Sheet (4' x 8') 24,000 0.5 12,000 Steel flat iron 1/2 inch width Feet 700 2 1,400 Hinge 3 inches Each 800 1 800 Total (for one unit) 25,000 Total (for one unit) USD 20 Table 4: Labor requirement to fabricate one unit Type of labor Number of days Remarks Skilled welder 01 maximum 01-day Helper 01 maximum 01-day 17 Figure 23: 3D view of the lid – Isometric view Figure 24: The lid 18 Figure 25: A lid with holding handles 3.3 SMOKING RACK – STEEL Material selection guide Frame: Made with 1/8 inch x 1 1/ 4 inch x 1 1/4 inch and weld the 1 inch width flat iron crossing each side Mesh: 1/2 inch x 1/2 inch steel mesh Construction steps:  First, make the metal frame using the stainless angle iron.  Fix the stainless-steel mesh to the frame. 19 Table 5: Material requirement for a smoking rack (metal) Material Specifications Unit Unit cost (MMK) Quantity required Cost (MMK) Angle iron 1/8 inch x 1 1/ 4 inch x 1 1/4 inch Feet 450 14 6,300 Steel flat iron 1 inch width Feet 900 8 7,200 Steel flat iron 1/2 inch width Feet 700 2 1,400 Stainless mesh 1/2 inch x 1/2 inch steel mesh Linear feet 1,400 16 22,400 Total (for one unit) 37,300 Total (for one unit) USD 28 Table 6: Labor requirement for fabricating two smoker rack units (metal) Type of labor Number of days Skilled welder 01 Helper 01 20 Figure 26: 3D view of the smoking rack – Isometric view 3.4 SMOKING RACK – WOODEN Material selection guide Frame: Made with class – 1 timber Mesh: 1/2 inch x 1/2 inch galvanized/ stainless steel mesh is fixed Construction steps:  First, make the wooden frame using the class - 1 timber;  Fix the stainless-steel mesh to the frame. 21 Table 7: Material requirement for one unit of wooden smoking rack Material Specifications Unit Unit cost (MMK) Quantity required Cost (MMK) Class-1 timber 3 inch x 1.5 inch Linear feet 18 Class-1 timber 1 inch x 1.5 inch Linear feet 18 Stainless mesh 1inch x 1 inch type mesh Square feet 16 Total Table 8: Labor requirement for fabricating two units of smoking racks (wooden) Type of labor Number of days Skilled Carpenter 01 Helper 01 Figure 27: 3D view of the wooden rack 22 Figure 28: Wooden racks Figure 29: Additional wooden trays for increased processing capacity 23 Figure 30: A wooden rack and Daw Vuli with near finished smoked rohu 3.5 FAT COLLECTION TRAY Construction steps:  First mark the six holes (2.5-inch radius) on the tin sheet. Each raw should have three equidistant holes  Cut out and remove the holes. Then, bend the outer upwards using a hammer and grind the edges until they are smooth  Cut six circles, each 8-inch in diameter and make them into the cone shaped cap.  Fix those cones shaped cup using ½-inch plate iron as shown in Figure 33. Each cone should be supported with three risers. 24 Table 9: Material requirement for one unit of fat collection tray Material Specifications Unit Unit cost (MMK) Quantity required Cost (MMK) Flat tin sheet 14 gauge (2.3 mm) Square Feet 1,750 22 38,500 Steel flat iron 1/2 inch width feet 700 16 11,200 Iron pipe 1/2 inch galvanized feet 450 1 450 Total (for one unit) 50,150 Total (for one unit) USD 38 Table 10: Labor requirement (to fabricate two units of fat collection trays) Type of labor Number of days Skilled welder 04 Helper 04 25 Figure 31: 3D view of the fat collection tray – Isometric view Figure 32: Cone shaped cap 26 Figure 33: Well-fixed coned shaped caps Figure 34: Fat collection tray with conned shaped cap 27 3.6 FURNACE BOX Construction steps:  Fabricate the furnace box (2’11” x 2’2” x 10.5”) with the 16-gauge (1.8 mm) tin sheet  Cut remove and 1’8” x 2’ hole from the bottom of the box where fuelwood ash will fall  Make the air tubes using ½ inch iron tubes as shown in the Figure 37 and Figure 38 and fix the inlet to the front side  Fix the ash pan to the bottom of the furnace using an angle iron (Figure 36 and Figure 42)  Weld the caster wheels onto the four corners  The push/ pull handle is made with 1-inch iron tube. The handle should be waist height for easy operation. Table 11: Material requirement for furnace Material Specifications Unit Unit cost (MMK) Quantity required Cost (MMK) Caster wheel 2 1/2-inch size iron made each 3,000 4 12,000 Flat tin sheet 16 gauge (1.8 mm) sheet (4'x8') 41,000 1 41,000 Angle iron 1/8inch x 1 -1/4-inch x 1 - 1/4 inch feet 450 24 10,800 Steel mesh 1/2-inch x 1/2-inch steel mesh Square feet 1,400 10 14,000 Iron pipe 1-inch galvanized pipe feet 800 8 6,400 Iron pipe 1/2-inch galvanized pipe feet 450 9 4,050 Steel flat iron 1/2-inch width feet 700 2 1,400 Total (for one unit) 89,650 Total (for one unit) USD 67 Table 12: Labor requirement for one unit of furnace Type of labor Number of days Skilled welder 03 Helper 03 28 Figure 35: 3D view of the metal box for a furnace. The opening for the ash pan is in the middle of the box. Figure 36: 3D view of the ash pan 29 Figure 37: 3D view after ash pan and air tube (side view) Figure 38: 3D view after ash pan and air tube (front view) 30 Figure 39:3D view after ash pan and air tube with handle (front view) Figure 40: 3D view of the ember/charcoal mesh (front view) 31 Figure 41: 3D view of the furnace (front view). The ventilation tube simply lets the airflow in the furnace. Figure 42: 3D view of the furnace (bottom view) 32 Figure 43: Furnace box Figure 44: Opening for the ash tray 33 Figure 45: Fixing the air tubes Figure 46: Join the air tubes properly 34 Figure 47: Fixing the ember/charcoal tray. Figure 48: Fix the ember/charcoal tray just on the top of the air tubes giving enough space for fuelwood 35 Figure 49: Bottom of the furnace Figure 50: Making ember before smoking 36 Table 13: Summary of the cost of the FTT components Item Number of units Unit cost (MKK) Cost (MMK) Cost (USD) FTT Kiln 1 228,600 228,600 173 Smoking lid 2 25,000 50,000 40 Smoking Rack (metal) 2 37,300 74,600 56 Smoking Rack (wooden) (assumed the cost is same as the metal rack) 4 37,300 149,200 112 Fat collection tray 2 50,150 100,300 76 Furnace 2 89,650 179,300 134 Total material cost (rounded value) 941,400 700 Labor cost for all construction is assumed as 1/3 of the material cost (MMK 941,400 *1/3) = MMK 313,800 / (USD 700*1/3) = USD 233. This is a rough estimation and the numbers may change according to local conditions1. 4. REFERENCES FAO, 2017. An innovative way of fish drying and smoking: FAO Thiaroye Processing Technique (FTT-Thiaroye). [online] Available at: http://www.fao.org/3/i8301e/i8301e.pdf. Ndiaye, O., Sodoke Komivi, B. and Diei-Ouadi, Y. 2014. Guide for developing and using the FAO-Thiaroye processing technique (FTT-Thiaroye). Rome, FAO. 67 pp. 1 To be calculated based on cost of the wooden racks.