How to Build a Fish Oil Processing Plant with a Strategic Systematic Approach?

Building a fish oil refining, Omega-3 enrichment, and purification plant is no easy task.

It demands expert knowledge, strategic planning, and seamless execution.

With the right expertise, strategic planning, and advanced technology, you can achieve a plant that delivers high-quality products and scales to meet the growing demand of both local and international standards.

We’ve been fortunate to work closely with a seasoned plant manager from China’s leading fish oil processing industry with over two decades of experience.

Almost the manager have witnessed and contributed to the progress the fish oil processing industry has achieved in its current market position.

With their unparalleled expertise, I’ll walk you through a strategic roadmap for building a fish oil production of omega-3 PUFA concentrates on a project involving a 10,000-ton-per-year crude fish oil processing facility.

The project integrated advanced equipment and cutting-edge technologies, meeting stringent local and international standards. This case study demonstrates how strategic management and process optimization can transform production performance.

Let’s explore this case and how you can apply these insights to improve your business performance.

Case Study: 10,000-Ton Per Year Fish Oil Processing Plant

Background

A state-of-the-art fish oil processing plant with the goal of producing pharmaceutical-grade omega-3 concentrates and food-grade fish oil supplements. The processing plant was designed, engineered strategically, and constructed to meet:

• A 10,000-ton annual production capacity.
• Compliance with international standards, including GMP, HACCP, and GOED.
• Advanced process technology for high-purity EPA/DHA fractionation, enrichment and concentration.
• Energy-efficient solutions to reduce operational costs.

Challenges

1. Meeting high-purity and high concentration specifications (EPA/DHA EE > 84%).
2. Ensuring compliance with both domestic and export standards.
3. Designing a scalable facility to accommodate future growth.
4. Minimizing environmental impact through sustainable practices.

Project Approach and Execution

1. Strategic Planning and Regulation

The project was led by a plant manager with over 20 years of experience in fish oil production. A comprehensive framework was developed with a process roadmap that included:

• Defining Objectives: Focused on achieving pharmaceutical-grade purity and aligning production with export markets in Europe and North America.
• Stakeholder Alignment: Collaborated with engineers, regulatory experts, and suppliers to ensure all aspects of the plant met technical and compliance requirements.
• Phased Implementation: Divided the project into three key phases: design and procurement, construction and installation, and commissioning and optimization.
• Plan resource allocation (staff, materials, energy) for each process step, ensuring that the plant operates at optimal efficiency without unnecessary resource strain.

2. Advanced Technology Integration

To achieve the desired quality and efficiency, we incorporated the following advanced equipment:

• Short Path Molecular Distillation Units: Ensured high-purity omega-3 concentrates with EPA/DHA > 60%.
• Esterification Process Units: A key technology in the deep processing of fish oil. Implementing additional reaction stages to enhance the conversion of mono- and diglycerides into fatty acid ethyl esters can significantly improve the overall efficiency and yield of the esterification or transesterification process.
• Centrifugal Separators: Enhanced separation of esterified fish oil from impurities during reaction and refining.
• Crystallization Process Units: Removed waxes from the oil to produce clean, neutral, high-quality fish oil.
• Urea Complexation Process Line: An optimized process practise to crystallize the Straight-chain saturated or monounsaturated fatty acids from polyunsaturated fatty acids fractions.
• Storage tanks: Properly fabricated and constructed storage tanks to meet the practical working mechanism of sanitary and process flow.
• In-Line Monitoring Systems: Real-time monitoring of critical parameters, ensuring consistent product quality.

3. Facility Design

We prioritized a layout that optimized workflow, minimized contamination risks, and supported future scalability:

• Zoned Layout: Separate areas for raw material handling, differentiate raw material processing with chemical synthesis, and packaging.
• Quality Control Labs: Fully equipped labs adjacent to the production area for on-site testing.
• Energy Efficiency: Incorporated heat and solvent recovery systems to reduce energy consumption.
• Data-Driven Improvement: Use data from daily operations, quality control results, and maintenance records to identify trends and areas for improvement. Systematic use of data analytics can help optimize yield, reduce downtime, and improve efficiency.
• Feedback Loops: Establish feedback loops with production and quality control teams to make real-time adjustments in response to process changes or unexpected issues.
• Periodic Process Audits: Conduct periodic process audits to assess overall system performance, identify bottlenecks, and recalibrate processes in line with evolving market demands or regulatory requirements.

4. Compliance and Certification

Your plant shall be ensured to meet both local and international standards by:

• Implementing robust GMP and HACCP protocols. Continuously monitor changes in regulatory requirements across targeted markets, updating processes, documentation, and training programs as needed.
• Conducting regular audits and staff training programs.
• Collaborating with third-party labs to certify the final products.

5. Sustainability Measures

The plant adopted eco-friendly practices, including:

• Utilizing food-grade material for construction and practice that complies with lipid processing standards.
• Keep an eye on consumer trends in omega-3 and fish oil products, adjusting production as necessary (e.g., increased demand for higher purity or specialized products) to stay competitive.
• Installing wastewater treatment systems to comply with environmental regulations.
• Using energy-efficient equipment to minimize carbon footprint.

Results and Key Outcomes

• High-Purity Product: The plant consistently produced fish oil with EPA/DHA concentrations exceeding 84%.
• Regulatory Compliance: Achieved GMP and HACCP certification, enabling exports to Europe and North America.
• Cost Efficiency: Advanced equipment reduced energy consumption by 30%, lowering operational costs.
• Sustainability: By-product utilization and waste treatment minimized environmental impact.
• Scalability: The process equipment was designed for future expansion, with the capacity to double output when needed.

Lessons from the Case Study

1. Clear Objectives Drive Success: Setting specific goals for product quality, feedstock quality , practice compliance, and capacity helps guide every decision.
2. Technology Matters: Investing in advanced equipment ensures efficiency, quality, and compliance.
3. Strategic Regulation Is Key: Aligning with regulatory standards early avoids costly delays and rework.
4. Sustainability Adds Value: Eco-friendly practices not only reduce environmental impact but also enhance brand reputation.

How Can You Apply These Insights?

If you’re planning to build or upgrade a fish oil processing plant, here’s how to get started:

• Define your product goals and market requirements, such as product purity and Quality Standards. Food-grade: Typically around 30-50% Omega-3 concentration. Pharmaceutical-grade: Higher concentrations (70% or more) for supplements and medical use.
• What’s the aim for low levels of contaminants (e.g., heavy metals, PCBs, dioxins) to meet stringent safety standards? High purity and quality directly impact your product’s marketability and regulatory compliance.
• What’s the Product Formats? Concentrated Oils: For supplements, functional foods, and pharmaceuticals. Soft Gel Capsules: A popular delivery format for consumer convenience.
• Collaborate with process experts and practice experts to design a process workflow tailored to your feedstock and product needs.
• Invest in advanced technology for quality and efficiency.
• Balance production costs with the need to offer competitive pricing.
• Ensure compliance with global standards to access new markets.
• Plan for scalability to future-proof your facility and competitiveness.

Are You Ready to Elevate Your Fish Oil Production?

Let’s work together to build modern processing plants and equipment units that meet your goals and exceed industry standards. With our advanced equipment and strategic planning expertise, we can help you achieve high-quality production while reducing costs.

Reach out to me at livia.zhou@greatwallcontrol.com to discuss your project. Together, we’ll transform your vision into reality.

Questions You May Ask Before Starting Your Fish Oil Processing Plant?

1. What are your product goals?

Are you producing pharmaceutical-grade omega-3 concentrates or food-grade fish oil supplements? Your product goals determine the refining and purification processes. Learn about EPA/DHA standards here.

2. Do you understand the latest industry trends?

Over the past 20 years, the industry has moved towards higher purity, sustainability, and advanced automation. Are you leveraging these advancements? Explore industry trends.

3. How will you plan your facility layout?

An optimized layout ensures efficient workflow, minimal contamination, and streamlined maintenance. Contact us for a solution.

Map out key processes: degumming, neutralization, winterization, molecular distillation, deodorization, esterification, and EPA/DHA concentration.

Separate raw material handling, refining, and packaging zones to avoid contamination.

4. What technology will you use for purification?

From short path molecular distillation to high-performance liquid chromatography, the right technology ensures consistent quality and compliance. Read more about refining technologies.

5. Are you prepared for regulatory compliance?

GMP, HACCP, and GOED certifications are crucial for global market entry. Check regulatory standards.

6. How will you manage by-products?

Fish oil, wastewater, and other by-products need responsible management to reduce waste and generate additional revenue.

7. Do you have a clear project management strategy?

A strategic plan with milestones and risk assessments is essential for staying on budget and schedule. Discover project management tools.

Set measurable milestones (e.g., 30% equipment installation, 50% regulatory compliance achieved).

Use project management tools to track progress and adjust timelines as needed.

8. What steps will you take to future-proof your facility?

Scalability and adaptability are key to long-term success. Read about future-proofing production.

Strategic Insights from Two Decades of Industry Experience

1. Start with Clear Objectives

The plant manager I work with always stresses the importance of clarity. Define your product goals, production capacity, and market expectations upfront. This clarity drives every decision, from technology selection to plant layout.

• Action Step: Engage stakeholders early to align objectives. Remember, your end product determines the process flow and equipment needs.

2. Leverage Industry Advances

The fish oil industry has evolved significantly over the past two decades. Advanced molecular distillation techniques now allow for unparalleled purity, while automation enhances efficiency and reduces human error.

Partner with experts who understand these technologies and can customize solutions for your needs.

3. Strategic Facility Design

A well-designed facility is a game-changer.

My plant manager colleague emphasizes separating raw material zones from processing areas to reduce contamination risks. Plus, ensuring ample space for quality control labs can save time and improve efficiency.

Work with experienced designers who prioritize workflow and regulatory compliance.

4. Focus on Compliance and Certifications

Regulatory compliance is non-negotiable.

The plant manager’s decades of experience have taught us that robust documentation, regular audits, and trained staff are the backbone of compliance.

Establish SOPs for every process step and invest in staff training programs.

5. Embrace Sustainability

Sustainability isn’t just a buzzword; it’s a business imperative.

The plant manager advocates for turning by-products like fish oil distillation residues into secondary revenue streams while ensuring wastewater treatment aligns with environmental standards.

Incorporate eco-friendly technologies and explore ways to monetize by-products.

6. Plan for Scalability

Designing for today’s needs is short-sighted.

The plant manager advises building flexibility into the facility so it can adapt to future market demands without requiring a complete overhaul.

Invest in modular equipment and leave room for expansion in your layout.

7. Implement Rigorous Quality Control

From testing EPA/DHA ratios to ensuring purity, quality control is critical. In-line monitoring systems can provide real-time data, minimizing waste and ensuring consistency.

Set up a fully equipped lab and implement continuous monitoring technologies.

8. Strategic Project Management

With two decades of plant management experience, my colleague emphasizes the importance of systematic project management. Phased approaches, clear milestones, and proactive risk management are essential.

Meanwhile, we work with reliable equipment manufacturers who offer customization and after-sales supports.

Use project management tools to track progress and ensure accountability. Hire skilled operators, engineers, and quality control personnel. We are capable of providing training on equipment operation, compliance, and troubleshooting.

Why Take Action Now?

The fish oil market is growing rapidly, with increasing demand for high-purity omega-3 products. Companies that invest in advanced facilities today will lead the market tomorrow.

Are you ready to take the next step? Let’s work together to build your fish oil refinery and purification plant. With my expertise and the strategic insights of a plant manager who has mastered this industry, we can create a facility that not only meets your goals but also exceeds industry standards.

Reach out to me at livia.zhou@greatwallcontrol.com to discuss how we can improve your business performance. Let’s transform your vision into reality.

Conclusion

Building a fish oil refinery and purification plant doesn’t have to be overwhelming. With two decades of experience behind us, we’ve developed a strategic, systematic approach that ensures success.

Let’s talk and start building your future today.

reference resource：

https://pmc.ncbi.nlm.nih.gov/articles/PMC9865908

https://www.sciencedirect.com/science/article/abs/pii/S0255270120306334

https://www.abcmach.com/oil-pressing/fish-meal-and-fish-oil-production.html

https://www.imarcgroup.com/fish-oil-processing-plant-project-report

https://www.sciencedirect.com/topics/food-science/omega-3-fatty-acid