How Kaia Seafoods, KAPP, and Sæplast are helping protect premium seafood from the moment it comes on board

Alaska Pacific cod is already one of the world’s great seafood products. It comes from cold, clean waters and has the natural quality, texture, and flavor that premium markets look for.

For Kaia Seafoods, the challenge is not to create that quality. It is to preserve it.

Onboard the F/V Kaia in Dutch Harbor, Alaska, Erik Velsko, Lacey Velsko, Captain Murray, and the crew are showing what it takes to protect that value from the first moment the fish comes out of the water. Their focus is not simply on landing more fish. It is on landing better fish, fish that arrives fresher, stronger, and with more of its natural quality intact.

That mindset is at the heart of Kaia Seafoods.

Quality does not begin at the processing plant. It begins on deck. It begins with how the fish is handled, how quickly it is chilled, how carefully it is stored, and how consistently that process is repeated in real fishing conditions.

As Lacey Velsko explains in the film, this is about building a seafood business around higher standards rather than shortcuts.

“Alaska cod is already an exceptional product. Our job is to protect that quality from the moment it comes on board.”
Lacey Velsko
Co-owner and Business Partner, Kaia Seafoods

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Quality That Deserves to Be Protected

In Alaska, fishermen work with an exceptional raw material. Pacific cod has the potential to become a premium product, but that potential can be lost quickly if temperature, handling, and storage are not controlled from the start.

Every minute matters.

When fish is exposed to temperature changes, rough handling, or uneven chilling, quality begins to decline. Texture, appearance, freshness, shelf life, and ultimately value can all be affected before the product ever reaches the dock.

Kaia Seafoods is taking a different approach.

Instead of treating chilling as an afterthought, Kaia has built it into the center of the onboard process. The goal is simple: protect the fish while it is at its best.

That is where KAPP’s OptimICE® slurry ice technology plays a critical role.

OptimICE® surrounds the fish with liquid slurry ice, allowing for fast, uniform chilling and stable temperature control throughout the trip. For Kaia, that means the catch can be cooled quickly, handled gently, and held in a controlled environment from vessel to dock.

The result is a more consistent product — and a better way to preserve the natural quality of Alaska cod.

A System Built for Real Fishing Conditions

This film brings the story on board the F/V Kaia, where quality has to work in practice, not just in theory.

Captain Murray and the crew are responsible for making the system work in demanding North Pacific conditions. On deck, there is no room for complicated processes that slow down the operation. The equipment has to be durable. The workflow has to be practical. And the quality system has to fit the vessel's rhythm.

That is why the partnership between Kaia Seafoods, KAPP, Sæplast, and iTUB is so important.

KAPP provides the slurry ice technology. Sæplast provides the durable insulated tubs. iTUB supports the logistics that make the tub system practical for the operation. Together, the system helps Kaia protect the catch from the start.

The fish is not simply stored. It is actively protected.

“On deck, the system has to work. The tubs, the ice, and the handling all have to fit the rhythm of the boat.”
Captain Murray
Captain, F/V Kaia

From Vessel to Dock, Every Step Matters

For Kaia Seafoods, quality is not one decision. It is a chain of decisions.

It is the choice to use better tubs.
It is the choice to chill faster.
It is the choice to reduce unnecessary handling.
It is the choice to protect the fish before quality is lost.

From the moment the cod comes on board, the process is designed to preserve value. Sæplast insulated tubs help protect the product physically and thermally. KAPP’s OptimICE® slurry ice helps maintain rapid, consistent chilling. The onboard crew brings the discipline and attention to detail needed to make the system work trip after trip.

That combination is what makes the difference.

It is not about volume alone. It is about respect for the fish, respect for the work, and respect for the value that can be created when quality is protected from the beginning.

A Family Business Raising the Bar

With Erik and Lacey Velsko, Kaia Seafoods is also a story about building something for the future.

Their approach reflects a broader shift in the seafood industry. Premium markets are asking for better quality, better handling, and more consistency. Buyers can see the difference. Processors can work with the difference. And consumers ultimately benefit from a better product.

Kaia is showing that Alaska seafood can compete not only on origin and volume, but on quality, presentation, shelf life, and value.

That requires a different mindset. It also requires the right partners.

Working with KAPP and Sæplast, Kaia is helping demonstrate what a modern onboard cold chain can look like for Alaska cod. The fish already has exceptional natural quality. The system is there to protect it.

Setting a Higher Standard for Alaska Seafood

This story is not just about equipment.

It is about changing expectations for how Alaska seafood can be handled, chilled, and delivered. It is about moving away from the idea that success is measured only by how much fish is landed. It is about proving that quality-focused fishing can create more value from every catch.

For Kaia Seafoods, the mission is clear: preserve the quality Alaska cod already has and deliver a product that reflects the fish's true value.

With KAPP’s OptimICE® technology, Sæplast insulated tubs, and a crew committed to doing things right, the F/V Kaia is helping set a higher standard from sea to shore.

Because when the fish is this good, every step should be designed to keep it that way.

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In seafood processing, freezing gets a lot of attention.

We talk about fast freezing, stable storage, cold-chain control, shelf life, yield, and product quality. All of that is important. But there is another step that often receives far less attention, even though it can have a major impact on the final result:

Thawing.

For many processors, thawing is still treated as a necessary pause in production. Frozen raw material arrives, water is used, time passes, and eventually the product is ready for the next step.

But thawing is not just “defrosting.”

It is a critical processing step that can affect yield, texture, food safety, water use, labor, production planning, and ultimately the value of the finished product.

The hidden cost of uncontrolled thawing

In many seafood plants, thawing frozen fish can take several hours or the entire length of a full production day. In some cases, the process relies on totes, hose stations, continuous overflow, and large amounts of water.

At first glance, the water volume in each tote may not seem excessive. A tote is filled, the product begins to thaw, and the water continues to move. But once the process runs continuously for several hours, the initial fill can account for only a small share of the total water use.

In a typical tote-based thawing setup, the water used per tote can multiply many times over during one thawing cycle. When that is scaled across many totes, several batches per day, and a full production season, the result can move from “normal process water” to a very large annual water footprint.

For some operations, tote thawing can represent significant water use on a daily basis and millions of gallons over a full year. In larger layouts or expanded production, the number can climb even further.

That matters.

Not only because of the cost of water, but because of the cost of handling, chilling, pumping, draining, and managing that water through the plant.

Summer makes the problem harder.

Water-based thawing becomes even more challenging during warmer months.

When incoming water temperature rises, processors may need more cooling capacity to maintain the desired thawing conditions. That can increase the load on chillers, utilities, and plant infrastructure.

The issue is not only:

How much water are we using?

It is also:

• What temperature is that water?
• How much energy is needed to control it?
• How consistent is the process from batch to batch?
• What happens to product quality when the water temperature is too high?

If the process depends on continuous overflow, higher summer water temperatures can quickly turn into a quality, efficiency, and infrastructure challenge.

Thawing is a heat-transfer problem.

At its core, thawing is about adding heat to a frozen product in a controlled way.

That sounds simple, but fish is delicate. If heat is added too slowly, thawing becomes a bottleneck. If heat is added too aggressively, the product can be damaged.

The challenge is to thaw fast enough to support production, but gently enough to protect the raw material.

This is especially important for frozen fish blocks and individually frozen products, where the outer layers may thaw faster than the inner layers. If the surface is exposed too long while the core remains frozen, processors risk quality loss, drip loss, and inconsistent temperature throughout the product.

That is why time, water temperature, flow, product movement, circulation, and equalization all matter.

Water is useful, but it needs to be controlled.

Water is commonly used for thawing because it transfers heat more efficiently than air and helps keep the product surface moist. In some tote-based systems, processors also use air agitation or bubbling to improve water movement around the product.

This can help circulation, but the process still depends on good control of water temperature, flow, overflow, and total water use.

Water-based thawing can create problems when the process is not properly controlled.

Too much water increases cost and waste.Water that is too warm can affect product quality.Inconsistent flow can create uneven thawing.Continuous overflow can hide the true cost of the process.Water management must also be designed to support food safety, sanitation practices, and product quality.

The goal should not simply be to use more water, more air, or higher temperatures to thaw faster. The goal should be to create a controlled process that delivers the right product condition at the right time, with the least possible waste.

Better thawing improves more than quality.

Improving thawing is not only about making the product look better.

It can improve the entire production flow.

When thawing is predictable, production teams can plan more accurately. Product can move into cutting, portioning, brining, packing, or further processing at the right time. Labor can be used more efficiently. The plant can avoid having too much product waiting or not enough product ready.

Better thawing can help processors reduce:

• Water consumption
• Energy waste
• Drip loss and yield loss
• Manual handling
• Waiting time
• Raw material variability
• Unnecessary overflow
• Utility load during warmer months

And it can help improve:

• Yield
• Texture
• Surface quality
• Food safety
• Production planning
• Throughput
• Finished product value
• Process consistency

In other words, thawing is not just a utility step. It is a value-protection step.

From thawing time to thawing control

Many processors measure thawing mainly by time.

“How long does it take?”

That is an important question, but it is not the only one.

A better set of questions might be:

• How much water are we using per tote, per batch, and per day?
• How much of that water is actually needed?
• What is the water temperature during the process?
• How does summer water temperature affect quality and cooling demand?
• How consistent is the product temperature at the end?
• How much drip loss or yield loss are we seeing during and after thawing?
• Is the product ready for immediate processing?
• Can we reduce thawing time without damaging the product?
• Can we reduce overflow without losing control?
• Can we improve circulation without unnecessarily increasing water use?

The future of thawing is not just faster thawing. It is smarter thawing.

It is about controlling the process so seafood processors can protect the value already created through catching, handling, chilling, freezing, storage, and transport.

Where technology comes in

This is why controlled thawing technology has become an important focus area for KAPP.

With RoteX Thawing®, the goal is not simply to thaw faster. The goal is to make thawing more predictable, efficient, and gentle on the raw material.

The system is designed around control of thawing time, water temperature, throughput, and energy consumption. It supports low-temperature thawing, helps reduce drip loss, and prepares the product for immediate downstream processing.

But the bigger point is not the machine itself. The bigger point is the shift in mindset.

Thawing should be treated as a controlled processing step, not a passive waiting period.

When processors move from uncontrolled to controlled thawing, they can reduce variability, improve yield, reduce water and energy waste, and better protect product quality.

A process worth rethinking

Seafood raw material is too valuable to lose quality during thawing.

Processors are under constant pressure to improve yield, reduce waste, manage labor, lower water and energy use, and deliver consistent quality to customers. Thawing sits directly in the middle of all those priorities.

For that reason, it deserves more attention.

Not as an afterthought.

Not as a bottleneck.

But it is a controlled processing step that can help seafood companies protect quality, improve efficiency, reduce water use, and get more value from every kilo of raw material.

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How Hildur SH-777 is using OptimICE (CO2) to protect the catch from sea to shore

For a fishing operation like Hildur SH-777, quality begins the moment the fish comes onboard.

Operating out of Rif on the Snæfellsnes peninsula in West Iceland, the crew works in an environment where speed, consistency, and careful handling are critical. Their daily trips, focused mainly on cod and haddock, depend on quickly and evenly chilling the fish so that freshness, texture, and product quality are preserved all the way through landing, processing, and export.

That is where OptimICE (CO2) from KAPP has made a real difference.

For Hildur SH-777, this is not only a story about slurry ice. It is also a story about being among the early adopters of a more future-oriented onboard chilling solution. KAPP’s CO2 OptimICE systems use a 100% CO2 refrigerant and are designed to combine high chilling performance with lower environmental impact and lower operating cost.

A daily operation where every minute matters

Hildur SH-777 is a modern steel vessel working in demanding conditions where the catch must be handled correctly from the very first step. Once the fish comes onboard, the process moves quickly: the fish is bled, cleaned, and prepared before being placed in tubs or in the hold, where slurry ice is applied between layers and over the top.

For the crew, this is not just routine. It is the foundation of product quality.

With daily landings and fish moving into further processing and export, there is little room for delay or inconsistency. Temperature control and fast chilling are essential to protecting the value of the raw material. That is why the choice of chilling method matters so much onboard Hildur SH-777.

Why the crew chose OptimICE

Before OptimICE, traditional ice created more manual work and a slower chilling process onboard. Shoveling ice took time, added physical strain, and did not provide the same level of fast, even coverage around the fish.

According to Guðmundur Ragnar Guðmunduson, second engineer onboard Hildur SH-777, one of the biggest benefits became clear immediately:

“What we gain most is time.”

Guðmundur Ragnar Guðmunduson, Second Engineer, Hildur SH-777

That time matters because it helps bring the fish down to temperature faster, which directly affects quality.

As Guðmundur explains:

“We are much quicker getting the fish down to roughly about zero, which preserves the meat and fish very, very well.”

Guðmundur Ragnar Guðmunduson, Second Engineer, Hildur SH-777

For Hildur SH-777, this improvement is not only about making the process easier. It is also about using one of the early OptimICE (CO2) installations — combining the quality benefits of slurry ice with a natural refrigerant platform that reflects where cooling technology is heading. KAPP presents natural refrigerants as the future and positions CO2 OptimICE as a way to reduce environmental impact without giving up performance.

Better chilling means better quality

For Hildur SH-777, OptimICE is not only about making the process easier. It is about protecting the catch more effectively.

The crew repeatedly cited improved product quality as one of the system's biggest advantages. Faster, more even chilling helps preserve freshness, texture, and overall condition from the moment you step onboard.

Guðmundur describes the impact clearly:

“OptimICE, first of all, increases the quality majorly.”

Guðmundur Ragnar Guðmunduson, Second Engineer, Hildur SH-777

He also notes that bringing the fish to the desired temperature more quickly improves the final result across the board.

For an operation where the quality of the raw material directly affects the final product, this also means something else: better chilling helps preserve more of the catch's value. That is one of the strongest themes in this case. Faster pull-down, more even coverage, and better temperature control all help protect the catch, supporting quality, presentation, and downstream value.

Slurry ice that reaches every part of the fish

The system's technical strength is something the crew sees in practice every day.

According to Jón Kristinn Guðbjartsson, chief engineer onboard Hildur SH-777, the advantage of slurry ice is that it moves around the fish much more effectively than traditional ice.

“It covers every square centimeter of the fish.”

Jón Kristinn Guðbjartsson, Chief Engineer, Hildur SH-777

Because the slurry flows between layers and into spaces that regular ice cannot reach in the same way, the cooling effect is faster and more even.

Jón explains it simply:

“It chills everything very quickly.”

Jón Kristinn Guðbjartsson, Chief Engineer, Hildur SH-777

That difference is central to the onboard process. It means the fish is better protected during the most critical part of the journey — from catch to hold.

One of the first CO2-based OptimICE systems

What makes this case especially interesting is that Hildur SH-777 is not just using OptimICE; it is using one of the first CO2-based OptimICE systems.

That matters because refrigerant choice is becoming an increasingly important part of the conversation around responsible cooling. KAPP’s CO2-based OptimICE slurry ice machines are designed to reduce carbon footprint while also lowering operating costs. The company also states that replacing a refrigerant such as R-449A with CO2 lowers Global Warming Potential (GWP) from 1397 to 1.

For Hildur SH-777, that adds another layer of value to the installation. The system is helping the crew chill faster and better protect quality today, while also pointing toward a more sustainable future for onboard refrigeration. It is a practical example of how performance and environmental responsibility can move forward together.

Built for demanding days at sea

The real value of a chilling system becomes most obvious when the pace is high.

On larger fishing days, when Hildur SH-777 may be handling significant volumes on board, the system must keep up continuously without compromising quality or workflow. The crew described this consistency as crucial. When the operation is moving fast, they need a system that runs all day and, according to the crew, OptimICE does exactly that.

This is not only about output. It is about confidence. The crew knows the system can support the vessel through a full working day while maintaining the quality standards they need.

That reliability is part of what makes this more than a technology story. It is an operational story. A chilling solution only creates real value if it performs under demanding conditions and high volumes. For the crew onboard Hildur SH-777, that reliability is part of what makes the system work.

Easier handling, less physical strain

Another benefit the crew emphasized is the difference in daily handling.

Traditional icing places greater physical strain on the crew due to the manual work involved. With slurry ice, the process is easier and less demanding onboard. That may sound like a practical detail, but on a working fishing vessel, it has real value. Reduced strain, smoother handling, and a more efficient workflow all contribute to better overall operations.

For the crew, this has become part of the everyday advantage of using the system.

Built on practical innovation

For Hildur SH-777, confidence in the solution is about more than performance alone. It is also about knowing the system is built on real industry knowledge and practical understanding of onboard operations.

As one of the first CO2-based OptimICE installations, the system represents not only a step forward in chilling performance, but also a more forward-looking approach to refrigeration. For operators, that means a solution designed around the realities of fishing at sea, where reliability, product protection, and ease of operation matter every day.

“You pay for quality.”

Perhaps the strongest statement in the interview is also the simplest.

At the end of the day, the crew sees OptimICE as a solution that improves quality, supports the workflow, and protects the value of the catch.

Guðmundur sums it up in a line that captures the whole story:

“It’s quicker, it’s easier… you pay for quality. That’s the point.”

Guðmundur Ragnar Guðmunduson, Second Engineer, Hildur SH-777

That is what this case is really about.

For Hildur SH-777, OptimICE has become a practical part of the operation, helping the crew chill faster, handle fish more efficiently, reduce physical strain onboard, and maintain higher quality from sea to shore. And because this is one of the first OptimICE (CO2) systems, it also shows how high-performance onboard chilling can move in a more sustainable direction without losing sight of what matters most at sea: protecting quality and preserving value in the catch.

In a business where better handling leads to better products, and better products lead to greater value, that makes all the difference.

How Erik Velsko Elevated Quality and Price with OptimICE®

Erik Velsko
Owner and Operator, Kaia Seafoods
Homer, Alaska

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Erik Velsko has spent his life on the water.

He grew up in the fishing industry, starting at a young age alongside his father. Over the years, he worked his way through different fisheries and operations, gaining experience from small boats to large-scale commercial fishing in the Bering Sea. Like many in the industry, his early career was shaped by one clear objective. Catch as many fish as possible.

“For a long time, success in this business was measured in volume,” Erik explains. “The guys who caught the most fish made the most money. That was the mindset.”

But the industry has evolved. Markets have become more demanding, buyers more selective, and margins more dependent on quality rather than just quantity. Erik began to see that simply landing fish was no longer enough.

“The turning point for me was realizing that the value of the fish doesn’t come from how much you catch. It comes from how well you handle it.”

A Shift in Mindset

Running his own operation at Kaia Seafoods, Erik began to view the entire value chain differently. The question was no longer how to maximize volume. The question became how to maximize value from every single fish.

That meant focusing on quality from the very first moment.

“When the fish comes out of the water, that’s when the clock starts. Everything you do after that either protects the quality or reduces it.”

Traditional methods, including flake ice and conventional chilling, were not delivering the consistency he sought. Cooling was uneven. Handling required more labor. And most importantly, the end product did not always reflect the full potential value of the catch.

“There were too many variables. You could do everything right, and still end up with fish that didn’t look or perform the way you wanted.”

Erik needed a system that would remove that variability and give him control.

Discovering a Better Way to Chill

That is when he was introduced to OptimICE® and a different way to control quality.

Unlike traditional ice, OptimICE® is a liquid slurry ice that completely surrounds the fish. Instead of cooling from the outside in, it delivers rapid, uniform chilling throughout the entire product.

“What stood out immediately was how fast and consistent the cooling is,” Erik says. “You are not guessing anymore. You know the fish is being treated the same way every time.”

The system allows the fish to be brought down quickly to optimal temperature and then held there consistently throughout the trip. There are no hot spots, no uneven cooling, and no need for constant manual handling.

“It takes a lot of the uncertainty out of the process. Once the fish is in the system, you know it is being preserved the right way.”

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Quality You Can See

The impact was immediate.

From appearance to texture, the difference in product quality became clear. Fish handled with OptimICE® maintained a fresher look, better structure, and more consistent condition by the time it reached buyers.

“You can see it right away. The fish looks better. It feels better. It holds up differently.”

Maintaining a stable temperature throughout the entire process is critical. With OptimICE®, the fish remains at a consistent low temperature without freezing, preserving its natural quality while slowing down bacterial activity and degradation.

“The biggest thing is consistency. Every fish is treated the same way, and that shows when you land your catch.”

This level of control gives Erik confidence in what he is delivering. It removes the guesswork and replaces it with a repeatable process.

Less Handling, More Efficiency

Beyond quality, the operational improvements have also been significant.

Traditional icing methods require manual labor, constant attention, and physical handling of ice. With OptimICE®, much of that work is eliminated.

“There is less manual work involved. You are not shoveling ice or trying to manage it throughout the trip. The system does the work for you.”

This not only reduces labor demands but also allows the crew to focus on other critical tasks onboard.

“It simplifies things. It makes the whole operation more efficient.”

In a business where time, effort, and crew capacity all impact profitability, these improvements matter.

The Real Impact. Value

While quality and efficiency are important, the ultimate measure of success is the value of the product.

This is where Erik has seen the most meaningful change.

“When you deliver a better product, the market responds.”

Buyers recognize the difference in quality. Better handling leads to better presentation, longer shelf life, and improved usability for processors and distributors. That translates directly into stronger pricing.

“We are getting paid for the quality now. That is the difference.”

Instead of competing on volume alone, Erik is now positioned in a higher-value segment of the market. His catch is not just another delivery. It is a premium product.

“It changes how your fish is perceived. And that changes what it is worth.”

A Different Way to Compete

For Erik, adopting OptimICE® was not just a technical upgrade. It was a strategic shift.

“It is not about catching more fish. It is about making each fish worth more.”

That shift has allowed him to move away from the traditional race for volume toward a more sustainable, profitable model.

“When you focus on quality, you are not just working harder. You are working smarter.”

This approach aligns with where the industry is heading. As supply chains become more quality-driven and consumers demand better products, the ability to deliver consistent, high-quality seafood becomes a competitive advantage.

Looking Ahead

Erik believes this shift toward quality will only accelerate.

“The industry is changing. Buyers are paying more attention. They know what a good product looks like.”

For fishermen and operators who want to stay competitive, the message is clear.

“If you are serious about improving your product and getting the most value out of your catch, you have to look at how you handle it from the start.”

OptimICE® has given Erik the tools to do exactly that.

“It gives you control. It gives you consistency. And in the end, it gives you a better product.”

Closing Thought

For decades, success in fishing was defined by how much you could catch.

Today, it is increasingly defined by what your catch is worth.

Erik Velsko has made that transition. By focusing on quality, consistency, and control, he has elevated not just his product but his entire operation.

And in doing so, he turns every trip into a higher-value delivery.

Stop leaving money on the table with outdated chilling methods.

Discover how the right technology can elevate your product's market price.

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By KAPP | Performance Backed by Proof

When it comes to chilling fish, there’s a lot of tradition and a lot of guesswork. But a new scientific study out of Iceland cuts through the noise with hard data.

In a tightly controlled trial, researchers at Matís compared fish cooled in an older RSW system with those chilled using modern slurry ice.

Same vessel. Same species. Same processing. Just different chilling methods.

Here’s what the numbers showed:

What’s the Cost of Doing Nothing?

• More downgraded or rejected fish
• Shorter shipping and sales window
• Less leverage with premium buyers
• Lost margins due to quality inconsistency

If you’re running an older RSW system, and many vessels in Alaska still are, these numbers are a wake-up call.

Rethink Your Onboard Setup

Modern chilling systems aren’t just about bells and whistles. They’re about data-backed performance that improves:

• Profitability
• Shelf life
• Cold chain efficiency
• Your long-term competitiveness

At KAPP, we’ve helped vessels in Alaska and Iceland move from tradition to transformation by upgrading their chill and watching the value follow.

📩 Ready to stop guessing and start measuring? Let’s talk data-driven chilling.

This article is based on the: Pacific cod shelf-life experiment report – Effects of onboard slurry ice cooling and tub storage on quality parameters: 04_25_Slurry vs RSW - MATIS report final version.pdf

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By KAPP | Temperature Control from Deck to Dock

In the seafood industry, we talk a lot about “cold chain integrity.” But what if the weakest link isn’t in transport or storage, but right where the fish is caught?

That’s the finding of a recent study (March 2025) from Iceland’s Matís research institute, which compared two identical cod trips: one using traditional RSW cooling, and the other using a modern slurry ice system.

The chilling difference?

• The slurry ice method extends the shelf life of Pacific cod by six days or longer compared to traditional RSW chilling.

That single variable led to significant differences in shelf life, drip loss, microbial activity, and, most importantly, the final price.

Cold Chain Starts at Sea

In Alaska, many vessels still rely on older RSW systems with slow down cooling, uneven temperatures, or slow circulation. And while processors and logistics providers have invested heavily in downstream cold chain systems, those upgrades can’t fix damage that’s already done.

If fish are warm in the first 3 hours, they’re compromised for the next 30 days.

This is especially true for:

• Longliner and pot cod fisheries
• Halibut boats operating multi-day trips
• High-value groundfish targeting export markets

Start Strong. Stay Cold.

Investing in first-mile chilling technology pays off across the entire cold chain, from dockside QC to final delivery. That’s why more vessels are turning to KAPP’s OptimICE® slurry systems to:

• Cool faster
• Protect quality
• Avoid spoilage
• Extend their sales window

Let’s fix the weakest link and put Alaska’s cold chain where it belongs: on top.

📩 Reach out to learn how OptimICE can give your vessel the cold start it needs.

This article is based on the Pacific cod shelf-life experiment report – Effects of onboard slurry ice cooling and tub storage on quality parameters: 04_25_Slurry vs RSW - MATIS report final version.pdf

By KAPP | Engineering the Cold Chain of the Future

Sustainability isn’t just about fuel usage or fishing quotas anymore. In today’s market, shelf life is a sustainability metric, and it’s one that the seafood industry can’t afford to ignore.

A recent independent study by Icelandic researchers at Matís made one thing clear: the way fish are chilled onboard directly determines how long they’ll last, and how much of each catch is truly utilized.

Using two identical trips on a 29-meter trawler, researchers compared fish chilled in:

• A 30-year-old RSW tank (like many still used in Alaska)
• A modern slurry ice system designed for rapid, uniform cooling

The results were hard to ignore:

• Fish chilled in slurry ice lasted at least 5 days longer
• Had better texture, appearance, and flavor
• Suffered less water loss and yield shrinkage
• Higher quality scores indicating greater market value potential

What This Means for Alaska

For vessels, processors, and communities relying on seasonal harvests, maximizing the usable life of your product isn’t just smart; it’s sustainable.

Let’s face it: fish that spoil early get thrown away, sold cheap, or turned into secondary products. That’s lost revenue and wasted resources.

Every day of shelf life you gain means:

• More market options
• Better logistics
• Lower waste
• Less pressure to rush product to port

Make Sustainability Pay Off

Modern chilling isn’t a luxury, it’s a competitive advantage. And it helps Alaskan fishermen, processors, and communities do more with every fish landed.

KAPP’s OptimICE® slurry ice system is already at work on vessels in Alaska, helping them:

• Improve cold chain performance
• Increase usable product yield
• Hit export specs with confidence

Let’s build a sustainable seafood future, one cold degree at a time.

📩 Let’s talk shelf life.

This article is based on the: Pacific cod shelf-life experiment report – Effects of onboard slurry ice cooling and tub storage on quality parameters: 04_25_Slurry vs RSW - MATIS report final version.pdf

By KAPP | The Cold Chain Starts at Sea

In today's seafood industry, freshness is non-negotiable. Processors, retailers, and end consumers demand high quality, and that starts the moment fish are brought onboard.

That's why more vessels are adopting slurry ice systems, like OptimICE®, to ensure consistent, sub-zero cooling from catch to consumer.

What Is a Slurry Ice System?

OptimICE® is a liquid slurry ice technology that replaces conventional flake ice and RSW. It produces a flowable ice mixture from seawater or saltwater, rapidly chilling fish to below 0°C / 32°F — typically reaching -0.5°C / 30.5°F within 2 hours — without freezing the product.

Unlike flake ice, which melts unevenly, or a dated RSW system that struggles to maintain uniform cooling, slurry ice surrounds each fish, delivering fast, even, and gentle chilling that preserves freshness and texture.

The result? An unbroken cold chain, from the deck to the dinner plate.

How It's Integrated Onboard

Here's how OptimICE® fits into modern vessel operations:

• Slurry Production Slurry ice is produced onboard using seawater or brine, chilled through a compact refrigeration system.
• Storage Tanks: The ice slurry is stored in insulated tanks with continuous agitation to maintain a uniform mixture, ensuring it is ready for immediate use.
• Distribution System Pumps and pipes carry the slurry directly to key points onboard — bleeding tanks, processing lines, and fish holds — ensuring fast and consistent chilling at every stage.
• Hands-Off Handling Because the slurry flows like water, it automatically surrounds the fish, reducing manual ice handling, bruising, and temperature variation.

Whether you're fishing for cod, halibut, salmon, or other species, OptimICE® keeps the catch at its best, from sea to shore.

Why It Outperforms Flake Ice and RSW

The comparison below is based on a typical onboard processing environment for whitefish or groundfish (e.g., cod, pollock). In this scenario:

• Fish are caught at 10°C (50°F)
• Seawater temperature is 12°C (53.6°F)
• Fish are chilled and stored in tubs
• The goal is to reduce core temperature to 0°C (32°F) or below, without freezing the product

Why It Matters

In today's seafood market, quality beats quantity — and that starts at sea.

With OptimICE®, fish are chilled instantly and gently from the moment they're caught. This protects texture, appearance, and freshness, resulting in better handling, minimal bruising, and lower bacterial activity during the entire journey from catch to consumer.

That translates directly into:

• Higher-grade product classifications
• Longer shelf life
• Improved food safety
• And most importantly: a better price per kilo

By investing in rapid, even chilling, onboard, fleets can maximize the value of every fish, not just the volume of their catch.

In a market that increasingly rewards premium quality, OptimICE® gives you the edge where it matters most.

Let's Talk

Want to explore how OptimICE® can be integrated into your operations, onboard or onshore?

Message me directly at fridrik@kamitech.com or visit www.kapp.com to learn more.

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By KAPP | Smarter Chilling. Better Seafood.

You don’t need a PhD to know that fresh fish sells better. But a recent Icelandic study reveals just how much temperature control onboard can make or break the value of your catch. In Alaska, you can do everything else right, the gear, the timing, the crew, and still leave money on the table if your chilling system doesn’t get the job done fast.

That’s the reality that Icelandic researchers at Matís explored when they ran a head-to-head comparison between two fishing trips for Pacific cod. One used an old-school RSW tank. The other used a modern slurry ice system. Both were processed the same way, landed at the same plant, and tracked through shelf life and auction.

What They Found:

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Key insight: The fish were identical at the point of harvest. But by the time they hit the market, one batch fetched a higher price simply because it was chilled faster and more evenly.

Why This Matters to Alaska

Many Alaskan vessels, especially in the groundfish and halibut sectors, are still using aging RSW systems that can’t cool quickly or uniformly. And with today’s markets demanding traceability, consistency, and longer shelf life, that’s a growing liability.

Alaska competes in global markets that reward quality, shelf life, and handling. Whether you sell directly, through processors, or at auction, buyers know the difference, and they’re paying for it.

The Fix: Upgrade Your Chill

It’s time to stop thinking of chilling as a support system and start treating it as a profit system. Whether you're looking to boost your brand's value, reduce rejected shipments, or hit premium markets, chilling is the first step.

At KAPP, we deliver modern slurry ice systems like OptimICE®, engineered to give you:

• Faster cooling
• Uniform temperatures
• Extended freshness
• Better returns

Better chilling starts onboard. Better prices start with you. Let’s talk about bringing smarter chilling to your boat.

📩 Contact us today.

This article is based on the: Pacific cod shelf-life experiment report – Effects of onboard slurry ice cooling and tub storage on quality parameters: 04_25_Slurry vs RSW - MATIS report final version.pdf

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On October 22nd Jakob Valgeir ehf and KAPP Skaginn signed a contract for a new Tub Handling System and an IQF infeed system that will be installed at the company’s new fish processing plant in Bolungarvík. The construction of a new extension to the facility is expected to be completed at the beginning of 2021. The extension will increase the plant’s freezing capacity by 4 tons an hour.

Jakob Valgeir Boosts Automation with KAPP Skaginn Tub Handling System

Cooperation creates value in the fish processing industry
“It is very enjoyable when two companies from the same region work together on new developments in the Icelandic fishing industry,” says Ingvar Vilhjálmsson, Regional Sales Manager at KAPP Skaginn. “The Tub Handling System is designed to increase the automation and productivity of the plant and support good raw material handling.”

Increased automation for consumer packaging
The new processing facility will be connected to the older plant and the tub handling system will serve both. With new addition in housing and equipment, Jakob Valgeir is increasing its focus on packing products into consumer packaging and taking them directly to market.

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Icelandic Pelagic processor Loðnuvinnslan (LVF) has contracted KAPP Skaginn for a new pelagic processing system for their operation in Fáskrúðsfjörður, Iceland.

Loðnuvinnslan Boosts Pelagic Processing Capacity with KAPP Skaginn System

LVF has chosen KAPP Skaginn to supply a new pelagic processing system, designed to increase automation and processing capacity as well as improve yield and throughput. Their contract with KAPP Skaginn is for a system that will support a continuous production of high-quality pelagic fish at a capacity of up 400 tons per 24 hours.

The company operates a pelagic freezing plant in Fáskrúðsfjörður that specializes in processing capelin, herring and mackerel.

Timing is everything in pelagic processing. ‍

Timing is everything in the pelagic processing business. The resource is seasonal and the operation depends on vulnerable external resources that need to be harnessed at the right time, with the right methods in order to gain maximum yield and quality of the finished product. In order to get the most out of the season LVF wanted to update their operation and have it ready for the next round as capelin and capelin roe is caught and processed between January and March, mackerel and Norwegian-Icelandic herring from July to October and of Icelandic herring from October till the end of the year.

Close cooperation.

“It’s very important to be able to work as closely with the supplier as we’ve been able to do in this project with KAPP Skaginn“, says Friðrik Már Guðmundsson, Managing Director of LVF. “Their expertise and our experience have resulted in the creation of a promising new solution for our entire pelagic factory. The upgrade will increase the automation of our operation and enable us to increase our production capacity,”

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Upgrade to increase throughput.

KAPP Skaginn’s system is very efficient, built around a technology that has serves some of the largest pelagic processors in the world. The advanced automatic system includes a bagging system, high-tech plate freezers and automatic palletizing system, all of which will be integrated with existing equipment, including third party robots to create an efficient, high-throughput pelagic plant.

Experts in high-tech, turnkey pelagic plants.

As turnkey pelagic processing plants have been a staple of KAPP Skaginn‘s production for a long time, it did not take long for a trio of KAPP Skaginn pelagic processing experts to design the system on the spot. It took three men just under a month to scope, spec and implement a contract for this sophisticated, automated upgrade to the existing operation at LVF’s facility.

Working fast to meet the client’s needs.

“We handled this quickly and worked very closely with the customer. Our cooperation has been great from the start and it is a pleasure to be able to continue to work with LVF and expand our services to their operations,” says Ingvar Vilhjálmsson, Regional Sales Manager KAPP Skaginn. “The LVF team were very thorough in their preparation so it was easy for us to create a processing flow that meets their requirements in a relatively short time.”

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Iceland’s Eskja ramps up its impressive production capacity with the addition of two new automatic non-pressure non-pressure plate freezers from KAPP Skaginn.

Eskja Expands Production Capacity with KAPP Skaginn Plate Freezers

Smart processing plant

‍In 2016, KAPP Skaginn and Eskja built a state-of-the-art pelagic fish processing plant in Eskifjörður on the east coast of Iceland. The plant marked a significant move for Eskja from processing at sea to land-based operations. By making use of cutting-edge technologies and advanced automation, Eskja has been able to significantly increase its production capacity and product quality to further differentiate itself in the marketplace. The plant has proven to be an overwhelming success and has served as a showcase on how companies can upgrade their facilities with robotics and automation to achieve the data-driven smart processing of the future.

Full production capacity‍

Building on the companies’ successful collaboration, Eskja has now opted to add two more non-pressure plate freezers to their extensive range of equipment from KAPP Skaginn. This move allows the plant to finally reach its intended production capacity. KAPP Skaginn originally designed the plant with future expansions and improvements in mind, thereby ensuring that additions like these are not only possible but effortless and trouble-free.

The freezers will be installed and implemented into Eskja’s processing plant this December, increasing the total production capacity by over 100 tons every 24 hours before next year’s capelin season. The automatic non-pressure plate freezers use up to 40% less energy than conventional blast freezers and allow for automatic operation, infeed and outfeed. As an integral part of KAPP Skaginn’s turnkey solutions, these highly efficient freezers contribute to increased yield, better handling of raw materials and reduced drip loss.

KAPP Skaginn and Eskja march onwards‍

Always looking for opportunities to do better, shorten processing times and increase yield and product quality, the two companies have collaborated for years, fine-tuning machinery and processes with a data-driven and innovative mindset. This recent purchase by Eskja is only a stepping stone on the companies’ path towards a more efficient and profitable processing plant.

The first RoteX Thawing™ system to be delivered to the Benelux in 2022 is set to support quality refreshed product in a new market.

KAPP Skaginn is proud to announce the first sale of its revolutionary RoteX Thawing™ system in Benelux. The deal was secured in close collaboration with Dutch food equipment supplier IB Food Machines, who facilitated the sale. Based out of Urk, Netherlands the company advises food processing companies worldwide on their production process. The innovative, patented thawing system is designed to deliver high quality re-freshed product that matches the quality of fresh.

KAPP Skaginn Delivers First RoteX Thawing™ System to the Benelux Market

Creating opportunities in new markets

“Closing this sale is a promising start for future cooperation between KAPP Skaginn and IB Food Machines in the area,” says Arnþór Halldórsson, Regional Sales Manager at KAPP Skaginn. “Changes in market conditions and fishing quota allocations over the last few years have resulted in increased demand for thawing systems that allow producers to source frozen product and defrost when fresh fish is not available. The challenge is to maintain freshness and quality and the RoteX Thawing system is designed to do just that. The RoteX Thawing system is filling a gap in the market, allowing customers to produce quality refreshed product that matches the quality of fresh.

The best choice for thawing

IB Food Machines is an agent for equipment manufacturers in the Benelux, and supplies both used and new equipment. KAPP Skaginn is the latest addition to their portfolio. When IB Food Machines set out to find a best in class thawing system for its client, the RoteX Thawing™ system was the best tool for the job. The system will be able to defrost and equalize 2.500 to 4.000 kg of fish per hour depending on fish size and species, and will be delivered in early 2022. Uniform product temperature is achieved with inline thawing and cooling. The process is continuous, eliminating stagnant equalization and storage in tubs, vats or totes and thereby minimizing manual labor and saving time. The system will deliver optimal thawing and cooling before production, which will preserve the quality to match that of fresh fish.

Increased shelf life and better production yield for onshore and onboard processing

Utilizing a patented process, the RoteX Thawing™ system keeps the frozen product in constant motion for faster and more efficient thawing. Thawing and equalizing are performed in a continuous flow resulting in higher production yield and better shelf life on the refresh market.

Preventing drip loss, increasing yield, and saving on both water and labor, the RoteX Thawing™ system has become the favored thawing solution of producers around the world, and is available for both onshore and onboard applications.

As Brazil’s food production industry continues to set records, demand for KAPP Skaginn’s unique IQF freezers in the country grows.

KAPP Skaginn Expands in Brazil with IQF Tunnel Freezers for Poultry and Seafood

When thinking of Brazil, freezing temperatures are far from the first thing that comes to mind. Yet, as Brazil’s population grows, and its industry undergoes a rapid modernization, the need for reliable high-volume food production is on the rise. Leading fish, poultry and meat producers are now employing state-of-the-art IQF freezers from KAPP Skaginn to ensure consistency, yield and throughput in their facilities while reducing losses and retaining the value of their products.

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Vertically integrated operations around the world

‍BRF S.A., one of the largest food companies in the world, now awaits delivery of a multi-lane IQF Tunnel Freezer to its poultry production facility in Dourados, Brazil. The freezer was fabricated by KAPP Skaginn in Akranes, Iceland and is now on its way across the Atlantic. The installation will be carried out by KAPP Skaginn’s agents in Brazil under Icelandic supervision early this November. BRF employs over 100.000 people in its facilities in Latin America, Europe, Asia and the Middle East, and has over 30 brands in its portfolio.

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Technology that keeps getting better

‍KAPP Skaginn has supplied BRF with multiple IQF freezers over the years, with the largest purchase being three units with capacities ranging from three and a half to six tons per hour in 2015 for BRF’s operations in Toledo, Brazil. When KAPP Skaginn announced updated versions of the already well-established IQF Tunnel Freezers, BRF immediately reached out, eager to put the new multi-lane model through the paces.

The new freezer is equipped with three separate full freezing and crust freezing belts with a throughput of up to six tons per hour. With up to 40% faster crust freezing, KAPP Skaginn’s IQF Tunnel Freezer delivers top-quality output with a small footprint and high energy efficiency. A similar IQF tunnel freezer has also been delivered to BRF in Abu Dhabi where it awaits installation.

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Fit for fish and poultry

‍BRF is not the only customer in Brazil that has been impressed with KAPP Skaginn’s freezing technology and equipment whose flexibility and output quality make it the best choice for a wide range of applications. C.Vale is a respected pork, poultry and tilapia producer in the Mato Grosso do Sul and Paraná region where aquaculture is a growing industry. C.Vale acquired its first KAPP Skaginn IQF Tunnel Freezer for its tilapia processing facility in 2018. Pleased with both product quality and operational stability, C.Vale has now taken delivery of two more IQF tunnel freezers, one each for poultry and fish and the freezers are set to be installed in late October this year.

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Same core - different setups

‍KAPP Skaginn’s IQF Tunnel Freezing technology is suitable for a range of applications, from pelagic species, groundfish and salmon to poultry, meat and a variety of seafood. At their heart, the freezers are essentially the same. Differing mostly in infeed systems and the number of lanes, C.Vale’s new freezers both deliver a throughput of 4 tons per hour. Thanks to the easy customization of KAPP Skaginn freezers, each one has been designed to perfectly slot into C.Vale’s production lines. A double-lane configuration was chosen for tilapia while a triple-lane setup provides the best results for chicken production.

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A robust and growing market

‍KAPP Skaginn has developed a close relationship of collaboration with its clients in Brazil through Mauro Tiecher of Tectru Skaginn 3X’s local partner. Deliveries and installations have gone smoothly and operations have exceeded expectations. KAPP Skaginn hopes to build upon this success and continue working closely with BRF and C.Vale on future projects in the region and around the world. Brazil has shown itself to be a robust and reliable market for KAPP Skaginn which knows how to keep the local favorites cool.

Denholm Seafoods’ new ValuePump system transfers pelagic catch a record distance from vessels to plant in Peterhead, Scotland.

Denholm Seafoods Installs KAPP Skaginn ValuePump System in Peterhead, Scotland

This pelagic season in Scotland saw the first ever direct pumping transport of pelagic catch from ship to plant over a distance of 250 meters. Using KAPP Skaginn’s innovative ValuePump, Denholm Seafoods can now convey product gently through a closed, low-pressure pipe system with ice sludge directly from the ship into the production hall. Starting up in October 2021, the system is powered by KAPP Skaginn’s Value Pump and the accompanying pipe system that is connected directly to the delivering pelagic trawler.
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A pump for positive effect

“We wanted to automate more of our processes and find a solution that would positively affect our production flow, quality and costs,” says Richard Duthie, Commercial Director of Denholm Seafoods. “Our efforts to streamline our operation and implement further sustainability measures by not using trucks for catch transport led us to working with KAPP Skaginn on this project.”
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Maximizing yield, quality and throughput

Denholm Seafoods operates three modern purpose-built quayside plants in Peterhead, Scotland, which process herring, mackerel, horse mackerel and blue whiting. Different trawlers supply Denholm Seafoods with the raw material, each with their own type of delivery system that can be connected to the ValuePump transfer line at the dock. The new method not only keeps costs down, eliminating truck traffic between trawler and factory, but also maintains a regulated, steady flow of raw material into production that maximizes yield, quality and throughput.
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A groundbreaking solution for catch transport

“No one has used this method before over this distance. We decided to go for it and chose KAPP Skaginn as our partner,” says Wayne Summers, Engineering Manager at Denholm Seafoods. “We’ve had a long-standing relationship with them and we knew what they could do. With them and our inhouse experts we developed a groundbreaking solution for catch transport that helps us enhance our operation and keep our quality levels where we want them.”  
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Pumps 60 tons of fish over 250 meters

Located in a new reception house on the quay, the system is made up of stainless-steel pipelines, a reception tank with conveyors and the automatic ValuePump that transfers 60 tons of pelagic fish per hour over a distance of 250 meters. “The screw pump method treats the raw material well, maintaining the quality of the catch through the process,” says Duncan Yule, Engineering Manager at Denholm who participated in the development of the project. “Our flow control is now a stepless process making it easy to adjust the capacity and throughput to what we need for production.”

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‍Energy saving method supports sustainability

The ValuePump process creates substantial energy savings both in terms of the operational costs of the system itself — the ValuePump’s energy consumption is far less than that of conventional pumps — and in terms of eliminating traffic on the docks and the accompanying fuel consumption. “We have strict quality control standards that are designed to deliver quicker turnaround for our customers and keep our products sustainable,” says Duthie. “This latest addition to Denholm Seafoods operation is yet another step in lowering our carbon footprint.”

Better flow control, better temperature control

The new system delivers product optimized for further processing in a steady, regular flow, from vessel to factory. “There is a steady flow of fish in fluid ice from the pump into the plant without any pulse or variations,” explains Johannes Weber, Mechanical Design Engineer at KAPP Skaginn, who oversaw the installation at Denholm. “With a continuous pace and a well-regulated, steady temperature, Denholm now has a consistent automatic supply of quality raw material coming in for further processing.”  
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Gentle product handling maintains quality

During the Mackerel season, Denholm Seafood has seen the Value Pump deliver high quantities of raw material at a steady pace over longer distances than possible before. The gentle propelling principle of the ValuePump treats the raw material gently and along with the cooling capacity of the fluid ice, maintains the quality and value of the fish in the pipeline. “The ability to further cool the product in the system has proven to be very beneficial,” explains commercial director Duthie. “As a matter of fact, our Japanese buyers have commented on the better quality of our product after we installed the ValuePump.” Better quality is also gained by preventing product from being exposed to external stressors in the transfer process.
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Collaborative effort key to success

"We started this development project after seeing trials in Iceland. When we saw the potential of the prototype there was no turning back. We had to have it,” says Duthie. “Our collaboration with KAPP Skaginn has gone really well and their hands-on approach has delivered the result we wanted. It has all worked out well, the system exceeded our expectations and the project has been successful."

Mowy’s factory manager dubs the RoteX Sub-chilling system the Rolex of cooling in an interview with iLaks.no

Mowi Improves Salmon Quality and Sustainability with RoteX Sub-Chilling™ System

‍Mowi, the world’s largest producer of Atlantic salmon, decided to invest in the innovative and iceless SUB-CHILLING™ system from KAPP Skaginn in May 2020. Less than a year later the system was up and running in Mowi’s facility in Herøy, Norway. The facility is the largest salmon slaughterhouse to date that uses the patented cooling technology to deliver quality, freshness, and sustainability to its customers around the globe.

Making headlines

iLaks.no, Norway’s most read aquaculture-news site recently did a feature on Mowi’s new SUB-CHILLING™ system, where factory manager Gunnar Hamarsland declared his satisfaction with the system, describing the results as fantastic: “To put it metaphorically, the tank is a RoteX, but I have named it the Rolex,” he said to journalist Steve Hernes.

Iceless sub-zero chilling with a 100 cubic meter RoteX tank

The heart of the SUB-CHILLING™ system at Mowi’s facility is a 100 cubic meter RoteX tank designed to keep fish chilled, ice-free and fresh for longer without freezing the product. Utilizing saltwater that doesn’t freeze at 0° the system turns the fish itself into the cooling refrigerant. The fish stays cool for longer without the need for ice, maintaining better product quality and extending shelf life by up to 7 days.

Shipping more products in each trailer

The lack of ice not only contributes to improved product quality but also plays an important role in improving the sustainability of large and small operations and delivering significant savings in shipping. iLaks.no reports that the weight of ice in a single semi-trailer can be up to 4 to 5 tons. By removing the need for ice more products can be shipped for the same price.

Scaling success to reach 100% of production

So far, Mowi has delivered over 100 tons of fish using far less ice than before to customers in Europe and Asia as part of the system’s testing phase: “Our goal is to do this on a much larger scale. So far, we have run this as separate orders, where we do our tests and measurements here, while the customer reports the status of the fish on arrival,” said production manager Tom Leirvik to iLaks.no, noting that so far the feedback they have received has been very positive. “The experiments we have done since March have confirmed the theory itself, that it is fully possible [to ship fresh fish without ice]. We intend to run this on 100% of our production,” added Hamarsland.

Up and running after 3 weeks

The installation took around three weeks to complete and included extensive upgrades and improvements to existing systems at the facility. A system for mixing salt and water was installed with 700 meters of stainless-steel pipes and 125 remote-controlled valves. “We worked hard for three weeks to get the system up and running. This was an important milestone for us since Mowi is a large and forward-looking company seeking to reduce their carbon footprint and optimize their operations along the way, using our SUB-CHILLING™ technology,” explains Magni Veturliðason, General Manager of KAPP Skaginn AS, Norway.

Better quality with faster ROI

KAPP Skaginn’s SUB-CHILLING™ system is suitable for a range of applications both onboard and on-land and can be configured for a wide variety of species. Tried and tested by whitefish and salmon producers in Iceland and Norway, the system has proven to deliver quality, freshness, and a high return on investment. As the seafood industry in general and salmon in particular, continue to grow in the coming decades, SUB-CHILLING™ is set to play an important role in reducing transport costs, improving shelf life and preserving quality and leading the way to a more sustainable industry.

KAPP Skaginn installs a brand-new production deck built around the RoteXTM chilling and bleeding system that delivers superior raw material quality.

Eskøy Installs New Onboard Whitefish Factory with KAPP Skaginn’s RoteX™ System

A fully equipped new processing deck aboard former longliner, now Danish seine trawler, Valdimar H marks the latest success in the well-established relationship between Norway’s Eskøy AS and KAPP Skaginn. As part of a complete rebuild of the ship, the turnkey onboard factory features a RoteX bleeding and chilling system for immediate processing, along with a full gutting, by-catch and heading line from KAPP Skaginn. As a longstanding supplier to Ice Fresh Seafood, Eskøy is committed to full traceability, sustainability and maximum raw material utilization. With this installation completed in December 2021, Valdimar H is about to set sail and deliver the high-quality product Eskøy set out to achieve.

Building on 13 years of success

“We chose KAPP Skaginn because of their tried and tested systems, which we have used onboard our ships since 2009,” says Hrafn Sigvaldason, CEO at Eskøy AS. “Any project involving KAPP Skaginn has stood the test of time and the service has been outstanding.” For over a decade, Eskøy and KAPP Skaginn have thus continued to foster their relationship, which is rooted in a shared vision: Providing customers and consumers with high-quality sustainable products while ensuring maximum efficiency and superior product handling.

Full control over bleeding and chilling

The heart of the production deck is the highly popular RoteX Onboard bleeding and chilling solution. The high-capacity system provides complete control of the process with integrated software for time and temperature management. This guarantees that every single fish receives exactly the same level of treatment so that excellent fillet quality can be achieved.

Better handling, faster processing

“What we are looking to achieve with this investment is fast and effective bleeding and chilling of the catch, along with an excellent production flow without having to drop or lift the fish,” says Hrafn Sigvaldason. “This solution thus provides much better handling while allowing us to process the fish faster, something that will pay dividends down the line.”

High throughput and efficient by-catch handling

Once the catch has been bled and chilled in the RoteX, it enters the production line where the primary catch of cod and haddock is sent on to gutting and heading before entering the hold. By-catch is kept chilled in tubs and processed later, allowing for flexibility and prioritization in production.

Better quality, longer shelf life with Sub-Chilling

Research has shown that rapid chilling during the initial stages of processing results in an extended rigor mortis period that increases the overall quality and shelf life of the product. Longer and consistent shelf life creates favorable opportunities in logistics as well as considerable savings, something KAPP Skaginn has sought to capitalize on in its design. Eskøy’s new production deck was planned with expansion in mind. Down the line, the RoteX system can be fitted with KAPP Skaginn’s Sub-Chilling technology, which can further improve the quality and handling of the catch. For Eskøy this is a key factor in expanding their business in the future.

Precision automation and quality control

Ragnar A. Guðmundsson, Director of Sales Operations in Scandinavia and Europe at KAPP Skaginn considers this project as yet another success. “Working with Eskøy for the last decade has been a pleasure. Hrafn and I share the background of growing up in a small fishing village and being around fishing and fish processing our whole lives. We have been able to build upon this to communicate clearly and collaborate on numerous projects with remarkable results. They have sought us out for the precision automation and quality control that we pack into a small footprint for our onboard equipment and the service we have delivered,” explains Ragnar.

Sub-Chilling for Noruega in the North Sea

“As more producers set their sights on shorter production time and superior catch handling, we have seen our onboard operations grow significantly with several successful projects installed, planned and underway,” says Ragnar. “Another exciting project in Scandinavia at the moment is Noruega’s trawler Havfjord, which is being built at the Karstensens Shipyard in Skagen, Denmark. We are supplying them with a Sub-Chilling system that will keep the North Sea catch as fresh as can be and guarantee the absolute best results.”

Icelandic family run fish processor Fiskkaup has signed a contract with KAPP Skaginn to install an onboard processing deck for their new vessel Kristrún RE-177. The new facility is designed to process high-quality frozen Greenland halibut. The two companies have had a long-standing relationship. KAPP Skaginn supplied Fiskkaup’s previous onboard system as well as equipment for their modern processing facility in Reykjavík.

Fiskkaup Installs New Onboard Processing System for Kristrún RE-177 with KAPP Skaginn

Sustainable system for onboard halibut processing

‍The new production system from KAPP Skaginn is designed with efficiency, quality raw material handling and sustainability in mind. Committed to responsible fishing in harmony with the environment, Fiskkaup has a Marine Stewardship Council (MSC) certification as a sustainable fishery and is a part of the Iceland Responsible Fisheries consortium. KAPP Skaginn developed an innovative and flexible processing deck in line with the company’s sustainability principles, emphasizing maximum raw material utilization, freshness and quality.

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Back for more based on durability and reliability‍

“Our facilities are all first-class, and the newest technology is used to ensure constant quality all year round,” explains Ásbjörn Jónsson, CEO of Fiskkaup. “KAPP Skaginn outfitted our previous vessel with an onboard system in 2012 that has operated seamlessly ever since. The reliability and efficiency of our existing solutions from Skaginn 3X was one of the reasons we decided to contact them again to install a new processing system for Kristrún RE-177.”

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Maximum quality and raw material utilization is key ‍

Fiskkaup is one of a few companies in Iceland that specializes in the fishing and processing of Greenland halibut. Their operation hinges on quality and they have mastered it well. By processing and freezing the fish at sea – when it is of the highest quality – the company is able to provide a steady supply of quality product to the Asian market. Heads and tails are also processed and frozen onboard as they also go for a robust price in the same market. KAPP Skaginn’s new onboard facility is thus designed to maximize both quality and the total available catch value.

“Product quality and maximum raw material utilization are very important to us,” says Ásbjörn Jónsson, CEO of Fiskkaup. “We are supplying high-quality Greenland Halibut to the Asian market and every part of the fish counts, as demand from the market has been strong. The new system is designed to utilize the entire fish and deliver quality product.”

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Close cooperation with management and crew ‍

As a family business, with decades of experience in supplying high-quality fish products to their customers, Fiskkaup works closely with both their suppliers and their staff. The crew onboard Kristrún – led by captains Helgi Aage Torfason and Pétur Karls­son – worked closely with KAPP Skaginn to create the most ergonomic layout and the most efficient production flow possible. These experienced fishermen hold the 2021 record for the largest Greenland halibut catch, netting over 2000 tons on the previous ship.

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Ergonomic system with a small footprint ‍

“This project was a pleasure to work on as both the management of Fiskkaup and the ship’s captains and crew were involved from the start,” says Böðvar Már Styrmisson, sales engineer for the project at KAPP Skaginn. “This ensured that we designed an ergonomic, efficient system based on interdisciplinary cooperation where engineering, processing, manufacturing and firsthand production experience came together to create the best system for this vessel. The guys onboard know what works and what they need and we are dedicated to deliver durable, robust systems that withstand the harsh conditions of processing at sea.”

Set to increase throughput and yield with the same manpower
The system is ergonomic and compact, utilizing space and available manpower to the max. “We are set to deliver increased throughput and better yield with the same manpower as Fiskkaup’s previous ship had,” explains Ingvar Vilhjálmsson, KAPP Skaginn’s Regional Sales Manager for Europe. “Our flexibility enables us to meet diverse needs from our clients. In this case we are integrating existing pieces of heading and freezing equipment into our overall design with KAPP Skaginn’s buffering, grading, bleeding, cutting and packing applications.”

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Offering quality production at sea

Decades of developing onboard systems in close cooperation with customers has made KAPP Skaginn one of the major onboard systems suppliers in the North Atlantic. Combining fisheries experience and industry know-how with engineering ingenuity and robust mechanical design has allowed the team at KAPP Skaginn to deliver production systems that suit a variety of vessels,species and production needs. The new Greenland Halibut production deck for Kristrún RE-177, is yet another onboard system the company is proud to be apart of.

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Brødrene Karlsen Installs Norway’s First RoteX Sub-Chilling™ Tank from KAPP Skaginn

Brødrene Karlsen AS is a production company for farmed and wild fish products located at the island of Husøy in Senja, northern Norway. The location, which is at the gateway to the Barents Sea, provides them with a very good source for extremely fresh and high-quality products. In collaboration with a modern and active fleet, they have gained a position in the market, which is associated with highly good product quality. 

Br. Karlsen AS is now taking another step in raising product quality in the market by investing in a new buying station for wild-caught whitefish. This buying station, supplied by Melbu Systems AS, focuses on gentle and efficient processing of the fish with a particular focus on optimizing its quality. In collaboration with Melbu Systems AS, KAPP Skaginn will deliver a RoteX Sub-Chilling™ tank to Br.Karlsen AS. They will therefore be the first whitefish facility in Norway to install this unique cooling solution. 

The concept of SUB-CHILLING™ is to chill the fish down below zero degrees Celsius, where the core temperature of the fish gets close to -1°C. Although the temperature of the fish is below the freezing point of water, the fish remains fresh and unfrozen in a subzero state. A Sub-Chilled fish is refrigerated in such a manner that it is not necessary to add ice to the fish boxes, which means that transport weight is reduced and the problem of water run-off from trailers is eliminated.

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KAPP Skaginn Sub-Chilling™ also ensures the lowest possible bacterial growth in the fish, which in turn means longer shelf life out in the market. The fish become firm and fine and are very suitable for further filleting with a clearly reduced risk of fillet gaping. All in all, this means that KAPP Skaginn Sub-Chilling™ is a very good cooling solution for the environment, product quality and production economy in the industry.

KAPP Skaginn has signed a contract with BlueWild, Norway, to supply a full fish processing factory onboard the company’s innovative new trawler. The trawler is designed to deliver sustainability, quality, and efficiency on all levels. From new propeller technology and groundbreaking trawl handling, to ecofriendly catch pumping and innovative production facilities, the new trawler is set to revolutionize onboard processing with its ECOFIVE concept.

KAPP Skaginn to Equip BlueWild’s Groundbreaking ECOFIVE Trawler with a Full Onboard Factory

A milestone agreement for onboard factory

“The agreement marks a turning point for us,” says Ragnar A.Guðmundsson, KAPP Skaginn’s Director of Sales for Scandinavia and Europe. Mr.Guðmundsson has led the project from KAPP Skaginn end from the beginning. "We have worked closely with the Bluewild team for the last two years. After many meetings and researches the team effort paid off and we will deliver a new and exciting onboard processing solution that harmonizes really well with their strategy."

Fish processing innovation

The concept of responsible fisheries is at the core of the new project. ECOFIVE – the new and innovative concept developed by Bluewild and their partners – is designed to deliver the highest-quality products possible with reduced energy consumption. The concept is nominated for The Nor-Fishing Foundation Innovation Award 2022.

“It’s an incredible opportunity to be chosen as the fish factory supplier for such an innovative project,” says Mr. Guðmundsson. “Our onboard processing system fits incredibly well with the principle of sustainable fishing, maximum product utilization and increased product and by-product value.”

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Sustainable fish processing principles in play

Catch is transferred directly into water-filled storage tanks below the waterline where it remains alive before being taken to the factory facility. Overpressure release is used to bring the live catch to KAPP Skaginn's processing line on the factory floor. The turnkey processing system will process fillets, loins, center pieces, tails, and bellies from whitefish, cooked and single-frozen consumer prawns or deliver blocks of industrial shrimp for further production on land.

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Top quality, from filleting to frozen product‍

"Our focus is on quality and maximum product utilization,” explains Guðmundsson. “This means that each and every piece offish receives top treatment throughout the process, from filleting to frozen product. In addition, the system’s full product utilization methods are designed to deliver maximum by-product value, that means every part of the fish is processed for human consumption."

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Collaboration is the key to success‍

The ship and all of its systems are designed and built by incredibly professional teams from the Westcon shipbuilder, Ulstein Design & Solutions AS, CFlow Systems, PTG and now KAPP Skaginn.  "We are honored that the customer has chosen our company for this project and very proud to be a part of this group", says Mr. Guðmundsson. “Our experience in the Icelandic and international fish industry has allowed us to build world-class teams. Our people bring in-depth processing knowledge, extensive technical expertise, and innovative thinking to this venture.”