Transitioning Sea Farms to Clean Battery Power

Throughout the duration of the grant, TBY completed Tasks 1-7, as described in Section b. Methods above. The results are summarized below.

Task 1: Survey

We performed a combination of phone, online, and in person interviews and data collection sessions, supported by ArcGIS Survey123, iPad photos and notes, notepads, and Fluke meters. We documented what challenges sea farmers face, what ambitions, and wish list items they have, and what equipment they are currently using, when, and for how long. We measured inrush and steady-state loads. We met with sea farmers in Maine, Massachusetts, Rhode Island, New Jersey, Georgia, Alaska, Washington, Prince Edward Island, Nova Scotia, and beyond. Results have been summarized in spreadsheets, photos, PowerPoint presentations, and prototyping budgets. The final survey data is available to the program director in Appendix A of the printed report. Nick Planson led the work on this task, with support from Chad Strater, and Kyle Dorsey over the second half of 2023.

Task 2: Duty Cycle Analysis

Duty cycle analysis data was collected from over 40 in-person farm visits in Task 1, as well as additional remote interviews of sea farm owners and operators. Farms varied drastically in size, complexity, and maturity; thus, a wide swathe of opportunities were identified. Some farm visits and data collection occurred via the Survey123 iPad-based app; however, the vast majority of input was from conversation, notes, and photographs. High-level fuel consumption and maintenance estimates were sufficient to determine the costs and logistics of operating existing farm machinery, thus it quickly became clear that collecting detailed fuel logs, receipts, and maintenance records was unnecessary and an inefficient use of farmers’ time. All necessary data was collected for needs assessment and solution design in the next tasks of the project. Throughout the second half of 2023 TBY staff, aquaculture farmers, and technical resources reviewed the data collected, use profiles, fuel usage, equipment used, seasonality, geographical considerations, and access to charging infrastructure to identify the best opportunities for electrification. Much depends on the size of the sea farm and the farming techniques. Smaller farms primarily rely on gasoline-powered generators and pumps; larger farms rely on gasoline-powered hydraulic power packs. Noise reductions are the primary driver of interest from sea farmers in electrification; emissions reduction, greater reliability, and cost improvements are secondary drivers. A detailed analysis with graphics and charts will be included in the final report.

Data collection and high-level analysis was completed by Nick Planson, Chad Strater, and Kyle Dorsey between August 2023 and November 2023. This was about a 60-day delay on our original target, which is mostly attributed to securing assessment times with farms during their peak season. 

Task 3: Identification of DC motors and DC hydraulic power packs

This task was originally delayed by 60 days from our original deadline due to the timeline change in Task 1. TBY, Philip Rench, and HRE worked with equipment manufacturers, sea farmers, and other marine operators to identify DC motors and pumps that will meet the needs of aquaculture farms. We then vetted the identified equipment with sea farmers to confirm suitability and deployed them on sea farms on a trial basis.

HRE used the duty-cycle analysis results from Task 2 to calculate battery requirements for the DC motors and power packs. We identified the ideal source of applicable batteries, Epoch Batteries, based on their marine credentials, 11-year warranties, and on-board Bluetooth monitoring and heating. HRE has begun designing the general wiring, safety measures, and controls required for safe and reliable operation and have conducted desktop validation of the performance expectation provided by sea farms. The purpose of this validation is to confirm and compare the battery, motor, and pump manufacturers’ described performance with known variables, use case-specific factors, and stakeholder needs and risk tolerance. We have also identified and acquired readily available floating platforms for this equipment and have learned thoroughly from the sea farming industry on what has and hasn’t worked well when using solar/electric on sea farms. This has informed our team’s designs and equipment selections. Preliminary electrical designs have developed alongside the equipment selection. Work is ongoing to identify and size the correct solar panels, racking, and charge controllers for these implementations.

TBY and HRE have completed a working draft of the Single Line Diagram and Equipment Layout in standard Electrical Drawing Software, AutoCAD. The draft ensures that the equipment layout allows for the specified use case of the pontoon as defined by the sea farmers, while meeting the highest electrical safety standards for working conditions.

The latest review of electrical loads (Tumbler Motor, Outboard Propulsion Motor, Line Hauler Motor, and Water Pump) require updates to the battery configuration. The teams have also identified a use case in which Torqeedo Batteries will be utilized alongside Epoch batteries which will require a redesign of the charging configuration.

The final steps of the electrical design will be sizing conductors, protection devices and electrical enclosures for safe operation based on maximum load conditions. This will be accompanied by details for attachment points and a Bill of Materials detailing equipment specs. 

Task 4: Construction and testing of power solutions

In Task 4, we constructed and tested beta-prototype configurations of battery-powered equipment, including tumblers, sorters, and haulers based on the needs and solutions identified in the previous tasks. We focused on sourcing the necessary equipment and collecting feedback to assess the success of the prototypes and address any issues.

The prototypes generally performed well in the demanding conditions of sea farms. Battery-powered tumblers and sorters showed significant reductions in operational noise and emissions, aligning with farmers’ priorities identified in earlier tasks.

Farmers reported high satisfaction with the noise reduction and ease of use of the battery-powered equipment. The reliability of the equipment was positively noted, with minimal downtime and maintenance required during the testing period. Some performance issues arose and are being addressed on an ongoing basis. Figures 1-5 show the completed prototypes. 

Task 5: Cost-benefit Analysis

TBY, with assistance from Atlantic Corporation, conducted a comprehensive cost benefit analysis of fossil fuel powered gas generators vs an electric alternative. We explored the usage of three different models of gas generators which differed in their cost of purchase as well as fuel consumption.

We completed a Lifecycle Financial Analysis and calculated the overall costs associated with three models of gas generators, namely the Ryobi 3400, the Predator 4375 and the Honda EU2200i. We also calculated the overall costs associated with the electric alternative.

We then did a cost benefit analysis and compared the economic benefit of using each of the three models of gas generators vs using the electric alternative.

In addition to the economic benefits, we also looked at the environmental benefits (reduced carbon emissions) associated with using the electric alternative.

We determined that the electric alternative offers substantial economic as well as environmental benefits which will make it an attractive option for sea farmers everywhere. The economic benefits will include increased ROI, and the environmental benefits will include reducing their environmental impact through decreased air, water, and noise pollution.

Task 6: Deploy and test portable battery-powered systems on sea farms

The primary objective of Task 6.1 was to deploy and test portable battery-powered systems on active sea farms in Maine. These deployments were critical to evaluating real-world performance, usability, reliability, and environmental resilience of the clean energy systems developed throughout this project. Deployment and testing were led by Nick Planson and Chad Strater of The Boat Yard, with support from Kyle Dorsey and partner technicians. We deployed portable battery-powered equipment at six diverse sea farms across coastal Maine:

• Blackstone Point Oysters – Damariscotta, ME
• Nauti Sisters Sea Farm – Yarmouth, ME
• Madeleine Point Oyster Farms – Freeport, ME
• Beso del Mar Oysters – Harpswell, ME
• Butterfield Shellfish – Brunswick, ME
• Maine Ocean Farms – Casco Bay, ME
• Cranberry Oysters – Great Cranberry Island, ME

Each site was selected for its unique environmental conditions, operational scale, and farming methods (oysters, kelp, and multi-species operations). Prototype battery systems were delivered to these farms between April and August 2024 and tested in situ for daily farming activities such as tumbling, washing, line hauling, and sorting.

Sea farmers were provided with training, documentation, and support from TBY personnel to integrate the equipment into their regular operations. Performance data was gathered via onboard battery diagnostics and in-field observations. Qualitative feedback was collected through structured check-ins, field notes, and follow-up interviews.

Deployment occurred between April and September 2024, with monitoring continuing through the end of the project window. The systems performed successfully across all six farms, with the following key findings:

• Performance: Battery-powered systems consistently met operational needs for the majority of farm tasks. Runtime was sufficient for daily operations, and overnight recharging with standard shore power or solar panels proved viable.
• Noise and Emissions Reduction: Farmers universally appreciated the reduced noise levels, and the elimination of exhaust fumes compared to ICE generators.
• Reliability: Minimal maintenance was required overall. However, several farms experienced issues with malfunctioning water pumps and intermittent failures of control buttons. These reliability concerns prompted additional troubleshooting, redesign, and testing of pump hardware and control interfaces.
• Usability: The lightweight and modular nature of the systems made transport and set up straightforward. Some farmers requested physical design improvements, including handles or wheels to assist with mobility on boats and docks.

Real-world deployments confirmed the technical feasibility and broad appeal of the battery systems. The feedback gathered has informed final adjustments to improve durability and ease-of-use. These findings directly shaped Task 7.1 outreach materials and commercialization strategy. Our next steps related to this task include:

• Upgrade waterproofing and connector designs to improve performance in rough marine conditions
• Develop a user guide for safe and optimal operation based on field testing
• Explore packaging options (handles, waterproof containers, trolleys) to improve transport and mobility on boats and docks

Task 7: Outreach and presentation of results

In Task 7, The Boat Yard worked to disseminate the results of this SARE-funded project to stakeholders across the U.S. aquaculture industry. Outreach efforts were multifaceted and included:

• Participation in aquaculture conferences and industry events
• Presentations at co-ops and extension-hosted workshops
• On-site demonstrations with farmers and service providers
• Digital and print communications through The Boat Yard’s website and social media
• Collaboration with Maine Sea Grant, Maine Aquaculture Innovation Center, and Maine Aquaculture Association for wider dissemination

Additionally, the project was presented at several high-visibility venues and industry events, including:

• Aquaculture America 2025 (poster presentation)
• Maine Aquaculture Association Annual Meeting
• Northeast Aquaculture Conference & Exposition (NACE)
• Maine Fishermen’s Forum (panel + presentation)
• Massachusetts Aquaculture Association annual meeting
• Cleantech Open Regional and Global Forums
• Maine Oyster Festival
• Maine Outdoor Economy Summit
• Common Ground Fair
• Work Boat Conference meetings
• Canadian Maritimes customer discovery trip

Social media content also reached a broad audience and helped stimulate inquiries from sea farmers and sustainability-focused marine technology companies. The Boat Yard also used direct farmer engagement and community events, like the Common Ground Fair, to answer questions, gather feedback, and support easy adapters of the technology. Our outreach efforts reached farmers, educators, clean energy professionals, aquaculture innovators, and policymakers – building momentum toward wider adoption of zero-emissions sea farm systems.

This Task was completed by Nick Planson, Chad Strater, and Kyle Dorsey with support from participating sea farms, Maine Ocean Farms, Nauti Sisters Sea Farms, and other partner organizations, as listed above. Outreach activities took place from Spring 2023 through February 2025.