Martin Engineering celebrates 50 years of air cannon technology

April 19, 2024 - Martin Engineering is marking the 50th anniversary of its invention of the world's first low-pressure air cannon. Air cannons have transformed material flows in bulk processing systems, eliminating problematic internal buildups and blockages. After five decades of continuous innovation, Martin Engineering remains at the forefront of air cannon advancements, enabling industrial plants to run more profitably, efficiently and safely than ever.

Martin Engineering Business Development Manager Mike Masterson and Product Manager Sid Dev working at the Air Cannon test stand at the company’s industry-leading Center for Innovation.

The company launched the world's first low-pressure pneumatic air cannon - its legendary Big Blaster - in 1974. It was devised and developed by Carl Mason, a member of Martin's senior team and cousin of the firm's founder Edwin F Peterson.

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The patented technology was designed to dislodge stubborn material stuck to the inside walls of hoppers and silos by firing precisely timed bursts of compressed air to keep bulk material flowing and preventing the growth of serious build-ups and blockages.

The air cannon was originally aimed at the same quarrying applications as the legendary Vibrolator, the Marin-patented industrial ball vibrator on which the company's success had been built since its inception in 1944.

By the 1980s, as Martin Engineering expanded its global presence, the Big Blaster was already being reimagined for use in high-temperature industrial applications to maintain the flow of sticky materials through the process and minimise unscheduled downtime.

Martin air cannons soon proved to be a game-changer for sectors such as cement, for the first time signalling an end to workers having to access the interior preheater vessels to manually break off hefty material build-ups using a high pressure water jet - one of the most unpleasant and hazardous jobs on a cement plant.

By the 1990s Martin Engineering had developed an extreme heat and velocity version of the Big Blaster, the XHV, with an all-metal construction capable of withstanding the harshest of conditions. In the 2000s Martin became the first to introduce safer positive-pressure firing valve with its Tornado air cannon - technology that prevents unintentional firing if there's a drop in system pressure, and also allows solenoid valves to be positioned up to 60m (200ft) from the air cannon for easier access and maintenance. Designed with safety in mind, the positive firing valve also delivers a more powerful blast.

Soon after that came the introduction of the Hurricane valve, located in the rear of the air cannon tank rather at the tank and nozzle junction, greatly improving safety and ease of maintenance. The exterior-facing design eliminates the need for removal of the tank so maintenance is a simple one-worker operation requiring only minutes for replacement.

In 2008, Martin Engineering opened its industry-leading Center for Innovation, which accelerated the company's air cannon technology advancements including:

SMART Series Nozzles with multiple nozzle tips, one of which features a retractable design that extends the 360˚ nozzle head into the material stream only when firing, protecting it from repeated abrasions and extreme temperatures. Its clever Y-shaped assembly means the nozzle can be installed, accessed and serviced without removing the air cannon or further disruption to the vessel structure and refractory.

The Martin Thermo Safety Shield acts as a safety barrier to allow timely and safe maintenance of air cannon systems. It protects workers from exposure to severe temperatures so that maintenance can take place safely and production stays on schedule.

Martin Engineering's current ground-breaking air cannon designs are the result of the research and development in the Center for Innovation, located at the company's headquarters in Neponset, Illinois. The centre will open its doors to visitors in the Summer of 2024 as part of the 50th anniversary celebrations.

Brad Pronschinske, Martin Engineering's Global Air Cannon Product Manager, said: "From the very beginning our air cannons were specifically designed to produce a quiet but powerful, high-velocity discharge of plant-compressed air to dislodge buildups and enhance material flow. They were developed to be capable of handling the high temperatures, harsh gases and abrasive, corrosive materials associated with heavy industries, and yet have low maintenance requirements and low costs. Since the launch of the Big Blaster 50 years ago we have continued to innovate, introducing smarter and ever more powerful air cannon systems that improve efficiency, productivity and safety.

"We're especially proud that Martin air cannons have become so important in reducing the health and safety risks associated with clearing blockages manually - such as working in confined spaces, working at height, falling materials and working in hot and dusty environments. Our team is always working on new developments and we're looking forward to bringing the next generation of air cannon technologies to our customers all over the world."

For more information, visit HERE.

The Global Miller
This blog is maintained by The Global Miller staff and is supported by the magazine Milling and Grain
which is published by Perendale Publishers Limited.

Applications now being accepted for the Poultry Industry Safety Recognition Award

April 19, 2024 - The Joint Poultry Industry Safety Award Program is currently accepting applications from poultry industry facilities with outstanding safety programs. The award program is open to National Chicken Council (NCC), National Turkey Federation (NTF) and US Poultry & Egg Association (USPOULTRY) members with poultry processing plants, further processing facilities, egg processing plants, hatcheries, feed mills, animal support services and rendering facilities that, through the implementation of innovative and effective programs, have injury and illness rates below the industry average for three consecutive years.

Based on the latest data available from the Bureau of Labour Statistics, the slaughter and poultry processing OSHA's total recordable illness and injury rate for 2022 was 5.7 cases per 100 full-time workers. The 2022 rate of 5.7 represents an outstanding 75 percent decrease from 1994.

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"Prioritising the safety and wellbeing of employees is an ongoing commitment for the poultry industry. These dedicated employees play a crucial role in the poultry industry's mission to produce nutritious and affordable food, and the industry is committed to investing in processes and procedures to diminish workplace hazards to protect our people," said Allan Foy, Corporate Safety Director, Farbest Foods, and chair of the joint Industry Safety and Health Council. "Progress is made year-over-year in reducing illness and injury and, over the last few decades, has resulted in significant achievements in protecting worker safety."

The Joint Industry Safety and Health Council is made up of members from NCC, NTF and USPOULTRY. Collectively, the three organisations represent 95 percent of the nation's poultry products, and their members generate more than 1.3 million total US jobs.

Award program rules, regulations and application forms are available HERE. The application deadline is May 24. The annual awards will be presented during the National Safety Conference for the Poultry Industry, August 19-21, at the Hilton Sandestin Beach Golf Resort & Spa in Destin, Florida.

For more information, visit HERE.

The Global Miller
This blog is maintained by The Global Miller staff and is supported by the magazine Milling and Grain
which is published by Perendale Publishers Limited.

Latest technology on display in Sprays and Sprayers Arena at Cereals 2024

April 18, 2024 - The Syngenta Sprays and Sprayers Arena has long been a 'shop window' at the Cereals Event for the latest innovation and technologies - and this year will be no different, with a display of new developments in pioneering precision application practices.

These new developments could herald a step change in approaches to agronomy decisions and sprayer technologies, according to Harry Fordham, Syngenta's new farming technology lead. He believes that precision application and artificial intelligence are opening opportunities to be far more targeted in production application for more specific treatments.

"This will deliver both agronomic advantages and reduced environmental impact," says Mr Fordham. "Ultimately growers can achieve better results, from reduced overall product use, and Sprays and Sprayers is a showcase for these new technologies."

Along with the chance to experience the very latest in current sprayer technology, Mr Fordham says that Syngenta application specialists will also be on hand at the event to offer insight into the future, too. "The immense potential of precision application includes innovative concepts of satellite mapping with variable rate treatment, prescription application, optical sensor spot spraying, and drones - along with other techniques.

"The move towards more precise techniques that allow better targeted application is essential for the efficiency of farm production. And with better targeting comes the chance to meet regulatory objectives that will assure future product availability."

In the demonstration arena, more than 10 manufacturers will be showcasing their kit. So what can visitors expect to see? Here's just a sample of some of this year's demonstrators.

Amazone

Amazone will be sticking with its usual trio of the UX 01 Super - a top of the range UX 4201 with 36, 24 and 12m Super-L3 boom options - a UF 1602/24m with FT1502 front tank, and a Pantera 4504 with the 36, 24 and 12m Super-L3 boom, plus all the latest gadgets.

On the stand will be the new Pantera 7004 with its variable front and back track adjustment and self-levelling suspension, along with an 8000-litre UX 7601 - which will be used to demonstrate the functionality of AmaSelect individual nozzle control technology, alongside AmaSelect Spot and CurveControl.

"Our aim at Amazone is to provide responsible and sustainable spraying technology which maximises chemical efficacy and minimises input costs," says the firm's Simon Brown.

"Using our hi-tech features like the DirectInject, ConourControl and AmaSelect Spot, the complete wet system and boom technology is designed to have the correct nozzle size and type, applying the most appropriate tank mix at the right rate, to the selected plants, with minimum drift and overlap."

Fendt

Fendt will also be returning to the arena with a much-loved favourite - the Fendt Rotator 600 self-propelled sprayer.

"The Fendt Rogator 600 continues to be popular amongst farmers and contractors alike, with various boom widths, axle configurations and two ride heights available across the range," says Ed Bennett, Fendt Marketing Manager, UK and Ireland.

"The MY24 model features recent developments, including improved nozzles, plumbing and easier options for tank cleaning, which are all aimed at maximising uptime and output without compromising on the job.

"We look forward to demonstrating this machine once again, and welcoming customers to our stand throughout the show."

John Deere

A trio of sprayers from the John Deere household will be making their way around the arena at this year's Cereals Event, including the R740i 24m trailed sprayer, the R9620 36m trailed sprayer and the 340M self-propelled sprayer.

The event will be the first large outing for the 340M and its Cereals debut, says the firm's Mark James. "All three of the machines we are showing have our unique PowrSpray dual-circuit solution system, with benefits including fast filling for a quick turnaround and more hectares sprayed per day.

"They also all feature our in-house developed individual nozzle control system, reducing overlaps and misses to the minimum, helping to reduce input costs."

In terms of their connectivity, the trio also boasts John Deere's ISOBUS control systems capable of variable rate applications, spot-spraying, documentation and work planning with synchronisation to the John Deere Operations Centre.

Kuhn

Kuhn will be showing the benefits of its Metris 4102 trailed sprayer in the Sprays and Sprayers arena, which is claimed to offer users increased output and technology to improve application uniformity.

The sprayer has a 4100-litre polyester tank featuring a deep sump, offering a low centre of gravity. Application is controlled via Kuhn's Diluset+ system which gives users the benefits of semi-automated filling with a pause mode, in-cab display and partial rinsing of the sprayer from the tractor.

Continuous Circulation - Electric circulation (CCE) offers electronic continuous circulation to increase spraying quality and ensure each nozzle is primed to apply the correct amount of liquid, while the RHPA 24m tri-fold booms give operators a lightweight boom option. The sprayer also includes Kuhn's Boom Assistant Slant, which features two ultrasonic sensors for height and tilt boom control, combined with a CCI A3 joystick. This gives users up to 30 controls via one joystick, for quick and simple operation and folding.

"Cereals also provides us with a great opportunity to demonstrate the benefits of our Metris 2 sprayer range," adds Edd Fanshawe, Kuhn's arable and connected services product specialist. "With a 4100-litre capacity, it has wide appeal to many users looking to increase output and maximise spray quality via the latest technology."

Visitors can expect to see the below list of manufacturers demoing in this year's Sprays and Sprayers Arena - but more demonstrations are soon to be announced, so keep an eye on the website:

• Amazone
• Bargam Agriculture
• Bateman
• Berthoud
• Chafer
• DroneAg (robotic demos)
• Fendt
• Hardi
• Househam
• John Deere
• Knight
• Kuhn
• SAM crop sprayers

FSOOTY 2024

The winner of this year's Syngenta Farm Sprayer Operator of the Year (FSOOTY) will once again be crowned in the Syngenta Sprays and Sprayers arena on the first day of the event (11 June).

"This prestigious award recognises the professionalism of sprayer operators across UK farms," says Iain Lindsay, Syngenta application specialist. "Past winners have demonstrated their skills and expertise in every area of crop spraying, from the initial agronomy decisions through to the storage and handling of products, and to the final point of accurate and, above all, safe application."

For more information, visit HERE.

The Global Miller
This blog is maintained by The Global Miller staff and is supported by the magazine Milling and Grain
which is published by Perendale Publishers Limited.

Earth anchors keep farm structures grounded

April 17, 2024 - To provide protection and flexibility for seasonal needs, the agricultural sector relies on storage buildings for equipment, livestock shelters and temporary crop storage. Farmers often use storage buildings such as sheds or warehouses to store and organise farming equipment, tools, machinery and supplies.

There are many reasons why these farm structures need to be secured to the ground and stabilised, including:

• Protecting farm workers, equipment, livestock and crops from accidents due to unstable structures
• Preventing liability, tipping, shifting or structural collapse during strong winds or storms
• Securing buildings to the ground to enhance structural stability, especially in areas prone to seismic activity or soil erosion
• Meeting building code, public safety or insurance requirements

The technology or methodology utilised to secure a structure can take many forms. It can be as basic as using concrete blocks or ballasts placed on the corners or along the perimeter of a building to provide weight and stability. More sophisticated solutions may use foundation systems that include footings, piers or concrete slabs to provide a stable base for the building.

An increasingly popular and economic solution to this issue is earth anchors. These heavy-duty aluminium anchors are driven or screwed into the ground and attached to structures using cables, straps or brackets. The anchors can be easily installed into sane, soil, hardpan, asphalt and even underwater.

Securing metal buildings

Koehn Building Systems, a member of the Metal Building Contractors & Erectors Association (MBCEA), works with building owners, facility managers and qualified architects to design and erect pre-engineered metal buildings throughout Missouri and surrounding states. Their agriculture building services include the full spectrum of both new construction projects, farm and ship capacity expansion projects, as well as minor and major renovations. The company as worked on a wide range of building types such as sheds, feed mills, equipment storage, hay storage, grain storage, cold storage, storage with distribution access, farm shops and shops with living quarters.

According to Jerel Koehn, Co-Founder of Koehn Building Systems, the company recently began using earth anchors, specifically Penetrators from Rhode Island-based American Earth Anchors (AEA), as temporary bracing guide anchors for pre-engineered metal buildings during construction.

AEA's Penetrators are screw anchors made of heat-treated 356 aluminium that can be installed with a portable impact wrench, machine PTO drive fitted with a suitable tool, or the company's manual ratcheting T-Handle. The screw anchors are available in lengths from 9' to 46' and can provide 2500 to 14000 lbs of holding power in asphalt or hard pan soil.

According to Koehn, pre-engineered metal buildings can be utilised as warehouses, distribution centres, industrial facilities, auto dealerships, airplane hangars, offices, gyms, churches and living quarters.

The benefits of pre-engineered metal buildings include the speed of acquisition (being mostly off-the-shelf standard parts) and the rapidity of erection. These attributes save construction time (and cost) and speed occupancy. Due to the inherent strength of metal buildings and their built-in support structure, their clear span can far exceed wood framed buildings. In addition, pre-engineered metal buildings tend to have longer life spans than traditional wooden structures since they do not age as quickly from damaging elements such as weather and termite damage.

Koehn was concerned about strong winds that might possibly rise to 35 mph or higher during a storm, given that the structure's permanent bracing is not designed to withstand high wind conditions when unshelled. Koehn Building Systems holds an AC478 accreditation, administered by the International Accreditation Service, that includes standards and guidelines for maintaining safe work practices.

With these concerns at top of mind, Koehn began searching for a solution to secure the structure temporarily, prior to sheeting. Koehn initially learned about Earth Anchors in a publication of the Metal Buildings Institute that addressed temporary bracing of metal buildings. He also attended an industry conference where earth anchors, and specifically the Penetrator screw anchors, were discussed.

Although earth anchors are not mandated by building codes or regulations for pre-engineered metal buildings, after his personal research Koehn was convinced that AEA's anchors offered a superior solution. The company now utilises 46-inch Penetrators as temporary bracing for metal buildings. The number of anchors required varies and each is installed strategically to support end walls with vertical columns using guy-wires.

"The earth anchors definitely give me peace of mind. When I install the 46-inch long Penetrators, we can drive them into the ground and attach them with a cable. I can walk away from the project and feel totally safe and secure that we have done everything we can to prepare for any type of weather," says Koehn. 

Koehn considers the affordable earth anchors a "cheap insurance" against strong wind.

An earth anchor for every structural grounding need

Although Koehn Building Systems uses the Penetrators, there are other types of earth anchors. Selecting an optimal anchor for a temporary structure requires matching the anchor to the nature of the project and configuration of the structure, the type and characteristics of the ground, and the anticipated loads (principally wind in most cases). Key considerations include the class of soil and the project's load capacity requirements (eg Factor Safety to be applied to the maximum anticipated load). Calculating the required load capacity involves many factors.

"When considering load capacity, you need to consider the soil's real-time moisture content and compaction. In addition, you need to review the earth anchor's root penetration, installation method, pullout load angle and any other factors that may be unique to the installation's particular time and place," says Cy Henry, President of AEA.

According to Henry, besides screw anchors, other earth anchor options include bullet anchors and arrowhead anchors, which are installed using a drive rod.

Bullet anchors, named for their bullet shape, are ideal for holding in tough soil such as hard clay, gravel or soil intermixed with roots. An anchor is connected to a galvanised steel aircraft cable (typically available in 36, 60 and 130" lengths, but customisable) that attaches to the structure.

Similarly, arrowhead anchors offer superior holding in hard, compact and rocky soil. Once in the earth, the anchor twists like a toggle bolt and will not release from the ground without cutting the cable or digging it out. The arrowheads come in 4, 6, 8 and 10-inch sizes with 48, 60, 72 and 120-inch galvanised steel aircraft cable as standard. Custom cable lengths and stainless cable are available for special order.

"Arrowhead anchors are a great solution for softer and sandier soils. These anchors have more surface area in the ground when they flip around," says Henry.

Grounded in safety

No matter the type of agricultural environment, the need to ensure that the structure is completely secured to the ground is paramount to the safety and integrity of all the farm workers, livestock, equipment and crops that it protects.

"Building codes and regulations often mandate anchoring for temporary and modular structures. If you fail to secure a structure properly, it can result in code violations, occupant safety risks and valuable equipment and inventory losses, as well as property owner-operator legal liabilities," says Henry.

Whether the need for a farm structure in a particular location may be temporary or permanent, there can be no compromising on how well it is secured to the ground. Earth anchors matched to the specific conditions of use will help to ensure that the structures remain securely and safely grounded.

For more information, visit HERE.

The Global Miller
This blog is maintained by The Global Miller staff and is supported by the magazine Milling and Grain
which is published by Perendale Publishers Limited.

New meta-analysis results show inclusion of yeast cell wall extract during mycotoxin challenges benefits egg production

April 17, 2024 - A new study highlights the significant positive effects of yeast cell wall extraction supplementation on layer performance during mycotoxin challenges, Alltech announced this week.

Published in March 2024 in the journal Toxins, 'Meta-Nalaysis of the Effects of Yeast Cell Wall Extract Supplementation during Mycotoxin Challenges on the Performance of Laying Hens' demonstrated that the inclusion of yeast cell wall extract (YCWE, Mycosorb^®, Alltech, Inc., KY) supplementation during mycotoxin challenges results in an increase in layers' body weight by 12.5 grams, and a substantial increase in egg production and egg weight by 4.2 percentage points and 1.37g respectively.

The meta-analysis showed that layers fed mycotoxins experienced lower body weight (by 50g), decreased egg production (by 6.3 percentage points), and reduced egg weight (by 1.95g) compared to control-fed birds. Economic analysis suggested that the inclusion of YCWE not only supported performance but could also result in a positive return on investment. Based on results from the meta-analysis, production and profitability, calculations were made, resulting in:

• +2.7 eggs per hens housed (HH) over 9.5 weeks
• +29.7g edible protein output per HH
• 4.65:1 ROI

"To the researchers' knowledge, this is the first time a meta-analysis study has been conducted with laying hens which evaluates the influence of not only mycotoxins alone but also the use of a mycotoxin mitigation strategy on key performance parameters," Dr Alexandra Weaver, global technical support for the Alltech Technology Group team.

The meta-analysis assessed a total of 25 trials and the data was extracted from eight trials that met the inclusion criteria. These trials represented a total of 12 treatments and involved 1774 laying hens. The meta-analysis confirms that mycotoxin presence had an impact on body weight, egg production and egg weight and the role of YCWE mitigated the effects on egg production and quality, even at high mycotoxin levels. Therefore, the use of YCWE could contribute to increased edible protein output and increased farm economics during mycotoxin challenges.  

Overall, the meta-analysis underscores the importance of addressing mycotoxin challenges in layer production and highlights the potential role of YCWE in minimising these effects and enhancing profitability. 

 Backed by more than 40 years of scientific research, Alltech provides nutritional solutions and products that contribute to the success of the global animal health industry. This new study is a demonstration of Alltech’s continued commitment to delivering smarter, more sustainable solutions for agriculture that deliver targeted health benefits while increasing productivity, enhancing animal welfare, reducing environmental impact and increasing producer profitability.

For more information, visit HERE.

The Global Miller
This blog is maintained by The Global Miller staff and is supported by the magazine Milling and Grain
which is published by Perendale Publishers Limited.

Feed production of the future: The potential of insects as an alternative source of protein

April 15, 2024 - Can the industrial breeding of insects as animal feed contribute to feeding the growing world population? The 'Inhouse Farming - Feed & Food Show', which will take place from November 12-15, 2024 at the trade fair grounds in Hanover, is dedicated to answering this question.

The B2B platform organised by the DLG (German Agricultural Society) focuses on technologies and solutions that show that insects can now be used economically as an alternative source of protein for sustainable animal feed. 'Inhouse Farming' optimally complements the world's leading trade fair, EuroTier, and EnergyDecentral, the leading international platform for decentralised energy supply, which will take place at the same time, offering new perspectives and business models for the entire value chain.

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For Professor Mills Borchard, Head of DLG Research and Development, insects are the missing link in the circular economy. "They could be the animal feed of the future, as they provide valuable proteins, fats and other nutrients. Their production is also very resource-efficient." But what makes them the raw material for the feed production of the future? Answers to this question will be provided at the 'Inhouse Farming - Feed & Food Show' in Hanover in mid-November.

Focus on the black soldier fly

Seven insect species are now authorised in the EU for use as processed animal protein in livestock feed. The larvae of the black soldier fly (Hermetia illucens) have proven to be ideal for the production of animal feed. Their protein content is comparable to that of soya bean meal - 40 to 47 percent in dry matter. "The potential of larvae is huge," confirms Dr Frank Hiller, CEO of Big Dutchman. This is because they produce high-quality protein from otherwise hardly usable residues, which is ideal as animal feed. Hiller assumes that the alternative protein source can permanently replace a significant proportion of the soya imported to Europe. For this reason, Big Dutchman has pooled its existing expertise in the field of insect farming and production in Better Insect Solutions, which was founded in 2020. The company, which specialises in complete solutions for insect farming, will be presenting its systems at the 'Inhouse Farming - Feed & Food Show'.

What these look like in practice could be seen in Hvirring (Denmark) in November 2023 - when the Enorm Biofactory, currently the largest insect farm in Northern Europe, was opened. Larvae of the black soldier fly are bred on site on an area of 22,000 square metres and processed into insect protein and oil. Large parts of the technology, including the climate control systems for the breeding and fattening area, the exhaust air purification and heat recovery, the liquid feeding system and the boxes for fattening, were supplied by Better Insect Solutions. The experts plan and build complete high-tech insect farms for investors, including breeding, fattening and processing. The highly automated, modular fattening systems in the product range are aimed more at farmers who want to add another mainstay as insect fatteners.

Opportunities for livestock feeding

The black soldier flies bred in the Enorm Biofactory are given food consisting mainly of waste from the regional food industry. After around twelve days, the larvae are processed into insect oil and meal, with have already shown promising results in trials on farms in terms of production and animal health in poultry and pigs. The aim is to produce 100 tonnes of larvae on a daily basis. Europe's farmers want to avoid importing some of their soya from overseas in future by using insect-based protein feed. Even though beneficial insects have been authorised as an ingredient in fish feed since 2017, such animal feed has so far been a niche product in Europe. Only since September 2021 has it been possible to feed processed animal protein from farmed insects to pigs and poultry in the EU under a special regulation. This opens up new growth areas for producers of insect proteins such as Livin Farms AgriFood, Illucens and Viscon.

However, experts like Professor Nils Borchard see even more potential applications. In addition to being used as animal feed, the farmed insects or their constituents could also be used in the production of meat substitutes and other foods as well as in the manufacture of cosmetics. Until now, the production of insect protein has often been difficult from an economic point of view, as the production and processing methods are not yet able to compete with conventional animal feed. "Utilising agricultural by-products and by-products from the food industry as feed for insect breeding can help reduce production costs," says Borchard. How the potential of organic residues and waste can be exploited is therefore one of the questions that will be discussed at the 'Expert Stage: Inhouse Farming' on November 12 as part of the Insects theme day. The IPIFF (International Platform of Insects for Food and Feed), a non-profit EU organisation representing the interests of the insect production sector, is an expert partner in the development of the content.

Insects as upscaling professionals

The answer to this question has long since attracted the attention of research institutions and start-ups. There are more than enough residual materials, because "in the European Union, around 58 million tonnes of unused food are produced every year," explains Professor Jörg, Woidasky from the Pforzheim University of Applied Sciences. The university has been cooperating with Alpha-Protein, a start-up from Bruchsal, Germany, for several years. "In addition to selecting suitable by-products from the food industry, we were also able to optimise the handling of the sensitive animals," explains the expert in sustainable product development. Alpha-Protein uses these by-products as food for the mealworm (Tenebrio molitor) and upcycles them into a protein-rich raw material with vitamins, unsaturated fatty acids and minerals.

"In addition, we obtain a nutrient-rich plant fertiliser when rearing the mealworms which has many other positive effects such as soil activation and long-term fertilisation. Last but not least, by utilising discarded insect skins (ie exuviae), we achieve full recycling of all our material flows," says company founder Gia Tien Ngo. These are produced during the natural moulting process and are used to manufacture sustainable products such as alternative plastics. The researchers will now build on the results of the first project. The focus here is on the systems and automation of the rearing process. Industrial production is currently being planned in Ludwigshafen, Germany on an area of two hectares. The plan is to produce 1000 tonnes of dried insects and over 5000 tonnes of fertiliser annually. The plan is to feed used bread from bakeries in the region as a primary source of animal feed.

Challenges of automated breeding

The control of environmental factors such as temperature and humidity, the precise handling of sensitive fly eggs and the uniform portioning of freshly hatched larvae are complex tasks that need to be solved when automating breeding - a topic that the exhibiting companies at the 'Inhouse Farming - Feed & Food Show' are also addressing. WEDA Dammann & Westerkamp, a specialist in feeding technologies, will also be present in Hanover. The company from Lutten recently supplied a corresponding system, including control and process visualisation, to the Portuguese company EntoGreen. The larvae of the black soldier fly are fed with the residues in the system of containers and mixing tanks until they reach their final weight. The integrated dosing system ensures a customised combination and precise portioning of the feed substrate in the fattening containers. The residues on which the larvae thrive consist of regional vegetable residues that can no longer be used for food production. "The system generates a substrate for a larval output of around 25 tonnes per day. Its modular structure makes it easy to scale for future expansion," explains WEDA Export Manager Gabriel Schmidt. A new system is already being planned and is expected to produce up to 45 tonnes of live larvae from 2025 with a daily raw material input of 210 tonnes. 

For more information, visit HERE.

The Global Miller
This blog is maintained by The Global Miller staff and is supported by the magazine Milling and Grain
which is published by Perendale Publishers Limited.

Researchers evaluate slow versus fast growth rate regimen and its relation to animal welfare

April 15, 2024 - USPOULTRY and the USPOULTRY Foundation announce the completion of a funded research project by researchers at University of Georgia that evaluated slow versus fast growth rate regimen and its relation to animal welfare. The research was made possible in part by an endowing Foundation gift from Wayne-Sanderson Farms.The research is part of the Association's comprehensive research program encompassing all phases of poultry and egg production and processing. 

Project #719: longitudinal assessment of skeletal and cardiac structures in broilers reared under slow versus fast growth rate regimen and its relation to manifestation of lameness, ascites and woody breast condition

(Dr Prafulla Regmi, Department of Poultry Science Department, University of Georgia, Athens, Ga)

Dr Prafulla Regmi, assistant professor at the University of Georgia, and other colleagues conducted a study of the longitudinal assessment of skeletal and cardiac structures in broilers reared under slow versus fast growth rate regimen and its relation to manifestations of lameness, ascites and woody breast condition. The goal of the study was to identify physical and physiological markers associated with welfare issues in broilers grown at different rates. Findings suggest that growth restriction can improve welfare outcomes of broilers. However, the extent of restriction does not necessarily have to be below 50 g/d as recommended by some third-party organisations. Furthermore, reducing growth rate does not increase breaking strength of the bones.

For more information, visit HERE.

The Global Miller
This blog is maintained by The Global Miller staff and is supported by the magazine Milling and Grain
which is published by Perendale Publishers Limited.