Dutch Industries Contained Composting for Larger Livestock Operations
Dutch Industries began developing the Dutch Composter, for livestock mortalities, several years ago. After investing considerably in research, development, product prototypes and testing, the Dutch Compost Unit earned “Outstanding Exhibitor” in the New Inventions Category of the 2005 Farm Progress Show held in Regina, June 15 to 17.
The New Inventions area has been an integral part of the Farm Progress Show for over 5 years now. Sponsored by the RBC Royal Bank, this venue encourages entrepreneurs to display their latest agricultural inventions in an area totally dedicated to innovative products.
The need for the Dutch Composter arose out of concern for environmentally friendly disposal of livestock mortalities. The increasing size and concentration of livestock operations as well as concern for the environment has resulted in producers reevaluating how they are going to deal with mortalities.
There are a number of means by which producers have and can deal with livestock mortalities (dead stock). The age old tradition of hauling dead stock back to the bush for “natural degradation” is rightfully coming under increasing scrutiny from all parties. The potential for ground water contamination, pathogen transfer, scavenger and pest accumulation are all considerable with this method.
Burial is another option that can be effectively used by producers. The method of burial allows carcasses to remain basically intact under the ground for a number of years. Though covered with soil the opportunity for scavengers to recover carcasses and or ground water contamination still are considerable.
Rendering is an option that has worked well for some producers. With reduced demand for rendered products, increased distance to rendering plants and the need to keep the carcasses chilled prior to pick up have added to the cost and reduced the convenience of this option.
Incineration is another option that has been used by producers. The initial capital investment as well as operating costs (these units require fossil fuels to operate), make this option cost prohibitive.
Bin composting is another alternative for producers. With this method there are 3 – 4 bins set up. Mortalities are layered into bin one with a bulking agent (carbon source such as straw or wood shavings). When bin one is full this layering process is carried out in bin two. Bin one is “agitated” once a month or so with a front end loader. Aeration and bin rotation carries on in this fashion. The capital cost of pouring concrete and having roofing can be considerable. Pests, scavengers and odour are also real concerns with this system. The “speed” at which this system operates is also very weather dependent. To complete the process it can take 18 months or longer.
Enter the Dutch Composter. Though the target market for this product is swine and poultry operations the funnel shaped unit can handle the initial addition of the entire carcass of a cow or bull. The unit can be loaded with a front end loader, or hoist incorporated into the unit. The Compost Unit is completely contained, there is little odour, no leachate or opportunity for scavengers or insects to be present.
A system of metal teeth in conjunction with a mixing arm improves aeration to ensure that oxygen is present to increase the speed of composting. Not only does this mechanism ensure adequate aeration it creates a smaller particle size in the mix, which again serves to increase the speed of composting.
A carbon source, such as straw or saw dust (anything with a high carbon to nitrogen ration) must be added to encourage microbial growth as mortalities have a carbon nitrogen ratio that is too low for effective composting. Dutch Industries has found that a 5:1 ratio of mortalities to carbon source is usually adequate for a speedy composting process. For every 5 lbs of mortality added simply add 1 pound of straw or wood chips.
While composting is a natural process, it requires proper conditions to occur rapidly, minimize odour generation and prevent nuisance problems. Radiant heaters in the unit provide heat such that the temperature that is most hospitable to efficient composting microbes is maintained. The highest rate of composting occurs between temperatures of 43-66 C (110-150F). Temperatures in excess of 55 C (131 F) will kill many parasites and fecal and plant pathogens within the pile. Temperatures in excess of 66 C (150 F) will have a negative effect on all microbial activity and slow the composting process. The Dutch Composter is designed to maintain a temperature of 43-66 C (130 to 150 F).
The Dutch Compost unit was designed to accelerate the natural process of composting. As a result it creates a contained environment that can compost livestock mortalities within 5 – 7 days. The operating cost of this unit is approximately $0.015/lb of mortality, significantly lower than many of the alternative available today.
The compost material exiting the system has considerable value as a soil amendment. Total nitrogen concentration is in the 5 – 7 % range depending on the amount of bulking agent added etc. The reduction in material weight is @80%!! That is 1000 kg’s of inbound material will result in 200 kg’s of composted product.
In terms of using the composted product for land application similar precautions should be taken as for manure. In fact product exiting the Dutch compost unit has considerably less E-coli than liquid hog manure.
The design of the machine was based on the needs of large swine operations and can handle the output of a 1000 sow farrow-to finish-operation.
In terms of prions responsible for BSE the Dutch Compost unit would have negligible impact on their survival. If there suspect product at the very least the compost unit would reduce the volume of material requiring further processing by 80%.
The Dutch Composter will efficiently meet the needs of mortality disposal on many medium to large size livestock operation, as well as potentially for small to medium size abattoirs.
Contact your local Dutch dealer or Dutch Industries Ltd. directly at sales@dutchind.com, or call @1-800-663-8824 for further details.
