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LargeLarge--Scale VermicompostingScale VermicompostingLargeLarge Scale VermicompostingScale Vermicomposting
Thomas HerlihyMay 20 2008May 20, 2008 NC State University Vermicomposting WorkshopRaleigh, NC
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Who Who RT Solutions, LLCDBA W PDBA Worm Power
• Created solely to develop y pprofessional horticultural products based on vermicomposting technologyvermicomposting technology
• Own & operate “state-of-the-art” vermicomposting facilityp g y
• Recognized technology leader in the field
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Background Background ––Waste IssuesWaste IssuesFederal and state regulations are changing the way manure is managed – (human & animal)g ( )
• Nutrient Managment Plans required with loading limits • Manure can only be applied at rates equal to crop’s nitrogen
lremoval.
• Nuisance parameters / quality of life issues Ri ht t F dj t l d fli t ( t i t• Right to Farm vs. adjacent land owner conflicts (new tensions at the growing rural / suburban interface)
• Increased focus on agriculture’s impact• Increased focus on agriculture s impacton air, soil and water quality
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Background Background ––Waste IssuesWaste Issues
Economics of manure management (the CRUCH)
• Large farm operations (compensate for revenue/animal)• More animals = more manure• Regulations limit manure application rates (tons manure/acre) • Results in more land needed (acreage)• Costs increase dramatically as distance from farm to field• Costs increase dramatically as distance from farm to field
increases
Excess manure becomes a waste issueExcess manure becomes a waste issue, as the value of manure can not offset handling costs($/ac spreading costs > $/ac fertilizer value)
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One Potential SolutionOne Potential SolutionLarge-Scale Vermicomposting of Animal Manures
• A publicly and environmentally acceptable solution for manure management.
• A reliable technology capable of producing a marketable “premium” organic product at a competitive rate.
• Multiple animal operator’s benefits: reduced land application costs (labor and equipment) nutrient timing & compactionequipment), nutrient timing & compaction.
• Win–Win–Win Scenario for:• Animal operation• Vermicomposting company• Consumer of the worm castings VermicompostingVermicomposting
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The Search The Search Conducted a six month search across the Eastern U.S. to find the RIGHT Opportunity:pp y• A progressive owner, willing to sign a long term Operation
Agreement
• Suitable piece of ground for the project (developable)
• Operator with more manure than can be economically used
• Ability to secure an increasing supply of manure (future growth)
• Proximity to target marketing sectors (product support)
• Close proximity to major transportation routes
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Why Vermicompost in New YorkWhy Vermicompost in New YorkNew York State is a Major Agricultural State – A leading state in grape, apple production and dairy production -g p , pp p y pWe all don’t live in Manhattan.
675,000 cows in active production, produced in excess , p , pof 10 billion lbs of milk (USDA 2003)
D i d d i f 16 billi lb /Dairy manure produced: in excess of 16 billion lbs/year
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Site Selection Site Selection –– Coyne FarmsCoyne FarmsLocation: Avon, NY - (3rd largest concentration of dairies USA))
1,000 milking cow operation (dair of distinction)
BUFFALO ROCHESTER SYRACUSE
(dairy of distinction)
• Generate approximately 107,000 lbs/day of manure slurry (53+ tons/day)
FINGER LAKES
AVON
y y ( y)
Less then 1-mile from major interstate
Close proximity to target market sectors
Great people to work with!
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Coyne FarmsCoyne Farms1,000 Registered Holstein milkers & 600 heifers.
4th Generation family “Dairy of Distinction”“Dairy of Distinction”
Average Cow weighsAverage Cow weighs 1,800 lbs
Average cow produces 80 lbs/day of milk100 lbs/day of manure00 bs/day o a u e
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Interstate 390
ProposedVermicomposting
Facility
Coyne FarmMain Facility
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RTS Process Flow / DesignRTS Process Flow / Design
Manure Lagoon
Screening
Raw manure
Vermicompost Material Worm
Castings Water
Manure Separator
Liquid Manure
VERMICOMPOSTING
Flow-Through Digesters
(Worms Worms and more Worms)
+ Worm
Compost
Manure Solids (nitrogen)
Hay/corn Silage
( b )
(Worms Worms and more Worms)
Composted Dairy Manure
Storage
(carbon)
Mixing
Pre-Vermicomposting Conditioning
(composting active aeration) Mixed Material
y
TARGET MARKETS
Distribution
(C/N Ratio) Pathogen Reduction Weed Seed Destruction
Material TARGET MARKETS
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Site PermittingSite PermittingPermitting – (local/state) in-house engineers prepared all permits and received approvals in 4 monthsp pp
Site Designed for efficient material handling (1.25 person)
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Site Design Site Design –– Manure Separator FacilityManure Separator FacilityManure Separator (manure in – effluent & solids out)
Solids delivered for vermicomposting
Liquid diverted to existing lagoons
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Separator Facility ConstructionSeparator Facility Construction
Construction of separator facility (June 2005) Final separator facility (December 2005)
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Separator Facility ConstructionSeparator Facility Construction
prototype manure separator (above).
Fan centrifugal model shown to the right.g g
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Separator Facility ConstructionSeparator Facility Construction
1,000,000 & 7,000,00 gallon manure effluent lagoons
Effluent is injected into crop fields behind chisel plow
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Site ConstructionSite Construction
Site clearing and pad construction for processing and conditioning buildings (Feb. 2005)g ( )
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Site ConstructionSite Construction
Continued building construction of processing and conditioning buildings (March 2005)( )
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Facility ConstructionFacility Construction
Construction of composting building & aeration bays (May 2005)( y )
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Facility ConstructionFacility Construction
Construction of composting aeration system (May 2005)( y )
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Facility ConstructionFacility Construction
Installation of flow-through digesters (June 2005)( )
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Facility Facility ComissioningComissioning
Introduction of worm species to vermicomposting digesters
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Facility ConstructionFacility Construction
Construction of raw storage building (November 2005)( )
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Finished Facility ConstructionFinished Facility Construction
Overall facility (December 2005)
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RTS Process Flow / DesignRTS Process Flow / Design
Manure Lagoon
Screening
Raw manure
Vermicompost Material Worm
Castings Water
Manure Separator
Liquid Manure
VERMICOMPOSTING
Flow-Through Digesters
(Worms Worms and more Worms)
+ Worm
Compost
Manure Solids (nitrogen)
Hay/corn Silage
( b )
(Worms Worms and more Worms)
Composted Dairy Manure
Storage
(carbon)
Mixing
Pre-Vermicomposting Conditioning
(composting active aeration) Mixed Material
y
TARGET MARKETS
Distribution
(C/N Ratio) Pathogen Reduction Weed Seed Destruction
Material TARGET MARKETS
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Site Design Site Design –– Vermicomposting FacilityVermicomposting Facility
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Process ControlsProcess ControlsRaw materials stored in
covered facilitycovered facility Materials are mixed with
large agriculturallarge agricultural equipment to specific parameters• Porosity, MC, C:N ratio,
bulk densityR d ibl i• Reproducible recipes (weighted within 10 lbs)
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Process ControlsProcess ControlsMixed materials loaded into
aeration baysaeration bays
Thermophillic CompostingThermophillic Composting• 14 days with one turn• Min of 3-days @ 55 degree C
Weed seed destruction• Weed seed destruction• Pathogen reduction (PFRP) • Acts to stabilize the material
Oxygen and temperature are measured with feedback to airmeasured, with feedback to air flow - rate & volume controls
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Feeding Material is spread in a uniform 1” layer across the surface of each digester.g
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Process ControlsProcess ControlsWorms are fed the uncured compost p• Only when ready!!!
Building was engineered with automatic ventilation, watering, heat and directed g,lighting systems - happy worms = a good night’s sleepsleep.
Harvested by multipleHarvested by multiple hydraulic systems -
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Process ControlsProcess ControlsGood animal husbandry of worms is most critical
Homogenous moisture content of material
Monitor temperatureMonitor temperature continuously (tipping point)
Look for cocoons and reproductionreproduction.
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Harvest Worm worked material is removedfrom bottom of each digesterfrom bottom of each digester
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Process ControlsProcess ControlsFinished product screeningscreening• Robust aggregate
screener• 3 current product lines• Bulk packaging• Retail packaging
Finished product storage
All d t k t i f ll• All product kept in fully enclosed buildings
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Facility OperationsFacility OperationsFinished product distributiondistribution• Nationwide shipping
contracts• Local shipping
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The Worm Power Line of ProductsThe Worm Power Line of ProductsThe Worm Power Line of ProductsThe Worm Power Line of Products
• Solid vermicompost products and a liquid extract product are sold in bulk and small retail packaginga d s a eta pac ag g
Worm Power (solids)Bulk in 1 cu-yd crates (commercial growers)Retail in a variety of small packagesRetail in a variety of small packages
Worm Power Shower – liquid vermicompost product (under development)development)
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Research and DevelopmentResearch and Developmentpp
• Worm Power has been awarded eight grants from Federal and State Agriculture Agencies over theFederal and State Agriculture Agencies over the past 4 years to develop vermicomposting and vermicompost products.
• Funded Research includes*• Funded Research includesLarge Scale VermicompostingVermicomposting and dairy manure managementVermicompost use in vegetable productionVermicompost use in potting mixturesVermicompost use in potting mixturesVermicompost in diseases suppressionDevelopment of liquid vermicompost extractsMechanisms for disease suppression from vermicompost
*Worm Power has a long-term research collaboration with multiple departments at Cornell University
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RT Solutions LLCRT Solutions LLC
Worm Power Brand ProductsWorm Power Brand ProductsWorm Power Brand ProductsWorm Power Brand Products
Worm Power is designed to be the nation’s largest
li f i lsupplier of organic plant growth and protection products based on ourproducts based on our patented earthworm composting technologyp g gy
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Future Facility DevelopmentFuture Facility Development
-Roll movie-
Thanks for your attention