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Principals and Practices of Commercial Scale Principals and Practices of Commercial Scale Principals and Practices of Commercial Scale Principals and Practices of Commercial Scale Vermicomposting and Earthworm HusbandryVermicomposting and Earthworm Husbandry
Thomas Herlihy NC State Vermicomposting Workshop RT Solutions, LLC -Worm Power June, 2009
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Shameless Promotion Shameless Promotion
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-science” vermicomposting p gfacility
• Internationally recognized t h l l dtechnology leader
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Background Background –– Our StoryOur StoryConducted a six month search across the Eastern U S to find the RIGHT Opportunity:Eastern U.S. to find the RIGHT Opportunity:
• A progressive animal agriculture operation (supermarket effect),
• Willing to sign a long term Operation & Supply Agreement
• Suitable piece of ground for the project (developable)
• Operation with more manure than can be economically used
• Ability to secure an increasing supply of feedstock (future growth)
• Compatible on a business and human level
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Site SelectionSite SelectionNew 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, (3rd in nation) , p , ( )produced in excess of 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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Secure Consistent FeedstockSecure Consistent FeedstockLocation: Avon, NY -(State’s largest dairy ( g yconcentration)
Located on 1 600 head
BUFFALO ROCHESTER SYRACUSE
Located on 1,600 head dairy, adjacent to another 1,700 head operation
FINGER LAKES
AVON
Less then 5-miles from the two primary shipping p y pp gmodes
Great people to workGreat people to work with!
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Coyne FarmCoyne Farm1,000 Registered Holstein milkers & 600 heifers.
Our coworkers
4th Generation family owned and operated “Dairy of Distinction”Dairy of Distinction –Not organic certifiedAverage Cow weighsAverage Cow weighs 1,800 lbs Daily Husbandry
Consumes 300 lbs/day of feed and water
• Yields 85 lbs/day of milkYi ld 120 lb /d f• Yields 120 lbs/day of manure
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Interstate 390
ProposedVermicomposting
Facility
Coyne FarmMain Facility
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Production ProcessProduction Process
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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Separator Facility ConstructionSeparator Facility Construction
Construction of separator facility (June 2005) Final separator facility (December 2005)
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Manure Separator Manure Separator F d t k P tiF d t k P tiFeedstock PreparationFeedstock Preparation
protot pe man re separator (abo e) prototype manure separator (above).
Fan centrifugal model shown to the right.
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Manure ManagementManure ManagementIntegrating Plant and Animal AgricultureIntegrating Plant and Animal Agriculture
1,000,000 & 7,000,00 gallon manure effluent lagoons
Effluent is injected into crop fields behind chisel plow
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Manure ManagementManure ManagementIntegrating Animal and Plant AgricultureIntegrating Animal and Plant Agriculture
Separated manure effluent is pumped from lagoons through 5,000’ of drag hose to subsurface i j tinjector
•Conserves nutrients
•Reduces •Odors •Road traffic•Soil compaction•Application costs
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Site DevelopmentSite Development
Site clearing and pad construction for processing and conditioning buildings (Feb. 2005)g ( )
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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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Vermicomposting FacilityVermicomposting Facility
Completed December 2005
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Process FlowProcess Flow
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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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 Controls
Mixed 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 Controls
Worms 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 Controls
Good animal husbandry of worms is MOST critical
Uniform moisture content of material
Monitor temperatureMonitor temperature continuously (tipping point)
Look for cocoons and reproductionreproduction.
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Animal HusbandryAnimal Husbandry
• Good vermicomposting requires basic i l h b danimal husbandry
• If you treat your worms like a garbage disposal don’t be surprised by the resultsdisposal don t be surprised by the results
• Careful feeding, watering and environmental controls lead to healthier
d l l i i !and larger worm populations – surprise!• Keep a log book and record
observations feedings and harvestsobservations, feedings and harvests.• Use your nose as part of your monitoring
program.
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Animal HusbandryAnimal HusbandryThe importance of earthworms in breaking down organic matter was
first emphasized by Charles Darwin in 1881
• While feeding the worm's rudimentary crop & gizzard act to physically breakdownact to physically breakdown ingested material
• Material passes through the worm's GI tract andworm s GI tract and becomes “biologically inoculated”
• Physical, chemical andPhysical, chemical and biological process accelerates decomposition & stabilization
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Animal HusbandryAnimal HusbandryOther Considerations
•Worms do not have large mouths YesWorms do not have large mouths. Yes they will breakdown big pieces of organic matter, but do you want to wait.
•Economical vermicomposting means maximizing production in the shortest time.
•Use your log book to correlate processing rates to feed and environmental conditions.
S lit l f t•Seasonality plays a factor
•Don’t worry about pure cultures (species)
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Harvest Worm worked material is removedfrom bottom of each digesterfrom bottom of each digester
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Product Quality ControlProduct Quality ControlFinished product screeningg• Robust screener• 3 current product lines• Bulk packaging• Retail packaging
Finished product storageg• All product kept in fully
enclosed buildings and containers (seasonality ofcontainers (seasonality of sales)
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Facility OperationsFacility OperationsFinished product distributiondistribution• Nationwide shipping
contracts• Local shipping
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Vermicompost ProductsVermicompost ProductsVermicompost ProductsVermicompost Products
• Solid vermicompost products and p pliquid extract product can be sold in bulk and small retail packaging
SolidsSolidsBulk in 1 cu-yd containers (commercial growers)Retail in a variety of small packagesy p g
Liquid vermicompost extractsBulk 275 gal carboySmaller retail
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Research and DevelopmentResearch and Developmentpp
• Worm Power has been awarded nine research grants from Federal and State Agriculturegrants from Federal and State Agriculture Agencies over the past five years to develop vermicomposting systems and vermicompost products.
• Funded Research includes*
Large Scale VermicompostingVermicomposting and dairy manure managementVermicompost use in vegetable productionVermicompost use in vegetable productionVermicompost use in potting mixturesVermicompost in diseases suppressionDevelopment of liquid vermicompost extractsMechanisms for disease suppression from
ivermicompost
*Worm Power enjoys a long-term research collaboration with multiple departments at Cornell UniversityUniversity
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Shameless Promotion Part IIShameless Promotion Part II
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