Progress 05/01/06 to 12/31/07
Outputs
OUTPUTS: We are developing alternative manufactured bedding for use in concentrated animal feed operations (CAFO). Traditional bedding sources of pine shavings and rice hulls for bedding are depleting. Other less desirable biomass exists, but most are not effective bedding; to meet the demand for animal bedding at a customary cost, these lesser desirable sources of materials are currently in use. Through the manufacturing process materials including biomass, agricultural crop residue, byproducts, and recycled matter are converted into a group of bedding products developed to manage poultry manure. The processing and combinations of materials creates superior bedding that should sequesters nitrogen in manure which in turn increases the residual value of the litter while also reducing odor and pollution from manure. This bedding product is a tool to manage manure nitrogen as a resource. By following our phase one USDA - supported research, we developed manufacturing concepts to allow
creation of the lightest bedding product. We also learned methods to incorporate fractional percentages of additives dispersing them evenly through the bedding product. With continued USDA support, we will combine the phase one knowledge of the beddings physical properties with our privately funded research to produce a chemical method which will sequester nitrogen as it is excreted. In this research, we successfully manufactured various 3-D shapes of alternative poultry bedding. The bedding's various material components combined with the effect on bulk-density (BD) of the 3-D shapes was evaluated; product samples were analyzed for percent ash content, bulk density, and absorption. This data was compiled with product data from two additional manufactured bedding products we pioneered. The compilation of data was graphically illustrated to demonstrate the effect that formulation, bedding size and shape, as well as manufacturing process have on bulk density and coverage depth of
alternative bedding. Economics play a key role in the market acceptance of manufactured bedding. Cost and coverage depth (bulk-density) are the key values for the integrator. As traditional bedding sources dwindle, manufactured bedding will meet the growing need for animal bedding created by the food animal industry. Without bedding, the quality and safety of our food is substantially reduced. The bedding products we developed benefit the poultry growers with better animal performance, reduced feed conversion, higher quality grade meat, and heavier body weight. The advantage of the improved grow-out environment is evident. Our next stage research adds chemical accelerants that improve the product's benefits for use in concentrated animal feed operations.
PARTICIPANTS: Timothy Cathey, PI Invented the bedding product, designed the custom equipment and manufacturing process. Mr. Cathey purchased the equipment, assisted with its instillation and managed the facilities up-fit. As the process came on line he developed the formulations and produced the various bedding products. As president of Novovita he was reasonable for the end product, intellectual property and patents on the concept. During the trial runs for the research, Mr. Cathey developed formulations, made design changes to the equipment Dr. Jesse Grimes, NCSU Department of Poultry Science Provided in-kind support with the turkey-grow out facility, personnel to conduct the turkey trial, and collaborated on the research project. Dr. Grimes conducted the turkey trial which were sponsored by Cotton, Inc. and Prestage Farms Inc. Dr. Medwick Byrd, NCSU, Department of Wood and Paper Science Provided in-kind support with laboratories and equipment and collaborated on the research
project. Dr. Byrd assisted in manufacturing process start-up and in developing the standard operating procedure for the proprietary process. Dr. Byrd collected and analyzed production samples to provide data on the product's physical characteristics. Dr. Byrd's support added consistency, repeatability, and credibility to the manufactured bedding product. Charles Stevenson, Leesville Road High School, Science Department Provided in-kind support and collaborate on research projects. Mr. Stevenson assisted with the equipment instillation, and start-up of the manufacturing process. Mr. Stevenson's assistance was invaluable in analyzing problems, formulating solutions, and implementing the solutions. Mr. Stevenson's support included process suggestions and his hard labor required to initiate a continuous manufacturing process. Jim Smith, Novovita, Inc. Provided in-kind support for project organization, manufacturing process staffing, and hands on assistance with process development. Thomas
Crawford, NCSU, Environmental Engineering, Intern Mr. Crawford provided general project support, labor, and data collection. Amanda Humphries, Novovita, Inc. Ms Humphries provided assistance with organization, office / documentation and clerical work. Marvin Beland, RST Inc. Provided manufacturing facilities and personnel to operate the proprietary manufacturing process. Mr. Beland also provided in kind support with invaluable contacts for services, support personell and logistics support. He also assisted in the hands on work of starting the process facilities operation.
TARGET AUDIENCES: This research addressed the need of the poultry integrators and farmer growers by developing an alternative bedding to replace dwindling supplies of traditional bedding. The market segment processes 7.7 billion broilers and 256 million turkeys each year. The bedding market size is 6.2 million tons of bedding each year. We look forward to supplying superior manufactured bedding to these concentrated animal feed operations.
Impacts
Cost and bulk-density are the most importance factors for acceptance of alternative bedding by the poultry industry. Bulk density affects the depth of bedding on the floor of the animal habitat. Bedding shape affects bulk density and how bedding intermixes with manure are critical factors in manufactured bedding performance. Our original approach was to develop absorbent bedding and mimic shaving's shape; however, this shape did not move or intermix with manure. Thus, to increase intermixing, we developed a 3-D bedding during this research The result was manufacturing 3-D shaped bedding with reduced cost at the expense of a higher bulk density product. The increased bulk density reduced the coverage depth for a given weight of bedding. Overall, this bedding formula was more economic than previous formulations. Analysis of the bedding product samples from the experiments revealed relationships between particle size, formulation, and manufacturing process variations on
the bulk density of the bedding product. These relationships were not apparent prior to the data analysis. Analysis of the graphically depicted data predicts the cost and physical characteristic of manufactured bedding as the component materials are varied. These predictions gave us tools to develop the lowest bulk density 3-D shape alternative bedding. This research and data analysis coupled with our parallel research into the chemistry of the manure break-down reaction, resulted in further deviation from our original approach. Our next phase research further reduces manufacturing cost by using existing equipment at toll manufacturers. Using the knowledge developed in our phase one research we can predict the cost per coverage area of manufactured bedding. With additional USDA support, we will manufacture the new formulation including the accelerant chemistry and test the resultant product in concentrate animal feed operations.
Publications
- Grimes, J., 2006, The use of cotton gin waste, cotton stalks, and aGroChips as bedding material for Large White turkeys, "Annual Summary of NCSU Poultry Activities." 17th Edition, Pages 73-74 North Carolina State University, Department of Poultry Science, College of Agriculture and Live Sciences, http://www.cals.ncsu.edu/poultry/UploadedFiles/File/Sam_Pardue/Annual %20Activities%20Report%202006.pdf (accessed 4-2008)
|