Progress 09/01/20 to 04/30/21
Outputs
Target Audience:The objective of this USDA SBIR Project is to investigate and develop a simple, effective automated cattle feeding system that supports the needs of small and mid-sized farms. The target audience is livestock feeding operations with 100-2500 head of cattle on feed. Since December 2019, Provender Technologies has worked from an office space at the Zeal Center for Entrepreneurship. The Zeal Center is Sioux Falls' startup ecosystem hub and is home to many of the State's business resources such as the Small Business Administration, Small Business Development Center, Manufacturing & Technology Solutions, Governor's Office of Economic Development, Enterprise Institute, and South Dakota Biotech. The Zeal Center has helped the PI to build a network while learning from successful entrepreneurs, business owners, and investors that frequent the facility. The PI has worked closely with a part-time cattleman to design, fabricate, and test the Automated Cattle Feed Composing System of the Phase I project. Brian, 38, built a 14,400-square-foot state-of-the-art cattle barn in 2017 and raises about 750 head per year, with about 600 head housed and fed in the barn at any one time. Brian is employed off the farm as a full-time crop insurance adjuster. His cattle barn allows him to continue his family's farming tradition on land that has been in his family since 1876. Brian is allowing Provender Technologies to use his cattle barn as the test site for the Phase I project. Brian's farm is located about 12 miles west of Sioux Falls, SD and is a 15-minute drive from the PI's office space. In August, 2020 Brian hosted the South Dakota Cattlemen's Association at his farm for a meal and tour of his cattle barn. For the past three years, Brian has supported the USDA NRCS New Agent Training Program by hosting tours at his farm showcasing his cattle feeding operation and conservation practices. Brian has made large improvements to his farm to improve the environment and the lives of his neighbors. He serves as a board member for the Minnehaha conservation district. Brian is actively engaged in the USDA SBIR Phase I project, and his feedback has helped guide the design of the Automated Feed Composing System of the USDA SBIR Phase I project. To date, Brian has donated his time as well as the use of his facilities and equipment in support of the USDA Phase I effort. Having guidance from Brian and feedback from other cattle producers and industry experts, the PI is confident that Provender Technologies is developing an automated cattle feeding system that meets the needs of small and mid-sized farmers. The PI is also working with a larger cattle producer, Nick, who feeds 3000 head of cattle. Nick is interested in automation for his cattle feeding operation. In 2020, Nick worked closely with Trioliet, one of the largest manufacturers of automated cattle feeding systems, and explored how commercially available automated feeding solutions could help his operation. Nick received written quotes of $500,000 for the Trioliet automated feeding system. Nick has determined that commercially available systems are not cost-effective for his operation. As a larger mid-sized livestock producer, Nick has provided valuable insights to the PI as to how automated feeding can best support his cattle feeding operation and similar-sized feeding operations. SBIR data rights pertain to this Phase I project. The data generated during Phase I is proprietary to Provender Technologies. During the first five months of this Phase I effort, Provender Technologies has been fortunate to receive advice from industry experts at CHS, Diamond V, OCP Group, Raven, Land O'Lakes, Microsoft, Cloverdale TMR, and Bremer Bank to name a few. The USDA SBIR Phase I Grant has allowed Provender Technologies to make exciting progress. Many publications have featured Provender Technologies' press release announcing the Phase I award. The articles drew great interest, and Provender Technologies' press release featured on SiouxFalls.Business was one of the top-shared articles of 2020. Changes/Problems:In working towards meeting the first objective of the project, it was revealed a need for simplifying and reducing the cost of feed hoppers used for storing and dispensing feed components for automated feeding. Provender Technologies discovered a simple and effective method for storing and dispensing feed components. The systemcosts much less than commercially available feed hoppers and could greatly reduce the handling of feed components saving time and reducing fed loss. Having guidance andfeedback from cattle producers and industry experts, the PI is confident that Provender Technologies is developing an automated cattle feeding system that will meetthe needs of small and mid-sized farmers. The PI believes that the project is progressing exceedingly well, and that the project is on track to meet the proposed USDA SBIR Phase I technical objectives: Design, Fabricate, and Test an Automated Feed Composing System Evaluation of Continuous Mixing Process for Composing Cattle Feed Mixtures USDA SBIR Final Report What opportunities for training and professional development has the project provided?This SBIR project has allowed the PI to learn valuable business management skills, grow his network, build relationships with local agriculture interests, as well as hone his speaking skills. Provender Technologies was selected to participate in the Plug and Play business accelerator in Fargo, ND. During the three-month accelerator program October 26, 2020- January 13, 2021, the PI met weekly with AgTech mentors from all backgrounds within the AgTech industry and had focus sessions with program directors from CHS, Microsoft, Bremer Bank, and OCP. If Provender Technologies' project goals continue to align with those of CHS Animal Nutrition, CHS may be interested in supporting Provender Technologies through a pilot project in 2021. Even though the accelerator program ended in January, the PI will continue to utilize the Plug and Play network and accelerator resources. Of the 13 startups participating in the program, Provender Technologies was awarded the Plug and Play Startup Innovation Award. During the Phase I effort, Provender Technologies has been fortunate to receive advice from industry experts at CHS, Diamond V, OCP Group, Raven, Land O'Lakes, Microsoft, Cloverdale TMR, and Bremer Bank to name a few. On August 14, 2020 the South Dakota Cattlemen's Association hosted a meal and cattle barn tour at Provender Technologies' project test site. The PI used this opportunity to discuss automated cattle feeding with the farmers in attendance. Approximately 80 cattle producers from the Sioux Falls, SD area attended the event. On Jan 13th, 2021 the Provender Technologies presented in the North Dakota Ag Expo. The virtual expo was attended by many potential partners, collaborators, investors, and industry experts. The PI pitched Provender Technologies and the need for automation on cattle feeding operations. Provender Technologies was awarded $25,000 through the South Dakota Proof of Concept program. The funds are being used to help cover the costs of materials and supplies. Due to expected State spending cuts, it was uncertain whether or not Provender Technologies would receive an award. However, the reviewers believed that the project holds a great deal of potential to benefit many industries in South Dakota and the application was approved. Following the Phase I project, Provender Technologies will apply for another Proof of Concept fund to help bridge work between Phase I and Phase II and help commercialize the results of the SBIR project. Provender Technologies was selected to participate in the Autodesk Foundation Technology Impact Program. Through this esteemed program, Autodesk offers startups access to three-year subscriptions, valued at up to $600,000 USD - the program supports startups that are innovating in a social or environmental impact area such as energy and efficiency, water & sanitation or health. Provender Technologies received a software donation of the Autodesk Product Design & Manufacturing Collection as well as the Architecture Engineering & Construction Collection valued at over $15,000. The software will be a great help in commercializing automated cattle feeding technologies, and it will allow Provender Technologies to do so while keeping development costs to a minimum. This supports the project and company goal of provide cost-effective automation equipment to family farms which are critical for sustaining and strengthening the social fabric of rural communities and caring for our biological and natural resources. How have the results been disseminated to communities of interest?Following notice of the Phase I award, the PI worked with the South Dakota SBIR Program Director to issue a press release to the following media outlets and business organizations: * SBDC stakeholders: Advisory Board members, SBA staffers, GOED staffers, SBDC employees and associates, economic development officials, and other SBDC supporters. * Publications: Parkston Advance (weekly), Freeman Courier (weekly), Mitchell Daily Republic, Aberdeen American News, Brookings Register, Madison Daily Leader, Rapid City Journal, Black Hills Pioneer (Spearfish), Yankton Press & Dakotan, Huron Plainsman, Pierre Capital Journal, Sioux Falls Argus Leader, and Watertown Public Opinion. * TV and radio stations: KELO-TV (Sioux Falls), Dakota News Now TV (SF), KEVN-TV (Rapid City) KNBN-TV (RC), KOTA-TV (RC), S.D. Public Broadcasting (radio), WNAX radio (Yankton), KORN radio (Mitchell), Dakota Radio Group, and Sarah Heinrich of KFGO Radio in Fargo. * Other media and business organizations: Associated Press (SF), S.D. Cattlemen's Association, AgWeek magazine and regional TV show (Fargo), S.D. Chamber of Commerce, and Greater Sioux Falls Chamber of Commerce (Chamber News magazine). The PI was featured on the SiouxFalls.Business website, the front page of the Mitchell Daily Republic, the front page of the Parkston Advance, the front page of the Parkston Advance, was featured in the Farm Forum Green Sheet, Cattle Business Weekly, and the Future Farmer Magazine, and discussed the project on WNAX radio, to name a few. On Jan 13th, 2021 the PI presented in the North Dakota Ag Expo pitchingProvender Technologies and automated feeding technologies for the cattle feeding industry. The virtual expo was attended by many potential partners, collaborators, investors, and industry experts. SBIR data rights pertain to this Phase I project. The data generated during Phase I is proprietary to Provender Technologies. Developments are pending intellectual property protection. The system and process for automating the cattle feeding process will not disseminated prior to commercialization or until proper intellectual property protections are in place and the dissemination of results aligns with Provender Technologies' go-to-market strategy. What do you plan to do during the next reporting period to accomplish the goals?During the next reporting period, the PI will continue to work closely with farmers in the development of the automated feed composing system and testing of the continuous mixing processing for combining feed ingredients. A prototype is being constructed which will help further test the functionality of the feed composing system. The prototype will be used to store and dispense large quantities of feed ingredients to be used in rations for feeding 600 head of cattle. Different feed ingredients will be dispensed from the feed hopper. The functionality of the feed hopper will be tested and the design refined in an effort to dispense all types of ingredients necessary for a finishing ration. The design of the feed hopper is meant to address the short-comings of the conventional feed hoppers used in automated cattle feeding systems. A continuous mixer will be tested for combining feed components of a feed ration. Feed components will be apportioned prior to being fed into the continuous mixer. The mixing performance of the mixer will be tested and the results compared to the conventional TMR mixer at the project test site, as outlined in the Phase I proposal. A final report will be compiled and submitted summarizing the findings of the project.
Impacts
What was accomplished under these goals?
Small family farms are steadily declining in number. The average age of today's farmer or rancher is 59 years old, and many are retiring without a successor. Many would-be farmers simply don't want - or can't afford - to take over the family business. If our vibrant rural communities are to endure, farming must become more profitable and appealing for the next generation of small producers. Automation is a key technology for increasing productivity and helping farmers remain competitive. In this USDA SBIR Phase I project, Provender Technologies is developing an automated system for preparing cattle feed rations. The principal investigator is working with two cattle producers to design and test the system. Having guidance from these cattlemen as well as other livestock producers and industry experts, the PI is confident that Provender Technologies is developing an automated cattle feeding system that meets the needs of small and mid-sized farms. During this first reporting period, the PI investigated and tested methods for storing and dispensing feed components. New, cost-effective methods for storing and dispensing feed componentshave been discovered, and a feed composing system has designed and is being further tested through continued prototyping. The design is simple and effective and is believed to be capable of cutting feeding times in half, while improving the accuracy of feed mixtures and reducing feed loss. Further testing will provide accurate data on the true potential and feasibility of Provender Technologies' automated feeding system. The research will also aid in the design and implementation of the Phase II effort. Automation can help farmers feed more cattle in less time while making the best use of resources. With more time, farmers are able to focus on family, be more involved in their communities, and explore economic opportunities such as farm expansion, farm diversification, or other off-farm employment. The first objective of this Phase I SBIR Project is: Design, Fabricate, and Test an Automated Feed Composing System 1) Major activities completed / experiments conducted; Two prototypes of feed hoppers for storing and dispensing feed components were constructed.The PI investigatedfeed hopper designsand met with several fabricators to explore how costs could be minimized in the manufacture of such feed hoppers. The PI also investigated the repurposing shipping containers, roll-off dumpsters, and conventional forage boxes for cost-effective storage and dispensing of feed ingredients to be used by a feed composing system. The functionality of each prototype feed hopper was tested by dispensing dry distiller grains, high moisture corn, and chopped corn silage in a controlled manner. The PI has worked with two contractors to develop a control system for storing feed recipes and controlling the dispensing operation of feed hoppers according to the desired ration. In addition, the control system is capable of dispensing ingredients from hoppers within a specified tolerance and storing data from dispensing operations. 2) Data collected; -Layout drawings for automated feeding system -Design of continuous mixer -Pricing of feed hoppers and electrical and hydraulic power systems -Procedure for total mixed ration feeding process audit -Procedure for total mixed ration feed testing procedure -Feedback from industry experts on importance of uniform feed mixture andcontinuous mixer design and implementation -Feedback from farmers on feed hopper designs and functionality, andelectrical power system vs hydraulic power system 3) Summary statistics and discussion of results and The PI is working closely with two cattlemen to design, fabricate, and test the Automated Cattle Feed Composing System of the Phase I project. Simplicity of the feeding system is a top priority for both producers. The testing of the feed hopper prototypesrevealed many shortcomings of conventional feed hoppers used in automated feeding systems. For example, the one or more feed bunkers of automated feeding systems are commonly constructed from heavy-gauge stainless steel and have many moving components introducing potential break-downs. More so, the feed bunkers of these systems provide no value to a livestock feeding operation outside their role in the automated feeding system - the feed bunkers must be routinely filled using a wheeled loader, and the feed bunkers are suitable only for storing feed ingredients in small quantities to be used by the feed handling system. Furthermore, these feed handling systems do very little to minimize the handling of feed ingredients and improve the feeding efficiency of cattle feeding operations. For example, during a feeding process, feed ingredients must be routinely collected from feed storage areas and transported to the automated feeding system to fill the feed bunkers. This is not an efficient process, and such use of feed hoppers is not scalable to be a preferred feeding solution for sizeable feeding operations. Farmers strongly favor hydraulic power systems over electric systems, whenmaintaining the system themselves. Farmers are familiar with hydraulic systems and have the resources for making mosthydraulic repairs themselves. Both farmers that are helping guide the Phase I project strongly support the design of the feeding system, and are happily supporting the project with their own time and resources in hopes that it will lead to an automated feeding solution for their operations. 4) Key outcomes or other accomplishments realized. Farmers have helped guide Provender Technologies' development of a feeding system during this first reporting period. Tests of the prototype components indicatethat the feed composing system could help cattle producers feed their cattle twiceas fastas conventional feeding practices.Theautomated system is expected to greatly reduce the handling of feed resulting in less feed loss and less use of diesel-powered machinery. The automated feeding system has the potential to greatly improve the productivity of small and mid-sized farms and will help ensure the longevity of small farms and rural communities. The second objective of this Phase I SBIR Project is: Evaluation of Continuous Mixing Process for Composing Cattle Feed Mixtures 1) Major activities completed / experiments conducted; The PI met with industry experts and designeda continuous mixer with their guidance. The mixing drum is being fabricated by a manufacturerin Sioux Falls, SD, and a stand for the mixer is being fabricated by the PI. 2) Data collected; The PI has discussed methods for sampling and testing the performance of the continuous flow mixer to be tested in the Phase I effort. In order to run more tests, it will be beneficial to test the performance of the mixer without having to send samples to a testing lab. Working with an industry expert, the below testing procedure was defined. This procedure will be used to test the performance of the continuous flow mixer in comparison to the conventional horizontal auger mixer located at the test site. 3) Summary statistics and discussion of results and Working directly with farmers in the development of the feed composing system, it is evident that the farmers are much less interested in improving the mixing process as they are in automating the handling and measuring of feed components. However, in speaking with industry experts from Diamond V, CHS, and Land O'Lakes, the PI received encouraging feedback and further validation that improving the consistency of feed mixtures willgreatly benefit the livestock industry, both beef and dairy. The PI will test the continuous mixing process in the remaining duration of the project and will include the results in the final report. 4) Key outcomes or other accomplishments realized. Nothing to report. The third objective of this Phase I SBIR Project is: USDA SBIR Final Report Nothing to report.
Publications
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Progress 09/01/20 to 04/30/21
Outputs
Target Audience:According to the USDA, cattle production is the most important agricultural industry in the United States, consistently accounting for the largest share of total cash receipts for agricultural commodities. Small and mid-size farms are concentrated in the Midwest and Northern Plains states - a region particularly well-suited for raising cattle because of lower feed costs. Many producers who operate small and mid-size farms are employed off the farm. Being pulled many directions results in unbalanced workload demands which can negatively affect business outcomes and work/life balance. Raising cattle can help farmers diversify income streams, make use of available feedstuffs, and provide fertilizer for cropland. However, the time, labor, and management necessary for feeding cattle has resulted in some farmers switching entirely away from animal agriculture to grow only cash crops. Labor-saving innovations and technologies that give farmers "more accurate or timely information" are needed for sustaining small and mid-size farms; notably, such innovations must be accessible without posing unacceptable financial risks for small and mid-size farms. Furthermore, data management systems are needed to link small and mid-size farms to local and regional markets. Small farms, as part of a larger system, can supply market needs, capture cost savings, and take advantage of the same premiums afforded large producers. Automation technology has been instrumental in providing efficiencies and a competitive edge to many industries and market segments. Yet, aside from a small number of automated cattle feeding systems targeted at the dairy industry, automation for feeding cattle has yet to be cost-effective for most small and mid-size farms in the U.S. due to the large upfront capital cost. Automation in crop production has been key for expanding farm operations. Automation in livestock production will be even more valuable to small and mid-size farms because it will take the manual, time-consuming, repetitive work out of feeding cattle, and it will help small and mid-size farms to convert feedstuffs of the farm (many otherwise unusable forages) into valuable, nutritious beef. Changes/Problems:In the Phase I project, Provender Technologies designed and tested an automated cattle feeding system and evaluated continuous mixing for preparing feed rations.Evaluations of the proposed continuous mixing process showed no improvement over conventional mixing methods, and it did not easily integrate with existing feeding practices. In pursuing a better solution with the help of cattle feeders, an innovative, cost-effective, easily-integrated feeding system was developed. Provender Technologies will continue focusing onimprovingthe uniformity of cattle feed rationsby automating the following factors: mix time after the last added ingredient, loading position of the ingredient, load size, hay quality and processing, loading sequence, liquid distribution, and vertical mixer auger speed. The USDA/NIFA SBIR Phase I projectresulted in Provender Technologies' full-size functioningprototype (alpha stage), patent pending livestock feed management and handling system. The innovative system dispenses feed components directly from conventional concrete storage bunkers and improves the uniformity of feed mixtures by carefully controlling the mixing process. The system will help farmers in the U.S. to reduce feed handling losses; enable precision in feeding rations and in tracking data essential to management; and increase energy, time, and labor efficiencies resulting in greater profitability. What opportunities for training and professional development has the project provided?This SBIR project has allowed the PI to learn valuable business management skills, grow his network, build relationships with local agriculture interests, as well as hone his speaking skills. Provender Technologies was selected to participate in the Plug and Play business accelerator in Fargo, ND. During the three-month accelerator program October 26, 2020 - January 13, 2021, the PI met weekly with AgTech mentors from all backgrounds within the AgTech industry and had focus sessions with program directors from CHS, Microsoft, Bremer Bank, and OCP. If Provender Technologies' project goals continue to align with those of CHS Animal Nutrition, CHS may be interested in supporting Provender Technologies through a pilot project in 2021. Even though the accelerator program ended in January, the PI will continue to utilize the Plug and Play network and accelerator resources. Of the 13 startups participating in the program, Provender Technologies was awarded the Plug and Play Startup Innovation Award. During the Phase I effort, Provender Technologies has been fortunate to receive advice from industry experts at CHS, Diamond V, OCP Group, Raven, Land O'Lakes, Microsoft, Cloverdale TMR, and Bremer Bank to name a few. On August 14, 2020 the South Dakota Cattlemen's Association hosted a meal and cattle barn tour at Provender Technologies' project test site. The PI used this opportunity to discuss automated cattle feeding with the farmers in attendance. Approximately 80 cattle producers from the Sioux Falls, SD area attended the event. On Jan 13th, 2021 the Provender Technologies presented in the North Dakota Ag Expo. The virtual expo was attended by many potential partners, collaborators, investors, and industry experts. The PI pitched Provender Technologies and the need for automation on cattle feeding operations. Provender Technologies was awarded $25,000 through the South Dakota Proof of Concept program. The funds are being used to help cover the costs of materials and supplies. Due to expected State spending cuts, it was uncertain whether or not Provender Technologies would receive an award. However, the reviewers believed that the project holds a great deal of potential to benefit many industries in South Dakota and the application was approved.Provender Technologies has been encouraged to apply for the South Dakota SBIR Supplemental Award by the South Dakota Director of Commercialization and the SD SBIR Program Director. The $25,000 SBIR Supplemental award is meant to bridge work between the Phase I and Phase II projects and to support commercialization of the SBIR project. Provender Technologies was selected to participate in the Autodesk Foundation Technology Impact Program. Through this esteemed program, Autodesk offers startups access to three-year subscriptions, valued at up to $600,000 USD - the program supports startups that are innovating in a social or environmental impact area such as energy and efficiency, water & sanitation or health. Provender Technologies received a software donation of the Autodesk Product Design & Manufacturing Collection as well as the Architecture Engineering & Construction Collection valued at over $15,000. The software will be a great help in commercializing automated cattle feeding technologies, and it will allow Provender Technologies to do so while keeping development costs to a minimum. This supports the project and company goal of provide cost-effective automation equipment to family farms which are critical for sustaining and strengthening the social fabric of rural communities and caring for our biological and natural resources. How have the results been disseminated to communities of interest?Following notice of the Phase I award, the PI worked with the South Dakota SBIR Program Director to issue a press release to the following media outlets and business organizations: * SBDC stakeholders: Advisory Board members, SBA staffers, GOED staffers, SBDC employees and associates, economic development officials, and other SBDC supporters. * Publications: Parkston Advance (weekly), Freeman Courier (weekly), Mitchell Daily Republic, Aberdeen American News, Brookings Register, Madison Daily Leader, Rapid City Journal, Black Hills Pioneer (Spearfish), Yankton Press & Dakotan, Huron Plainsman, Pierre Capital Journal, Sioux Falls Argus Leader, and Watertown Public Opinion. * TV and radio stations: KELO-TV (Sioux Falls), Dakota News Now TV (SF), KEVN-TV (Rapid City) KNBN-TV (RC), KOTATV (RC), S.D. Public Broadcasting (radio), WNAX radio (Yankton), KORN radio (Mitchell), Dakota Radio Group, and Sarah Heinrich of KFGO Radio in Fargo. * Other media and business organizations: Associated Press (SF), S.D. Cattlemen's Association, AgWeek magazine and regional TV show (Fargo), S.D. Chamber of Commerce, and Greater Sioux Falls Chamber of Commerce (Chamber News magazine). The PI was featured on the SiouxFalls.Business website, the front page of the Mitchell Daily Republic, the front page of the Parkston Advance, the front page of the Parkston Advance, was featured in the Farm Forum Green Sheet, Cattle Business Weekly, and the Future Farmer Magazine, and discussed the project on WNAX radio, to name a few. On Jan 13th, 2021 the PI presented in the North Dakota Ag Expo pitching Provender Technologies and automated feeding technologies for the cattle feeding industry. The virtual expo was attended by many potential partners, collaborators, investors, and industry experts. SBIR data rights pertain to this Phase I project. The data generated during Phase I is proprietary to Provender Technologies. Developments are pending intellectual property protection. The livestock feed management and handling systemdetails will not be disseminated prior to commercialization or until proper intellectual property protections are in place and the dissemination of results aligns with Provender Technologies' go-to-market strategy. What do you plan to do during the next reporting period to accomplish the goals?
Nothing Reported
Impacts
What was accomplished under these goals?
The SBIR Phase I effort investigated the development of an innovative, cost-effective system for automating the cattle feeding process. Customer Focus The PI, Henry Wegehaupt, locatedtwo cattle producers who had considered purchasing automated cattle feeding systems. The first producer had priced automated feeding systems in 2017, and the second producer was actively pricing an automated feeding system and received quotes in December 2020. Both farmers provided feedback to the PI which helped guide the Phase I project. Storing and Dispensing Feed Components The PI investigated feed container designs which would enable cost-effective storage and dispensing of feed ingredients to be used by a feed composing system. The PI evaluated manufacturing feed storage containers with local manufacturers.In addition to evaluating the manufacturability of low-cost storage containers, the PI explored repurposing shipping containers, modifying roll-off dumpsters, and retrofitting commercially available forage wagons. The PI constructed a prototype feed containerby retrofitting a feed wagon having a chain floor with an electric drive and gear reducer. Because most commercially available systems use a feed container with a chain floor, this made for a good first prototype test. Functionality of the prototype feed hopper was tested by dispensing dry distiller grains, high moisture corn, and chopped corn silage in a controlled manner. Push Floor Bunker Prototype With each additional motor and moving component on a feed storage container, the complexity of a system increases. In search of a simpler method for dispensing feed from storage containers, the PI proposeda push floor discharger. The PI constructed a temporary prototype 12' x 25' feed bunker equipped with a hydraulic push floor for dispensing feed components. Feed Composing Controls With the help of two consultants, the PI developed a control system for dispensing feed components from the concrete bunker equipped with a hydraulic push floor discharger. Each of the three push floor ladders were programmed to operate independently or continuously cycle. Feed Storage and Dispensing Functionality of the prototype feed bunker was tested by dispensingdistiller grains, high moisture corn, chopped corn silage, and processed hay. This initial testing was successful in that all ingredients were able to be dispensed from the feed bunker in a controlled manner, butthe system needs to be optimized to better handle each individual feedstuff. For example, hay and silage do not flow as easy as grains. Continuous Mixing In the Phase I project, the PI proposed using a continuous flow mixing process to combine feed components and improve the uniformity of feed mixtures. The PI relied on advice from industry experts in designing a continuous flow mixer for combining feed components. Continuous Mixing Results The PI evaluated the use of a continuous mixing process for improving the uniformity of feed mixtures and reducing the cost of an automated feeding system. The coefficient of variation (CV) was be used to measure mixer performance and mixture uniformity.Feed tests from the continuous mixing process measured a CV of 16% and 9% respectively as compared to the 3.6% and 2.2% CV results achieved using traditional equipment. Ideally a CV of less than 5%would have been obtained with the continuous mixing process. It was determined that a better method for improving theuniformity of feed rations is to use conventional feed mixing equipment and carefully controlthe following factors: mix time after the last added ingredient, loading position of the ingredient, load size, hay quality and processing, loading sequence, liquid distribution, and vertical mixer auger speed Results of the SBIR Phase I Project The Phase I project resulted in the design and working protype of an innovative, cost-effective, scalable automated system for storing and dispensing cattle feed ingredients be combined in mixer. Provender Technologies' Automated Feeding System (PTAFS)measures and mixes feed components directly from conventional concrete storage bunkers according to a formulated ration. Each concrete bunker is retro-fitted with a specialized hydraulic push floor dischargerwhich dispenses feed from the bunker. As feed is dispensed from the bunker, it is measured and transported to a stationary mixer via a horizontal conveyor. This system reduces the handling of feed components by dispensing ingredients directly from a bulk feed storage site and eliminates the need for specialized feed containers. Lower capital expenses - Commercially available automated feeding systems require a specialized building structure to house the feeding system equipment, whereas the PTAFS is integrated into existing concrete feed storage bunkers.The PTAFS can retrofit a farm's existing feed storage facility and can accommodate a large range of sizes exceeding those of commercially available systems. Reduced Operating Costs - Due to the design of the system, the PTAFS is able to receive semi-truck deliveries of feed components, whereas commercially available systems must be filled from storage bunkers via a wheeled loader. By storing larger volumes of feed and reducing the handling of feed components with a wheeled loader, the PTAFS decreases operating costs. It is estimated that the PTAFS willreduce wheeled loader operating time by 75% and feed truck mixing and delivery time by 50%. Reduced Feed Loss - The PTAFS reduces the handling of feed components. The storage bunkers of commercially available systems must be filled once every two days on average. The grain industry assumes a 1% feed loss every time a feed component is handled. Most feeding operations experience total feed losses of 5-20%, including losses from using a wheeled loader to transfer products. Improved Feeding Efficiencies - Feed rations are formulated according to the livestock's nutritional requirements and the desired performance of the livestock. During any or all the steps involved, the composition of the as-fed ration of feed ingredients can be compromised. If the as-fed ration of feed ingredients deviates from the formulated one, the livestock may not receive the optimal nutrition that was intended for them. The resulting inconsistency in the diet is undesirable and can lead to a drop in daily weight gain. These inconsistencies can also distort feed ingredient usage numbers, feed orders for feed ingredients, on-hand amounts of feed ingredients, formulation of feed rations, efficacy of feed ingredients, and the ultimate desired viability of livestock and corresponding livestock operations. The carefully controlled dispensing, weighing, and mixing of the PTAFS helps ensure the as-fed ration matches the formulated ration. Simple Maintenance - The PTAFS is a concise design and requires minimal maintenance. Concrete feed bunkers typically last 50 years, and the PTAFS machinery can be maintained to last that same time period. All push floor dischargers of the system are powered by a single hydraulic power unit. Most farmers are capable of maintaining the hydraulic system of PTAFS including the hydraulic power unit, valve blocks, cylinders, hoses, and fittings. The push floor ladders are constructed of structural steel and can be replaced if damaged or worn. Readily Available Financing - Cattle producers can apply for programs to help finance Provender Technologies' automated feeding system. The USDA Farm Storage Facility Loan Program provides low-interest financing for producers to store, handle, or transport eligible commodities they produce. Provender Technologies automated feeding system will also qualify for grants and guaranteed low-interest loansthrough USDA Rural Energy for America Program (REAP) due to the expectedenergy savings the system delivers.
Publications
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