Source: UNIVERSITY OF FLORIDA submitted to NRP
COVID-19 RAPID RESPONSE: IMPROVING FOOD SECURITY IN THE FACE OF PANDEMICS / COVID-19: DIVERSIFYING PROTEIN VIA MECHANIZED HIGH DENSITY MEALWORM FARMING
Sponsoring Institution
National Institute of Food and Agriculture
Project Status
COMPLETE
Funding Source
Reporting Frequency
Annual
Accession No.
1023980
Grant No.
2020-33610-32576
Cumulative Award Amt.
$106,500.00
Proposal No.
2020-06017
Multistate No.
(N/A)
Project Start Date
Sep 1, 2020
Project End Date
Apr 30, 2021
Grant Year
2020
Program Code
[8.12]- Small and Mid-Size Farms
Recipient Organization
UNIVERSITY OF FLORIDA
118 NEWINS-ZEIGLER HALL
GAINESVILLE,FL 32611
Performing Department
(N/A)
Non Technical Summary
Improving Food Security in the Face of Pandemics / COVID-19: Diversifying Protein via Mechanized High Density Mealworm FarmingOur target problem is the unsustainable, unstable food supply for animal protein in the face of pandemics such as COVID-19 (SARS-CoV-2 coronavirus). Current sources of animal protein such as mammals and poultry are unsustainable and pose production and biosecurity risks. We must learn lessons from the COVID-19 pandemic and make appropriate changes, including how our food is produced. Pandemics cause supply chain problems in animal protein. However, insect farms are easily quarantined and continue production with skeleton staff. Insects have a good shelf-stability, eliminating need for culling. There is almost no risk of viruses jumping from farm raised edible insects to humans, making them safe for consumers and farm workers. Insect farming being indoors means no exposure to environmental pathogens. With our innovation, small to midsize farms could easily farm mealworms for non-seasonal production, providing much needed income. Diversification of our food supply is critical for food security. The good news is insects, ie. mealworms (Tenebrio molitor), are a sustainable solution. They use less energy, feed, land and water than other livestock, contributing less to climate change and pollution. Over 30 companies in the US already offer products with crickets as a key ingredient. All Things Bugs LLC led the development of crickets as a protein source, selling over 15,000 pounds of Griopro® cricket powder. However, cost of insects is higher than beef, yet beef requires 10 to 100 times more resources. Equipment and technologies for insect farming are primitive and manual (unchanged in 60 years) resulting in high costs. Major food manufacturers are ready to use insects as a key ingredient, but cost must be on par with other proteins. Thus, there is a need for innovation in US mealworm farming to compete globally.The insect based food market, primarily crickets, is valued at $105M, growing to $1.53 billion by 2021. To become competitive, the industry must innovate and diversify. Mealworms have advantages over crickets. They are more disease resistant, produced at higher density and are amenable to mechanized automated farming. The mission of this SBIR is to contribute value and ingredient diversity to the food industry. Our innovation is a state-of-the-art, Insect Production System (IPS) designed to reduce cost, increase efficiency and scale of mealworm farming. Such innovation could lead to the highest production efficiencies of any protein production system. With this system, we believe mealworms can be produced at or below $1 per pound.This Phase I project will develop a mechanized mealworm production system. With these funds we will: 1) Test materials, parts and concepts to refine our design, 2) Construct a prototypes of our IPS and 3) Test the prototype to monitor mealworm mortality and overall system function. If successful, this project will be a critical step toward revolutionizing the food industry by adding value to an industry based on an entire Class of animals largely ignored - Insecta.All Things Bugs LLC (www.crickepowder.com) (founded 2011), is an industry world leader. Recently, major news sources have covered insect as a food source, often mentioning his company. Examples include: Huffington Post, Forbes, Fortune, The New Yorker, Fox News and others. Dr. Dossey published the first comprehensive book, "Insects as Sustainable Food Ingredients" covering all aspects of insects as food. Using patent pending technology, his company has sold to numerous food companies, and received over $4 million in research funding from USDA, DARPA, OCAST and Bill & Melinda Gates Foundation.
Animal Health Component
(N/A)
Research Effort Categories
Basic
(N/A)
Applied
(N/A)
Developmental
100%
Classification

Knowledge Area (KA)Subject of Investigation (SOI)Field of Science (FOS)Percent
40231101130100%
Knowledge Area
402 - Engineering Systems and Equipment;

Subject Of Investigation
3110 - Insects;

Field Of Science
1130 - Entomology and acarology;
Goals / Objectives
Our target problem is the unsustainable, unstable food supply for animal protein in the face of pandemics such as COVID-19 (SARS-CoV-2 coronavirus). Current sources of animal protein such as mammals and poultry are unsustainable and pose production and biosecurity risks. We must learn lessons from the COVID-19 pandemic and make appropriate changes, including how our food is produced. Pandemics cause supply chain problems in animal protein. However, insect farms are easily quarantined and continue production with skeleton staff. Insects have a good shelf-stability, eliminating need for culling. There is almost no risk of viruses jumping from farm raised edible insects to humans, making them safe for consumers and farm workers. Insect farming being indoors means no exposure to environmental pathogens. With our innovation, small to midsize farms could easily farm mealworms for non-seasonal production, providing much needed income. Diversification of our food supply is critical for food security. The good news is insects, ie. mealworms (Tenebrio molitor), are a sustainable solution. They use less energy, feed, land and water than other livestock, contributing less to climate change and pollution. Over 30 companies in the US already offer products with crickets as a key ingredient. All Things Bugs LLC led the development of crickets as a protein source, selling over 15,000 pounds of Griopro® cricket powder. However, cost of insects is higher than beef, yet beef requires 10 to 100 times more resources. Equipment and technologies for insect farming are primitive and manual (unchanged in 60 years) resulting in high costs. Major food manufacturers are ready to use insects as a key ingredient, but cost must be on par with other proteins. Thus, there is a need for innovation in US mealworm farming to compete globally.The insect based food market, primarily crickets, is valued at $105M, growing to $1.53 billion by 2021. To become competitive, the industry must innovate and diversify. Mealworms have advantages over crickets. They are more disease resistant, produced at higher density and are amenable to mechanized automated farming. The mission of this SBIR is to contribute value and ingredient diversity to the food industry. Our innovation is a state-of-the-art, Insect Production System (IPS) designed to reduce cost, increase efficiency and scale of mealworm farming. Such innovation could lead to the highest production efficiencies of any protein production system. With this system, we believe mealworms can be produced at or below $1 per pound.This Phase I project will develop a mechanized mealworm production system. With these funds we will: 1) Test materials, parts and concepts to refine our design, 2) Construct a prototypes of our IPS and 3) Test the prototype to monitor mealworm mortality and overall system function. If successful, this project will be a critical step toward revolutionizing the food industry by adding value to an industry based on an entire Class of animals largely ignored - Insecta.All Things Bugs LLC (www.crickepowder.com) (founded 2011), is an industry world leader. Recently, major news sources have covered insect as a food source, often mentioning his company. Examples include: Huffington Post, Forbes, Fortune, The New Yorker, Fox News and others. Dr. Dossey published the first comprehensive book, "Insects as Sustainable Food Ingredients" covering all aspects of insects as food. Using patent pending technology, his company has sold to numerous food companies, and received over $4 million in research funding from USDA, DARPA, OCAST and Bill & Melinda Gates Foundation.
Project Methods
Objective 1: Test materials, parts and system components and concepts to refine the final Phase I Insect Production System (IPS) design. Method of approach: Our team will evaluate materials, surface modifications, parts, mechanisms, and automation features needed for a successful and functional IPS prototype.Objective 2: Construct at least 1 complete prototype of the Insect Production System (IPS).Method of approach: All Things Bugs LLC (along with Dr. Aaron T. Dossey; President, Founder and Owner) is one of the world's leading firms in insect based food and edible insect mass production technologies. The New Product Development Center (NPDC) team has a rich history in new product design that stems from more than a decade of providing engineering support to small- and medium-sized companies in Oklahoma. Our team is well-equipped to produce a state-of-the-art mechanized (automated in Phase II) mealworm farming system under the guidance of Dr. Dossey (see biographical sections below). The goal of our design is to develop a mechanized mealworm farming system that will minimize human labor input to the process while providing an optimum environment for mealworm growth and minimizing waste.Objective 3: Test prototypes growing trays through a 4 month mealworm growth cycle (and make modifications and re-designs as needed. At the end we should have a working prototype. Method of approach: Initially in Objective 3 we will evaluate our completed Insect Production System (IPS) modules for their ability to hold all sizes of mealworms without escape, open and eject full grown larval mealworms, separate them from waste and feed and convey them to a harvesting bin/box.

Progress 09/01/20 to 04/30/21

Outputs
Target Audience:Our target audience are both potential and active farmers of insects. Mealworms are a great source of protein, but cost of production, and, therefore, market price, have limited their use. Our efforts to automate mealworm farming will reduce the market price of this promising protein source, opening up oportunites for many new farmers of mealworms. Changes/Problems:We have not experienced any significant problems or set-backs on this project. Our results and progress have exceeded expectations. Our primary limitation is access to funds to build a prototype insect farm so that we can fully develop, evaluate and commercialize our insect farming technologies in a real world pilot or commercial scale. Access to funds for equipment, property, buildings and staff to operate such a commercial research facility are critical for SBIR funded technologies to make it to market. What opportunities for training and professional development has the project provided? Nothing Reported How have the results been disseminated to communities of interest?Interviews with small and mid-sized mealworm farmers during Phase I: During talks with several mealworm farmers (see letters of support) we were able to get substantial critical feedback that will make our Phase II mealworm farming systems very successful and desirable on the market. These farmers have given us insights as to the methods they currently use which are largely manual and do not utilize the benefit of collecting and quantifying the amount of eggs added to feed. Thus, our approaches to mealworm farming developed in Phase II will make many tremendous improvements to these farmers' production efficiencies. We found that all mealworm separation from waste at harvest is done manually. Our systems will alleviate that labor burden and drastically improve their efficiency. Mealworm WASTE is valuable! Another discovery from interviews with mealworm farmers that heavily illuminated substantial commercial opportunity for our Phase II systems is that mealworm frass (the waste produced by mealworms) is a highly desirable fertilizer / soil amendment product particularly by organic farmers and greenhouse farmers. The chitin contained in this waste as well as the waste itself is valued by organic farmers to improve plant productivity and alleviate certain pests such as nematodes. Thus, in Phase II, we will carefully consider the value and post-harvest handling and packaging of mealworm waste as a valuable byproduct - and will add that as a commercial opportunity in the Mealworm Farming Manual we will develop in Phase II Objective 3. BONUS extra results from Phase I: In addition to the Phase I work that was proposed and now completed, we collaborated with the Oklahoma State University's Agricultural Economics department to develop a detailed customizable economic analysis spread sheet for mealworm farmers of all sizes. We have shared this with a few mealworm farmers and they have told us that it is extremely valuable. Additionally, it has been a very useful tool to engage with these farmers to collect data on the economics of their existing farm operations and how/where they can be improved. Thus, in Phase II (Objective 3) we will further optimize this spread sheet as part of our offerings to mealworm farmers who buy our systems as part of our Turnkey Mealworm Farming Manual and System What do you plan to do during the next reporting period to accomplish the goals? Nothing Reported

Impacts
What was accomplished under these goals? During the first several months of this USDA NIFA SBIR Phase I research project we have had good success on the technical/scientific aspects of the project and derived from its activities, products and results. Going forward we will construct our Phase I mealworm farming prototype and evaluate it's efficacy and usefulness for mealworm feeding and harvesting as well as develop our research plans and commercialization strategies in preparation for Phase II. Below are the areas of success we have achieved to date in the areas of 1) technical/scientific advancement/discovery and 2) preliminary commercialization success. Government funding for these types of technology commercialization resources is needed for technology startups such as ours who do not have reasonable access to capital otherwise. Technical/Scientific Advancement/Discovery: For this project we developed, produced, and evaluated high density prototype mealworm rearing chamber modules. Phase I models are utilized in a commercial setting by 1 or 2 employees for an entire small or mid-sized farm but maintain elements that can be ready for automation in Phase II. The program also evaluated the cost effectiveness of our systems based on interviews with several small mealworm farmers. One of the keys to success for this program is a system that the small farm operator can afford to implement. We kept the design simple and low-cost while efficiently mechanizing it so that one or two employees could run an entire small or mid-sized mealworm farm with significant revenue. The following outlines our accomplishments, successes and discoveries in Phase I, particularly those that will be utilized to optimize experimental and commercialization success in Phase II: Objective 1: Test materials, parts and system components and concepts to refine the final Phase I Insect Production System (IPS) design. During the objective we successfully achieved the following discoveries and developments: Determined the minimum anglefor the sides of the mealworm growth trays that will contain them without them being able to crawl out, yet allow for complete dumping of all tray contents at harvest. Evaluated the structural integrity and costs of various materials for the frames and trays for the mealworm growth units and determined that a steel frame with aluminum or plastic trays are the most cost effective while providing proper structural integrity for supporting the mealworms and their feed. Objective 2: Construct prototypes of our Insect Production System (IPS) for mealworms. From data collected in Objective 1 (Objectives 1 and 2 overlapping) fully functional Phase I IPS Drop Model MW. During the objective we successfully achieved the following discoveries and developments. Evaluated the feasibility and overall productivity (harvest efficiency, labor burden and mealworm farming density) of a one sided 6 tray height unit or a combined 8 or 12 tray unit (with 2 sets of trays facing one another). We determined that a combined 8 tray unit is ideal given the weight of the mealworm and feed material and ability for 1 employee to roll the full unit over a central dump site (centrally located in the farm) for quick and easy harvest. This would hold approximately 400 pounds of total mealworm, feed and waste material and produce 100-200 pounds of full grown mealworms in a single growth cycle/harvest per unit occupying 27 square feet of space. These units, based on interviews with several small and mid sized mealworm farms, are optimized ideally for productivity for any mealworm farmer at any scale from using just 1 unit in a small farm up to as many units as the farm would wish to operate: eg: very scalable. Also, these units are optimized for addition of automatic controls and full automation of the mealworm farming when combined with our planned innovations for this Phase II project. Completed a stress analysis on the frame to achieve the minimum use of steel in the frame while maintaining a safety factor of 2. Successfully constructed and demonstrated the efficacy of a proprietary systemto automatically dump all of the trays in the unit at a controlled and adjustable rate. The design links all 4 trays on one side that offers ease of dumping and good speed control during the dump. Determined that a combined 8 tray 2 column format is the ideal structure for optimizing both growth density. COMPLETED: We now have a full engineering drawing assembly and manufacturing package complete with all specifications needed to manufacture additional prototypes of our auto-dumping mealworm growth tray "IPS" systems. Thus, we are fully prepared to produce additional units for further testing and optimization in Phase II. In Phase II we will collect additional data at our facility and at least one small partner mealworm farm toward the final design of the Phase II model which will be ready for mass manufacture and sale to small and mid-sized mealworm farmers across the US. Objective 3: Test prototype trays for a 4 month period to monitor mealworm mortality and overall system function, looking for mealworm escapes and efficiency of harvesting as well as ease of cleaning, and make modifications and re-designs as needed. During the objective we successfully achieved the following discoveries and developments: Discovered that to move mealworm material, feed and waste at harvest, creates a large cloud of mealworm waste dust. This is a significant environmental hazard for mealworm farm staff. Thus, in Phase II, we will handle the mealworm and waste material at the time of harvest and for post-harvest handling in a way that mitigates dust hazzard. We believe that our systems do not pose a significant dust cloud risk as compared with manual harvesting. BONUS Phase I Experimental Results: Conducted experiments which determined (during a full 4 month growth cycle) a preliminarily optimized quantity of mealworm eggs to feed ratio for optimizing feed use. We also developed a mealworm egg collection protocol/system. This will be further optimized in Phase II. This was an additional last minute experiment we conducted for this project that was not in the original proposal. This was very helpful information going forward! This demonstrates to us that we can produce over twice as many mealworms in these tray units as we had originally anticipated in our Phase I proposal.

Publications