SBIR-STTR Award

Farms are faced with increasing problems managing manure from animal operations. Alternate innovative methods to deal with the handling and distribution of the manure solids materials and nutrients are needed to allow farms to economically comply with increased regulations. The purpose of this project is to further the development of a concept to utilize farm animal waste material in a manner that will generate economic gain and help farms comply with regulations by distributing the excessive nutrients to low nutrient areas actually requiring additional nutrients. This can be accomplished by the successful use of processed manure to manufacture seed pots and planting pots using substantially all animal generated waste material. OBJECTIVES: The two components of feed material to the anaerobic digester are cow manure and contaminated bedding material. Changes in animal food sources and changes in bedding material generate variability in the feed to the digester and consequently the discharge material from the digester. Before commercializing COWpots, Freunds Farm must understand the effect of herd management on the amount and characteristics of the fibers in the digester output. Differences in bedding sources from farm to farm are the biggest variables affecting manure fiber characteristics. We intend to research the effect on the fiber of two standard bedding practices: sawdust and chopped newspaper. We also will study the effects of different diets on manure fiber. Two different diets will be a high fiber diet with the cows on pasture and a low fiber diet when the cows are feed mostly corn. Our cows are on pasture in the summer and they are confined to the barn during the winter. We will quantify the effect of the changes in bedding and diet on the amount and size of the manure fibers, and the effect the changes in fiber have on the production of pots. Our research will answer the following performance and durability-related questions: (1) How can we ensure the durability and uniformity of COWpots in the context of different bedding and diets? (2) What production procedures for COWpots need alteration due to differences in manure fiber caused by bedding and diet changes? (3) How does the durability of the pots affect growth rate of greenhouse seedlings and field grown plants? APPROACH: The methodology we will use to test herd management effects will be to compare COWpots against each other and against peat pots as the standard. The ultimate criterion of success for the project will depend on COWpots performance EXPERIMENT PART 1 The effect of diet and bedding on manure fiber characteristics involves two types of bedding, sawdust and shredded newspaper, and two diets, a low-fiber grass-based diet and a high-fiber corn-based diet. This will give four different manures to test: sawdust-low-fiber; sawdust-high-fiber, newspaper-low-fiber, and newspaper high-fiber. Analysis on a portion of each of four digested samples will be done to determine the total amount of material usable for pot molding Based on the resulting analytical data, twelve total samples, 3 from each digested manure type, will be selected for subsequent sand and fines removal treatments at pilot scale. EXPERIMENT PART 2 The effect of the different manure fibers on the durability and wet strength of horticultural pots will be determined by the samples on a laboratory forming machine to make pots using a consistent addition of supplemental fiber. . The finished pots will be tested for durability and wet strength after being subjected to actual green house practices. EXPERIMENT PART 3 The effect of the diet and bedding on the growth of plants in the pots will be done using winter squash in the pots and in field trials. The experiments will have five treatments: peat pots and pots made from the four manures samples generated in experiment Part 1. The treatments will be arranged in a randomized complete block design with four replications. A winter squash variety we have used in the past, Jet (F1) from Johnnys Seeds, will be sown in the pots in the commercial greenhouse at the Freund Farm. Routine procedures will be used to grow the squash to transplanting size. Plants will then be transplanted to a local field test and allowed to grow to maturity using standard practices. Final data relative to bloom count and/or generated fruit weights by the various plants will be used to evaluate performance

Freund's Farm, Inc. has developed an innovative process that transforms cow manure into value-added, biodegradable containers for horticultural use. Work performed to date has demonstrated that container pots can be molded from processed manure that offer the desired characteristics of biodegradability and decomposability, allow for exceptional penetration of plant roots through pot walls, and provide nutrient content. Further work is needed to improve the efficiency and consistency of the solids separation done on the discharge from the anaerobic digester since the solids stream is the source of material that is ultimately used to form the pots. Also further work is needed to determine if it is possible to use the bio-gas in a direct fired drying unit without imparting undesirable odor to the horticultural containers. This utilization of the bio-gas will help the product economics if it can be done satisfactorily. The work to be performed under this grant will characterize and identify the solids separation method that separates solids from the liquid manure discharging from the anaerobic digester. This project will also determine the practicality of direct firing bio-gas fuel generated from the digester to efficiently dry the formed horticultural pots in a manufacturing facility. Prototype horticultural containers will be fabricated using Freund's Farm's existing manure digester and pulp molding equipment. The test pots formed will be tested for horticultural performance and odor at the University of Connecticut and in a greenhouse and farm settings. OBJECTIVES: The project is broken down into 3 separate but related work efforts called Experiments. EXPERIMENT 1 Solids Separation The objective of Experiment 1 is to research methods of manure solids separation to reduce water content consistently to facilitate composting. The solids separation has been accomplished with a single stage screw press but this alone it is not practical to routinely control the moisture content of the solids separated to the degree and consistency needed. High and inconsistent moisture levels in the solids that feed the in-vessel composter have resulted in inconsistent modification of fiber characteristics. These variations in the fibers cause variation in the quality of the molded pots. Investigation of the options to make the separation a proven two step process will be researched EXPERIMENT 2 Bio-gas fuel The objective of Experiment 2 is to research methods required to replace indirect fired oil heat with direct fired bio-gas in the drying ovens. Biogas is produced from the Freund manure digester. Biogas is a potential fuel, available for manufacturing horticultural containers. Because bio-gas is a low heat fuel, it is necessary to direct fire a dryer to reasonably use the gas. The primary concern with direct fired bio-gas is that it will impart an odor or other undesirable properties(effecting horticultural performance) to the pots or deposit by -products of combustion that are harmful to plant development EXPERIMENT 3 Phytotoxicity The objective of Experiment 3 is to research the plant growth characteristics using the horticultural containers. Previous trials with different formulations of manure pots have produced inconsistent results. In some trials manure pots were superior to conventional peat pots, and apparently provided available nutrients. In some cases, manure pots were inferior, but the cause was not evident. The production process has evolved to the point that re-evaluation of current process pots is warranted. The changes induced with the work in experiments 1 and 2 also cause the need to test the effect, if any, of those changes. The objectives of this research are: 1. To evaluate manure pots for effects on plant growth prior to transplant. This objective will include the effects of source material characteristics on the performance of manure fiber pots. The primary focus will be on the potential for growth stimulation from nutrients supplied by the pots, and potential negative effects including stunting or phytotoxicity. 2. To investigate cause(s) if stunting or phytotoxicity is observed. 3. To evaluate physical properties of manure pots relevant to production and transplanting, including durability and root breakthrough. APPROACH: The project is broken down into 3 separate but related work efforts called Experiments. EXPERIMENT 1 Solids Separation - The approach to this work will be to investigate the options to make the separation a two step process focused on being able to adjust to the varying characteristic of the digester effluent. After equipment trials are complete, appropriate equipment will be leased and installed to run an extended trial through the four seasons to prove the ability to routinely control the composting step with consistent material moisture inputs. The results will be measured by the measurement of the horticultural and mechanical characteristics of the pots in University, commercial greenhouse and the farm environment. EXPERIMENT 2 Digester Bio-gas Fuel - The approach to this work will be to construct a pilot batch dryer that will run on both bio-gas and fuel oil and be direct fired. The design will allow for adaptation to propane if necessary. The primary need is to determine that the pots are not encumbered with an unacceptable odor and that their ability to nurture plant development is not compromised by exhaust gas products. The economic feasibility of using bio-gas as the fuel source for horticultural pot drying will be determined from the results. Building and operating a pilot test dryer is the only alternative for testing direct fired bio-gas drying for this product. Bio-gas has been used for drying agricultural products and waste sludge in sewage treatment plants, however, odor of the final product was not a consideration. Drying equipment suitable for horticultural pot drying and built to withstand the environment generated by the exhaust gases from the combustion of bio-gas is not on the market. The results will be measured by the measurement of the horticultural and mechanical characteristics of the pots in University, commercial greenhouse and the farm environment. EXPERIMENT 3 Phytotoxicity Experiments will be conducted in the Floriculture greenhouse at the University of Connecticut. Horticultural containers will be obtained from Freund's Farm as manufactured. Peat pots (Jiffy Products, Batavia, IL) of a similar size will be used as controls. Standard growth trials will be conducted with each batch as received. Trials will include three species of plants. Plants will be grown from direct seeding in the pot to transplant stage, approximately six weeks Seeds will be germinated in a mist bed using bottom heat to ensure rapid and consistent emergence. Standard methods will be used for fertilizer application, irrigation to generate an array of combinations various nutrient and water exposure combinations. Pots and plant tissue samples will be analyzed for nutrient content using standard procedures at the UConn Plant Nutrient Analysis Laboratory. Durability and root grow-out will be evaluated based on subjective observations.