Researchers at the University of Waterloo are developing technology to produce renewable natural gas from manure so it can be added to the existing energy supply system for heating homes and powering industries. That would eliminate particularly harmful gases released by naturally decomposing manure when it is spread on farm fields as fertilizer and partially replace fossil natural gas, a significant contributor to global warming.
"There are multiple ways we can benefit from this single approach," said David Simakov, a professor of chemical engineering at Waterloo. "The potential is huge."
Simakov said the technology could be viable with several kinds of manure, particularly cow and pig manure, as well as at landfill sites.
In addition to being used by industries and in homes, renewable natural gas could replace diesel fuel for trucks in the transportation sector, a major source of greenhouse gas emissions.
To test the concept, researchers built a computer model of an actual 2,000-head dairy farm in Ontario that collects manure and converts it into biogas in anaerobic digesters. Some of that biogas is already used to produce electricity by burning it in generators, reducing the environmental impact of manure while also yielding about 30 to 40 percent of its energy potential.
Researchers want to take those benefits a significant step further by upgrading, or converting, biogas from manure into renewable natural gas. That would involve mixing it with hydrogen, then running it through a catalytic converter. A chemical reaction in the converter would produce methane from carbon dioxide in the biogas.
Known as methanation, the process would require electricity to produce hydrogen, but that power could be generated on-site by renewable wind or solar systems, or taken from the electrical grid at times of low demand. The net result would be renewable natural gas that yields almost all of manure's energy potential and also efficiently stores electricity, but has only a fraction of the greenhouse gas impact of manure used as fertilizer.
"This is how we can make the transition from fossil-based energy to renewable energy using existing infrastructure, which is a tremendous advantage," said Simakov, who collaborates with fellow chemical engineering professor Michael Fowler.
The modelling study showed that a $5-million investment in a methanation system at the Ontario farm would, with government price subsidies for renewable natural gas, have about a five-year payback period.
A paper on modelling of a renewable natural gas generation facility at the Ontario farm, which also involved a post-doctoral researcher and several Waterloo students, was recently published in the International Journal of Energy Research.
With no incineration, leaving behind no waste or byproducts and in just 30 minutes, ReGreen Organic's innovative recycling process transforms waste into clean, sanitary, odor-free and marketable products: Fertilizers, compost, animal feed and fuel pellets. READ MORE
West Palm Beach is among many locations – like Calgary, Alberta, and Norco, California – where a significant amount of horses and riders cohabitate for competition and sport. The resulting waste bedding creates hundreds of thousands of tons of manure per region.
Enter HiPoint Agro Bedding Corp (HPAB), who has developed a process that takes waste shavings, cleans them, pasteurizes them and re-packages them for resale and reuse. The removed horse manure can then be aerobically composted or used to produce energy in an anaerobic digester.
HPAB is currently completing site validations across North America aimed at recycling waste bedding shavings in areas of high horse and rider populations. In many cases, inadequate stockpiling of manure has caught the attention of the U.S. Environmental Protection Agency and the public, causing significant environmental concerns with the use and improper disposal of equine bedding material.
As part of its 2018 budget, the Dane County Executive is allocating $200,000 to study the potential of creating a large-scale community facility where farmers could bring manure and have it composted. READ MORE
Funding was announced recently for two projects by the Centre de recherche en sciences animales de Deschambault (CRSAD), including $665,546 aimed at developing sustainable strategies for standardizing the manufacturing and use of recycled bedding in dairy production to improve the sector’s environmental performance without reducing the profitability of businesses, as well as to respond to consumer concerns.
With the funding, the CRSAD will be able to determine the best methods for manufacturing recycled bedding from manure and to make recommendations for the adoption of the best management methods, practices and technologies, with the welfare of animals and workers and the safety of products also taken into account. Dairy producers will be therefore able to reduce their operating costs and reuse or sell the energy produced by the biodigesters, which will provide farms with an additional income stream.
“The investment in research to improve livestock housing conditions in the dairy industry will enable Canadian producers to differentiate themselves, be more competitive, improve their businesses and, especially, enhance their living conditions and those of their livestock,” said Jean-Paul Laforest, president of the CRSAD.
He told a large tour of attendees from the North American Manure Expo in nearby Arlington that the fertilizer value and bedding potential of compost are already apparent on his family's Endres Berryridge Farm, operated with brothers Randy and Steve, but he is still learning about the energizing effect compost has on the soil.
One hint of that aspect of compost use is that his alfalfa acres that have been fertilized with compost for two years have out-yielded all other alfalfa fields. "It's enough to notice," he said. "That told me this isn't hurting me. There's something to it."
He also noted that one problem they had before utilizing compost in their system is that steep alfalfa fields could not be fertilized with liquid manure and as such started to decline in fertility. Once they had the environmentally friendly, stable compost, they could feed those fields with it. They also found that applying compost to a growing crop didn't harm the plants."There are not a lot of barriers to composting," he said. "No farmer is going to go into it as crazy as we did, but I got sick of digging holes in the ground to store manure. For us, this was a way to utilize the nutrients we already have in our farm system.
"I don't think farmers should ever have to give nutrients away," he said.
Two busloads of visitors from Manure Expo joined another busload of guests from the Madison Clean Lakes Alliance to visit the Endres farm on Aug. 22 and they asked some pointed questions of the compost experimenter.
He told them that he could probably build and use a liquid manure system more cheaply than operating his compost system. Just over a year ago the Endres family incorporated a large compost barn into a new set of buildings where they raise their dairy herd replacements.
Two identically sized barns (65 by 220 feet) house the farm's heifer calves from four months to 13 months of age. Both barns feature tunnel ventilation and additional cooling fans which aid fly control; the air moving at 5 miles per hour keeps flies away. "The compost process, with the heat that is generated, is also very friendly to fly control," he adds. READ MORE
These technologies can cover a range of innovations – generate energy from animal manure, reduce on-farm waste streams, and repurpose manure by creating marketable fertilizer and other value added products such as compost.
In October, MDA awarded Veteran Compost of Harford County, Maryland, and O2Compost of Washington State a grant for $350,300 to develop a compost demonstration project plus a public education and training facility in Anne Arundel County for livestock farmers.
The project will demonstrate aerated static pile (ASP) composting technology systems at three levels: small scale (one to four horses or livestock equivalents); medium scale: (five to 20); and large scale: (20 to 40).
All three compost systems will be solar powered to demonstrate off-grid sustainability. The medium and large systems will include storage tanks to retain roof water for use in the composting process.
The project will also include formal classes and hands-on workshops, public tours for students in kindergarten through college, and alliances with government agencies and non-profit environmental organizations. In addition, a compost cooperative website will be developed to bring together producers and end users of the finished compost products.
The compost systems that are displayed will be ones that have been in use since 2001. Peter Moon, owner of O2Compost, says he started out in the composting industry in 1989, designing and permitting large-scale municipal green waste systems. Then, in the mid-1990s, he started applying some of the industrial ideas to compost dairy and chicken manure.
After seeing a chicken farm that was composting mortalities that looked tidy but suffered from terrible odor issues, he decided that an aerated bin system was what was needed. It took him a few months to figure out the answer and was convinced that it would work.
“I ended up building a prototype in my back yard because I had to prove to myself that it would work, and it worked way better than I had hoped,” he says.
Today, O2Compost offers what they call Compost Operator Training Programs. They include four basic components – the design of the system, the aeration equipment package, a detailed training manual written in layman’s terms, and unlimited technical support – for a fixed fee.
“It’s this system and three stages of bins that will be on display,” he says. “Although I don’t know of any other company that is offering anything like it, I want to make clear I didn’t invent the concept of aerated composting. Aerated static pile (ASP) composting was first developed in the mid-1970s in Beltsville, Maryland. I just reconfigured it into an aerated bin system.”
When the MDA put out the RFP in 2016, Peter immediately thought of his client and good friend, Justen Garrity, owner of Veteran Company based out of Aberdeen, Maryland. The two had known and worked with each other since 2010 when Justen took Peter’s training program.
Veteran Compost has a 30-acre farm in Aberdeen and is dedicated to employing veterans and their family members and turning food scraps into high-quality compost. The crown jewel of Veteran Compost is its vermicomposting operation –it’s one of the only commercial worm composting operations in Maryland.
Peter approached Justen and suggested that, since the company was located in Maryland, why didn’t they set up a demonstration site with bins and a larger open aerated static pile system and use it to instruct farmers in Maryland and neighboring states. They could come to them, participate in a half-day workshop and then come out to the site and see it, sense it, understand it and learn.
Justen could immediately see the value in this partnership, and so did MDA. In 2016, O2Compost and Veteran Compost received the grant.
The project would already be operational today, except for one snag. Justen and Peter had challenges finding a good site, because people in the area have been reluctant to have a composting site near them because of potential odor issues. This is despite the fact that Justen’s composting facility in Aberdeen has received zero odor complaints from neighbors in the six years that it’s been operating.
“Justen has also had to go through a process with Anne Arundel County to allow for composting on agricultural zone property,” says Peter.
It has taken a long time and numerous public hearings, but recently the county commissioners voted unanimously to allow this activity on agricultural zoned land.
Ironically, these systems will demonstrate why compost doesn’t have to generate offensive odors for several reasons: the ASP compost piles are not turned; airflow is induced into the piles resulting in aerobic conditions throughout the pile; and a biofilter cover is used for in-situ treatment of off-gases.
“It has been my experience that most people think that compost piles need to be turned to get oxygen into it,” says Peter. “What they don’t understand is that when a biologically active pile is turned, the oxygen that is introduced into the compost is then consumed by the microorganisms and depleted within 30 to 45 minutes.”
With regard to composting at the training facility, Peter and Justen will induce airflow using a high pressure, high volume electric blower and push air into the pile to replenish the oxygen and displace CO2, heat and water out of the pile.
In short, ASP composting results in aerobic composting versus turned windrow composting, which results in anaerobic composting.
Drainage isn’t a factor for the smaller systems because the bins are covered with roof structures. However, for municipal scale compost facilities managing storm water, it is always an important consideration.
“For the larger systems, municipal-type scale, yes, typically we’ll construct a pond of some kind to handle any surface water run-off.”
The liquid collected is then re-introduce back into the compost pile as process water, or in some cases directed to a sanitary sewer for processing at the local wastewater treatment plant.
“Our goal with composting is to get the pile temperature throughout the pile to exceed 55oC (equivalent to 131oF) for a minimum of three days. Meeting these time-temperature conditions effectively destroys pathogens, parasites and weed seeds in the finished compost,” says Peter.
The objective is to produce a high quality compost product that is safe to use on pastures or in vegetable and landscape gardens.
Moisture is always an important factor when composting, and will be one of the things farmers will learn more about at the site.
“Our goal is to have the moisture content somewhere between 60 and 65 percent, going into the pile,” says Peter. “At that moisture content, it will feel quite wet and you can squeeze a handful and get a drop or two to come out. At this moisture content, it won’t drain free-water that could impact surface and ground water resources.”
Peter says with dairy and pig manure, even if it’s run through a separator and the fibrous material is stacked, the base can get saturated because the water just continues to drain out. It can fill the pipes under the stack with water. To avoid this, some type of dry “bulking” material can be added. Peter often encourages dairies to look to horse stables in their area or even equine events.
“Horse farms always have that same problem, but it tends to be very carbon rich and very dry, which is exactly what you want to marry-up with wet substrates.”
Flexibility is built into the system.
“For example, companies may accumulate their food waste in batches and then mix it up to compost out. Or you can build a pile over a 30-day period as you would on a horse farm,” says Peter. “The idea with the MDA grant is to teach people what is possible, and that there is a method that’s simple and effective and an excellent investment on their farm with an ROI of two to five years.”
There is also flexibility in the use of pipes. With small, aerated bin systems, the air is delivered by an air-floor and there are no pipes to work around.
For larger systems, aeration pipes can be laid directly on the ground with the pile constructed directly on top. Some farms sacrifice the pipe when they bring in their frontend loaders. Others choose a thick-walled HDPE pipe.
“That pipe can literally be pulled out from underneath the pile and reused.”
One of the key features of the system is low maintenance. Once the compost pile has been built, it’s pretty much hands off. The blower and timer to do all of the work.
“You monitor the composting process, but you don’t need the big windrow turner and someone out there driving it,” says Peter. “You’re not paying for fuel, maintenance or repairs and you are able to greatly reduce air emissions. ASP Composting requires about 25 percent of the space when compared to turned windrow composting, and it can be operated at less than 50 percent of the cost.”
Both Peter and Justen feel that once the training facility is in operation, which looks to be late summer of 2017, farmers will be excited to discover that aerated static pile composting yields too many benefits to ignore. It speeds up the process, reduces odors and basically eliminates neighbor issues. It also destroys parasites, pathogens and weed seeds in the mix, has a small footprint, reduces the cost of operation, can handle any organic waste material and is simple to operate.
“The question I get a lot is, ‘If this is all so easy and it’s everything you say it is, why isn’t everybody already doing it?’” asks Peter. “For some reason everybody is just locked onto the idea you need to turn the pile, but you don’t. We have over 1,200 systems in operation in 21 countries. It is a simple technology that is easy to learn – and it works.”
Nine consecutive days of temperatures above 100 degrees in the Central Valley area of the state resulted in a large jump in cattle deaths. According to an agricultural official in Fresno County, between 4,000 and 6,000 head of livestock died in the month of June due to the heat. Adding to the problem was the temporary shutdown, due to a mechanical problem, of the local rendering plant. As a result, a state of emergency was called in at least three counties and the California Dairy Quality Assurance Program (CDQAP) released an emergency mortality disposal advisory. Under the plan, producers were provided with three options to dispose of mortalities: directly transport the carcasses to an alternate rendering facility or permitted landfill; temporarily store mortalities on farm in compost piles until they could be permanently disposed of; or, as a last resort, bury the carcasses in an emergency landfill on farm, which still required a mountain load of paperwork and possibly thousands of dollars in fees.
According to the five-page advisory, producers were encouraged to put down a waterproof liner and use dairy manure solids as a composting agent, placing each adult carcass on a three foot bed of manure and then covering with a second layer of manure three feet deep. By doing this, farmers could buy themselves an extra six months of time before the carcasses needed to be disposed of permanently off farm.
“Staff will be looking for evidence of bones and carcasses that have been left more than six months,” the advisory warned, adding the number and identity of the animals composted plus documentation they had been properly disposed of would also be required.
While this isn’t the first time California has dealt with large-scale livestock deaths due to heat, it will be interesting to see how the agriculture and landfill industry deals with the added pressure to the carcass disposal system. With the threat of animal disease outbreaks, such as bird flu or foot and mouth disease, always in the background, this negative situation provides an opportunity to test-drive the official response. Heaven forbid it would be required on a state- or nation-wide scale but it’s always prudent to be prepared.
I look forward to any lessons learned which come after the debrief.
Speaking of composting, producers and custom manure applicators can learn more about the management practice and see relevant equipment in action during the North American Manure Expo, taking place in late August at the Arlington Agricultural Research Station near Arlington, Wisc. I consider Expo one of my favorite industry events of the year. What isn’t there to enjoy? Farmers, family, food, friends, farm equipment, information, demonstrations, community: the important things in life.
This Manure-a-palooza takes a year or more of planning to bring to fruition, including hours of committee meetings and conference calls. As a frequent participant in these morning gatherings, I can attest to the time and effort by industry volunteers that goes into preparing for this event. Be sure to check out the event website – manureexpo.org – and consider taking part.
“That is until somebody makes a mistake and pollutes someone else’s water, or they offend their neighbors with flies or odor,” he says. “That’s when the neighbor calls up the water conservation district and says, ‘Hey, this guy is piling manure up and he isn’t doing anything with it.’ Most of the cases in our county, where the guys (inspectors) have been called out, have not been on dairy farms or livestock farms, they’ve been on horse farms.”
Ober’s county, just east of Cleveland, has the second-highest horse population in Ohio, and he has worked extensively with equine professionals. His clients generally have small farms, small lots, with a relatively small number of animals. He advises them on hay quality, pasture management, and manure and nutrient management.
In his work, he has found that there are some common problems in the industry.
“When I talk to horse owners, of course the first thing they’re looking at is a nice new arena, or increasing the number of stalls. But what are you going to do with the manure?” he asks. “You have to think of that problem before you move ahead or move horses into the stalls. You can’t just pile it up at the back door and hope it goes away. Manure is a problem, it can offend the neighbors and it can definitely compromise water quality.”
The two areas of environmental concern are the manure produced inside the stable, and also the manure that is produced outside.
“In our area we normally have guys with four or five acres trying to keep six horses. That’s bad business, you can’t do that, especially if you’ve got a boarding stable. You’ve got to turn them out year round. What are you going to do with those horses when you turn them out? If you’re lucky the ground will be frozen but most often it’s just covered with snow and you’re going to turn it into a quagmire.”
“Here’s two things you have to look at; first, the manure inside the stable. What are you going to do with that?” he asks.
Of the manure produced outside, “what about the water quality issues outside that barn?”
“The first thing we’re going to look at is grazing, which is the traditional pastime of horses. They are just like sheep. They will graze right to the ground. Eventually, they will graze it down till everything is gone and then they will go after the grass under the fences. That is when you know you have hungry horses,” he says.
“One thing you have to understand about horses is that they are pretty much like a conveyor belt – food goes in, poop comes out and it’s continuous. Horses graze 22 hours out of 24.”
Artificial measures can be taken to protect pastures from excessive erosion due to weather, grazing or turnout.
“It is part of the real solution to all weather turnout. This has been a real boon for the horse industry, it’s not cheap but it is definitely part of the solution,” Ober says.
He explains that they take a pasture area that has been cordoned off and make sure it drains well, tiling it as needed. Then they bring in geodesic cloth and put it down as a ground cover to provide some support and so gravel is not lost. Then they cover it, first with a very coarse limestone, working up to a very fine limestone cover.
“This creates a pad that the horses follow and that solves the turnout problem,” he says. “They don’t need to be out on pastures in the middle of December punching the pasture up, then there’s a good rain and all the manure and soil that’s out there washes into the creek. That’s a problem you’ll have to deal with.”
The choice of bedding can be another issue.
“The big problem is that the majority of that bedding that is choosen is sawdust and wood chips,” he says. “It takes too long to break down, so you’ll need more microbial activity and that will suck up all the available nitrogen in the soil to break down the carbon in the shavings and bedding and you’ll have stunted grass.”
Ober notes that nitrogen ratios for wood chips, sawdust bedding are 200 to 750 to one.
“For straw bedding it’s 50 to 150 to one, which is not too bad to have to break down,” he says.
“You need to source the right bedding; straw is about $4 per bale, shavings $4 to $8. Overall cost is going to be about $45 to $46 for straw and $35 to $40 for wood shavings. Another factor to consider is that cleaning sawdust and wood shavings out of a stall is labor intensive and expensive.”
Ober points to an OSU fact sheet on nitrogen enhancement and says that if you are going to haul manure on a daily basis, you will want to add about a half cup of ammonium sulfate into your wheelbarrow load.
“This should give you enough nitrogen to start that break down process,” he says. “I would like to see maybe half to a full cup added, and I will tell you that it does work very, very well.”
Another option that people have used is the dumpster.
“This is a popular way because people today just don’t know how to get rid of horse manure. In one situation there is one dumpster for six horses that is picked up and emptied every three weeks. That works out to about $3,000 per year. If you are boarding horses, you have to consider the $250 to $300 a month for manure. That’s a major cost.
“Many farmers are using this system simply because their backs are against the wall,” Ober says. “You will save money during the summer months (when turned out) as opposed to winter but this is still not a good system for dealing with manure.”
Composting is another solid option for manure.
“We don’t see it used that much but there are definite advantages,” he says.
Make a pile about three feet high and seven feet wide, and aim for the optimal temperature of 160 degrees Fahrenheit.
“We want to maintain the moisture so that when you grab that material you feel the moisture. Too much water kills the bacterial action. You need to keep rotating the pile and aerating it. You will end up with a product that is very, very good and you’ll be able to save most of the nitrogen. If you bring it into a nitrate form it will not leave the ground as fast. This is another sound management tool.”
Ober explains that the reason composting is not yet popular in the horse industry is due to the carbon to nitrogen ratio.
“If you can get ahold of some other materials to get in there, some green materials, some other animal material, source all the green clippings or straw then bring it all together and bring it into a compost pile,” he says.
When it is done, the compost has been through a complete cycle and the product is very good and can be used in landscaping and throughout parks.
“The process kills pathogens, flies and bacteria,” Ober explains. “The difficulty is the high carbon to nitrogen ratios, and if you use just saw dust it could take up to two to three years to get that pile of compost down just right.
“We’re talking about horse manure. And, we can haul it to landfill sites or we can get it back out to the farm where it can do some good. It is a good product and full of nitrogen, potassium and phosphorus.”
The first thing you have to do if spreading horse manure on the field is to take a soil test.
“Not long after, we learned that the soil surrounding the farm where we had been spreading liquid manure was completely saturated with nutrients,” he remembers. “At the time, in the early 1990s, we had over 350 dairy cattle. Our extension agent suggested composting our solid manure and we decided to try it as a way to deal with the excess manure. The idea of selling the compost came later.”
There were no best practices available for manure composting – let alone much basic research – so Tim was left to experiment with different methods (more on that later). But success was achieved and by 1994, Bull Country Compost was born.
Demand was strong right away – Sigrist made the product attractive by offering delivery – but as word spread, demand started to outstrip supply. They needed more manure, and about three years in, another revenue stream was born through taking horse manure from their Amish neighbors along with manure from other area farms.
Nowadays, Bull Country Compost is one of the largest Class III EPA-inspected composting facilities in Northeast Ohio.
“In 2016, we sold over 45,000 bags of compost, up from 36,000 in 2014,” Sigrist says proudly. “But we actually sell more product in bulk cubic yards than in bagged form to both consumer and retail markets.”
Ten percent of the manure currently comes from their farm (Tim’s parents John and Linda sold the dairy cows in 2013 but continue to raise about 120 dairy heifers), with the remaining from other farms, auction barns and seasonal fairs.
“We have farms where we haul out once a year and others where we do pick-up every week,” says Sigrist. “All locations pay us to take it away and there is a monthly fee to have a dumpster placed. Due to wear and tear on the dumpsters and the extensive cost of trucking – and the fact that some locations are up to 100 miles away – we can’t haul it for free.”
Indeed, it was early on that Sigrist realized it would be easier to provide large manure collection bins at farms, and that number of bins continues to grow.
“They’re 30-yard roll-off dumpsters made by a nearby manufacturer,” he says. “Because manure is so corrosive, we have to continually repair and replace them.”
Back when he started, Tim knew the basics of composting. Factors such as the type of manure, composting method (oxygenation) and weather would all affect timelines and quality of the final product. He first tried windrows turned by tractor, but it was labor intensive and the Ohio rains kept the material too wet. He researched various types of vessel structures and built one of his own with a concrete base.
“It was 150-by-80 feet with a homemade top supported by wood beams,” Sigrist explains. “There were two rows of material 10-feet wide.”
Over time, he added more vessels, making them wider to accommodate larger equipment, better aerated and better able deal with excess water. Older vessels were aerated using pipes running through the manure, and newer vessels have aeration constructed into the concrete floor through ditches with perforated pipes. This arrangement allows liquid to flow out as composting proceeds.
“The liquid is captured in a drainage system that empties into our manure lagoon,” Sigrist explains. “There is a small fan in each vessel that feeds into the perforated pipes to aid air flow, and this significantly increases the temperature as well.”
Newer vessels also sport a higher hoop roof, which also boosts airflow.
The manure is composted for six to eight weeks being moved to one of three curing sheds for six to eight months. Screening is next, then bagging in the bagging shed or placement in piles for bulk sale. Sigrist created the bagging system using auger equipment and a homemade conveyor, with which four employees can bag and stack almost five tons of compost an hour.
In total, Bull Country Compost has eight vessels, with 3,000 yards of material continually being processed by about nine employees, some full-time and some part-time/seasonal (Sigrist says that similarly to many industries, finding people willing to do manual labor like bagging can be difficult). The entire operation stretches over three acres.
Multiple groups from both Ohio State University and various local soil and water conservation districts have toured the site, and Sigrist has hosted curious visitors from as far away as Alaska.
While years ago people were generally unsure about composted manure, that has changed.
“It’s been 25 years and we have many loyal customers,” Sigrist says. “Word of mouth is the best advertisement there is. Also, many of our retail locations have an open bag of compost beside the pallet of bags for sale, and this helps people to ‘see, smell and feel’ the compost. Also, through the media and internet, people’s general awareness of soil and environmental health has risen and many consumers have learned the difference between raw manure and compost on their own.”
The farm is still active, with the heifers and 500 acres of crops. Sigrist says the manure composting and farm activities support each other in unique ways, making the entire operation able to support multiple generations of his family.
The composting business has also allowed the family to branch out into offering other services such as custom litter spreader application and custom harvesting. No specific new markets or products are being pursued, but Sigrist says they are always keen to gain a larger share of the soil amendment market at garden centers, and always listen to feedback from customers and garden professionals.
“The entire journey has been a big learning experience,” he reflects. “From finding new markets and keeping up with growth to creating vessels and streamlining the process, we had to develop our own model as there weren’t any of its kind at the time.”
One project Sigrist hopes finish in the future is to pipe heat generated by the compost to the bagging shed.
“That way, bagging can start earlier in the year in more comfort,” he says. “I haven’t gotten to it yet, but in the meantime, we bought the employees nice insulated jackets!”
Moreman, a retired vocational agriculture teacher with an animal husbandry degree from Texas Tech University, began his career by managing a cattle feedlot. He then spent over 25 years teaching at Texas Christian University and Clarendon Community College, where he developed and taught a two-year program in ranch and feedlot management.
Six years ago, this 81-year-old launched a successful turnkey manure composting and organic fertilizer application business headquartered in Clarendon, Texas, that has since doubled in size with 15 employees. Clarendon is about 65 miles southeast of Amarillo.
The company’s motto is, “Giving nature a hand and conserving the land.”
“I feel very strongly about conserving our resources,” says Moreman. “I think composting is one of the better things that we do, and the area that we are in, you could have three different soil types in one field, from sandy loam, to dark clay, to caliche. Compost improves the soil structure and the ability for the carbon molecules to hold the nutrients in place till the plant can get hold of it.”
A group of eight feedlot owners, who together raise about 200,000 head of cattle, annually supply Moreman with the manure he needs to make compost. The company uses its compost turning equipment on land dedicated by each feedlot to convert over 720,000 tons of raw feedlot manure annually into about 300,000 tons of compost. It then sells the compost to farmers as organic fertilizer and a soil amendment, providing the equipment and personnel to land apply it for them.
Rolling Plains Ag Compost makes its money from the sale and application of the compost, with a percentage of that income paid to the feedlot owners for supplying the raw manure.
Moreman says that there are two main reasons why the feedlots are eager to work with Rolling Plains Ag Compost. Firstly, when the feedlot cleans its pens and stockpiles the manure, it typically is compacted in large chunks, which makes it very difficult to land apply. Its nutrient content is also highly variable in this form and it often is full of weed seeds. Because the raw manure is in larger chunks, it usually takes a couple of years to break down in the field, which is why farmers tend to not see any value from it until the second year after application. However, by providing the raw manure to a composter, the large chunks are broken down, it is easier to land apply, and the nutrients are available immediately upon incorporation. Also, farmers who have applied raw manure on their fields have found that this material tends to have unwanted debris like pipes and cables mixed in with it.
Secondly, working with a composter like Rolling Plains Ag Compost, reduces the feedlots’ potential liability concerning land applying of raw manure. Moreman says based on feedback from his feedlot suppliers, the decision to compost the manure rather than land apply it has made a big difference when it comes to dealing with organizations like the Environmental Protection Agency (EPA).
“Our feedlot operators tell us that if an inspector from the EPA or Texas Water Quality Board comes by and they see that they are composting that manure and hauling it out, the inspectors don’t ever bother them because that’s what they want to see done with it,” says Moreman. “But if the inspectors go in there and they have a huge pile that’s so big that it interferes with TV reception, then they get concerned.”
The composting processes gets rid of many of the pathogens and weed seeds in raw manure, and reduces the volume. Moreman says that it reduces the manure volume by as much as 5-to-1. So there is a lot less material to land apply and it tends to have more consistent nutrient content.
Because the feedlots feed their cattle concentrated rations, there is little, if any, roughage like hay or bedding material like straw mixed in with the manure, which actually makes it more valuable as a raw material for making compost because there is little to no filler.
“Dairy manure is probably worth about half as much as cattle feedlot manure because a dairy operation will typically feed a lot of hay and silage to their cattle,” says Moreman. “These beef cattle are on a high grain ration and they are not subjected to a lot of roughage, because these feedlot owners want their cattle to eat a lot of grain and convert that to beef. That’s kind of the name of the game.”
Moreman’s business operates year round. Employees are either creating the windrows, turning the windrows, or land applying the compost for farm customers.
“We are either putting compost on cotton, peanuts, corn, wheat or irrigated pasture,” says Jack. “There is a crop coming off at all times, so they need compost pretty much all the time.”
While there is year-round demand, there are times of greater and lesser demand. May to July tends to be the slowest time of year, after spring crops are planted.
An important selling point to marketing the compost to farm customers is its ability to improve the water holding capacity of the soils where it is applied. Water is a valuable commodity to farmers in that part of Texas. Adding compost to dense soils increases their aeration and drainage capacity, and increases the water holding capacity of sandy soils. Most of Rolling Plains Ag Compost’s customers participate in a program where they
land-apply compost on each parcel of land on a two-to-three year rotation.
The company has worked hard to build its farm customer base, and Moreman’s background as an educator has helped. He spends considerable time hosting seminars and speaking to individual farmers about the benefits of using compost. His effort has paid off.
“You can be assured of one thing that if they try it, we are going to make a sale next time around,” says Moreman.
While compost has significant nutrient value, it does not necessarily fulfil all the farmer’s nutrient needs but represents only part of the overall puzzle. The company’s customers understand that. Most will need to add some commercial fertilizer, depending on the crop they are growing.
Typically, a feedlot will stockpile its raw manure as it cleans its pens and then Rolling Plains Ag Compost will bring in their own loaders and trucks to transport the manure to a drainage-controlled parcel of land that the feedlot has designated as its composting area. This can measure anywhere from 20 to 40 acres.
The company will create a compost windrow that measures approximately six-feet tall by up to 16-feet wide. The windrow will be as long as required by the amount of raw manure being converted. In the past, they have measured anywhere from a quarter-mile to a mile long.
The composting process consists of windrow turning, temperature measurement and moisture measure to ensure that the microorganisms responsible for the biological conversion process within the windrows are doing their job.
Part of the reason for the turning process is to ensure that the windrows are well oxygenated to support the microorganisms. As the conversion process takes place, the windrows can heat up to as much as 160 degrees Fahrenheit.
To turn the windrows, Rolling Plains Ag Compost uses a CT718 compost turner by Wildcat, which is a Vermeer company. With a 44-inch diameter drum to turn, mix and aerate the material, it can process up to 5,000 tons of manure per hour. The turning takes place typically once a week.
After about six weeks, the raw manure has been converted to compost and it is ready for land application. Moreman says the compost turner is a large and powerful piece of equipment with a 500 hp Caterpillar engine. He adds that it is sturdy enough to break down the chunks in the manure pile.
Rolling Plains Ag Compost has its own fleet of semi-trailer trucks to deliver the compost to farm customers. At all stages of the pen cleaning, composting, and land application process, the company depends on a large fleet of John Deere loaders to move the material as needed.
Once the compost is delivered to the farm, the compost is temporarily stockpiled beside the field and then loaded into New Leader spreaders to land apply the compost. Rolling Plains Ag Compost owns four of them. New Leader is a type of nutrient applicator manufactured by Highway Equipment Company (HECO) located in Cedar Rapids, Iowa. In the Rolling Plains Ag Compost operation, the applicators are mounted on either Chevrolet or International trucks.
Moreman says that these New Leader nutrient applicators are large and purpose-built. The box consists of a stainless steel bed with a conveyor on the bottom. The conveyor propels the compost to the back of the box, where spinners broadcast the material onto the land. The company will deploy as many nutrient applicators as needed for each job, but when all four are working, their customers are amazed at how quickly the job gets done.
“They are also very accurate,” says Jack. “There is a GPS unit on them to ensure that you don’t leave any part of the field out, and if you do, it will tell you.”
In terms of application amounts, Rolling Plains Ag Compost recommends four tons per acre on irrigated land and two-to-three tons on dry land. Once the farmer has some experience using the compost, they usually make adjustments on future applications based on the responses that they have experienced.
After initially and enthusiastically backing a request for the facility, commissioners reversed themselves when farmers complained that the location of the facility in their midst would keep them from selling their fruits and vegetables. READ MORE
March 9, 2017, Ada, OH – An inspector with the Ohio Department of Agriculture says there are two common mistakes farmers make when applying manure in crop fields.
Kevin Elder is chief of livestock environmental permitting at the Ohio Department of Agriculture. He says the most common mistakes are an accidental manure discharge in tile outlets and applying manure to frozen ground. READ MORE
February 24, 2017, Central Saanich, BC – Stanhope Dairy Farm Ltd. and the District of Central Saanich have agreed to a settlement, allowing the operation to continue its farming practices.
“We are satisfied with this being an outcome. I know that there are some residents who have different feelings on this. What I would say is that the municipality weighed all the information and came to this conclusion and I think that the conditions placed are ones that we’re going to continue to observe and make sure that the conditions are honoured,” said Central Saanich Mayor Ryan Windsor. READ MORE
February 24, 2017, Wellington, FL – Palm Beach County commissioners approved a land use change that would allow a horse manure recycling facility to operate between Belle Glade and Wellington, the epicenter of the county’s equestrian industry.
The land use change will be transmitted to state officials for review and come back to commissioners for final approval in March or April when Horizon Compost hopes to get approval of its zoning application for a facility that would be located on 32 acres eight miles east of Belle Glade and eight miles west of Wellington. READ MORE
February 21, 2017, Spallumcheen, BC – Conservation officers are investigating after a manure storage lagoon on a Spallumcheen farm overflowed.
The spill occurred in the same area where residents have been raising concerns about high levels of nitrates in their drinking water source, the Hullcar Aquifer. READ MORE
February 6, 2017, Champaign, IL — Illinois Manure Share, created by the University of Illinois, is a manure exchange program that brings gardeners and landscapers searching for organic materials for use in composting or application in contact with livestock owners.
The program, initially intended to help commercial farmers find markets for their manure, has evolved over time. Today, most of the manure providers are horse farms and many of the buyers are from the Chicago area. READ MORE
January 16, 2017, Baltimore, MD – Supporters say the Perdue AgriRecycle facility a few miles from the Maryland state line is one solution for chicken farmers on the Eastern Shore who need to get rid of manure.
Along with the chicken litter, the Perdue facility receives hundreds of thousands of state taxpayer dollars each year. A state program reimburses farmers, brokers and poultry companies for half of their costs to haul manure around Delmarva and beyond. Perdue is one of the largest beneficiaries. READ MORE
November 11, 2016 – A study conducted by researchers from the University of Veterinary Medicine in Vienna, Austria, shows that the use of wood shavings and sawdust in dairy barns instead of straw bedding is especially good for cow claw health.
A comparison with other barn types demonstrated that cows kept in compost bedded barns exhibited a lower frequency and lesser severity of claw disorders. The results were published in The Veterinary Journal.
The comfort and wellbeing of the animals is an important consideration when dairy cows are kept in barns. The freedom afforded by loose housing systems such as freestall cubicle barns promotes the natural behaviour and health of the animals. The widespread switch from tie-stall housing to loose housing has seen a change in the type of claw lesions, but the frequency of claw disorders has been on the rise.
International studies have identified the compost bedded barn as the beneficial for claw health. Compost bedded barns use wood chips or sawdust as bedding instead of straw. The wood residue binds the excrement and daily aerating incorporates the manure and starts the composting process. This makes an even concrete floor important in the roaming area. Slatted flooring, in which manure and urine fall into a separate area beneath the floor, should only be installed in the feed alley. Fresh bedding should also be added daily following aeration.
A team of researchers from the University of Veterinary Medicine, led by Johann Burgstaller from the Clinical Unit of Ruminant Medicine, has for the first time compared the frequency of claw disorders and lameness in compost bedded barns and the more common freestall cubicle barns in Austria. The researchers investigated the frequency and severity of claw lesions in five compost bedded barns and five freestall barns.
“Lesions of low severity were categorized as grade 1, severe lesions as grade 3,” Burgstaller explained. “The results for the individual lesions were weighted and subsequently added together to calculate an index value for the claw health per barn. A high value indicates poor claw health; a low value indicates good claw health. This value, however, is also influenced by factors such as frequency of care, feeding and genetics.”
The compost bedded barns exhibited about one half the number claw disorders, such as foot rot or white line disease, as the freestall barns. Both the frequency and severity were lower. Lesions of grades 2 and 3 were seen only rarely. The compost bedding thus has a proven beneficial effect on claw health. Lameness, on the other hand, occurred at nearly the same frequency in both barn types. At about 18 percent, however, the average of the freestall and compost bedded barns was below the international and previous Austrian level of 25 percent.
Even if modern barn types give dairy cows more freedom to roam, the animals must still stand in manure and urine for longer periods of time. The excrement increases the floor humidity and has negative consequences for claw health. The result is claw lesions, such as foot rot or white line disease.
“Floor humidity softens the skin between the claws, which makes it susceptible to bacterial infections. The reduced horn quality can lead to lesions and, in serious cases, sole haemorrhages,” Burgstaller explains.
White line disease occurs when floor humidity attacks the sensitive junction between the sole and the wall of the claw. Sudden or rotating movements create pressure on the affected junction and the sole slowly separates from the wall. This type of claw disorder is one of the main causes of lameness.
Compost bedded barns that are aerated and refilled daily can counter claw damage over the long term. This requires more work and effort on the part of the farmers. But after one year of composting, they can use the bedding as fertilizer. According to Burgstaller, the situation for dairy cows living in freestall barns can also be improved with more frequent re-bedding to keep the area dry.
The main difference between the compost bedded barn and the freestall barn is that the former has just one large area for roaming.
“There are no cubicles. This is more in keeping with the pronounced social behaviour of cattle,” Burgstaller says.
A dairy herd is organized hierarchically. If a cow is forced to leave its place for an animal of a higher rank, it can get up quickly and move out of the way without any obstacles. The stable and nonslip surface also allows weaker animals to get up or lie down safely, which is an enormous advantage in cases of milk fever.
The article “Claw health and prevalence of lameness in cows from compost bedded and cubicle freestall dairy barns in Austria” by J. Burgstaller, J. Raith, S. Kuchling, V. Mandl, A. Hund and J. Kofler was published in The Veterinary Journal.
November 1, 2016, Glenwood, MN – Dorrich Dairy, just south of Glenwood, has a new manure composting system that converts manure into bedding for the cows. They are the first farm in the state to install such a system, and it is generating a lot of interest.
On a recent tour for international visitors, Greg Vold explained that last year, they purchased 80 semi-loads of bedding for their cows. READ MORE
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NutrientSmart 2.0Fri Mar 23, 2018 @ 9:00AM - 04:00PM
2018 Western United Dairymen Annual ConferenceWed Mar 28, 2018 @ 8:00AM - 05:00PM
6th International Symposium on Animal Mortality ManagementSun Jun 03, 2018 @ 8:00AM - 05:00PM
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2018 North American Manure ExpoWed Aug 15, 2018 @ 8:00AM - 05:00PM