Producing Quality Poultry Bedding with a Trailer Mounted System

Progress report for ONE19-346

Project Type: Partnership
Funds awarded in 2019: $29,993.00
Projected End Date: 09/30/2021
Grant Recipient: Penn Soil RC&D Council
Region: Northeast
State: Pennsylvania
Project Leader:
Wesley Ramsey
Penn Soil RC&D Council
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Project Information

Project Objectives:

This project seeks to demonstrate standardized, efficient production of poultry bedding with warm season grasses. We will fabricate a trailer mounted machine system to produce and package bedding. Unprocessed warm season grass will enter the equipment at one end and drop into an environmentally friendly (paper) bag at the other end. The unit will be moved from farm to farm processing and packaging poultry bedding. The machine will be demonstrated at agriculture events. The prototype unit will be demonstrated to manufacturing firms encouraging them to replicate production.  We propose to meet the standards cited in GNE 16-127. We also propose a mechanized process for filling the paper sacks to thirty pounds. Poultry farmers will benefit from a more eco-friendly yet cost effective bedding material, while warm season grass farms can produce greater revenue than other crops for smaller, market garden farms.

Introduction:

Historically, sawdust and wood chips have been a prime bedding for “back yard” chicken producers.  As the market for wood fuel pellets increases, the demand for sawdust and wood chips increases and the market price of the wood products goes up.  Biomass Magazine predicts pellet demand will increase 10 times over the next 5 years.  TreeSource Magazine notes that the U.S. exports more than 6 million tons of wood pellets a year globally, with the European Union strategy to reach 20 percent renewable electricity by 2020.  They are currently at 13.2%, indicating continued growth of wood pellet and other biomass fuel usage.  There is a better alternative to wood products for poultry farms.  As wood decomposes, it produces acid.  Landfills restrict the dumping of large quantities of sawdust.  Using chicken manure with sawdust on a backyard garden does more harm than good, as fecal material of chickens likewise is highly acidic. Disposing of chicken manure wood mix, then, becomes difficult.

Previous SARE projects have demonstrated the benefits and advantages of using warm season grass for poultry bedding.  Warm Season Grass must be processed properly to be useful as bedding.  Warm season grass grows to six feet or taller.  It must be reduced in size to 1.5 inches or less. The dust must be removed.  It must be packaged in a manageable container.  The container cannot produce condensation or the material will rot.  Part of the challenge then is to address these processing issues in a cost effective method, increasing availability to poultry farmers.  The Penn State Extension notes that currently the Northeast region is underdeveloped for biomass crop acreage and widespread availability of processing equipment. 

The complete mechanical system to produce acceptable poultry bedding does not exist.  SARE project FNE17-865  found some farmers have some of the equipment.  Where partial processing exists, it is very labor intensive.  The bedding produced often does not address all the characteristics listed above.  

Participants in SARE project ONE-18 320 attended a number of agriculture based events. Crop farmers and poultry farmers at Ag Progress Days, Harrisburg Farm Show, Bloomsburg Fair, 5 smaller county fairs and Keystone Farm Show expressed interest in using warm season grass poultry bedding.  Members of the Association of Warm Season Grass Producers are interested in producing warm season grass bedding to further develop their market. 

Three previous SARE projects explored warm season grass poultry bedding.  GNE16-127 Renewable alternative bedding for commercial broiler chicken production demonstrated that warm season grass, properly processed, works well as poultry bedding.  It established a set of standards for optimum bedding performance:  the smaller the cut, the better (less than 1.25 inches), avoid particles larger than 2-3 inches, and avoid and reduce dust.   

FNE17-865 Single-producer-scale preparation of warm-season grass for poultry bedding explored techniques to properly process warm season grass for poultry bedding.  It explored various grinding techniques.  It looked at dust removal, and it examined what packaging worked and what doesn’t.  Multiple samples were sent to a lab at Penn State University.  The samples were tested with a particle analysis device.  The analysis looked for dust content and oversize pieces.  The project, however fell short due to the only ‘in-field’ processor (New Idea Uni-Processor) being discontinued.  We are exploring mechanized filling of the bags in order to reduce cost.  Many farmers already have some of the necessary equipment.  Few farmers have all the equipment.  If not properly configured, the process can be very labor intensive. If not properly configured the resulting bedding will not meet the ideal characteristics identified by GNE-16 127 or the reduced cost for end-user consumption.  We are proposing a processor that is portable and will meet these standards.

ONE18-320 Developing Markets for Warm Season Grass within the Pennsylvania Farm Community demonstrated poultry producers would use it, if they could get it.  Grant participants attended various agriculture events and spoke about warm season grass poultry bedding. There was a great deal of interest by both crop farmers and poultry farmers.  As noted in the Final Report of FNE17-865, “every time we showed people warm season grass poultry bedding, they wanted to know where they could purchase some.” Additional issues were condensation (use of clear bags for transport and storage may have aided the issue), loading of super sacks for transport, and transportation to farms.    As noted in the final report, “unless the material is available to poultry farmers for purchase, the market will never develop.” The market could be a lucrative one for farmers growing warm season grass with the resolution of these issues. 

In terms of condensation, a lesson learned from FNE 17-865 was that plastic sacking material may not be the best product.  We propose to use paper sacks and have arranged through Target Corporation to purchase custom printed sacks at a reduced cost of $0.60/bag.  The bags have a capacity to hold thirty pounds. The sacks will be stored at each farm used for the harvesting of the grasses, and transportation for distribution in the beginning of the project will be the responsibility of each partner farm, where the grass is harvested.  We have held discussion with All Shred for CDL transport as the project progresses.

This project seeks to demonstrate standardized, efficient production of poultry bedding with warm season grasses. We will fabricate a trailer mounted machine system to produce and package bedding.  Unprocessed warm season grass will enter the equipment at one end and drop into an environmentally friendly (paper) bag at the other end.  The unit will be moved from farm to farm processing and packaging poultry bedding.  The machine will be demonstrated at agriculture events. The prototype unit will be demonstrated to manufacturing firms encouraging them to replicate production.  We propose to meet the standards cited in GNE 16-127.  We also propose a mechanized process for filling the paper sacks to thirty pounds. Poultry farmers will benefit from a more eco-friendly yet cost effective bedding material, while warm season grass farms can produce greater revenue than other crops for smaller, market garden farms.

 

Cooperators

Click linked name(s) to expand
  • Will Brandau (Researcher)
  • Leonard Reggie (Researcher)
  • Bruce Trumbower (Researcher)

Research

Materials and methods:

The engineering drawing of the portable poultry bedding processor is self explanatory.  It shows all 8 components of the system.  There is a top view showing their positions on the trailer.  There is a side view showing the horizontal layout of the components.  The estimated system height is 7 feet.  The estimated system weight is 1800 pounds.

The main activity during the latter part of 2019 was to collect the primary components needed to assemble the mobile poultry bedding processor.  Participant, Len Reggie did the component selection.  He passed the information to Wes Ramsey, Executive Director of Penn Soil Resource Conservation and Development Council.  Wes contacted the source of the item, placed the order, provided delivery instructions, and paid for the item.  Some of the items were shipped directly to the Reggie farm shop where assembly will take place.  Other items were picked up by another member of the team.  Primary components have been obtained.

7'x12' trailer
7′ x 12′ trailer

The component making the system portable is the 7’ x 12’, flat bed, wood deck trailer.  It was ordered online from Tractor Supply.  It arrived at the store in less than a week.  Store policy requires pick up within 7 days of arrival at the store or the item is returned.  Store policy also requires the trailer to be registered and tagged prior to removal.  Will Brandau obtained a truck with a trailer hitch.  He went to the store and obtained the sales slip and vin number.   From there he went to a registration and tag facility in Wilkes-Barre.  The trailer was registered in the name of the Association of Warm Season Grass Producers.  The State Tax and registration was paid by credit card.  With a temporary registration and a license plate he went back to Tractor Supply to pick up the trailer.  When he arrived he discovered the trailer hitch ball was the wrong size.  So, he purchased one that fit, hooked onto the trailer and headed to Len Reggie’s farm.  It was about an hour later that he arrived and dropped off the trailer in the yard outside the shop.

The hammer mill was from the MacKissic Company distributed by Canns-Bilco Outdoor Power Equipment.  Len Reggie arranged the purchase.  He passed the purchase details to Wes Ramsey who paid for the unit and arranged shipment to the Reggie Farm.  The unit arrived without incident.  Hammer mills from MacKissic are manufactured as trailer mounts with two places material can be inserted.  Len will disconnect the unit from the small trailer to which it is attached, close the side entry point and mount it on the 7’ x 12’ trailer.  The plan calls for the hammer mill to be powered by the gas engine that came with the unit.

Name decal of hammer mill
Mackissic hammer mill decal
MacKissic trailer mounted hammer mill
gas powered hammer mill on trailer mount
Side chute of gas powered hammer mill
Side chute will be removed and entry hole capped

We found from past experience hammer milling switchgrass produces a large amount of dust and small particles.  This must be removed.  The trommel screen will accomplish that.  The unit we are using in this project is one built as part of a previous SARE FNE-17 865 project.  It was in use at the Trombower Farm.  They were dedusting poultry bedding. Dedusting is a cleaning process to remove dust and fine impurities by screening or other pneumatic means.  They approached Len Reggie to build a slightly larger unit for them.  Len built the unit and when delivering the new unit he picked up the smaller screen for use in this project.  It is now at the Reggie farm ready to integrate into this system.

 

 

Trommel screen on original mounting
Trommel screen shown mounted on original frame

Front view of trommel screen

Trommel screen drive unit
Close up of trommel mill drive unit

The system is dependant on the ability to move the material from one process to the next.  The varied length conveyors will accomplish this.  Len has constructed many conveyors.  The chain is a key part of these units.  The 6 chain sections will be used to construct the needed units.  We are not sure if these conveyors will be electrically powered or hydraulically powered.  We have an available gas powered hydraulic pump unit capable of driving hydraulic motors on the conveyors.  These motors could be “tuned” to transmit material efficiently from each process at an appropriate speed.

 

 

 

 

All the parts in our possession need to be mounted on the trailer.  The conveyors need to be assembles and mounted.  The bale buster needs assembly and mounting.  The bagger needs assembly and mounting.  We need to decide how to power the conveyors, electric or hydraulic.  Hydraulic will reduce the electrical requirements for the whole unit.

 

drag chain for conveyors
Drag chains for conveyor

 

 

 

Research results and discussion:

 

 

Assembly of the unit is complete and the unit has been tested successfully.  Due to the COVID-19 Pandemic, the demonstration and evaluation phase of the project has been slowed down somewhat, although we continue to make modifications and tweaks to the operation of the process.  It is currently stored for the winter in the garage at the farm in Wapwallopen.  User training will be scheduled for next spring and summer.  The unit will be hauled to Ag Progress Days next August for demonstration purposes.

Test run video link:  https://projects.sare.org/wp-content/uploads/VID_20200702_101406.mp4

The material buster knives and hammer mill are both controlled by a single gas engine.  The conveyor belts and trommel mill work off electric motors.  They get power from a 4000 watt generator purchased with Association funds.  The generator attaches to a control panel.  The first conveyor has a fold out table attached to serve as a work area. The conveyor moves raw material into the holding tub Where knives shred the material and feed it into the hammer mill.

 

Electric motor
Control Unit
Holding Tub
Knives in Tub

 

 

 

 

 

 

 

 

 

The hammer mill has a screen with one inch holes.  The material is processed until it is small enough to fit through the holes.  A small percentage will slip through the holes length wise resulting in a longer stem. There are so few they are not an issue. The material exits the hammer mill onto a second conveyor.  That conveyor moves the material into the trommel mill for dust removal.

 

 

Hammer mill
screen
Exit from hammer mill
Conveyored into trommel mill
Out of mill into bags

 

 

 

 

 

 

 

 

 

 

 

 

 

The material is packaged in either super sacks or 30 cu. ft. paper bags.  Super sacks are transported with the four corners drawn together.  Paper bags are neatly folded and glued shut with a hot glue gun.

30 Cu. Ft. bag
Finished bags

 

 

 

 

 

 

 

 

 

Items in need of change adjustment or creation.

The black guard on top of the tub was removed. (completed)  Material coming up the conveyor would catch on it and obstruct the flow of material.

Tub with retainer
Tub

 

 

 

 

 

 

 

 

 

The tub and drive belt needs to be dropped down using the 4 adjustment screws.  This will allow the knives to cut deeper into the material.

Adjustment screws

 

 

 

The opening from the hammer needs to be enlarged.  Material hangs inside and does not get picked up by the conveyor.

Opening out of hammer mill

 

 

Install screen over gas motor air intake to prevent damage.

Gas motor intake

 

 

Resolve weed material wrappng around knife shaft.

Weeds on knife shaft

 

 

An insert inside the spark plug wire needs to be re-glued.  The old glue was removed.  Special high temperature tolerant glue is needed. This will be re-glued in warmer weather.

Spark plug wire
Insert with dried glue
Cleaned insert

 

 

 

 

 

 

 

 

 

Install drum switch on trommel mill motor.  This will allow motor to rotate both directions allowing two bag filling station to function.  i.e. One bag can be filling while second bag is being sealed. 

Drum switch

 

 

 

 

 

 

 

 

Adjust tent legs to cover trailer mounted equipment while on the job at individual farms during the demonstration and evaluation phase of project.

10 x 20 tent provided with trailer unit.

 

 

 

 

 

 

 

To Do List for next phase of Project:

Write maintenance manual. 

Schedule training. 

Schedule when farmers can use the unit.

Participation Summary
3 Farmers participating in research
Any opinions, findings, conclusions, or recommendations expressed in this publication are those of the author(s) and do not necessarily reflect the view of the U.S. Department of Agriculture or SARE.