Avian Bird Flu Response in BC - Composting Birds and Manure John Paul, Ph.D. Transform Compost Systems Ltd. Abbotsford, BC Canada
Introduction The Avian Flu in British Columbia required depopulation of 19 million birds. Approximately 2 million were in flocks that tested positive for the Avian Flu these were incinerated, landfilled, or composted on farm by the CFIA
The CFIA used a passively aerated composting method to biologically heat treat the birds and litter. Perforated plastic pipe was placed perpendicular to the windrows. The windrows were covered with sawdust and plastic and contained vents for air exhaust. Photo courtesy of BC Ministry of Agriculture, Fisheries and Food
Manure from farms that tested positive was treated on farm by Transform Compost Systems and the Sustainable Poultry Farming Group Photo courtesy of BC Ministry of Agriculture, Fisheries and Food
Introduction Of the remainder of the 19 million birds that tested negative for Avian Flu: Many of the broiler chickens went to market Some of the birds went to West Coast Reduction for rendering Approximately 1.3 million negative birds needed a home hence the initiation of the Vyefield Compost Site.
Avian Bird Flu Response in BC - Composting Birds and Manure The following persons represent the team involved with composting 1.3 million birds that tested negative for Avian Flu. Orlando Schmidt BC Ministry of Agriculture, Food and Fisheries Geoff Hughes Games BC Ministry of Agriculture, Food and Fisheries Mike Younie BC Ministry of Water, Land and Air Protection Ed Kielstra Vyefield Farms Ltd. Bryan and Alexis Arthur Pacific Forage Bag Supply Ltd. Dave Robertson Robertson Farms Harvey Funk Compost Technologies Inc. John Paul Transform Compost Systems Ltd.
Introduction The composting technology was selected by the BC Ministry of Agriculture. The finances for this project were provided by the BC Government Provincial Emergency Program. The BC Ministry of Water, Land and Air Protection assisted with the environmental considerations and the amendment to the Fraser Valley Regional District Solid Waste Management Plan. Pacific Forage Bag Supply Ltd partnered with Vyefield Farms to provide the equipment and services with the Ag Bag composting technology. Vyefield Farms donated their land, had their own Versa bagging equipment, and retained ownership of the compost. Harvey Funk of Compost Technologies Inc. Omaha, Nebraska (CTI) was hired by Vyefield Farms provide technical services and equipment for the CTI System composting technology, including the Versa Bagger. Dr. John Paul of Transform Compost Systems was hired by the provincial government to be the qualified professional on the project.
The Process Feedstock Delivery The birds were gassed with CO 2 on farm and the carcasses delivered to the bunker in enclosed trucks.
The Composting Process Feedstock Blending The birds were blended with ground woodwaste and poultry litter in the following ratio: One bucket of birds One bucket of manure Three buckets of woodwaste
The Composting Process Grinding the Blend The bird / manure / woodwaste blend was ground using a horizontal Beast grinder Separated dairy manure liquids were added during the grinding process to provide approximately 55% moisture by weight
The Composting Process Filling the Bags 30 Ag Bags (green bags) were filled with 550 cubic yards of material in each 10 ft diameter by 200 ft long bag. Two lengths of 4 perforated flexible corrugated tubing was inserted into each bag
The Composting Process Filling the Bags 16 CTI System bags (white bags) were filled with 1400 cubic yards of material in each 12 ft diameter by 350 ft long bag. Two 5 rigid perforated smooth wall reusable pipes were inserted into the bag during loading
The Result 39,000 Cubic Yards of Composting Material
Aerating the Composting Material in the Bags Each of the green bags was aerated using a Dayton Model 2C820 blowers 1/3 hp 270 CFM @ 4 W.C static pressure Each of the white bags was aerated using two Dayton Model 4C108 blowers 1 hp 559 CFM@ 4 W.C. static pressure CTI System bags (white) aerated 50% of the time 4 min on, 4 min off AgBag bags (green) aerated 33% of the time - 4 min on, 8 min off
Monitoring Odor 3 4 2 5 6 7 X 1 Composting Site Odor was monitored twice daily 8:00 AM, 8:00 PM at 7 different locations on roads around the composting site. Odor was distinct at times, but only directly downwind of the composting site. There were no odor complaints received by any agency
Monitoring Temperature Temperatures in each of the bags were recorded twice during the first week, and then weekly for a period of six weeks. Thirty data points were measured on each bag at each sampling time, at depths of 6, 3 and 6 into the bag using 6 probes. Surface temperature measurements were compared between green and white bags
Temperature ( o C) Monitoring Temperature 80 Average CTI System (White Bag) Temperatures 70 60 50 40 30 20 10 6 depth 3 depth 6 depth 0 0 1 2 3 4 5 6 Time (Weeks)
Temperature ( o C) Monitoring Temperature 80 Average Ag Bag (Green Bag) Temperatures 70 60 50 40 30 20 10 6 depth 3 depth 6 depth 0 0 1 2 3 4 5 6 Time (Weeks)
Monitoring Coliforms Total and fecal coliforms were measured in select bags after one week, two weeks and six weeks. 75 % of bags had less than 1000 MPN after one week 95 % of bags had less than 1000 MPN after two weeks 40 % of bags had less than 1000 MPN after six weeks
Moisture Separation Requires Removal From Bags > 70% moisture < 10% moisture < 10% moisture
Bag Contents are Removed and Windrowed Bags were opened after approximately 8-12 weeks Only a few small bones and some feathers remain of the chicken Bag contents are piled for further windrow composting
Windrows Are Turned Several Times During a 6 Week Process Coliform counts reduced after 2 to 3 turns Turning results in consistent moisture content further drying Compost maturity index (Solvita) increases from 4 to 6 (for CO 2 ) during windrow composting process White bag contents drier and less ammonia than green bags due to greater aeration rates
Temperature ( o C) Temperatures Remain High During Windrow Composting Temperatures in Windrows 80 CTI System (White Bags) 70 60 50 40 30 Ag Bag (Green Bags) 20 10 0 0 7 14 21 28 35 42 Time in windrow (days)
View of Site on August 14, 2004
View of Site on September 7, 2004
Analysis of Compost (from first 2 windrows) N P K 1 2-1 ph 7.8 C:N Ratio 18.6 EC 3.7 ds/m Meets all requirement for Class A compost as defined by the BC Organic Matter Recycling Regulations (later windrows were affected by precipitation that started mid-september much of this compost did not meet Class A compost requirements for coliform. Total and Fecal coliforms are < 3 MPN
Summary Composting in the bags resulted in a well contained process with little odor concern and no odor complaints. Temperatures were maintained well above temperatures required for pathogen kill. The carcasses were fully decomposed in the bags. Coliforms were killed initially, but some regrowth occurred on the outside of the bag, requiring further windrowing and turning. Increased aeration in the CTI System (white) bags resulted in a drier product with less ammonia The Solvita maturity index suggested that the 8 week bag process produced product with a maturity level of 4, suggesting further composting and curing was required The resulting product after windrowing is awesome but completely dependent on the weather (which turned rainy in September while all the windrows were still outside)
Assisting the BC Poultry Industry with Positive Birds and Manure Transform Compost Systems John Paul, Ph.D. President Transform Compost Systems Ltd. Abbotsford, BC Canada Email: info@transformcompost.com www.transformcompostsystems.com
Developing the Protocols Transform Compost Systems worked with the Sustainable Poultry Farming group to assist some of the poultry producers that were affected by the Avian Flu We followed four principles outlined by the CFIA when developing the protocol for treatment of the manure from farms that tested positive for Avian Flu. Minimize aerosol formation Minimize human health risk Ensure adequate pathogen kill Be practical
The Protocol for Broiler Breeder Manure The manure was somewhat mixed in the barn, then transferred by conveyor to a vertical auger mixer that blended the wet with the dry No other carbon or bulking agent added Result no aerosols and a blend that self heated within 12 hours
The Protocol for Broiler Breeder Manure The blend was windrowed using an Artex manure box The surface was sprayed and lime applied to the edge of the pile to control dark-winged beetles The pile was covered with a vapor barrier The pile was then covered with 4 of sawdust for insulation
Temperature o C The Protocol for Broiler Breeder Manure Temperature in Poultry Litter Windrows 60 50 40 30 20 10 0 6" 3' 0 2 4 6 8 10 Time (days)
The Protocol for Broiler Breeder Manure CFIA Sign-Off - Release to Spread
The Protocol for Layer Manure Some of the layer manure was very wet 70 to 80% moisture and very dense No concern with aerosols big concern with heat development
The Protocol for Layer Manure The layer manure was blended with up to 1:1 manure to sawdust or shavings (by volume) The windrow formation and management stayed the same as for broiler breeders.
The Protocol for Layer Manure The last farm varied we added forced aeration The poultry industry wanted rapid signoff on the manure Manure:sawdust in 1:1 v:v ratio 3 pipes on plastic on ground under a 14 ft wide by 6 ft high pile
The Protocol for Layer Manure We achieved 70 C within 24 hours signoff in 3 days There was negligible odor
Summary The protocol was successful 100% of the time Virus kill was achieved with minimal cost We used no to minimal bulking agent (maximum 1:1 by volume with wet layer manure) There were no odor concerns and no flies associated with process Passive aeration was successful with this virus Forced aeration is required to achieve higher temperatures that may be required for other pathogenic organisms
Other Interesting Tidbits We composted 31 tonnes of chicken and eggs 90 ft from the farm house. Recipe was 75% chicken and eggs by weight Forced aeration on static pile with biofilter material on top Zero odor
Other Interesting Tidbits We tried lime stabilization on manure using quicklime Achieved 80 C in minutes Too much caustic lime dust Not conducive to batch process