SBIR-STTR Award

Problem: Small farms have limited poultry and small ruminant processing facility choices in Indiana; while most facilities serving this function utilize standard construction methods, facilities utilizing alternative and renewable energy systems are nonexistent. Question: Can a facility be designed that utilizes alternative energy technologies that result in a net energy savings Purpose: The purpose of this study is to design a multi-use processing facility that utilize alternative and renewable energy technologies and alternative building techniques that will abide by all local building and health codes. OBJECTIVES: There are five primary objectives to this research project. 1. Establish baseline energy requirements, water needs, and waste generation for a small poultry processing facility (up to 500 birds per day). 2. Observe means and methods of other small poultry processing facilities. 3. Select available renewable and alternative energy technologies that fulfill the demands of poultry processing. 4. Evaluate existing local waste streams to identify possible building materials that may be used for the design and construction of a facility. 5. Design a multi-use processing facility that includes alternative building techniques and incorporating alternative and renewable energy technologies within the design (derived from objective #3), while satisfying all local building and health department codes. APPROACH: To design the facility, the largest energy user of the facility must be assessed; this will be the poultry processing portion of the facility. After this energy and waste audit is conducted, specific system components may be selected to fit the system requirements. In addition, observing other small operations will assist in a more complete view of how processors are currently operating. Once this information is compiled, final systems will be selected and designed into a multi-use facility that may be used for more than poultry processing; highly specialized systems may be effective for large scale production, but small infrastructure requires flexibility. The following outlines the approach of the research: 1. Development of a pilot modular facility for poultry processing only utilizing baseline equipment. a. The pilot facility will be modular in nature utilizing a semi-trailer as a structure. b. The pilot facility will utilize existing processing equipment with non-renewable technologies. 2. Collect energy use, water use, and waste generation of the modular facility. 3. Visit three small poultry processing facilities and record means and methods (that are allowed to be recorded) that are used. 4. Based on collection of data from the modular poultry processing facility, design and select system components that meet or exceed energy use, water use, and waste generation requirements for the poultry process. 5. Evaluate existing local waste streams to identify possible building materials that may be used for the design and construction of a facility. 6. Design a multi-use facility that includes alternative building techniques and incorporating alternative and renewable energy technologies within the design (derived from objective #4), while satisfying all local building and health department codes. a. Calculate the estimated life-cycle cost for a standardly constructed facility versus this alternatively constructed facility. i. Include per unit of energy used, i.e. 5 BTU/BIRD ii. Include per unit of water used, i.e. 5 GALLONS/BIRD iii. Include per unit of waste developed, i.e. 5 GALLONS/BIRD

Identification and Significance of the Problem or Opportunity: The meat processing infrastructure is declining and aging across the United States leaving small farms with limited poultry, natural pork, and ruminant processing options. Work to rehabilitate existing but aged processing establishments utilizing energy efficiencies and renewable energy design to increase the profitability is needed. Because current processing options are limited, local distribution systems are rare. Research Question: Can a successful local foods distribution model be replicated in a different area of the country with a processing facility as the centerpiece while utilizing renewable technologies to further enhance the marketability of the differentiated farm products while reducing energy operating costs Work Plan Summary: The work plan consists of two main research objectives. 1. Develop a plan for the revitalization of the aging processing infrastructure utilizing renewable energy systems and energy efficiencies to lighten large energy needs in small scale processing. The majority of small processing establishments were built before 1980 and are declining in number at an alarming rate (Henning, 2007). The processing infrastructure creates a bottleneck in the ability to get farm product to the consumer. Without local processing options the small family farm is no longer viable. Erick Smith, Principal Investigator, is uniquely qualified to work on this research. He brings skills as a professional engineer with a focus on electrical construction and sustainable design with an experience of 17 years in the industry married with a desire to provide local meat options and support the small family farm through his years working to create a viable small family farm to hand down to the next generation. He can not only work to create a lasting plan but disseminate the information collected to help other plant owners. Most often, plants would be owned by meat cutters, not engineers. Phase 1 research showed success in that a plan for revitalization was created, now that plan needs to be implemented and the results tested. 2.The processing facility is the center of an expanded distribution network. For this objective we would test the possibility of replicating a local foods distribution system developed in Kansas City by Diana Endicott, named Good Natured Family Farms. Diana Endicott successfully initiated a local foods distribution network in Kansas City supplying farm products from 100 family farms to Ball Foods, a local grocery chain. Instead of repeating her research, we have developed a consulting relationship with her so that we can utilize her expertise and expand upon her SBIR funded research in Indiana. Jessica Smith will serve as the Farm to Market Coordinator as Diana did in Kansas City. Jessica Smith has the education and background needed to represent the alliance and form marketing relationships. She has the ability through understanding and farm experience to talk to the producer. Through phase 1, we compiled a listing of 20 farms ready to form an alliance of growers to co-market product in Indiana. OBJECTIVES: Can a successful local foods distribution model be replicated in a different area of the country utilizing a processing facility as the centerpiece while utilizing renewable technologies to further enhance the marketability of the farm products while reducing energy operating costs 1.Research through collaboration with Diana Endicott into the replication of Good Natured Family Farms ideas and concepts surrounding successfully marketing for 100 familiy farms in Kansas City. i. How is Central Indiana different than Kansas City ii. What factors might cause variation in the way to approach local foods distribution here in Indiana iii. What equipment/infrastructure would be necessary to replicate the Good Natured Family Farms distribution model iv.Would it be advantageous to have a consistent brand across the country that represents local foods 2.Implementation of systems designed during phase 1 research. a. Installation b. Testing i.Data collection determining performance. ii.Are the systems performing as expected iii.What is the overall effect on energy usage iv.How much energy is saved utilizing the selected systems This research shall be useful for our own community of small farmers and other communities in need of a community based processing facility. The research into replication of a local foods distribution model will determine the feasibility of expanding the availability of local foods distribution across America. The research on small scale use of alternative and renewable energy sources will be valuable for anyone looking at alternative building techniques and renewable energy. Economic: By rejuvenating an existing small meat processing facility, it can be shown that this business can be successful with the appropriate markets and technologies. A total of 14 jobs will be created in year 1. After year 5, total revenue will be $1 million with the a local economic impact of 2.5 million utilizing the 2.5 multiplier (Meter, 2005). Social: It is well documented that in order to have a global impact, local change is necessary. (Agenda 21, 2002). Our business will be to provide a community resource to local farms. Our main goal in this aspect is to serve the community by providing a value added processing facility which can be used to process poultry or as a community kitchen for other small farmers and end users to process their goods, we believe this will add financially and thus sustainability to the entire project. (Research brief #54, 2001). Other Benefits - Educational outreach: The proposed multi-use value added processing business would be the centerpiece of other rural business opportunities for the producers which may not be labeled as value-added but would further add a sustainable revenue stream. We would like to use the proposed facility to launch us into our agri-tourism design. APPROACH: Food Distribution Research: 1. Meet w/ Diana Endicott w/ Good Natured Family Farms & chart out their distribution system via a graphical flow chart thereby laying the groundwork for the model in KS so it can be replicated in Indiana. 2. Compare Indiana (IN) to KS and identify similarities and differences. Make necessary changes to match IN's need. Create a graphical flow chart for IN, realizing that it is an anticipated process. Creating the detailed work plan and steps for IN's distribution model. 3. Begin marketing and securing contracts based upon the distribution model. Press releases, networking, involvement in organizations. Increase awareness and opportunities to quote and secure more contracts. 4. Implement needed system components based upon needs and planning 5. Track differences and errors and make alterations to the planned distribution system. By measuring volume and interest of the product we can identify if the methodology is working. 6. Follow up meeting with Diana Endicott and discuss success and failures and identify changes that may make a difference based upon her experience. 7. Test branding of Good Natured Family Farms and introduce Good Natured Family Farms to Indiana. Renewable Energy Research: 1. Prepare installation drawings based upon Phase I recommendations and review actual as-built conditions of the facility and identify best locations for tie-ins. 2. Installation work plan. 3. Receive quotations, contact installers and equipment suppliers and solicit quotations. 4. Schedule activities for coordination of system shutdown and tie-in. Identify all tasks and approximate time for installation. Knowledge of shutdown so production is minimally affected. 5. Install system components and commission system. 6. Begin energy usage tracking and perform energy audit. Confirm if system revisions resulted in a net energy savings.