Nature Creation’s solution and equipment is independently developed, which is based on the Black Soldier Fly protein process system. It mainly includes 7 parts: egg hatching and young larvae breeding system, automatic insect culturing system, unloading and conveying system, sorting system, cleaning and processing system, waste gas treatment system and storage system.
The solution covers the whole process of supporting equipment from egg hatching to final product processing, and provides a full-process environment control system to ensure that the project can comply with environmental laws and regulations as well as a good working environment on site.
The main function of the sorting system is to sort the materials conveyed by the conveying system, and to separate the Black Soldier Fly feces, larvae and impurities, so as to facilitate the subsequent processing of the Black Soldier Fly feces and larvae respectively.
The high-efficiency separator mainly uses the physiological habits of the Black Soldier Fly larvae to separate the Black Soldier Fly larvae and feces. Compared with the traditional air separator and screening machine, the high-efficiency separator has the characteristics of high separation efficiency and excellent separation effect. The efficiency can be greatly improved by using the high-efficiency separator in combination with the air separator and the screening machine.
The air separator mainly uses the difference in the suspension speed between the material and the light impurities to remove impurities with the help of wind. The purpose of air selection is to remove light substances such as insect skin, pepper skin and fiber mixed in the material.
The screening machine mainly uses the difference in particle size between Black Soldier Fly feces, larvae and impurities to achieve sorting. Large diameter impurities, medium diameter Black Soldier Fly larvae and small diameter feces are separated. Each layer of the screen of the screening machine is equipped with an anti-blocking cleaning device to prevent the screen from being blocked. The vertical vibration of the screening machine is small, which effectively reduces the dynamic-static ratio and the basic dynamic load. Compared with the traditional vibrating screen, it improves the life of the screen and screening precision.
The main function of the conveying system is to transfer the materials output by the discharging system to the sorting system. The escape of the Black Soldier Fly larvae in the traditional conveying system is easy to cause the belt jamming failure. In this system, the unique structure can effectively prevent the belt jamming of the conveying system, reduce the failure rate of the system and improve the stability.
Eggs and larvae are the basis for automated breeding. The Black Soldier Fly eggs and young larvae have poor resistance to stress, and their growth is easily affected by external environmental conditions. On the one hand, the breeding quality of eggs and young larvae will affect the output of the Black Soldier Fly products, and on the other hand, it will affect the treatment amount of kitchen waste, thus affecting the stability and continuity of the entire system. Therefore, it is necessary to carry out refined management and control of the breeding of eggs and young larvae.
Young larvae breeding
In the cultivation of young larvae, Nature Creation isolates the cultivation system of young larvae from the external environment through facilities, so as to avoid the impact of fluctuations in external environmental conditions on the growth of young larvae, and improve the efficiency of young larvae cultivation.
The young larvae cultivation system is equipped with a temperature and humidity control system, which can finely control the temperature and humidity to ensure that the larvae grow under the optimal conditions, and reduce the mortality of the young larvae, and improve the quality of young larvae.
The young larvae cultivation system is provided with a multi-layer three-dimensional shelf for placing the cultivation box. The three-dimensional structure can not only reduce the occupied area, but also facilitate the management and operation of technicians.
In addition, the production data recording system is also equipped in the egg hatching and young larvae cultivation period. The recording and analysis of key information such as egg quality, egg hatching time, young larvae feeding quality, and cultivation time can assist subsequent automation production of breeding systems.
In the egg hatching period, Nature Creation uses a constant temperature and humidity incubator to incubate the eggs to ensure that the eggs hatch under the optimum temperature and humidity conditions, reduce the loss rate of the eggs, and improve the hatching efficiency.
The automatic insect culturing system includes four parts: feeding system, lifting and transferring system, insect bank and discharging system, which are controlled by the central control system. The automatic insect culturing system is isolated from the external environment through the facility, and a negative pressure space is created through the ventilation system, which can avoid the pollution of the environment caused by the leakage of odor; it is also convenient for the ventilation and deodorization system to collect and concentrate the odor. It is also beneficial to manage and control the temperature and humidity in the automated insect culturing system.
The main function of the feeding system is to automatically add the pretreated kitchen waste solid residue to the corresponding culturing box. According to the commands of the central control system, the feeding system automatically adds a certain amount of kitchen waste solids into the culturing box, and stops when the feeding is completed and records the feeding quality.
Lifting and transferring system
The main function of the lift transfer system is to transfer the breeding box to the designated position through a combination of lifting, lowering, pushing out and other actions. Under the control of the central control system, the lift transfer system transfers each breeding box to the corresponding position according to the built-in program of the central control system. The movement trajectory of each breeding box is determined by the built-in logic of the central control system.
The insect bank is the carrying space of all the culturing boxes. It is a three-dimensional shelf type, and the culturing boxes are placed in the shelves of each layer. Through the lifting and transferring system, the culturing box can move according to the preset trajectory in the insect bank. The insect bank can reduce the land occupy and improve the processing efficiency of the automatic insect culturing system.
The main function of the discharge system is to pour out the materials in the culturing box after completing a culturing cycle. And transfer the material into the conveying system. According to the commands of the central control system, the discharge system operates according to the pre-set time and speed.
Central control system
The central control system is the brain of the automatic insect culturing system. The central control system realizes automatic feeding, transfer and discharge, reducing the dependence on labor, reducing costs, and improving the stability and continuity of the production of the whole system.
The storage system includes quick freezer, cold storage and dried larvae storage system, which ensures the stable quality and safe storage of products.
The freezer is mainly used for quick freezing of frozen fresh larvae after processing. The temperature difference of the freezer is large and the cooling speed is fast, which can efficiently freeze the larvae.
The cold storage is mainly used for the storage of frozen larvae. The cold storage also has a certain freezing capacity, but because the cooling capacity is relatively small, the freezing capacity is limited. Putting the processed larvae directly into the refrigerator may not freeze properly, which will lead to the spoilage and deterioration of the larvae.
Dried larvae storage system
Dried larvae are stored in a dry, cool, clean, well-ventilated warehouse, avoiding direct sunlight. Prevent dried larvae from getting wet, polluted by harmful substances and other damage.
The Black Soldier Fly larvae can be processed into frozen fresh larvae, dried larvae and other insect products through the processing system.
Frozen fresh larvae can be directly used in aquaculture, it is a perfect substitute for frozen trash fish. Feeding frozen fresh larvae to aquaculture can reduce water pollution and the use of antibiotics; dried larvae can be used as raw materials to be added to chicken feed, aquatic feed, pet feed and other feed products. The processing system mainly includes washing machine, frozen fresh larvae processing equipment, dried larvae processing equipment and others.
The washing machine adopts water bath type bubble cleaning and high-pressure spraying to realize the cleaning of Black Soldier Fly larvae. Through the tossing effect produced by the air bubbles during the release process, the larvae make an irregular and strong turning movement in the water, and the surface attachments of the larvae are removed. The cleaning process simulates the basic action of manual cleaning, which effectively avoids the damage to the larvae caused by bumps, knocks, and scratches during the cleaning process.
Frozen larvae processing equipment
When the frozen fresh larvae are processing, the larvae are added from the feeding port and enter the preprocessing tank, and the heat enters the jacket between the inner and outer cylinders through the pipeline to heat the inner cylinder and also heat the larvae. Under the action of the screw propeller, the larvae move forward while heating. After reaching the temperature and time required by the process, the larvae are output from the discharge port. According to the technological requirements of various larvae processing, larvae frozen processing equipment can realize the adjustment of preprocessing temperature and time. In order to check whether the temperature of the heated larvae meets the technological requirements, a thermometer is installed on the equipment, and the processing status can be checked at any time.
Dried larvae processing equipment
Dried larvae processing equipment includes microwave drying and low-temperature drying:
1. Microwave drying is a normal pressure puffing technology that uses microwave radiation heating to make the moisture in the material absorb heat and vaporize, thereby driving the puffing of the food material. Because of its fast heating speed and short heating time of food, microwave puffing can better retain the original flavor of the product.The dried Black Soldier Flies are golden in color and rich in flavor after microwave drying, and have high economic value.
2. Low temperature drying uses an air energy heat pump to dry the Black Soldier Fly larvae. This heat pump drying is relatively mild and close to natural drying. During the drying process, the evaporation rate of the surface water of the larvae is relatively close to the migration rate of the internal water to the surface, which can effectively retain the nutrients in the larvae. Compared with microwave drying equipment, low temperature drying equipment has the characteristics of large processing capacity, high processing efficiency and low energy consumption.
Negative pressure system
The entire automated insect culturing system creates a micro-negative pressure space through the facility, which isolates the automated culturing system from the environmental conditions. On the one hand, it can prevent the odor leakage from polluting the environment and causing harm to the human body; on the other hand, it is convenient for the ventilation and deodorization system to collect and centrally process the odor.
UV photolysis equipment
UV photolysis is the use of ultraviolet lamps to irradiate volatile organic compounds (VOCs) at close range, destroying chemical bonds, and oxidizing part of the volatile organic compounds into carbon dioxide, water and hydrogen chloride; Most of the small molecular compounds are containing C-O and C﹦O.
The spray tower is a kind of tower-type gas-liquid mass transfer equipment, the top of the tower is equipped with a liquid sprinkler, the sprinkler disperses the liquid into small droplets, the odor is transported to the spray tower through the ventilation pipe, and the odor is in contact with the droplets by countercurrent. The odor can be effectively decomposed into small molecules by acid washing, alkali washing, oxidation and so on.
Biological deodorization equipment
Biological deodorization equipment uses biological fillers as carriers to enable microorganisms to form biofilms on the surface of biological fillers in a suitable environment. The microorganisms in the biofilm use the inorganic and organic compounds in the odor as carbon sources and energy, maintain their life activities by degrading malodorous substances, and decompose malodorous substances into carbon dioxide, water, minerals and other substances to achieve the purpose of purifying odor gases.