Manure Processing Equipment
The BeddingMaster
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The perfect bedding from recycled manure
Manure is a valuable product that can raise money in livestock farming. With the installations, the manure is efficiently converted into valuable product for farmers and high comfort and health for cows. Profitability is achieved by reducing the manure processing costs and increasing the manure yields. Contributing to the circular economy is an interesting secondary factor. Mavasol wants to make livestock farms more profitable by effectively extracting added value from manure, reducing the manure problem and relieving the environment. The Beddingmaster is part of the Daritech manure processing systems. In addition to Beddingmasters, these mainly consist of separators, roller presses and transport systems. Mavasol designs tailor-made systems for the profitable processing of manure. By combining the age old science of composting with the knowledge and resources of Daritech, dairies will be able to say goodbye to sawdust and shavings, and hello to recycled manure as bedding material for their cows. Not only that, but they will be able to do so at a cost far lower than has been previously available in systems utilizing similar science. |
Here’s how it works:
Rather than wasting money each month on sawdust and shavings, Daritech has developed a long-term bedding solution for dairy farmers that uses recycled manure as bedding material. Unlike conventional composting or methods like windrows, in-vessels take up less land, process manure faster, and can handle a much wider array of material.
Scraped manure, or dehydrated flush manure, is fed directly into an Separator, specially designed by Daritech, to provide the ideal feedstock for the Beddingmaster, which is made up of manure solids at 36% dry matter.
The separated solids are fed into the Beddingmaster by passing through the fixed opening in the entry point. The fixed ends that do not rotate with the drum increase capacity by over 50%, resulting in more bedding for less money. This is the idea we all like to support.
The beauty of composting manure solids is that the aerobic bacteria which consume the organic matter are already in the solids, courtesy of the dairies’ cows. Once inside the Beddingmaster, the bacteria proliferate as they finish the job begun in the cows’ stomachs. A blower pulls air through the drum, ensuring an ample air supply, which mixes with the solids that are tumbling from the rotation of the drum. Within just a few hours, the activity of the bacteria has brought the temperature up to over 150°F (65°C) where it stays as the material moves through the drum like a plug.
During the process, the internal temperature, moisture, and aeration is controlled to ensure that no leachate or odor is produced.
Rather than wasting money each month on sawdust and shavings, Daritech has developed a long-term bedding solution for dairy farmers that uses recycled manure as bedding material. Unlike conventional composting or methods like windrows, in-vessels take up less land, process manure faster, and can handle a much wider array of material.
Scraped manure, or dehydrated flush manure, is fed directly into an Separator, specially designed by Daritech, to provide the ideal feedstock for the Beddingmaster, which is made up of manure solids at 36% dry matter.
The separated solids are fed into the Beddingmaster by passing through the fixed opening in the entry point. The fixed ends that do not rotate with the drum increase capacity by over 50%, resulting in more bedding for less money. This is the idea we all like to support.
The beauty of composting manure solids is that the aerobic bacteria which consume the organic matter are already in the solids, courtesy of the dairies’ cows. Once inside the Beddingmaster, the bacteria proliferate as they finish the job begun in the cows’ stomachs. A blower pulls air through the drum, ensuring an ample air supply, which mixes with the solids that are tumbling from the rotation of the drum. Within just a few hours, the activity of the bacteria has brought the temperature up to over 150°F (65°C) where it stays as the material moves through the drum like a plug.
During the process, the internal temperature, moisture, and aeration is controlled to ensure that no leachate or odor is produced.
A fully remote controlled and automated system, equipped with unique temperature sensors.
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Proven composting technology
With years of reliable and documented Beddingmaster success on dairies worldwide, Daritech/Mavasol offer a flexible in-vessel composter with a proven track record to handle your manure recycling needs. The Beddingmaster is available in varying sizes and configurations to fit your needs. With proper mixing and aeration, the in-vessel composting process can be greatly accelerated, leading to reduced land and storage requirements and much lower manpower and other operating costs. Built to last with extra heavy duty components, our Beddingmasters are custom designed to meet the unique goals and needs of each and every customer, making it possible to affordably process and recycle manure on site. By eliminating transport costs and tipping fees, farms will save money and help recycle their manure. |
All good and well, so far the story about the Beddingmaster. But how does it work in the daily practice of the farm?
We interviewed a few of our satified customers on their experience with the promises we have made.
We’d like to introduce them to you:
We interviewed a few of our satified customers on their experience with the promises we have made.
We’d like to introduce them to you:
For dairy farmer Frank Heilemann (48) from Rotenburg/Wümme (Germany) the conclusion is very clear: "We are very happy with purchasing the Beddingmaster."
With the Beddingmaster he uses the manure of his own 800 cows for high-quality bedding in his stables. |
Sjoerd van der Helm from Zuidschermer (The Netherlands) states: "Our 280 cows feel comfortable in material from the Beddingmaster"
Sjoerd van der Helm of H.K Holsteins started using a Beddingmaster in the summer of 2019; he is very satisfied with the box material. "The cows move around smoothly, lie comfortably, stay nice and clean and the cell count is under control." |
Martin Záhumenshý lives in Slovakia and was so satisfied that he has become an agent of Mavasol/Daritech. Now even more farmers in Central Europe can get to know this revolutionary way of working.
He likes to tell us about his farm. "We bought the farm from the state in 1992. We have expanded the company Agrocontact into two dairy farms of almost 2500 dairy cows and another 2000 young cattle." |
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Saving money, resources and time
Záhumenshý (Slovakia, 4500 cow cubicles) “Reusing the bedding material provides us with a direct saving of € 17.000 per 1000 cows on an annual basis. As the systems are very low maintenance, we have more time for other important tasks on the farm.” Van der Helm (The Netherlands, 280 cows) explains: “The installation is completely electric. The pumping and separation is all pre-set. This is an automated system and does not cost us any extra time or work, "explains Van der Helm. Heilemann (Germany, 800 cow cubicles): "The way things are going, the return on investment of the BeddingMaster is 2 years." Healthy cows are happy cows Cow cleanliness, udder health and milk hygiene also improved by using bedding from the Beddingmaster. Heilemann: "The bacterial research shows that our product is safe and that is also proven in the milk: the cellular amount is between 180.000 and 200.000 pro ml." Záhumenshý “The bedding material is regularly tested and the results are very positive: The bacterial test indicates that the product is safe, the bedding material is virtually sterile and this improves the comfort of our cows." Záhumenshý “We wanted to be able to separate the bedding material for the sheds of our cows and even to reuse it. The cows must have soft and comfortable bedding and it is important for the cows' health that the udders remain dry.” |
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Cows produce their own bedding
Heilemann: "Before we had the Beddingmaster installed at our farm, we used our own mix of straw, sawdust and lime. As the cows moving keeps pushing bedding out of the stables , it was necessary to add bedding material twice a week.The bedding costs were between € 70.000 and € 80.000 on a yearly basis. Visiting another farm he saw a Beddingmaster by sheer coincidence and he changed his bedding management. His new stable includes a Beddingmaster. Now everyday 30 to 35 cubic metres of produced manure are processed into bedding material. Van der Helm says: “The Beddingmaster has been deliberately chosen for the bedding material of the cow cubicles. The product is nicely loose and divides nicely into the cow cubicles; the cows are comfortable and happy. We really notice that the newly arrived cows get up faster than before and there are less slipping accidents because of the improved grip. " |
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Circular economy: investing in efficiency and recycling
Last but not least, the Beddingmaster helps the famers to tying the end of the chain to the start of the same chain. The circular economy is receiving increasing attention. Waste is becoming increasingly taboo. More and more citizens, governments and farmers are aware that we must change our linear economy into a circular economy. The circular economy is also about fewer and smarter raw materials, sustainable energy, preservation of culture and biodiversity and well-being. The Dutch agricultural sector is a global leader in circular agriculture. Mavasol is very proud to announce that several projects have received support of Dutch provinces and the European Agricultural Fund for Rural Development. This makes it clear that Mavasol helps farms with the transition to a circular economy. |
Beddingmaster images
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Some quotes
“We have a dry and more manageable manure product that we can store effectively and spread more uniformly, cutting down our requirement for bought phosphate and potash.”
“It's about future proofing our business. We've secured our use of what we see as the best bedding system for cow health and welfare, through recycling a finite resource, reduced our requirement for fresh water and cut our reliance on bought-in fertilisers.
Záhumenshý: Mavasol came up with a solution that made clean bedding and high quality process water possible.
The latter is important because we regularly have shortage of clean water in our region.
Van der Helm or one of his colleagues at the company refills the boxes every two weeks. "That way we can create and maintain nice bedding. The cows are lying down slightly tilted, which makes getting up easier. Before introducing the bedding we used waterbeds. We often saw newly-arrived cows rise very carefully. In cow cubicles with this bedding, that is a thing of the past. "
“It's about future proofing our business. We've secured our use of what we see as the best bedding system for cow health and welfare, through recycling a finite resource, reduced our requirement for fresh water and cut our reliance on bought-in fertilisers.
Záhumenshý: Mavasol came up with a solution that made clean bedding and high quality process water possible.
The latter is important because we regularly have shortage of clean water in our region.
Van der Helm or one of his colleagues at the company refills the boxes every two weeks. "That way we can create and maintain nice bedding. The cows are lying down slightly tilted, which makes getting up easier. Before introducing the bedding we used waterbeds. We often saw newly-arrived cows rise very carefully. In cow cubicles with this bedding, that is a thing of the past. "
Video's
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The most certified and validated manure processing system
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Continuous operation provides many options for conveyance of finished bedding. By the best monitored and controlled heating process.
Since 2013 there has being executed several tests on Beddingmasters . Tests have mainly focused on the presence of pathogenic bacteria. Tests were executed in the context of the European Regulation on Animal Byproducts (EU 1069/2009 and EU 142/2011). Obviously, the presence of pathogenic bacteria in the output of the Beddingmaster depends on the capacity and temperature on which the Beddingmaster is operated. We have tested the 6-20, the 6-32, and the 8-40 version of the Beddingmaster. All tests showed that these Beddingmasters can meet the required 5log10 reduction of Enterococcus faecalis as stated in 142/2011. In addition, periodic sampling of the output of the Beddingmaster showed that E. coli meet the <1.000 CFU/gr (normally results show <10 CFU/gr) as stated in 142/2011. Furthermore, normally Salmonella analyses showed “Not present in 25 gr” as stated in 142/2011. If operated in the correct way, and high enough temperatures are reached during composting, pathogenic bacteria (Enterococcus faecalis, E. coli and Salmonella) are sufficiently reduced to meet the requirements of the European Regulation on Animal Byproducts. What does a validation investigation involve? Demonstrate minimal killing of pathogenic micro-organisms during the fermentation or composting process. In a validation study, the killing of micro-organisms is investigated in the relevant installation. In collaboration with the Dutch Food and Consumer Product Safety Authority (NVWA) and the European NEN, this method has been laid down in a Dutch Technical Agreement (NTA8777) (Explanation). This research is conducted under accreditation. On the basis of the results of the research, requirements for the conduct of the proceedings are established and recorded in an HACCP protocol. |
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Mavasol: the company
Mavasol is introducing the principle of circular economy in manure, slurry, sand and waste processing. We help you reducing your environmental footprint by recycling natural resources as sand, solids, fertilizer and water. We provide tailormade solutions for your specific situation and needs. As the distributor of Daritech equipment outside North America we combine our innovative expertise and their patented machinery at all possible settings. |