Modular Insect Production System Vertical Density
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Solution Overview
Problem
There is a need for efficient, reliable, and scalable insect production systems that minimize human interaction, maximize insect production density, and provide adequate space for insect rearing while ensuring animal welfare, particularly in the context of increasing global population and potential resource shortages.
Innovation Solution
A system for producing spray dried insects using a spray dryer with multiple separators and a filtration process to separate and decontaminate insect mixtures, incorporating a rotary atomizer and a filter to remove water from the gas supply, and utilizing a mesh or screen to separate insects, which includes a method of mixing insects with water and biocatalysts to create an exoskeleton-laden mixture, filtering out exoskeletons, and then spray drying the mixture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional insect rearing facilities are used, then insects can be produced, but the facilities occupy large physical space and cannot achieve high production density
Solution Approach 1:
The patent implements vertical stacking of multiple rearing trays within a single facility structure, where each tray contains insects at different developmental stages or species. This nesting arrangement allows multiple production units to occupy the same footprint space, dramatically increasing production density without expanding the physical facility area.
Solution Approach 2:
The system transitions from horizontal expansion to vertical utilization by stacking rearing trays in multiple levels. This dimensional change allows the facility to exploit the vertical space dimension, achieving higher production capacity within the same ground footprint by arranging trays in vertical columns rather than spreading them horizontally.
2Productivity
If manual insect rearing methods are used, then insects can be produced, but extensive human interaction is required which reduces efficiency and scalability
Solution Approach 1:
The rearing system is designed with self-regulating features including automated feed distribution mechanisms that deliver nutrition to trays without manual intervention, and environmental control systems that automatically maintain optimal temperature and humidity conditions. The stacked tray design also enables self-contained operation where each level manages its own microenvironment, reducing the need for continuous human monitoring and adjustment.
3Productivity
If high density insect rearing is implemented, then production capacity increases, but insects may suffer from discomfort, disease, and injury due to insufficient space
Solution Approach 1:
Each stacked tray is designed as an independent module with optimized dimensions and spacing tailored to specific insect species requirements. The system allows different trays to have different local conditions (ventilation patterns, access points, spacing) suited to the specific welfare needs of the insects they contain, rather than applying uniform conditions throughout the entire facility.
Solution Approach 2:
The facility is divided into multiple discrete, independently manageable trays stacked vertically. Each tray acts as a separate containment and rearing unit with its own environmental controls and access mechanisms. This segmentation allows high overall production capacity while maintaining appropriate space and conditions within each individual tray, preventing overcrowding and associated welfare issues.
4Reliability
If conventional water treatment is used, then water can be provided to insects, but water from harsh environmental conditions cannot be adequately cleaned and decontaminated
Solution Approach 1:
The system introduces an intermediary water treatment stage between environmental water sources and the insect rearing environment. This intermediary treatment process includes filtration and decontamination steps that remove harmful environmental contaminants while preserving essential water quality, creating a buffer that protects insects from harsh external water conditions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables efficient, high-density insect production with minimal water and feedstock usage, producing high-quality insect-based products suitable for human and animal consumption, as well as lipid extraction for various applications, while ensuring animal welfare and reducing environmental impact.
Implementation Method 1
a spray dryer (KAP) having: (a0) an interior (KAP'); (a1) a top (K-T) and a bottom (K-B) that are spaced apart along a vertical axis (KYY); (a2) a liquid input (KAR) that is configured to introduce an insect liquid mixture (H39, KAS) to the interior (KAP') of the spray dryer (KAP); (a3) a gas input (KAQ) that is configured to introduce a heated gas supply (KAG') to the interior (KAP') of the spray dryer (KAP)
Implementation Method 2
incorporating a rotary atomizer and a filter to remove water from the gas supply
Implementation Method 3
utilizing a mesh or screen to separate insects
Data Source
AI summary
Variable-scale, modular, easily manufacturable, energy efficient, reliable, and computer operated Insect Production Superstructure Systems (IPSS) may be used to produce insects for human and animal consumption, and for the extraction and use of lipids for applications involving medicine, nanotechnology, consumer products, and chemical production with minimal water, feedstock, and environmental impact. An IPSS may comprise modules including feedstock mixing, enhanced feedstock splitting, insect feeding, insect breeding, insect collection, insect grinding, pathogen removal, multifunctional flour mixing, liquid mixing, shaping, cooking, flavoring, biocatalyst mixing, exoskeleton separation, liquid separation, and lipid extraction. An IPSS may be configured to be constructed out of a plurality of containerized modules.