Sustainability and the intelligent use of resources are key issues in feed production. Together with Innovafeed, we demonstrate how the circular economy can be successfully implemented. Our technology enables the French manufacturer of insect proteins to transform its by-product, insect frass, into sustainable fertilizer pellets, thus closing the nutrient cycle.
Innovafeed produces high-quality insect proteins in Nesle, which are used in feed for poultry, pigs, aquaculture, and pet food. The larvae are fed on grain waste from a neighboring starch manufacturer. In addition to proteins and oils, this process produces insect frass, a mixture of nutrient medium residues and larval excrement. Rather than disposing of these residues, they are dried and pelleted using our technology and returned to the region's fields as high-quality fertilizer. This completes the cycle, as the pellets promote the growth of new cereal crops and ensure the sustainable use of all resources.
From raw material to pellet
The processing of insect frass begins with drying it in our fabric belt drier. This optimally prepares the material for pelleting while performing two tasks simultaneously. First, it transports and dries the frass. Second, the exhaust air is filtered through the fabric belt. This enables us to reliably comply with the statutory dust emission values. An automatic belt cleaning system prevents blockages, and a special turn-over device ensures uniform drying.
Then, our flat die pellet mills take over the shaping process. The insect frass is pressed through the flat dies and formed into pellets, which are cut to the desired length. The large pelleting chamber allows the use of additional pan grinder rollers, enabling the pellet mill to operate at a reduced speed – making it energy-efficient and quiet. “The reduced speed ensures a pleasantly low noise level, which is good for the health of our employees. Material wear is also significantly reduced,” explains Capucine Lefaucheux, Process Engineer at Innovafeed.
Since going into operation in spring 2021, our flat die pellet mill has enabled continuous, high-performance production of fertilizer pellets, playing a crucial role in the production of environmentally friendly pellets. We designed, delivered, and installed the complete plant, which consists of a fabric belt drier and pellet mills. Regular servicing by our French branch ensures consistently high availability and smooth operation of the line.
Added value for agriculture
The finished pellets contain nitrogen, phosphorus, and potassium, which are important nutrients for plant cultivation. They improve soil quality, increase yields, and reduce the need for chemical fertilizers, which are often produced using a lot of energy. For farmers, this means easy dosing, uniform spreading, and efficient transport thanks to the pellets’ higher bulk density.
The Nesle project demonstrates how modern technology and sustainable agriculture can work together. “Instead of disposing of our by-products, we can integrate them into a new production process and thus close the nutrient cycle,” emphasizes Christophe Ligny, Production Manager at Innovafeed. The finished pellets are used regionally in Picardy – a win-win for farmers and the environment.
