1. Your name: / 1) Peter Bogdanov
2) Layne Bogdanov
2. Name of the host organization: / Brest and Cherven Farms
3. Name of the assignment: / 1) Vermiculture Production and Management
2) Vermiculture Marketing
4. Dates of the assignment: / June 19 – July 6, 2006
II. Recommendations to the Host Organization
Recommendations to Mr. Anatoliy Tubolets and Mr. Vladimir Kulik, owners BelRosBioTech, Cherven (referred to as “Cherven Farm”)
[Please note: These recommendations also apply to Mr. Vitaly Promchuk and Mr. Vladimir Kluka in Brest, Belarus.]
a. Many of the things we found at the Cherven Farm demonstrated suitable vermicomposting practices to sustain a viable and successful operation in two areas: in the successful sale of earthworms for fishing bait and in the successful sale of bio-gumus at a retail level. The owners demonstrate more than average understanding of production and marketing and, even if they continue at their present rate of production, they are sure to achieve a certain level of success. We found that once we validated many of their current practices, they were pleasantly relieved to know that they were on the right track. Perhaps they needed some small amount of encouragement to allay their insecurity. Now that we have validated many of their operations, they can proceed with greater confidence and perhaps more speedily. In other words, they need not worry that they are doing something “wrong.” They are doing many things properly. Much of the fruit of their learning has come as a result of trial and error, often the best teacher.
b. In order to boost their production and sales, we have a number of recommendations which, if they are followed, may prove beneficial. These suggestions come from our experience in having visited many other facilities over the past ten years and through our association with those who practice vermiculture worldwide.
a. Feedstock Acquisition. Currently the owners are paying for the delivery of cow manure to their operation. In order to increase their overall profits, they must concentrate upon acquiring a consistent feedstock that can be brought to them free of charge. We understand that there is growing concern in Belarus with the accumulation of manure as a waste product from Confined Animal Feeding Operations (CAFOs). Ecologically, the build-up of manure piles and consequent leaching of nitrates is a cause of groundwater contamination. The owners of the Cherven Farm must begin to form a plan to acquire feedstocks from CAFOs that will alleviate manure build-up and serve as a ready source for feedstock. It makes little sense, financially and ecologically, to buy manure from a dairy when the dairy operator should be willing to give it away free or even to deliver it a processing facility. In the US, such organic waste facilities receive a fee to accept the waste brought by others. While Belarus may not yet have such a structure in place, the Cherven Farm owners should seek to provide a solution for the waste management problems of manure producers (“generators of organic waste”). We repeatedly used the phrase, “One man’s garbage is another man’s gold.” The “gold” that Cherven farms can receive may be in two forms: the actual manure and the value of the avoided delivery cost they would otherwise have to pay if they picked up the material themselves. They could structure relationships with manure producers by showing that they are actually “doing them a favor” by accepting their waste.
b. Feedstock Age. Currently the Cherven Farm’s owners are using cow manure that is approximately one year-old. With age, this feedstock has diminishing nutritional properties for earthworms. We recommend the owners use fresher feedstock, i.e., manure that is only days or weeks old. There will be more microorganisms present in such material, although there are certain associated risks with using such material, which will be addressed below.
c. Feedstock Preparation. Much needs to be understood and demonstrated to worm workers about the dynamics of thermophilic (high heat) composting. In advanced vermicomposting practice, successful practitioners concentrate upon feestock preparation to enhance the quality of their earthworms and overall productivity of vermicomposting. Specifically, Cherven Farms should collect fresh cow manure and perform “Pre-Composting” of the material as follows: 1. Leach the material with water to rinse away as much urine as possible. (Note: The resulting leachate should be sprayed on fields to avoid collection and consequent groundwater contamination from a lagoon or pond.) 2. It is imperative to collect a certain amount or bio-mass of material in one place in order for the thermophilic microorganisms to do their job. Thus, we recommend a container of approximately 1 cubic meter with aeration holes on the sides. This container may be filled with manure and, if the container has holes on the bottom, the leaching process may be begun here. Once the container has been filled with properly leached manure, the material will be moistened adequately with the appropriate 30:1 C:N ratio required for successful thermophilic composting. We recommend that a compost thermometer be obtained in order to monitor the temperature inside the pile. Within 24-48 hours the temperature will rise in the internal core of the pile to approximately 55 degrees Celsius (131 degrees F). (This has the advantage of killing human pathogens and weedseeds.) 3. To speed the process and ensure even composting throughout the pile, it is recommended to turn the pile every other day, if possible. This may be done by turning the sealed container upside down or turning the interior contents with a pitchfork. Keep the material within the container. The microorganisms need oxygen and moisture to do their job. The material should always be consistently moist-- “wet as a wrung-out sponge.” 4. After 4-5 days there will be considerable volume reduction. There may be as little as one-half the volume left from what it looked like at the beginning. That is because the microorganisms are reducing the particle size and there is a loss of volume due to the production of heat energy. 5. After approximately 14 days the material will have cooled down enough to begin applying to worm beds at regular intervals. Once the initial batch of pre-composted manure has been made, another new batch may be started. (Note: There is some understanding of “fermentation” of organic residues by worm farmers in Belarus. This is not the same as “Thermophilic Composting,” described above. Fermentation produces methane gas and is an anaerobic process that will leave the resulting solid organic substrate in a form that is not suitable material for worms or for use as finished compost. We strongly recommend a program of systematic education in the fundamentals of thermophilic composting, such as is taught throughout the US by such organizations as the US Composting Council, various universities, such as The University of Maine Composting School, and several other organizations, such as municipalities that have developed Best Management Practices in Composting. VermiCo has a detailed section in its Best Management Practices in Vermicomposting Manual devoted to the scientific understanding and application of thermophilic composting. This manual is now in the possession of Svetlana Maximova.) We strongly recommend a future visit to Belarus to educate worm workers, farmers, and waste managers in the fundamentals of thermophilic composting.)
d. Feedstock Application to Worm Beds. We recommend more regular application of fresh feedstocks to worm beds. Currently the Cherven Farms do not feed often enough and the feedstock used is old. Scientists claim that the regular application of small layers of feedstock to the surface of worm beds is the desirable protocol. Since this is new information for vermiculture operations in Belarus, we recommend the creation of one or more “pilot” projects or windrows in addition to the practices already in use. Thus, with little risk to worms or ongoing practices, the owners and staff can experiment with alternative methods of vermicomposting practice. We recommend the application of 5 to 10 centimeters of feedstock 2 or 3 times per week. With such small layers, and, because much of the heat energy has already been “cooked out” of the fresh manure, there should be little danger of overheating the worm beds. Generally speaking, it takes considerable bio-mass (one cubic meter) of feedstock to produce and maintain thermophilic levels of temperature (above 40 degrees Celsius). Overheating a worm bed is dangerous, but the danger is minimized when the above practices are followed. Typical overheating of worm beds is caused when too much feedstock is added to a worm bin or worm windrow when the available number of worms in the pile are too few to satisfactorily handle the material.
e. Windrow construction. Currently the Cherven Farm uses a lateral method of feeding rather than the vertical method. This means that fresh feedstock is applied at one side of the row and worms migrate laterally, leaving their casts on the distant side where bio-gumus may be harvested later. This method has been in use satisfactorily in the US and is acceptable practice. It is best to avoid the creation of any windrow to exceed 1 meter in height as anaerobic conditions at the bottom of the pile may likely occur. Lateral feeding generally does not produce pile height above one meter, but it is wise to heed such caution and train staff accordingly.
f. Application of water. Cherven farms currently waters worm beds by garden hose. At present the amount of water seems adequate. However, the owners may wish to experiment with pilot rows to see if the addition of more water either helps or hinders their current practice. Earthworms are 80-90 percent water and require a very moist environment. However, over-watering may produce anaerobic conditions in the bottom of the bed. Nevertheless, under-watering also inhibits worm activity. Since gravity constantly pulls water away from the surface—and the surface is where the fresh feedstock is available and where worms are most plentiful—there is a dilemma about frequency of watering. Many successful systems use frequent misting of water rather than heavy application of water from a hose. Frequent misting encourages earthworms to remain at the surface to consume the fresh feedstocks. Cherven Farms may wish to devise a sprinkler mist irrigation system for frequent misting of their worm beds.
g. Porosity of worm beds. Oxygen is required in successful vermicomposting. Anaerobic conditions inhibit worm activity, produce foul odors, and may produce phyto-toxins (toxins injurious to plants). To maintain porosity (passageways of free-air-space within the pile allowing oxygen and water to penetrate), larger, bulkier materials in the pile are helpful, such as straw or “chunky” material. These oversize objects may be screened out later. Some practitioners use a perforated tube at the bottom of the pile (open at both ends) to allow oxygen to circulate at the bottom of the pile, where the smallest particles and most water lie, and where oxygen may be least abundant.
h. Row construction. Due to the limitations of the available indoor space, not all areas of the Cherven Farm are accessible to tractors equipped with bucket-loaders. In order to minimize manual labor, rows need to be set up in order to allow tractors with buckets to bring in fresh material, form rows, feed rows, and remove finished product from the rows.
i. Site design. Currently it appears that Cherven Farms has adequate Start to Finish flow design in place. Manure is stacked on the outside of the building and brought in through one set of doors. Processing, packaging and storing occur in other parts of the building. Owners should evaluate their present operation and determine whether it is the best possible scheme to employ to minimize wasted effort. A “Flow-through” design allows for material to be processed efficiently. We encourage planning that sees future growth.
j. Predators. Currently there are a few birds and possibly, birds’ nests in the rafters of the farm. We know of one case in a California worm farm where a few visiting robins encouraged other migrating robins to pay a visit, resulting in the complete eradication of all earthworms in a one-week period. Other predators are ground moles in outdoor worm rows. Placing rows on concrete eliminates the threat from ground moles. We recommend that birds be removed from the buildings where current rows are situated.
k. Other feedstocks. It is imperative to obtain feedstocks at no cost (stated above). In time, this may mean opportunities arise to obtain feedstocks other than cow manure. Vermiculture utilizes many organic feedstocks: Paper waste, cardboard, manures from herbivorous animals: cows, horses, pigs, brewery waste, food waste, biosolids, and other organic residues. We recommend the owners begin experimenting with vermiculture using feedstocks other than the cow manure they currently use. This will also serve as an advantage for the creation of unique products and blends in the future. For example, because pig manure vermicompost contains high amounts of useable ammonium (more than cow manure), a “Super Bio-Gumus” may be marketed in the future.
l. Equipment. Currently Cherven Farms uses two pieces of equipment created as sifters. This equipment successfully sifts out the larger pieces of material to create a uniformly screened end-product. Owners seem content with their current machinery. As their operation grows they will require equipment capable of larger volumes. We recommend they begin to look at purchasing or creating a rotating trammel screen that will simultaneously harvest earthworms and sift vermicompost to a finished screen-size.