Are you looking for parameters and dimensioning to build your factory or pilot-plant?
Insect.Systems can provide an initial quick project set-up, factory blueprints and equipment list,
or
More detailled plans and calculations can be worked on a project basis as follows:
â‘ Project Feasibility Plan & Scenarios
For operations using above 50 tons of feedstock per day, Insect.Systems provides the technical project plan, feasibility and calculations, for your specific situation:
- A factory will be different if making insect meal by pressing dry larvae, than when using a wet decanter process.
- Similarly, a different technology package will be required is the feed substrate used, is made of mixed waste stream, or just brewers’ grain.
Such factors have a huge impact on the design, and need to be taken into account from the start of the project.
Typical deliverables can include:
Operational Mass Balance
Process flow diagrams
Area m2 of the facility
Systems and equipment list
Installed kW, water usage, emissions, etc
Initial 3D model
Estimative CAPEX and OPEX
② Factory Design & Construction
For the design and build of the factory Insect.Systems provides engineering services at several levels:
- Design of Feed preparation Plant, Rearing, Reproduction and Processing.
- Selection of HVAC, level of automation, etc.
- The logic and design of all steps focuses on HACCP / FSCC 22.000
- Support for permit requests and certifications.
- Interaction together with the customer with selected suppliers
All-round equipment and selection of suppliers
In the Factory Design phase we can involve our network of suppliers, or the preferred suppliers of the customer. Our goal is to use 90% off-the-shelf equipment, specialised equipment being only necessary for the for insect reproduction breeding.
③ General Support, Factory Start-Up & Training
During any of the stages of the project, our experts can provide expert support on a wide range of areas such as, reproduction-breeding, HVAC settings for your conditions, development and making the end-products, to name a few.
FEED PLANT
support
Feed formulations.
Validation of feed and trails.
Enzymic pretreatment and fermentation of feedstock.
REPRODUCTION
support
Fly and pupae handling.
Scaling-up the egg production.
Hatchability of neonates.
NURSERY
support
Optimisation of nursery survival.
Working methods for the nursery operation.
REARING
support
Feed and climate settings.
Optimal rearing methods.
Harvesting and cleaning.
PROCESSING
support
Meal and oil production.
Definition of the product specifications.
Preparation of samples for customers.
Specialised equipment for counting
NeoCounter
- Detection counting of hatchlings or adult sized
- Analytical data for each individual !
- Direct dosing to starter crates
- Validated for BSF and Tenebrio
- Available in various sizes
- 2.000 – 3.000 neonates / second
- Customisable and scalable for most egg or hatchlings supply
- Integration with conveyor belt
Specialised equipment for fly management
FlyTube3
FlyTubes are made-to-order articles, minimum 200 units.
Not sold as loose units, only as part of a Breeding engineering project.
- Tube dimensions: 3050 x 2050 x 3 mm, ~ 1 m3
- Stackable.
- Control and monitoring of lighting, attractant supply, air-changes per hour, temperature and humidity.
- Stocking with flies or pupae.
FlyTunnel 10 / 16 / 24 m3
FlyTunnels are made-to-order articles, minimum 50 units.
Not sold as loose units, only as part of a Breeding engineering project.
- Standard sizes 12, 16 or 24 m3.
- Full control and monitoring of lighting, attractant supply, air-changes per hour, temperature and humidity.
- Automatic or manual washing and draining.
All-in-one
- The Fly.Factory is an all-in-one technology package for BSF rearing and reproduction.
- The design includes all steps from larvae and prepupae growing, fly management, egg collection and finally counting-dosing the day-hatchlings to the starter (nursery) crates.
- For the CAPEX/OPEX calculations all equipment is included and the final dimensioning is done per project, per customer.
••••••  (click here) to see video of the fly.factory
- 12-15kg eggs/day ~ 3.000 m2
- Available from 5 kg of eggs onwards
- Includes engineering, specialised equipment and installation
- On-site training and start-up
- The engineering and technology package of Fly.Factory®  includes the Feed Plant, Growing chambers, Reproduction and Processing to end-products.
- Special emphasis is placed on the Reproduction section which includes:Â FlyTunnels, incubation rooms for eggs, equipment for the preparation and dosing of starter feed, preparation and storage of the feed, dosing of weighed or counted neonates to starter crates (nursery), etc.
- The systems are fully integrated with PLC’s, SCADA, data capture, monitoring and analytics.
Engineering of Breeding projects and the Fly.Factory are executed in collaboration with Christof Industries GmbH
Alvaro Manzanares
Insect Production & Technology.
MSc. Bioprocess engineering
Flavio Candia
Business Development.
MBA – Mechanical Engineer.
Shantanu Upadhyay
Design and Automation.
MSc. Automotive Engineer
Bridget Ristow
Feedstock and Nutrition
MSc Animal Nutrition
(External expert partner)
Liske van Greunen
Insect Processing Specialist
BSc. Food Science
(External expert partner)
Office address: Grasweg 52-C, 1031 HX Amsterdam, the Netherlands.
Telephone nr: +31 6 48801399