Insect.Systems specialises in designing BSF facilities using mixed organic waste streams. Such feedstock streams include discarded animal feed streams, dairy products, by-products from fruit and vegetables processing, supermarket waste, packed foodstuffs, etc.
① Project Feasibility & Scenarios
For projects above 50 tons of feedstock per day, Insect.Systems provides technical feasibility and calculations for the business-plan and key metrics for investors and financial institutions.
Included in the scope:
✓ Feedplant grinding, mixing and feed dosing to crates.
✓ Reproduction breeding pupae, flies, eggs and neonates techniques.
✓ Rearing, HVAC-climate settings, crates for different uses, conveyor systems.
✓ Harvesting methods and complete equipment for wet processing to insect meal and lipids.
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
• Delivery of all design and engineering steps of the project
• Project preparation for Basic Engineering and EPC
• Support for permit requests and certifications
• Design criteria HACCP / FSCC 22.000
• Access to a broad range of pre-selected suppliers
All-round equipment and selection of suppliers
During 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 expertise support on a wide range of areas such as, reproduction-breeding, HVAC & room design, processing to end-products, interactions with suppliers, to name a few.
Project Assessment. For starting project Insect.Systems can carry out a Project Assessment, in which we define jointly what the best approach could be to kick-start your project. This is usually a good step when starting from scratch.
FEED PLANT
support
• Feed formulations.
• Validation and trails.
• Feedstock pretreatment.
REPRODUCTION
support
• Fly and pupae SOPs.
• Scale-up egg production.
• Neonates hatchability
NURSERY
support
• Optimisation of nursery survival.
• Validation and SOPs nursery operation.
• Transfer to Rearing.
REARING
support
• Feed and climate SOPs.
• SOPs for optimal rearing.
• Harvesting and cleaning.
PROCESSING
support
• Meal and oil production SOPs.
• Product specifications.
• Samples design 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.
- Control and monitoring of lighting, attractant supply, air-changes per hour, temperature and humidity.
- Washable and drainable.
All-in-one
- The Fly.Factory is an all-in-one technology package for reproduction breeding of BSF.
- It includes all steps from prepupae growing to pupae handling, fly management, egg collection and finally counting-dosing the day-hatchlings to the starter (nursery) crates.
- All equipment is considered, quantified and costed, and the final dimensioning is done per project, per customer.
•••••• (click here) to see video of the fly.factory
- For 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 Fly.Factory® includes the HVAC systems, data capture, monitoring and analytics, infrastructure for pupae maturation and synchronisation, FlyTunnels, incubation rooms for eggs in custom egg matrixes (collectors), 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 Fly.Factory and engineering of Breeding projects is 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, 1031 HX Amsterdam, the Netherlands.
Telephone nr: +31 6 48801399