Task
A rethink in food production is giving rise to new industries – one promising way is the use of new, reproducible protein sources for animal feed production. In 2024 the Hungarian company Agroloop uses VENTAFLEX air ducts to build a state-of-the-art facility where soldier flies are industrially bred and used on a large scale. Since this involves both adequate animal husbandry and the preliminary stage of food production, the production is subject to strict regulations. The living conditions of the insects are demanding in terms of the special air quality: both hygiene and a constant temperature with relatively high humidity are crucial here... because without a “comfortable environment,” the insects lose the desire to reproduce.
VENTAFLEX is a specialist in systems of this type operating throughout Europe
The highly insulated ducts transport air of the desired quality to its destination with unparalleled efficiency. Stale air is reliably discharged to the air handling unit, which in this case is located on the roof of the building. This highlights another advantage of the VENTAFLEX system: the material is lightweight, and the complex duct installation is well compatible with the structural design. The final strong argument for using VENTAFLEX products is the high resistance of the duct surfaces to chemical influences – e.g., from the ammonia produced during the production process.
VENTAFLEX -solution
VENTAFLEX Classic air ducts:
- total of 844 meters round: ø 420, 580, 650, 920, 1090 in sections of 0,5, 1, and 2 m
- total of 55 meters oval: ø 1270 in sections of 1 and 2 m
- 542 fittings: 90°, 45°, 30° curves, T-pieces
- 201 special components: special T-pieces; connections to air handling units, offsets
- 1952 supplies: connecting clamps, fastening clamps, compensators, wall/roof ducts
Advantages due to the VENTAFLEX system
- Savings in operating costs – up to 40% less energy loss, up to 10% less pressure loss, and up to 99% less leakage loss
- Individual adaptation to requirements through custom-made products
- Certified hygiene conformity of ducts in accordance with VDI 6022
- Up to 70% lower weight – advantages in transport and installation
- The surface of VENTAFLEX air ducts is resistant to aggressive ammonia vapors. A unique selling point: other materials, including high-quality stainless steel, are unsuitable for this application
BACKGROUND
Controversial topic: Protein extraction from soybeans
The luxury of being able to eat meat comes at a high environmental cost
The demand for energy-rich food is growing in parallel with the world's population. This poses a particular challenge for meat production: Is there enough nutritious feed available, and where and how is it produced? Fattening farms rely on supplementary protein feed in order to operate in a controlled and economical manner. Most of this protein is obtained from soybeans, which only thrive under specific climatic conditions. The problems associated with soy protein production are now well known: from the clearing of large areas of forest in the growing regions to the uncontrolled use of genetic engineering and chemicals, to long transport routes and economic dependencies. There are many other unpleasant side effects.
An elegant alternative that can be implemented here in Europe is the use of other protein sources – ideally in the form of a circular economy. The idea of focusing on insects as suppliers of important nutrients seems to be a promising solution. Not to forget, we are talking about animal feed, i.e., protein-rich nutrition for meat suppliers such as livestock and fish, but also for pets such as dogs and cats.
Agroloop breaks new ground: How environmentally friendly production using insects works
Small-scale livestock farming
Soldier flies originate from South America and are recognized as “farm animals” in the EU. The controllable husbandry and feeding, the high reproduction rate, and the short development time of the insect make it attractive for economic use as a source of animal protein.
Waste materials become raw materials
The insects are fed with by-products from the food industry. These include leftovers from fruit, vegetable, and grain processing that are no longer suitable for human consumption. These plant-based raw materials are collected and crushed into a mash-like feed mixture.
The food: only the finest
Only packaging-free, plant-based products may form the basis of soldier fly food to ensure healthy larval rearing and prevent the transmission of diseases. Animal products (except milk and eggs), kitchen waste, meat and bone meal, and medical and chemical waste are prohibited.
The heart of protein production is the “nursery”
The soldier flies are brought to a special breeding and reproduction station to lay their eggs. When they hatch in the incubation station, the metamorphosis stage begins, which is crucial for protein production. The larvae are fed a mixture of residual materials in rearing blocks until they reach their optimal size.
Double yield from “cleaning out” and harvesting
The digestive remains of the larvae, called “frass,” are collected and sieved. This substrate, which also contains chitin from the insects' molting, forms the valuable basis for a natural fertilizer. The adult larvae are harvested before pupation, thoroughly washed, and then dried to prepare them for further processing.
Value creation: completely residue-free!
On the one hand, the dried larva material is pressed to extract oil, which is used as a feed additive or in the pharmaceutical industry. The remaining press cake (“larva cake”) is finely ground and, with a protein content of 60% and approx. 15% oil with a broad amino acid profile, is considered high-quality animal feed. On the other hand, the dried larva material is used as a feed additive or in the pharmaceutical industry. The remaining press cake (“larva cake”) is finely ground and, with a protein content of 60% and approx. 15% oil with a broad amino acid profile, is considered high-quality animal feed.
VENTAFLEX – the right partner for “green” projects
At the 2023 Sustainable World Conference in Budapest, Agroloop was awarded the prestigious national prize for “Green Innovation of the Year.”
