JULY/AUGUST 2011
`
`Manure
`Turnover:
`
`Nebraska dairy develops composting enterprise
`
`Exhibit 1020
`Bazooka v. Nuhn - IPR2024-00098
`Page 1 of 32
`
`

`

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`Exhibit 1020
`Bazooka v. Nuhn - IPR2024-00098
`Page2 of 32
`
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`Exhibit 1020
`Bazooka v. Nuhn - IPR2024-00098
`Page 2 of 32
`
`

`

`Contents
`
`6M
`
`anure turnover
`Nebraska dairy taps all avenues to develop composting enterprise
`
`9W
`
`ill we be side-dressing manure in the future?
`10
`Safe manure handling vital
`Pathogens in manure can cause health problems if the manure isn’t man(cid:10)aged properly
`
`12
`Fine tuning an operation
`Ed and Tom Maljaars take their dairy to the next level with new barn, st(cid:10)orage pit, large liquid
`storage tank, and composter
`
`16
`Iowa pork producers seek manure solutions from pit to field
`20
`Dairy manure goes urban
`22
`In the News
`25
`On Track
`30
`Innovations: Lagoon treatments
`
`Cover: Prairieland Dairy uses a special attachment called a Brown Bear PTO-PA 3(cid:10)5C auger
`aerator to turn their compost windrows. Contributed photo
`
`Manure Manager • July/August 2011 3
`
`Exhibit 1020
`Bazooka v. Nuhn - IPR2024-00098
`Page 3 of 32
`
`

`

`July/August 2011
`Volume 9 • No. 4
`Published by:
`Annex Publishing & Printing Inc.
`P.O. Box 530
`Simcoe, Ontario N3Y 4N5
`Editor
`Margaret Land • (519) 429-5190,
`(888) 599-2228, ext 269
`mland@annexweb.com
`Contributing Editors
`Tony Kryzanowski, Diane Mettler,
`Lukie Pieterse
`Advertising Manager
`Sharon Kauk • (519) 429-5189,
`(888) 599-2228, ext 242
`skauk@annexweb.com
`Sales Assistant
`Mary Burnie • (519) 429-5175,
`(888) 599-2228, ext 234
`mburnie@annexweb.com
`Production Artist
`Kate Patchell
`VP Production/Group Publisher
`Diane Kleer
`dkleer@annexweb.com
`President
`Mike Fredericks
`mfredericks@annexweb.com
`
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`No part of the editorial content of this publication
`may be reprinted without the publisher's written
`permission. ©2011 Annex Publishing & Printing
`Inc. All rights reserved. Opinions expressed in this
`magazine are not necessarily those of the editor or
`the publisher. No liability is assumed for errors or
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`
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`Website: www.manuremanager.com
`
`4 Manure Manager • July/August 2011
`
`By Margaret Land
`
`What’s happened to
`America’s Dairyland?
`
`A s editor of Manure Manager magazine, I keep myself abreast of happenings(cid:10)
`
`in the world of livestock and poultry production across North America and,
`sometimes, the world. I read about new manure co-operatives in Australia,
`new anaerobic digesters in Germany, new manure application rules in
`the United Kingdom and, of course, advances in manure technology and
`application innovation in North America. I also read about the not-so-good news,
`such as manure spills, runoff situations, split application hoses, farmer deaths due to
`hydrogen sulfide asphyxiation or drowning in manure pits. If it involves manure, I try
`to keep up-to-date on it.
`Because of this, I’ve been watching a situation developing in Wisconsin’s
`Bradford Township, located within Rock County, a 720 square mile south-central
`county of the state bordering with Illinois. According to the county’s website, the
`area’s rural land base and rich soils are predominantly used for agri(cid:10)culture with milk
`cows being one of the top livestock animals living in the county. Makes sense given
`that Wisconsin is the U.S.’s “Dairy State.”
`But it would appear Bradford Township residents and officials are growing tired of
`the dairy lifestyle. For several months now, area residents appear to have been looking
`for various ways to keep a Nebraska dairyman from locating his 5,200-cow expansion
`– Rock Prairie Dairy – within their community. Despite the fact the state’s Department
`of Natural Resources (DNR) has already issued a permit for the $35 million project to
`operate, it would appear that residents in the area are doing their best to keep the dairy
`from going into production. The latest ploy is a petition and referendum on a decision
`made by the township to allow the use of Midwest Area Disaster Bonds – part of a
`federal program to stimulate development in states affected by flooding in 2008 – to
`help lower interest rates on a loan to finance the project. The funny thing is Nebraska
`dairyman Todd Tuls hasn’t even applied for the bond program and has said he will be
`continuing the project even if the bonds aren’t available to him.
`This isn’t the first time residents have moved to block the dairy. Earlier this year,
`an ordinance was put forward by the Bradford Town Board to ban the use of center
`pivot sprayers as a way of applying manure to fields, a practice commo(cid:10)nly used in
`Nebraska and one Tuls had been considering using on his Wisconsin operation.
`But, after the Wisconsin Department of Health wrote a letter to the state’s DNR, he
`removed the 10 center pivots from his application.
`Wisconsin’s Department of Agriculture and Department of Natural Resources
`“encouraged” the state’s towns and counties to avoid ordinances restricting
`agricultural technology, according to a recent report in the Janesville Gazette. In a
`letter addressed to the Wisconsin Towns Association and the Wisconsin Counties
`Association, agriculture and DNR officials stated “the agriculture industry is obligated
`to utilize innovative technological solutions in order to feed the world.”
`But even with this advice, NIMBY-ism continues to thrive in Rock County.
`“I’m looking forward to finally having an open house so we can show people the
`whole thing,” Tuls is quoted as saying in the Janesville Gazette. “They can see what
`it’s all about, and we can put some of these false rumors to rest.”
`Good luck Tuls.
`
`Exhibit 1020
`Bazooka v. Nuhn - IPR2024-00098
`Page 4 of 32
`
`

`

`SLURRY WASTE APPLICATIONS
`Kifco’s Engine Drive Water-Reels allow for
`application of slurry waste with up to 3% solids
`and offer higher retraction speeds where lower
`application rates are necessary.
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`
`Come see our live demonstration at the North American Manure Expo, Northeast
`Community College’s Ag Complex, Norfolk, Nebraska
`July 20, 2011
`
`www.kifco.com • 800-452-7017 • sales@kifco.com
`
`Exhibit 1020
`Bazooka v. Nuhn - IPR2024-00098
`Page 5 of 32
`
`

`

`Manure turnover
`
`By Tony Kryzanowski
`Nebraska dairy taps
`all avenues to develop
`composting enterprise
`
`C ontinued production of compost
`
`using their dairy manure was
`just too good of an opportunity
`to pass up for the operators of
`Nebraska’s Prairieland Dairy,
`even when they switched from organic
`compost to inorganic sand bedding.
`Their perseverance has really paid off,
`proving that either way, composting is
`still a worthwhile business opportunity
`for many large farms.
`“When we originally started out
`marketing the compost in 2000, we
`were doing maybe 1,000 yards per
`year,” says dairy co-owner, Dan Rice.
`“Now we have grown to 10,000 yards
`per year and expect 25 percent growth
`in the next five years.”
`The 1,600-head dairy is located
`20 miles from Lincoln, Nebraska. In
`2000, four family farms that were each
`milking between 100 and 200 cows
`created a partnership to establish a
`new dairy. A new milking barn was built
`in the community of Firth, and over
`time, it has expanded to 1,400 milking
`cows. In addition to milk products, the
`dairy began producing compost for
`bedding until 2004 when it switched to
`sand. Today, the Prairieland Gold branch
`of the partnership produces a variety
`of compost mixes primarily in bulk.
`It’s been an evolution since the dairy
`began composting in 2000. Not only is
`the dairy composting its own manure
`solids, but it is also being paid to
`accept organic waste from surrounding
`municipalities and businesses. That
`waste consists of grass and leaves from
`local municipalities, as well as waste
`from large industrial companies that
`manufacture products such as dog
`food and baking products. Prairieland
`Dairy also accepts organic waste from
`grocery stores, and restaurants. Growth
`in food waste recycling programs
`among businesses is driving growth
`in the dairy’s composting operations.
`At present, outside organic waste
`represents about 25 percent of the
`dairy’s raw material, but Rice expects
`that to increase to 75 percent within
`
`In 10 years, Prairieland Dairy has grown its composting enterprise from 1,000 to
`10,000 yards per year, and expects 25 percent growth over the next five years.
`Contributed photo
`
`three years.
`“A lot of companies are
`implementing recycling of organics
`in our area and we are really excited
`about that,” he says.
`The cows are bedded in deep sand
`beds. The dairy uses a flush system
`of recycled water from its lagoons to
`flush the sand/manure mixture daily
`from the beds into sand lanes in the
`barn where the sand settles out from
`the manure solids. Once a week, the
`sand is collected from the sand lanes
`and recycled into the stalls. The manure
`solids are collected and processed
`through an Ag-Pro static screen
`
`separator, which separates the liquid
`and solid manure streams.
`“What we like about the Ag-Pro
`static screen separator is that there are
`no moving parts,” says Rice. “It is just a
`screen where the solids go off the front
`and the liquids go out the back. It is a
`very maintenance-free type of setup.”
`The dairy conscientiously designed
`the entire manure gathering and
`processing system to use only two
`pumps.
`“We kind of take pride in that from
`the sustainability and maintenance
`standpoint,” says Rice. “It really
`eliminates a lot of maintenance.”
`
`6 Manure Manager • July/August 2011
`
`Exhibit 1020
`Bazooka v. Nuhn - IPR2024-00098
`Page 6 of 32
`
`

`

`GEA Farm Technologies
`
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`Innovation brought to your farm
`
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`
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`30% and 34% which is perfect for green bedding.
`
`Ask your local GEA Houle Dealer about the GEA Houle separation system, the right
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`GEAHoule_Trailer_MM_2011-01
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`
`Exhibit 1020
`Bazooka v. Nuhn - IPR2024-00098
`Page 7 of 32
`
`

`

`Prairieland Dairy uses a special
`attachment called a Brown Bear PTO-
`PA 35C auger aerator to turn their
`compost windrows. Contributed photo
`
`Once separated, the solid manure
`proceeds to the dairy’s dewatering
`pad. At this point, it has about 85
`percent moisture content. For about
`two weeks, it is left on the dewatering
`pad, where the excess water drains
`off and the bacteria starts to grow.
`After two weeks, it has dried to
`between 75 and 80 percent moisture
`and it is transported and placed in
`windrows on the dairy’s compost pad.
`This is where the solid manure is
`mixed with the food and yard waste,
`or sometimes referred to as “carbon
`sources,” in specific recipes that the
`dairy has developed primarily through
`trial and error to develop the specific
`compost nutrient mixes required
`by its customers. The windrows
`are monitored on a daily basis for
`moisture, temperature and oxygen
`levels. They are turned as needed to
`advance the composting process.
`“It varies, depending on the weather,
`how the bacteria is doing, how much
`oxygen they are using at that time and
`how much excess moisture we are getting
`from Mother Nature,” says Rice.
`He adds that moisture,
`temperature, and oxygen levels are
`three key elements to manufacturing
`quality compost.
`“The way I like to explain it is that
`our farm is all about bugs,” says Rice.
`“When we make up a ration for our
`cows, we don’t think about feeding that
`cow. We think about feeding the bugs
`in her rumen. We have to keep them
`happy and keep them working. Same
`goes for bugs in the compost pile. The
`compost bugs basically need feed,
`oxygen and water, so those are the
`three things we need to monitor.”
`In terms of the mix, Rice says
`they start the windrow with the end
`user in mind. For example, greenhouse
`customers want a final product derived
`from 100 percent manure.
`To turn the windrows, Prairieland
`Dairy uses a Brown Bear PTO-PA
`35C auger aerator attached to a farm
`tractor. Turning the windrows eventually
`lowers the moisture content to about
`30 percent. The compost ends up with
`about a 2:1:1 NPK rating and a 95
`percent coliform kill rate.
`Prairieland Dairy is considering a new
`compost turner system, driven primarily by
`the rising cost of fuel. One system being
`
`By composting their solid manure, Prairieland Dairy ends up with about half the
`volume produced by their 1,600-head dairy. Contributed photo
`
`8 Manure Manager • July/August 2011
`
`Exhibit 1020
`Bazooka v. Nuhn - IPR2024-00098
`Page 8 of 32
`
`

`

`considered is a forced air system.
`Once the biological composting
`process is complete, the compost
`is screened and mixed with other
`ingredients to achieve the final product
`expected by their customers.
`The dairy’s liquid waste stream is
`treated in a four-stage settling lagoon.
`The treated water is either recycled
`back to its flush tanks or is used to
`irrigate the company’s 600 acres. Some
`of the water is also used to irrigate
`and fertilize neighboring farmland.
`The dairy contracts the services of a
`custom manure drag hose contractor
`called Googles, headquartered in
`Columbus, Neb.
`Rice says composting its manure
`has definitely influenced the growth
`and success of the dairy itself.
`“We would need quite a large land
`base, if we didn’t have our composting
`operation, to grow our dairy herd to
`the 1,600 head that we have currently,”
`he says. “So it has helped us in that
`respect. Basically, if you compare what
`it would cost us to get rid of our manure
`from our 1,600 cows with the cost of our
`composting operations, yes, it has been
`a good thing for us to do and it is also
`the right thing to do environmentally.”
`It also has helped the dairy, which
`generates about 20,000 yards of
`solid manure annually, to more easily
`manage its manure.
`“We felt that composting was
`the best way for us to handle manure
`disposal because it cut our volume by
`
`half,” Rice says. “So, if we are going to
`have to move it off the farm and move it
`long distances, there is a whole lot less
`to move after you compost it.” He adds
`that compost is also much more readily
`available to plants as a fertilizer than
`raw manure when land applying.
`Prairieland Dairy switched from
`compost bedding to sand bedding in its
`barns primarily for business reasons, as
`staff market their own dairy products
`through another arm of the partnership
`called Prairieland Foods. Making the
`switch has delivered good results, as
`the somatic cell count in the dairy’s
`milk has dropped by half.
`“When we started marketing our
`own brand of milk, we really felt it was
`very important to have the very highest
`quality possible,” Rice says. Although
`the somatic cell count wasn’t a major
`concern when the dairy used compost
`bedding and it was comfortable for
`the cows, it was simply a matter of
`choosing to deal either with an organic
`material that encouraged growth of
`bacteria or a non-organic material like
`sand, which is sterile when it goes into
`the beds and does not promote bacteria
`growth. Given the drop in the milk’s
`somatic cell count, sand has become
`the preferred option.
`Although Prairieland Dairy made
`the switch to sand in 2004, recycling
`the sand bedding still generates a
`significant solid and liquid waste
`stream that requires management and
`disposal. So the dairy began developing
`
`compost and potting soil mixes to
`suit particular customer needs from
`the separated manure solids. One
`product is manufactured for a chain
`of nurseries in the Midwest called Earl
`May Nurseries.
`“We have a lot of fun with it,” says
`Rice. “It’s called the ‘Poo-In-The-Pot’
`program. We make a potting soil mix
`and put it into a compostable pot,
`which they use to grow the seedlings in
`the nurseries. Then those nurseries turn
`around and sell the plants in the Earl
`May Nurseries stores. It has been a very
`successful program for us.”
`The dairy is preparing to travel
`further down the green path, having
`developed a business plan to install
`an anaerobic digester. Rice says the
`partners feel that an anaerobic digester
`would be a great addition to their
`operation because they could use an
`existing resource to generate electricity
`and/or methane gas or heat to use in
`other parts of their operation.
`“Our business plan shows that we
`can power our dairy, our processing
`plant, and our town of Firth – which has
`about 600 people – through the use of
`our dairy manure and food waste,” says
`Rice. “So we think that it makes a whole
`lot of sense from a renewable energy
`standpoint and brings a great aspect to
`the dairy. It eliminates some of the odors
`and helps us be more sustainable.”
`However, that plan is currently on
`hold because of cheap electricity rates
`currently available in Nebraska.
`
`Will we be side-dressing manure in the future?
`Natalie Rector, Amanda Meddles and Glen Arnold;
`Michigan State University Extension and Ohio State
`University
`The 2011 spring is a reminder of how few days we
`may have to complete all our spring work; there may not
`be an opportunity for manure application. Ohio State
`University has been successfully testing a dragline system
`of manure application as a side-dress application on
`corn. This process can increase the application window
`of manure and apply nitrogen at a critical time for the
`corn plant, which can offset the cost of nitrogen fertilizer,
`replacing it with manure applications that were going to
`occur anyway.
`Is this cost effective and does it produce equivalent
`corn yields to side-dressed fertilizer? Results at OSU
`say yes. A PDF report on the financial implications is
`available. (http://www.agcrops.osu.edu/on-farm-research/
`archive/2009/research/2009/Manure Sidedress.pdf)
`A project in Wood County, Ohio is comparing side-
`dress applications of manure to conventional 28 percent
`UAN and dairy manure. The manure side-dressing unit
`
`has a “spool” that lays the dragline down as the tractor
`moves one direction down the field, and then picks the
`dragline up on the next pass and so on. It reduces odors by
`injecting manure into the ground where it is less exposed
`to air and wind movement. It also allows producers to apply
`manure into the summer as one would with conventional
`side-dressing applications.
`The research project will look at the viable corn plant
`population for silage as well as grain corn yield. Being able
`to side-dress manure with a dragline may be the answer
`to expanding the manure application window, reducing
`compaction and, anytime manure is injected, odors are
`reduced. This project should answer the question of
`whether the method provides more benefit to crop yields
`and silage mass than conventional 28 percent UAN. We are
`also slurry seeding fescue and rye grass into some of the
`plots during the manure side-dress application to see if it
`will provide a viable forage crop after silage harvest.
`Watch a video (http://www.youtube.com/
`watch?v=Q9zlpUP8j_k) of the dragline side-dress
`equipment in action.
`
`Manure Manager • July/August 2011 9
`
`Exhibit 1020
`Bazooka v. Nuhn - IPR2024-00098
`Page 9 of 32
`
`

`

`Safe manure handling vital
`P athogens in manure can cause
`
`health problems if the manure
`isn’t managed properly.
`Recent cases of people
`becoming ill in Europe from
`vegetables contaminated with human
`fecal matter remind producers that
`handling animal manure safely is
`important.
`“Animal manures contain
`pathogens that can cause health
`issues in animals and humans if the
`manure isn’t managed properly,” says
`Chris Augustin, nutrient management
`specialist at North Dakota State
`University’s Carrington Research
`Extension Center. “However, the majority
`of manure management systems can
`reduce manure microbe concentrations
`in excess of 99 percent.”
`Pathogens survive longer under
`wet conditions, and excess manure in
`a pen can dam water. Cleaning pens
`every few weeks improves pen drainage
`and reduces odor. Push-type blades
`can be used to clean pens; however,
`these blades can gouge a pen surface
`and reduce runoff efficiency. Pull-type
`scrapers seem to work the best and are
`less prone to damaging pen surfaces,
`Augustin says.
`Pathogens in field-applied manure
`may run off into surface waters. Applying
`manure 100 feet or more away from
`surface water can prevent the spread
`of pathogens. Augustin recommends
`producers apply manure to fields used
`for vegetables and root crops in the fall
`to allow time for the pathogens to die
`before spring planting. Producers should
`use spring-applied manure on fields
`where they grow grains.
`Composting manure is a speedy
`decomposition process. It not only
`reduces manure volume and odor, but
`
`also the temperatures the manure pile
`reaches during the composting process
`(in excess of 130° F) kill pathogens and
`weed seeds.
`The pile needs to be turned three
`to five times during composting. The
`pile’s heating cycles usually last a week
`or more. Each cycle must last at least
`three days to kill pathogens effectively.
`Manure spreaders, loaders and
`compost turners need to be cleaned and
`disinfected properly because they come
`in contact with livestock and manure,
`and they may harbor pathogens.
`“Cleaning and removing material
`from the equipment is 90 percent of the
`job, while disinfecting is only 10 percent
`of the job,” Augustin says.
`He recommends producers follow
`these steps:
`•
`Clean the equipment in a
`designated area away from
`livestock.
`Remove organic matter
`because it can serve as an
`infection reservoir.
`Power wash the equipment
`with hot water and detergent.
`Scrub tight areas with a stiff,
`hard-bristled brush.
`Allow the equipment to dry
`before disinfecting it. Wet
`equipment can dilute the
`disinfectant.
`Follow the instructions on
`the product label when
`disinfecting the equipment.
`Properly wash clothing
`worn while handling
`animals because it can
`be contaminated with and
`transport pathogens. Washing
`clothes with detergent and
`drying them at 140° F will kill
`harmful pathogens.
`
`•
`
`•
`
`•
`
`•
`
`•
`
`Anne Ehni, Wells County Soil
`Conservation District manager,
`demonstrates how to power wash a
`compost turner. (Photo courtesy of
`Anne Ehni)
`
`•
`
`Clean footwear with soap
`and water, and disinfect it. A
`mixture of five tablespoons
`of bleach per gallon of water
`works well for disinfecting
`footwear.
`“Manure pathogens can cause
`health issues, but properly applying
`manure, cleaning equipment and
`cleaning pens greatly reduces these
`issues,” Augustin says. “These practices
`are all important to protect our food
`supply.”
`
`If you have a coming
`event that would be
`of interest to manure
`management professionals
`and custom applicators,
`feel free to forward it to
`mland@annexweb.com.
`
`“We should have used
`CORNELL PUMPS ...”
`
`GOT MANURE? GET CORNELL!
`• Over 30 models of Solids-Handling pumps available
`• Low head transfer to High Head Boosters
`• High Effi ciency – fuel savings
`• Heavy Duty Construction – lower maintenance
`• 50+ years in Manure Handling
`• Innovative Designs for handling Liquid Waste Slurry
`• Providing pumps with long service life
`
`SELF-PRIMING
`
`HYDRAULIC
`SUBMERSIBLE
`
`6NHTB19
`
`CORNELL PUMP COMPANY www.cornellpump.com
`bjansen@cornellpump.com Phone: (503) 653-0330 Fax: (503) 653-0338
`
`10 Manure Manager • July/August 2011
`
`Exhibit 1020
`Bazooka v. Nuhn - IPR2024-00098
`Page 10 of 32
`
`

`

`FREESTALL BARN MANURE SYSTEMS
`
`CROSS-GUTTER SYSTEMGS
`B-15/16
`GUTTER-CAT
`CROSS CLEANER
`CROSS
`SCRAPER
`
`B-15/16
`CHAIN
`SCRAPER
`
`SHUTTLE-STROKE
`CROSS CLEANER
`
`FLUSH-FLUME
` SYSTEM
`
`ALLEY SCRAPER SYGSTEMS
`
`DURA-CHAIN
`SCRAPER
`
`XD-SERIES
`CABLE SCRAPERS
`
`VERTICAL
` PUMPS
`
`LIQUI-TRANS
`PISTON
` PUMP
`
`SEMI-TRANS
`PISTON PUMP
`
`SOLID-TRANS
`PISTON PUMP
`
`ELECTRIC
`PROP AGITATOR
`
`MECHANICAL
`PISTON
` PUMP
`
`TRANSFER PUMP
`SYSTEMS
`
`MANURE APPLICATION EQUIPMENT
`
`SPREADER TANKS
`
`SD-SERIES
`NON-STEERABLE
`
`HD-SERIES
`NON-STEERABLE
`
`AUTO-TRAC
`STEERABLE
`
`ULTRA-TRAC
`4, 6 or 8
`WHEEL STEERABLE
`
`JAMESWAY FARM EQUIPMENT, INC.
`FACTORY: St. Francois-Xavier (Quebec)
`USA WAREHOUSE: Tomah, WI
`PHONE: 819-845-7824
`
`PTO-DRIVEN PUMPS
`
`ULTRA-PUMP 3PH
`PUMPS & PROPS
`
`ULTRA-PUMP
`TRAILER LAGOON
`PUMPS & PROPS
`
`VERTICAL
`PTO
`PUMPS
`
`INJECTION SYSTEMS
`NUTRI-JECTOR HIGH-SPEGED
`INJECTION SYSTEM
`
`MULTI-JET
`APPLICATOR
`
`DOUBLE DISC
`APPLICATOR
`
`SEMI-TRAILER
`MOUNTED
`
`CENTRIFUGAL
`LOADING PUMP
`
`TRUCK TANKERS
`TRANSFER
`ARM
`KITS
`
`TRUCK
`MOUNTED
`
`Exhibit 1020
`Bazooka v. Nuhn - IPR2024-00098
`Page 11 of 32
`
`

`

`Ed and Tom Maljaars went into business together in 2004, buying a working, 80-acre dairy in Rosedale, B.C. Over the next
`seven years, they increased the cows they milked from 115 to 145, added substantially to the barn and liquid storage unit,
`incorporated a state-of-the-art composter and also built a new milk parlor. Contributed photo
`
`Fine tuning an operation
`
`By Diane Mettler
`Ed and Tom Maljaars
`take their dairy to the
`next level with new
`barn, storage pit, large
`liquid storage tank, and
`composter
`
`B rothers Ed and Tom Maljaars
`
`went into business together in
`2004. They bought a working,
`80-acre dairy in Rosedale, B.C.,
`and moved their families out to
`homes on the property.
`Since the two brothers had worked
`on dairies all their lives – Tom on the
`family dairy and Ed on other dairies as
`well – they had enough experience to
`know what they wanted to do, and they
`got right to work.
`Over the next seven years, they
`increased the cows they milked from 115
`to 145, added substantially to the barn
`and liquid storage unit, incorporated a
`
`state-of-the-art composter and also built
`a new milk parlor.
`
`The barn
`The brothers began in 2006 by adding
`on an additional 215 feet to the barn.
`Under the addition, they built a manure
`pit 20 feet by 120 feet and 10 feet deep.
`They also put alley scrapers along all four
`alleys, so everything from the barn could
`be scraped into the pit.
`Before buying the Bedding Master,
`they had to pump out of the pit into the
`Slurrystore once every three weeks, plus
`spend a lot of time agitating.
`
`The liquids
`At around the same time, the Maljaars’
`took their Slurrystore from 400,000 gallons
`to 600,000 gallons.
`“There was already a Slurrystore on
`the site and we added two rings,” says
`Tom. “Each ring is 4.5 feet, so we raised
`it nine feet. We don’t spread during the
`winter and by early spring it’s pretty full.”
`In the spring, the brothers hire
`Cascade Custom Pumping, who use a
`mile-long dragline to spread the material
`
`on the farm’s grass and cornfields.
`The difference between 2011 and
`2006 is that the Slurrystore contains
`mostly liquid and the solids have been
`removed with the incorporation of a
`composter.
`
`Bedding Master composter
`In 2010, the Maljaars’ purchased a
`Bedding Master from Pacific Dairy Center
`– one of the first ones of its size in the
`valley. “They come in three sizes, and we
`got the smallest,” says Tom. “Between the
`heifers and cows, there are around 270
`animals at the dairy and the system can
`handle that number easily.”
`The process is fairly simple.
`PDC installed an Agi pump with two
`10-horsepower motors in the manure
`pit by the barn. Manure is pumped
`from the barn to an EYS screw press
`separator at the same time the manure
`is agitated in the pit to keep it an even
`mix. The solids that come out of the
`separator are approximately 35 percent
`dry matter, which is required for effective
`composting. While the liquids move on
`to the Slurrystore, the solids feed into the
`
`12 Manure Manager • July/August 2011
`
`Exhibit 1020
`Bazooka v. Nuhn - IPR2024-00098
`Page 12 of 32
`
`

`

`One Product. Many Benefits.
`
`MicroSource® S...because pigs
`aren’t raised in a bubble.
`
`Now, more than ever, pork producers recognize the impact their operations can have on the world around
`them. Proactive eco-management with MicroSource S can help reduce environmental burdens. By feeding
`MicroSource S, producers benefi t from:
`• Reduction in noxious manure gases, like ammonia and VFAs, for less odor – resulting in better community
`relationships
`• Increased nitrogen retention in manure - resulting in improved N:P Ratio
`• Lower manure viscosity - resulting in less power required for pump outs and the ability to pump
`out more manure
`• Decreased stickiness of manure resulting in reduced labor requirements due to easier/less cleaning
`MicroSource S contains selected microbes that digest the solids in hog manure. It begins to work even
`before the manure hits the fl oor and continues to act on manure during handling and storage. Fed throughout
`the pig’s lifecycle, MicroSource S can help you better balance the challenges of e cient pork production with
`environmental stewardship.
`To learn more, contact your feed supplier, go to www.unlimitednutrition-na.dsm.com, or call 1 800 526 0189.
`
`MS-1-G Copyright ©2011 All rights reserved.
`
`Exhibit 1020
`Bazooka v. Nuhn - IPR2024-00098
`Page 13 of 32
`
`

`

`It takes about 24 hours for the
`composted solids to come out the
`other end of the Bedding Master.
`During the process, the solids have
`heated up to around 135 degrees,
`killing the pathogens and any bacteria.
`The material moves up a conveyer
`and onto a pile. The material is then
`scooped up and blown back into the
`stalls. Contributed photo
`
`Bedding Master, a large drum that is six
`feet in diameter and 16 feet long.
`The separator is programmed to be
`on for 10 minutes and off for 20 minutes.
`Tom says they can set any time they
`want, but at this setting, the level in the
`manure pit stays about the same, which
`is approximately four feet. “It is ideal to
`only have so much fed into the Bedding
`Master at a time,” says Tom.
`The drum turns continually and it
`takes about 24 hours for the composted
`solids to come out the other end. During
`the process, the