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From slurry to bedding material

Bauer Bedding Unit

As the costs for high-quality bedding mate­r­i­al have increased enor­mous­ly in recent years, more and more inno­v­a­tive dairy farms are using organic bedding mate­r­i­al. This is made of the undi­gest­ed fibres (feed residues) of the slurry. The BBU concept (BAUER Bedding Unit) sep­a­rates, dries and dis­in­fects undi­gest­ed raw fibres from the liquid manure. This means that oper­at­ing costs can be reduced while at the same time milk pro­duc­tion is opti­mized. Since this is an eco­log­i­cal cycle, not only the costs for bedding mate­r­i­al but also dis­pos­al costs can be saved. This organic mate­r­i­al is pro­duced direct­ly on the farm and is avail­able at all times.

Always avail­able BIO litter

enor­mous cost savings

Animals feel good

kuh auf bedding
Eco­nom­ic benefit of the use of recy­cled solids as bedding material

Bio Bedding material

  • No addi­tion­al bedding mate­r­i­al necessary
  • High accep­tance of the bedding mate­r­i­al by the cows
  • Increased milk production
  • Low costs for the pro­cess­ing of slurry
  • No addi­tion­al storage necessary
  • Comfort and well-being of the cows is increased
  • Very clean cows
  • Easy to use
  • Eco­nom­i­cal
  • Envi­ron­men­tal­ly compatible
  • Avail­able daily
  • Con­stant quality
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Func­tion­al­i­ty

Sep­a­ra­tion of solids from the slurry

The first step of the process con­sists of the sep­a­ra­tion of coarse fibres by a spe­cial­ly designed press screw sep­a­ra­tor. The solids are mainly undi­gest­ed residues from the feed, such as fibres from silage or straw. The sep­a­ra­tor presses out the solids, thereby reduc­ing the humid­i­ty level to a minimum. The drying drum is fed con­tin­u­ous­ly via an auger into a spe­cial­ly devel­oped rotat­ing drum made of stain­less steel.

Bauer - FAN Separator - Neil Harrison 030
Func­tion­al­i­ty

Drying through composting

The second step of the process takes place in an insu­lat­ed stain­less steel drum. There the solids are sub­ject­ed to an inten­sive bio­log­i­cal aerobic hygi­en­iza­tion process at tem­per­a­tures of over 65 degrees for several hours, whereby the bac­te­ria are killed or reduced to a minimum. This con­trolled process guar­an­tees a homog­e­nized product. This treat­ment of the solids sig­nif­i­cant­ly reduces the increase of mas­ti­tis pathogens. Lab­o­ra­to­ry tests from dif­fer­ent uni­ver­si­ties have shown that no detectable bac­te­r­i­al cells were present in the bedding mate­r­i­al after this process.

Com­post­ing process
Hygi­en­iza­tion drum
New dis­charge system
Auto­mat­ic weight adjustment
Touch Display
Com­post­ing process
BBU Aufbau
BAUER BBU

Com­post­ing process

The second step of the process happens in the BAUER com­post­ing drum, which is installed in an insu­lat­ed 40′ con­tain­er. The solids are fed into the drum via a patent­ed flap system so that the drum can be filled to over 70% of its volume. In the drum, the mate­r­i­al is con­tin­u­ous­ly mixed and sub­ject­ed to an intense aerobic process, during which air is sucked out of the drum to remove mois­ture from the system. For an optimal com­post­ing process, the air tem­per­a­ture is kept at around 65–70°C. A homo­ge­neous product is pro­duced by a stable, con­tin­u­ous process.

Hygi­en­iza­tion drum
BAUER BBU

Hygi­en­iza­tion drum

  • Drum installed in an insu­lat­ed 40′ con­tain­er in order to ensure the process even at low temperatures
  • Drum made of stain­less steel
  • Spirals made of stain­less steel which are welded into the drum guar­an­tee optimal homog­e­niza­tion of the material
  • 4 wheel fric­tion drive for the drum
  • All com­po­nents com­plete­ly mounted and deliv­ered as Plug & Play — version
New dis­charge system
Bauer BBU400 Austrag
BAUER BBU

New dis­charge system

Thanks to the new dis­charge system the drum can be filled to 70% of its volume, this means a daily pro­duc­tion of up to 46m3 of bedding material.

Auto­mat­ic weight adjustment
BBU Bauer Gewichtsverstellung
BAUER BBU

Auto­mat­ic weight adjustment

In order to ensure the fully auto­mat­ic con­trolled oper­a­tion, a special control unit has been devel­oped, which guar­an­tees a con­stant dry matter content of 36–38% at the sep­a­ra­tor outlet.

Touch Display
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BAUER BBU

Touch Display

The whole unit as well as the single com­po­nents can be con­trolled via the gen­er­ous­ly dimen­sioned touch screen panel. Data such as tem­per­a­ture and all setting para­me­ters of the unit can be stored on memory cards over a longer period of time in order to ensure trace­abil­i­ty. Fur­ther­more, periph­er­al devices can also be controlled.

  • Sub­mersible motor mixer
  • Sub­mersible motor pump
  • Sep­a­ra­tor for the BBU
  • 4 wheel fric­tion drive for the drum
  • Ven­ti­la­tor
Bauer BBU

Auto­mat­ed BIO process

The process is com­plete­ly auto­mat­ed. The slurry is pumped from the col­lec­tion tank into the press screw sep­a­ra­tor. The sep­a­rat­ed solids are fed to an auger, from where they are trans­port­ed to the stain­less steel drum, where an aerobic process begins. This happens at a tem­per­a­ture of 60 — 75 degrees Celsius without the supply of exter­nal energy. The bio­log­i­cal process is mon­i­tored via tem­per­a­ture mea­sure­ments and reg­u­lat­ed by the air flow. The Bauer Group offers the right size for every business:

10 m3 

BBU 400

Pro­duc­tion of organic bedding mate­r­i­al per day

24 m3 

BBU 1000

Pro­duc­tion of organic bedding mate­r­i­al per day

48 m3 

BBU 2000

Pro­duc­tion of organic bedding mate­r­i­al per day

Ques­tions about the Bauer Bedding Unit?

CONTACT

Contact

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    Hojas Hans-Peter

    Hans-Peter Hojas

    Product Manager — Slurry Technology