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Food Waste to Pig Feed, Taro by Hand, Soil from a Gulch

Paul Tower, Vincent Mina, Dave Sansone, David Fuertes, Bob Shaffer, Hawaiʻi farm and ag-business project leaders; chaired by Dr. William (Bill) Steiner, Pacific Agricultural Land Management Systems · USA (Hawaiʻi)

Bill Steiner, former UH Hilo dean of agriculture, opens with innovation in old Hawaiian farming (the Kohala field system) and his own oil palm trial, then hands off to five project leaders. Paul Tower pitches a planned Oʻahu plant turning food waste into pig feed, renewable natural gas, compost and hydroponic lettuce; Vincent Mina tells how a 2,000 sq ft greens farm on Maui led him to the Farmers Union; Dave Sansone shows low-effort agroforestry; David Fuertes shows a Kohala ʻohana taro, sweet potato and natural-farming livestock project that makes Microbes (IMO) a ton at a time; Bob Shaffer describes digging up a million cubic yards of buried bagasse and soil at the old Haina sugar mill for potting soil.

What they found

The question

What new projects could help Hawaiʻi feed and fuel itself, and what would help others adopt them?

How they tested it

Panel of five 10-minute project pitches with Q&A, Day 2 (Oct 2, 2015). Steiner asked each speaker: (1) what is the future of your approach in Hawaiʻi and its contribution to sustainable systems, and (2) what else (policies, education, equipment) is needed so others adopt it. No speaker presented a controlled trial; most numbers are plans or self-reported. Ray Maki (Permaculture Kauaʻi, HFUU state treasurer) was listed but did not attend.

What was compared
  • Food waste to feed and gas (Paul Tower) — Collect Oʻahu pre- and post-consumer food waste, remove contaminants, cook to FDA standard (212 F, 30 min minimum on the raw food), add whole organic non-GMO feed corn from Washington State ground on site for at least 12% protein pig feed; rest goes to an anaerobic digester for methane, CO2 for hydroponic greenhouses, water for a duckweed pond and irrigation, and compost.
  • Agroforestry 'let nature do the work' (Dave Sansone) — Biochar, then indigenous microorganisms; intercrop natives (moringa with koʻokoʻolau); lemongrass or vetiver bioterraces on contour; crotalaria sown dense and cut low before seed for mulch and nematode trapping; ground covers (ʻilima papa) in kalo; green-manure hedgerows; cranberry hibiscus as a rose beetle trap crop; Quesungual chop-and-mulch; cowpea for nitrogen.
  • Palili ʻO Kohala (David Fuertes) — Families farm kalo and sweet potato with natural farming, plant 400 plants a month, make poi and kūlolo; natural-farming pig and chicken house with a 20 by 50 ft extension for making Microbes (IMO), up to one ton per batch, turned daily with a tractor.
  • Honokaʻa Earth Products (Bob Shaffer) — Excavate a buried deposit of bagasse, mill mud and cane-field soil at the old Haina Mill; screen out gravel; blend with vermicast, compost and local cinder for potting soil; aerated static compost (14-day pathogen reduction) and vermicompost in the mill buildings.
Results
  1. Steiner imported 10,000 oil palm seeds of three strains from Costa Rica, about six or seven years earlier

    Proof-of-concept 2008–2013 on pests, elevation, soil, climate and yield; palms now fruiting. Slide: about 100 trees per acre, expected 450 gallons of oil per acre (expectation, not a yield). An extraction mill from India was due at Atto Assi's farm.

    ▶ 4:35 Said and shown on the slides

  2. About 400 tons a day of food waste on Oʻahu

    Pre- and post-consumer, Tower's estimate. The digester would take 200 to 400 tons per day.

    ▶ 9:45 As spoken

  3. Planned output: 10 million pounds a year of pig feed

    Slide: 'Plant sized for 10 million pounds of animal feed', pigs first, then fish and chicken. Target is a 50% cut in feed cost; slide says pig feed now costs over 50 cents a pound and fish feed over $1 a pound.

    ▶ 10:23 Said and shown on the slides

  4. Hawaiʻi's pig industry went from 65,000 sows to under 5,000

    Stated from memory as context; not sourced.

    ▶ 10:54 As spoken

  5. A $40 million plant, production hoped for late 2017 or early 2018

    To be funded by Hawaiian private investors plus a state bond the company will ask for. Still a plan at the time of the talk.

    ▶ 12:58 As spoken

  6. 160+ biogas systems in the US, 300 worldwide, first installed 1997

    Tower's former company's technology (slide: 160+ systems, 300 worldwide, first system 1997, three patents for biogas purification).

    ▶ 13:29 Said and shown on the slides

  7. Digester gas is about 60% methane and 40% CO2; split to 98–99% methane and 98% CO2

    CO2 goes to hydroponic greenhouses; 60,000 heads of lettuce a month planned on 40,000 sq ft by June 2016, at under half the delivered cost from L.A. (claimed).

    ▶ 15:45 As spoken

  8. 400 pounds of greens a week from 2,000 square feet

    About $100,000 a year gross; on a 7,000 sq ft lot zoned for truck farming; family farm since 1994 (slide).

    ▶ 30:54 Said and shown on the slides

  9. Cranberry hibiscus draws rose beetles off other crops

    Hibiscus acetosella used as a pest trap crop; the beetles eat it first and leave blueberries and other crops. Observation, not measured.

    ▶ 50:09 Said and shown on the slides

  10. Taro so big he can't lift it with one hand, grown with ground covers and little weeding

    Biological weed control with ʻilima papa in kalo. Anecdote.

    ▶ 47:58 As spoken

  11. Kohala goal: grow 50% of what the community eats by 2018

    From the North Kohala Community Development Plan (slide). Pre-contact North Kohala fed about 30,000 people; today about 6,000 people import about 85% of their food (slide).

    ▶ 59:58 Said and shown on the slides

  12. 400 plants a month; about 600 pounds a month harvested so far

    Ten-month crop; harvest began the month before. He says it converts to about 200 bags of poi every two weeks.

    ▶ 1:04:15 As spoken

  13. Pig and chicken house built for $15,000 in materials and over 1,000 volunteer hours

    A Boy Scout Eagle project; extended 20 by 50 ft in back to make Microbes (IMO), up to one ton at a time, turned daily with a tractor.

    ▶ 1:05:44 As spoken

  14. About 175 kids a year go through Fuertes's program

    Steiner's figure, hedged ('I think, 175 a year or something like that').

    ▶ 1:11:22 As spoken

  15. About 1 million cubic yards of bagasse, mill mud and cane-field soil buried behind the Haina Mill

    Dumped in a gulch for 60 years; capped with about six feet of clay. Slide: mill built 1914, abandoned since 1994, site bought January 2015.

    ▶ 1:15:54 Said and shown on the slides

  16. Lab tests from 40 sites came back non-detectable for pesticides, dioxin and heavy metals

    Samples at 9 and 18 feet, tested twice by a state- and county-approved lab. UH grew corn in the material twice and found no arsenic in leaf or grain. Reported by Shaffer; the lab reports were not shown.

    ▶ 1:16:10 As spoken

  17. The deposit runs hot: 150 degrees at 30 feet, 145 degrees when brought up from 18 feet

    Anaerobic heating; smells like hot molasses. Buried 20 to 50 years by his estimate.

    ▶ 1:18:33 As spoken

  18. The material is low in phosphate, rich in potassium, with fair calcium and magnesium and good micronutrients

    Little nitrogen. Top foot or two showed good fungal and free-living nematode diversity (Soil Food Web); deeper layers not yet tested for biology.

    ▶ 1:26:02 As spoken

Hold it loosely
  • These are project pitches. Paul Tower's plant did not exist yet; his feed, gas, lettuce and cost numbers are targets.
  • Every result is self-reported. No trial, control or written data was shown, except slides with summary figures.
  • Bob Shaffer's clean test results are reported, not shown; the deep, hot layers had not been tested for biology.
  • Vincent Mina's and Dave Sansone's results are their own farms' experience (anecdote).
  • David Fuertes's harvest had just started; 600 pounds a month is an early figure.
  • Some stretches of Q&A are inaudible, and several questions were lost.
For your farm
  • A plant the pests prefer (cranberry hibiscus for rose beetles) can be planted to draw them off the crop.
  • Dense crotalaria, cut low before it sets seed, can mulch a bed and may help with nematodes.
  • A community can make Microbes (IMO) at scale under one roof; Kohala makes up to a ton a batch.
  • Local waste streams (food scraps, old mill bagasse) may be worth testing as farm materials, but test them for contaminants first, as Shaffer did.

Next to Master Cho's teaching

  • Goes further

    Making Microbes (IMO) a ton at a time under a roof, turned daily by tractor Cho's IMO-3 is made under cover with temperature watched twice a day and the pile turned to keep it cool (below 120 F). Kohala's one-ton batches scale this up; the talk does not say whether they turn by temperature or by the calendar, or whether the floor is bare soil.

    cho_solutions, p. 17–18

  • Agrees

    Natural farming pig and chicken house: 'no flies, no smell' Cho writes that natural farming pig farms do not smell and have no flies, using a deep bedding floor fermented with IMO and FPJ.

    Cho, Janong Natural Farming (2003), p. 189

  • Agrees

    Old buried bagasse as a Microbes (IMO) substrate (audience idea; Shaffer: 'maybe') In his Hawaiʻi classes Cho built IMO-3 from bagasse, mill-run and biochar, so a cured bagasse substrate fits the method. Shaffer had not tried it.

    notes: cho-hawaii-2016-2017 — Recipes & methods demonstrated

  • Differs

    Turning food waste into pig feed Cho also wants farmers to feed animals on whatever local by-products are around. But Tower's plan is an industrial plant that cooks the waste and adds imported corn. Cho's way is on the farm, fermented with local microbes.

    2017/Advanced Cho/swine/IMG_1481 @ 0:00:00 (translated)

“In the back, we extended it 20 by 50, and we make IMO.”

▶ 1:06:23

“It ended up being dumped as a waste product in a gulch out in back.”

▶ 1:14:31

“There's only two things I found in this process and in my life that doesn't lie. And that's the body and that's the soil.”

▶ 32:15

“So rather than trying to fight them, give them what they want.”

▶ 50:18

“We don't want to export products. We want to export technology.”

▶ 26:08

In this talk

  1. 0:00Bill Steiner: innovation in old Hawaiʻi, peak oil, oil palm trial
  2. 6:46The panel and the two questions
  3. 8:02Paul Tower: food waste to pig feed, biogas and lettuce on Oʻahu
  4. 21:21Q&A with Paul Tower: power grid, corn, GMO, fuel standards
  5. 28:38Vincent Mina: a 2,000 sq ft family farm and the Farmers Union
  6. 37:50Q&A: zoning on residential land
  7. 39:50Dave Sansone: agroforestry that lets nature do the work
  8. 54:43David Fuertes: Palili ʻO Kohala, taro, sweet potato and an IMO house
  9. 1:11:52Bob Shaffer: potting soil from the old Haina Mill's buried bagasse
  10. 1:22:12Q&A with Bob Shaffer: methane, IMO substrate, nutrients, nematodes
  11. 1:28:25Steiner: threats on the horizon

Transcript

Transcribed and checked by hand against the recording. Click any time to play from there.