Published: April 27, 2007 02:19 am         

Particle ionization cleans air for livestock, workers

Originally published in the April 20, 2007, print edition.

Called electrostatic particle ionization, a relatively new U.S. Department of Agriculture invention is making news in the livestock world for one important reason: dust suppression.

In multiple USDA studies the EPI technology is proven to efficiently remove up to 78 percent of dust in the air in such heavy-traffic facilities as commercial hatching cabinets, broiler and caged-layer barns.

It has also been shown to reduce airborne levels of disease-causing bacteria such as salmonella by 95 percent or more; to reduce airborne disease transmission; and to kill airborne and surface bacteria at close range.

“Since the commercial launch, EPI is generating jaw-dropping achievements. It’s really exciting,” said Matt Baumgartner, environmental scientist with Baumgartner Environics Inc. “The EPI system will change a livestock environment overnight. It’s that good, and that quick in terms of its environmental impact.” BEI, an environmental engineering firm in Olivia, has the exclusive license for commercializing the EPI technology and sees the U.S. poultry industry as “early adopters” of the EPI system quickly followed by the U.S. swine industry.

Bailey Mitchell, with the USDA, spent several years researching the issues of dust reduction and disease in livestock facilities before getting a patent in 2000. His dust suppression technology also found a major reduction in ammonia, a common byproduct of waste products in many poultry barns contributing to obnoxious smelling air and respiratory health hazards for animals and workers.

An early success of EPI technology in the commercial world was a major egg production business facing an Environmental Protection Agency shut down in 2005 because of environmental issues.

Working with BEI, the firm installed an EPI system. In a six-month study, the technology stood up to the EPA challenge lowering dust emissions to an acceptable level

What makes the EPI system work? The word “electrostatic” gives a hint. Though the exact components are proprietary knowledge, BEI president John Baumgartner said the physics behind the system are relatively simple. EPI charges the air space, polarizing suspended dust particles forcing them to “ground out” to surfaces like litter or concrete floors.

Visualize the workings of a magnet and metal shavings. Just like metal shavings are attracted to the magnet, the EPI system “grounds-out” air-borne particles. Charging of the air space minimizes re-suspension of the particles from surfaces since any that tend to be re-suspended by animal activity will immediately be re-charged and re-attracted to the ground.

“The EPI system operates 24/7 and is continually providing this grounding effect. The result is removal of air-borne pathogens and clean, breathable air,” Matt Baumgartner said.

Early observations

“We’ve been extremely impressed with the efficacy of the system so far,” said Chris Huisinga, director of Business Development, Life-Science Innovations, which includes the Willmar Poultry Co., the nation’s largest turkey hatchery. Clean air is important to the Willmar Poultry. From 20-plus breeder barns, it produces 45 million eggs and hatches 30 million poults each season.

An EPI system was recently installed in one of their 75-foot by 200-foot turkey production buildings.

“We’re doing preliminary testing now to develop some empirical data; however, our early observation is that it’s an incredible system,” Huisinga said.

“The air was noticeably cleaner just hours after the system was turned on. And when you improve air quality, you’re likely to see healthier birds and potentially an increase in the number of eggs per hen. Even more important, workers are breathing cleaner air, too.”

The EPI system has no moving parts, is barely noticeable in a building, and its operating costs for a large commercial poultry barn are typically less than that of four, 60-watt light bulbs. “I’ve grown up in the turkey industry yet this system installed in our turkey barn was so unobtrusive, I didn’t even notice it,” Huisinga said.

Suspended 10 to 14 inches below the ceiling, stainless steel corona-discharge-points mounted on a stainless steel cable system is supported by insulators. The electrical components plug into any conventional electrical outlet, then quietly performs its electrostatic dust reduction within the confines of the building. Easily cleaned, it can also be pressure-washed which is a bonus within confinement hog finishing barns, which are pressure washed between repopulations.

A major distributor of the EPI system is Poultry & Livestock Supply of Willmar, which is currently offering “Market Leader” pricing for livestock producers who agree to share production data as a result of the EPI system. Typical retail pricing is projected at less than $1.50 per square foot of animal living space.

“I see this as a win-win situation for producers, for neighbors, for the total environment and most importantly for the health of livestock workers, and livestock,” said Perry Nelson, Livestock Equipment Sales, PALS.

He projected that the poultry industry will be the quickest adopters of the EPI system because the EPA saw the results when the system was put to the test in a large egg laying facility on the verge of being shut down by the EPA.

“That quickly lent credence to the system,” Nelson said. “My goal is to see how quickly EPA will recognize this as a means of correcting odor problems rather than with the more expensive biofilters now used. But EPA first needs performance data from hog barn installations so my mission is to get the EPI system installed in hog facilities ASAP.”

Once accepted by the EPA, Nelson sees the EPI as a great solution for the hog industry, which constantly is challenged by air-borne pathogen disease and odor issues, plus a healthier environment for both the hogs and the workers.

“The economics of hog production have changed so rapidly since ethanol started ramping up corn prices,” Nelson said, “that I don’t believe most producers have come to grips with how much money has to be trimmed out of their hog operations to keep them profitable.”

He described the EPI as a technology that both enhances the health of the hogs, while also providing an environment that makes the entire permitting process more attainable.

“We visualize this as a bottom-line positive investment,” Huisinga said. “There’s zero maintenance and an indefinite life span. It certainly looks like the right system to drastically impact air quality. Right now just looking at visual differences inside the building with the EPI system and the adjoining building without the system, it’s a no-brainer. We’re very optimistic about the system.”

For more information, contact Matt Baumgartner at mbaumgartner@bei-ec.com, Bailey Mitchell at baileywmitchell@charter.net, or Perry Nelson at perryn@willmarpoultry.com or log on to www.palsusa.com.

     

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