Description:AN APPARATUS FOR CONVERTING BIO-WASTE TO FEED, FERTILIZER AND INDUSTRIAL CHEMICALS

FIELD OF THE INVENTION
[0001] This invention generally relates to a field of bio-process engineering, more particularly to an apparatus and method for converting bio-waste to feed.

BACKGROUND
[0002] The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also correspond to implementations of the claimed technology.
[0003] Food waste refers to edible food that is discarded before or after spoilage despite being fit for consumption. Food waste typically, but not exclusively, occurs at the retail and consumption stages in the food value chain and is the result of negligence or a conscious decision to throw food away. Globally about one-third of the food produced ends up as waste and constitutes a major fraction of municipal solid wastes. Further, in developing countries like India these highly putrefiable wastes (i.e., liable to decay or spoil) pose a major threat to the environmental health. It has been reported that citizens of developed and developing nations generate 107 kg/year and 56 kg/year of food waste per capita, respectively. Next to China, India is the biggest contributor of food waste in the world. About 51% of MSW produced in India constitutes of food waste. The global food waste generation has been estimated to increase by 44% between 2005 and 2025. In India food waste is mostly dumped in the landfills, which leads to release of methane, carbon dioxide, and other toxic and/or global-warming gases. It also contributes to the proliferation of pests and diseases. Only a small fraction (i.e., 5-6%) of the food waste is bioprocessed either by animal feeding, composting, or anaerobic digestion. But all three of these options fall short in processing various kinds of food wastes, and also take impractically long time to accomplish.
[0004] Furthermore, abattoir waste comprises of animal feaces, blood, bone, fat, animal trimmings, paunch content and urine from operations or areas like lairage, stunning or bleeding, carcass processing and by-product processing. These constituents pose a serious threat to the environment, public health, and animal health, thereby contaminating natural resources and stressing the economy of the country. The known management methods for these bio-wastes are burial, composting, incineration, anaerobic digestion and blood processing. However, most of these methods are too expensive to use.
[0005] Previous research on organic waste treatment using Black Soldier Fly (BSF) has primarily focused on cattle and poultry manure, semi-digested agricultural residues such as coconut waste, soybean curd, maize barn, grasses, and brewery or distillery spent grain. However, limited studies have explored the processing of fruit and vegetable waste, human fecal waste, sludge, and fish waste. Even when semi-wet waste is utilized, it often requires additives like dry ingredients (e.g., hay, coco pith) and microbial inoculants (e.g., yeast, bacteria) to accelerate the zoo-composting process. Additionally, food waste undergoes multiple preparatory steps such as pulverization, disinfection, dewatering, and pre-treatment before bioprocessing, making the method resource-intensive and costly.
[0006] Existing BSF-based zoo-composting methods are highly mechanized, incorporating distinct units for each stage of the process, including mating, ovi-position, rearing, migration, collection, and harvesting. The systems rely on specialized equipment, automated controls, and substantial energy inputs, making them expensive to operate. Furthermore, their complexity necessitates skilled labor, further increasing operational costs. As a result, such methods remain inaccessible to the general public and even to municipal authorities in developing nations. In contrast, the proposed apparatus is designed to be modular, cost-effective, and easy to implement while maintaining high efficiency in waste processing.
[0007] According to a patent application “WO2007034504A2” titled “An apparatus and process for conversion of biomass/waste into bio-organic soil enricher & conditioner and fuel” discloses a device and a process for conversion of biodegradable waste into organic fertilizer and fuel for heating. The organic fertilizer produced by the disclosed method provides nutrients to plants and at the same time improves moisture retaining capacity of the soil, prevents erosion and leaching.
[0008] According to a patent application “CN103598148A” tilted “Black soldier fly cultivation system and method” discloses the invention provides a black soldier fly cultivation system and method. The cultivation system comprises a pupation device and an adult black soldier fly cultivation chamber. The pupation device is used for incubating black soldier fly pre-pupa into black soldier fly pupa, and pupation media with water is disposed inside the pupation device. The adult black soldier fly cultivation chamber is used for cultivating the black soldier fly pupa into adult black soldier fly. The method has the advantages that pupation is performed by using the pupation media with water after the pupation environment is researched, the pupation time is shortened from 7 days to 2-3 days, reproduction time of black soldier fly is shortened greatly, and large-scale neat pupation and batch pupa collection are achieved.
[0009] According to a patent application “US20110174222A1” tilted “Method for rearing soldier flies” disclose a method for producing BSF. The method comprising: providing adult black soldier flies in a breeding farm of black soldier fly; and providing, in the breeding farm, an induction medium comprising sawdust and, on the induction medium, a breeding induction apparatus having a plurality of breeding grooves in which to allow the adult black soldier flies to lay eggs.
[0010] However, the methods for managing abattoir bio-waste include burial, composting, incineration, anaerobic digestion, and blood processing. These techniques help in waste reduction and environmental protection but shows several drawbacks. Burial requires large land areas and poses risks of groundwater contamination. Composting is time-consuming and may not effectively process all types of waste. Incineration, though capable of destroying pathogens, demands high energy input and releases harmful emissions. Anaerobic digestion may generate biogas, but the process requires specialized infrastructure and controlled conditions, making it costly. As a result, the high costs associated with these methods make large-scale and efficient waste management difficult.

OBJECTIVES OF THE INVENTION
[0012] The objective of present invention is to provide an apparatus for converting bio-waste to feed, fertilizer and industrial chemicals.
[0013] Further, the objective of present invention is to provide the method for converting bio-waste to feed, fertilizer and industrial chemicals.
[0014] Furthermore, the objective of the present invention is to provide the apparatus for converting bio-waste to feed, fertilizer and industrial chemicals that is capable of processing the bio-waste (i.e., food waste, abattoir waste and fruit/vegetable waste) into the feed in rapid and inexpensive manner.
[0015] Furthermore, the objective of the present invention is to provide the apparatus for converting bio-waste to feed, fertilizer and industrial chemicals by accomplishing ovi-position, larvae hatching, rearing, migration and water treatment in a single unit.
[0016] Furthermore, the objective of the present invention is to provide the apparatus for converting bio-waste to feed, fertilizer and industrial chemicals that does not require any pre-treatment such as grinding, pasteurization, chemical and microbial treatment.
[0017] Furthermore, the objective of the present invention is to provide the apparatus for converting bio-waste to feed, fertilizer and industrial chemicals that does not produce any waste or by-products.

SUMMARY
[0019] According to an aspect, the present embodiments an apparatus for converting bio-waste to feed, fertilizer and industrial chemicals is disclosed. Further, the apparatus comprises a horizontal barrel-shaped reactor. Further, the horizontal barrel-shaped reactor is fed with bio-waste in a ratio 1:1:1 up to a height of 10-15 cm from the bottom of the reactor. Further, the bio-waste comprises food waste, abattoir waste and fruit/vegetable waste. Further, a lid attached on an opening of the horizontal barrel-shaped reactor via a plurality of hinges. Further, a gap formed between the lid and reactor is configured to allow female black soldier flies (BSF) to enter with the reactor for laying eggs on a first mesh trough. Further, the mesh trough comprises plurality of perforations of 1mm diameter for allowing larvae to fall over the waste after the hatching of the eggs. Further, at least two pair of slits attached with a flap integrated on either side of the reactor at a height of 20 cm from the bottom of reactor. Further, a pre-pupal stage larva is migrated through the at least two pair of slits to a larval collection trough, via the flap. Further, a leachate collection vessel installed at the bottom of the horizontal barrel-shaped reactor, via inclined trough. Further, a second mesh trough is integrated with the leachate collection vessel configured to pass leachate from the reactor to the leachate collection vessel.

BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The accompanying drawings illustrate various embodiments of systems, methods, and embodiments of various other aspects of the invention. Any person with ordinary skills in the art will appreciate that the illustrated element boundaries (e.g. boxes, groups of boxes, or other shapes) in the figures represent one example of the boundaries. It may be that in some examples one element may be designed as multiple elements or that multiple elements may be designed as one element. In some examples, an element shown as an internal component of one element may be implemented as an external component in another, and vice versa. Furthermore, elements may not be drawn to scale. Non-limiting and non-exhaustive descriptions are described with reference to the following drawings. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating principles.
[0021] FIG. 1 illustrates a side view of an apparatus for converting bio-waste to feed, fertilizer and industrial chemicals, according to an embodiment of the present invention;
[0022] FIG. 2 illustrates a top view of the apparatus having lid attached with first mesh trough, according to an embodiment of the present invention;
[0023] FIG. 3 illustrates a side view of a lid covering the opening of the reactor, according to an embodiment of the present invention;
[0024] FIG. 4 illustrates a perspective view of the first mesh trough, according to an embodiment of the present invention;
[0025] FIG. 5 illustrates a bottom view of the reactor, according to an embodiment of the present invention;
[0026] FIG. 6 illustrates a first side of view of the apparatus, according to an alternative embodiment of the present invention;
[0027] FIG. 7 illustrates a second side view of the apparatus, according to the alternative embodiment of the present invention;
[0028] FIG. 8 illustrates a top view of the apparatus, according to the alternative embodiment of the present invention;
[0029] FIG. 9 illustrates a cross-sectional view of the apparatus according to the alternative embodiment of the present invention; and
[0030] FIG. 10 illustrates bottom view of the apparatus, according to the alternative embodiment of the present invention.

DETAILED DESCRIPTION
[0032] Some embodiments of this invention, illustrating all its features, will now be discussed in detail. The words “comprising,” “having,” “containing,” and “including,” and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. It must also be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.
[0033] Although any systems and methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present invention, the preferred, systems and methods are now described. Embodiments of the present invention will be described more fully hereinafter with reference to the accompanying drawings in which like numerals represent like elements throughout the several figures, and in which example embodiments are shown. Embodiments of the claims may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. The examples set forth herein are non-limiting examples and are merely examples among other possible examples.
[0034] The present invention discloses a novel and effective apparatus for converting bio-waste to feed, fertilizer and industrial chemicals that is capable of processing the bio-waste that comprises food waste, abattoir waste and fruit/vegetable waste into feed in rapid and inexpensive manner.
[0035] FIG. 1 illustrates a side view (100) of an apparatus for converting bio-waste to feed, fertilizer and industrial chemicals, according to an embodiment of the present invention. FIG. 2 illustrates a top view (200) of the apparatus having lid attached with first mesh trough, according to an embodiment of the present invention. FIG. 3 illustrates a side view (300) of a lid covering the opening of the reactor, according to an embodiment of the present invention. FIG. 4 illustrates a perspective view (400) of the first mesh trough, according to an embodiment of the present invention. FIG. 5 illustrates a bottom view (500) of the reactor, according to an embodiment of the present invention.
[0002] In first embodiment, the apparatus (100) for converting bio-waste to feed, fertilizer and industrial chemicals comprises a horizontal barrel-shaped reactor (102), a lid (104) attached on an opening (106) of the horizontal barrel-shaped reactor (102) via a plurality of hinges, a first mesh trough (202) as illustrated in FIG. 2, at least two pair of slits (108) attached with a flap (110) integrated on either side of the reactor (102), a larval collection trough (112), a leachate collection vessel (116) and a second mesh trough (114) is integrated with the leachate collection vessel (116).
[0003] In some embodiments, the horizontal barrel-shaped reactor (102) may be crafted from high-density polyethylene (HDPE) material. Further, the thickness high-density polyethylene (HDPE) material may correspond to 2-3 mm thick. Further, the dimension of horizontal barrel-shaped reactor (102) may correspond to 150 cm in length, 30 cm in diameter, and 30 cm in height. Further, the horizontal orientation of the reactor (102) may promote efficient mixing and aeration of contents. Further, the design and material of the reactor (102) making the process cost-effective and eco-friendly.
[0004] In some embodiments, the horizontal barrel-shaped reactor (102) is fed with a mixture of bio-waste in a 1:1:1 ratio up to a height of 10-15 cm from the bottom of the reactor (102). Further, the bio-waste comprises food waste, abattoir waste and fruit/vegetable waste. Further, the food waste may be cooked or uncooked. Further, the abattoir waste comprises of animal feaces, blood, bone, fat, animal trimmings, paunch content and urine from operations or areas like lairage, stunning or bleeding, carcass processing and by-product processing. The controlled loading may ensure sufficient space for aeration and prevents the formation of anaerobic conditions, that may hinder decomposition and produce foul odors. The bio-waste mixture becomes an ideal substrate for Black Soldier Fly (BSF) larvae, which efficiently break down organic material into valuable products. Further, the user products comprise feed, fertilizer, and industrial chemicals.
[0005] In an example embodiment, the reactor (102) are first started with only fresh fruit wastes. The smell attracts the native female BSF to come in and lay eggs on the first mesh trough attached to the lid (104) of the reactor (102). Further, the reactor (102) may be fed other bio-waste (i.e., food waste, abattoir waste and fruit/vegetable waste) once the eggs are laid.
[0006] In some embodiments, the lid (104) attached on an opening (106) of the horizontal barrel-shaped reactor (102) via a plurality of hinges. Further, a gap formed between the lid (104) and reactor (102) is configured to allow female black soldier flies (BSF) to enter with the reactor (102) for laying eggs on a first mesh trough. The top portion of the reactor (102) comprises an opening (106). Further, the dimensions of opening (106) may correspond to 80 cm in length and 15 cm in breadth, covered by the lid (104). Further, the shape of the lid (104) may correspond to semi-circular. Further, the opening (106) may facilitate feeding of the bio-waste (i.e., food waste, abattoir waste and fruit/vegetable waste) into the reactor (102) and providing access for native female Black Soldier Flies (BSF) to lay their eggs. Further, when the lid (104) is closed, a 10 cm gap remains on either end, allowing the female BSF to enter the reactor (102). Further, the first mesh trough may be crafted with polyester with 1 mm perforations. Further, the first mesh trough is attached to the underside of the lid (104) and positioned directly under the opening (106) of the reactor (102). The first mesh trough may serve as a substrate for the BSF females to lay their eggs to ensure that the eggs are placed near the bio-waste (i.e., food waste, abattoir waste and fruit/vegetable waste) for allowing the larvae to access the bio-waste easily upon the hatching of eggs. The design may ensure efficient egg-laying and larval activity while maintaining ventilation and preventing anaerobic conditions within the reactor (102).
[0007] In some embodiments, the at least two pair of slits (108) attached with a flap (110) integrated on either side of the reactor (102) at a height of 20 cm from the bottom of reactor (102). Further, a pre-pupal stage larva is migrated through the at least two pair of slits (108) to the larval collection trough (112), via the flap (110). The at least two slits (108), each 90 cm long and 2 cm wide is positioned on either side of the barrel at a height of 20 cm from the bottom. The at least two slits (108) are fitted with flaps (110) that open outward into the larval collection trough (112). Further, the width of the larval collection trough (112) may correspond to 10 cm. As the Black Soldier Fly (BSF) larvae reach the pre-pupal stage, their natural migratory behavior drives them to exit the reactor (102). They move through the slit openings (106) over the flaps (110), further into the larval collection trough (112), Further, the design of apparatus (100) may facilitate the self-harvesting of pre-pupal larvae. Further, the pre-pupal larvae are used as excellent poultry feed and a potential source of several industrial chemicals.
[0008] In an example embodiment, the larval collection trough (112) is designed to guide the migration of pre-pupal larvae without the need for artificial light. Further, the placement of larval collection trough (112), dimensions, and the orientation of the at least two slits (108) and flaps (110) is configured to create pathway that aligns with the natural behaviors, ensuring that the larvae move out of the reactor (102) and into the larval collection trough (112).
[0009] In some embodiments, a leachate collection vessel (116) installed at the bottom of the horizontal barrel-shaped reactor (102), via inclined trough. Further, a second mesh trough (114) is integrated with the leachate collection vessel (116) configured to pass leachate from the reactor (102) to the leachate collection vessel (116). The bottom portion of the reactor (102) comprises a cut-out measuring 120 cm in length and 10 cm in breadth. Further, the cut-out may be covered with the second mesh trough (114) with a diameter of 0.4-0.5 mm. Further, the second mesh trough (114) may be configured to facilitate both leachate removal and air circulation.
[0010] Further, the second mesh trough (114) is bolted to prevent any gaps that may allow larvae to escape. Further, the leachate is a liquid by-product of waste decomposition, drains through the mesh into the slightly inclined trough, ensuring efficient flow. Further, the inclined trough directs the leachate into a common gutter. Further, the dimension of the gutter may correspond to 10 cm wide. Further, the gutter may be channeled to the leachate collection vessel (116).
[0011] FIG. 6 illustrates a first side (600) of view of the apparatus (100), according to an alternative embodiment of the present invention. FIG. 7 illustrates a second side view (700) of the apparatus (100), according to the alternative embodiment of the present invention. FIG. 8 illustrates a top view (800) of the apparatus (100), according to the alternative embodiment of the present invention. FIG. 9 illustrates a cross-sectional view (900) of the apparatus (100) according to the alternative embodiment of the present invention. FIG. 10 illustrates bottom view (1000) of the apparatus (100), according to the alternative embodiment of the present invention.
[0012] According to an alternative embodiment of the apparatus (100) for converting bio-waste to feed, fertilizer and industrial chemicals comprises a slanted-shaped reactor (602), a lid (604) attached on an opening (606) of the slanted-shaped reactor (602) via a plurality of hinges (802) as illustrated in FIG. 8, a first mesh trough (804), at least two pair of hollow pipes (902) as illustrated in FIG. 9 are encased within the slanted shaped reactor (602), a collection pit (904) as illustrated in FIG. 9, the bottom of the reactor (602) is covered with a plastic-coated steel mesh (1002) as illustrated in FIG. 10, followed by leachate collection vessel (608).
[0013] In some embodiments, the reactor (602) is the rectangular in shape with slanting side walls. Further, the reactor (602) may be constructed from high-density polyethylene sheets of 2-3 mm thickness for durability and resistance to environmental and chemical factors. Further, the dimensions of the slanted-shaped reactor (602) may correspond to 150 cm in length, 90 cm in breadth, and 25 cm in height. The slanting walls is configured to facilitate the movement of materials and larvae within the reactor (602), thereby improving aeration and bio-waste decomposition.
[0014] Further, the longer side walls of the reactor (602) are inclined at a 45° angle may facilitate the natural migration of larvae during their pre-pupal stage. The feed depth is maintained between 10 to 15 cm in order to optimize aeration and provide ample surface area for the larvae to feed efficiently. This controlled depth prevents anaerobic conditions, supports the larvae’s activity, and ensures effective decomposition of the bio-waste within the reactor (602).
[0015] In some embodiment, the top portion of the reactor (602) comprise as an opening (606). Further, the dimensions of the opening (606) may correspond to 80 cm in length and 45 cm in breadth. Further, the opening (606) is configured to pour bio-waste (i.e., food waste, abattoir waste and fruit/vegetable waste) within the inlet and allowing native female Black Soldier Flies (BSF) to enter the reactor (602) and lay eggs. The opening (606) is covered by a semi-circular lid (604) by means of the hinges (802). Further, the lid (604) may provide a 10 cm gap on either side when closed. Further, the gaps allow female BSF to access the reactor (602) without external intervention. Further, the first mesh (1002) trough made up of polyester net with 1 mm perforations is attached underneath the lid (604). Further, when the lid (604) is closed is in the close position, the first mesh trough (1002) may be lowered into the reactor (602), positioning the first mesh trough (1002) close to the bio-waste (i.e., food waste, abattoir waste and fruit/vegetable waste). Further, the first mesh trough (1002) is configured to provide substrate for BSF females to lay eggs to ensure that the eggs are in proximity to the bio-waste (i.e., (i.e., food waste, abattoir waste and fruit/vegetable waste) for optimal larval development. Further, the larvae fall directly into the bio-waste upon hatching of the eggs.
[0016] In some embodiments, the upper edges of the slanted walls of the reactor (602) are fitted with hollow pipes (902). Further, the diameter of each of the hollow pipes (902) may correspond to 10 cm in order to assist in the natural migration of pre-pupal larvae. Further, each of the hollow pipes (902) may be configured to provide a smooth and enclosed pathway that aligns with the instinctive behavior of the pre-pupal larvae to move toward dark, confined spaces during their pre-pupal stage. Further, the two hollow pipes (902) are converging into a common joint pipe that directs the pre-pupal (i.e., migrating larvae) into a collection pit. The process is configured to eliminate the need for artificial lighting or external stimuli to guide the pre-pupal larvae.
[0017] In some embodiments, the bottom of the reactor (602) may comprise a plurality of perforations. Further, the diameter of the each of the plurality of perforations may correspond to 3 cm and 10 cm apart from each other to facilitate the efficient drainage of leachate generated during waste decomposition. Further, the plurality of perforations may be configured to allow the liquid to flow freely in order to prevent pooling and maintaining optimal conditions for the biological activity of the Black Soldier Fly (BSF) larvae. The bottom of the reactor (602) is overlaid with a plastic-coated steel mesh (1002) of 0.4-0.5 mm diameter in order to ensure that larvae do not escape through the holes. Further, the fine mesh (1002) acts as a barrier for retaining the larvae while permitting the passage of leachate, thereby supporting effective waste management and the controlled rearing of larvae within the reactor (602).
[0018] Further, the drained leachate is collected in a slightly inclined trough beneath the reactor (602), configured to channel the liquid efficiently without blockages. The trough directs the leachate into a 10 cm wide common gutter, that leads to the leachate collection vessel (608). The process may ensure seamless flow of leachate in order to prevent contamination or stagnation while allowing collection and disposal or repurposing of the liquid by-product.
[0019] In an example embodiment, the reactor (102) are housed in a well-ventilated room with large windows to ensure ample sunlight in order to maintain the photoperiod needed for Black Soldier Fly (BSF) mating. Further, the windows are covered with PVC-coated fiberglass nets with 1 mm diameter holes, slightly open to allow native BSF to enter and initiate their lifecycle. The sunlight reduces the need for artificial lighting. Further, the potted plants with broad leaves are placed inside the room to in order to provide natural surfaces for BSF to rest and mate, creating an environment for their reproduction. Further, the containers are filled with dry sand and are positioned within the room to support pupation to ensure seamless transition in the BSF lifecycle. Further, the portion of the collected pre-pupal larvae is transferred to the pupal containers to sustain the breeding cycle to enable bio-waste processing and larvae production.
[0020] Further, the young larvae are put back into the reactor (102) for feeding and the ones in the pre-pupal stage are ready for use as animal feed, for bio-oil extraction, etc., after the completion of waste processing. The apparatus for converting the bio-waste into feed is configured to reduce the bulk of bio-waste by 75-80% within time period of 20-25 day. Further, the collected frass are kept for air-drying for a period of 1-2 days that may lead to maturation of the frass, which is further utilized as an organic fertilizer. Further, the frass comprises larval excrements, moultings, and undigested materials. Further, the fertilizer potential of frass is analyzed on a field scale by comparing with other organic fertilizers and synthetic fertilizers. Further, the analysis is performed on three seasonal vegetables. Further, the three seasonal vegetables comprise lady finger, cluster beans and spinach. It is observed that the plants amended with frass may show better germination, growth and yield than the plants grown with other fertilizers.
[0021] In an example embodiment, the reactor (102) is loaded with a 1:1:1 mixture of bio-waste (i.e., food waste, abattoir waste, and fruit/vegetable waste (i.e., dry weight basis) at a rate of 10 kg/day (i.e., fresh weight) every alternate day. The feeding schedule of the waste is continuous for 20-25 days, during which most larvae reach their final instar stage. Further, the reactor (102) are stirred and left open to allow the frass to dry for 2-3 days. Further, the frass and any remaining larvae are then harvested and transferred to a harvesting container, where the larvae naturally separate from the frass. The air-dried frass is collected and stored in airtight containers for future use, while the mature larvae are repurposed for animal feed, biofuel production, or pupation. Further, the portion of young larvae, along with a small amount of frass is reintroduced into the reactor (102) to restart the waste processing cycle to ensure sustainable and continuous operation.
[0022] In an example embodiment, the reactor (102) operates continuously for an extended period ranging from 6 months to 1 year, or until it becomes filled with frass. The reactor (102) is fed with a 1:1:1 mixture of bio-waste (i.e., food waste, abattoir waste, and fruit/vegetable waste) (i.e., dry weight basis) at a rate of 10 kg/day (i.e., fresh weight) every alternate day. During this time, the pre-pupal larvae self-migrate out of the reactor (102) into a larval collection vessel (116) to ensure minimal manual intervention. The collected larvae are divided into two groups. First, some are transferred to a pupation container to sustain the Black Soldier Fly lifecycle, while the remaining is used as animal feed or for other applications. Once the reactor (102) reaches its capacity with frass, the contents are harvested and processed in the same manner as the first operational strategy, to ensure efficient resource utilization and waste management.
[0023] FIG. 11 illustrates a flow chart of a method for operating the apparatus (100) to convert bio-waste to feed, fertilizer and industrial chemicals , according to an embodiment of the present invention.
[0024] At operation 1102, a horizontal barrel-shaped reactor (102) may be fed with bio-waste (i.e., food waste, abattoir waste and fruit/vegetable waste) in a ratio 1:1:1. The controlled loading may ensure sufficient space for aeration and prevents the formation of anaerobic conditions, that may hinder decomposition and produce foul odors.
[0025] At operation 1104, a lid (104) is attached on an opening (106) of the horizontal barrel-shaped reactor (102) via a plurality of hinges. Further, a gap formed between the lid (104) and reactor (102) is configured to allow female black soldier flies (BSF) to enter with the reactor (102) for laying eggs on a first mesh trough (202). The top portion of the reactor (102) comprises an opening (106). Further, the dimensions of opening (106) may correspond to 80 cm in length and 15 cm in breadth, covered by the lid (104).
[0026] At operation 1106, female black soldier flies (BSF) are allowed to enter within the reactor (102) for laying eggs on a first mesh trough (202). Further, the opening (106) may facilitate the feeding of bio-waste into the reactor (102), removal of processed frass, and providing access for native female Black Soldier Flies (BSF) to lay their eggs. Further, when the lid (104) is closed, a 10 cm gap remains on either end, allowing the female BSF to enter the reactor (102). Further, the first mesh trough (202) may be crafted with polyester with 1 mm perforations. Further, the first mesh trough (202) is attached to the underside of the lid (104) and positioned directly under the opening (106) of the reactor (102).
[0027] At operation 1108, the larvae are allowed to fall over the bio-waste after the hatching of the eggs, via plurality of perforations of 1mm diameter. The first mesh trough (202) may serve as a substrate for the BSF females to lay their eggs to ensure that the eggs are placed near the bio-waste for easy access by the larvae once hatched.
[0028] At operation 1110, a pre-pupal stage larva is migrated towards the larval collection trough (112), via at least two pair of slits (108). Further, the at least two slits (108) are fitted with flaps (110) that open outward into the larval collection trough (112). Further, the width of the larval collection trough (112) may correspond to 10 cm. As the Black Soldier Fly (BSF) larvae reach the pre-pupal stage, their natural migratory behavior drives them to exit the reactor (102) (102). They move through the slit openings (106), over the flaps (110), further into the larval collection trough (112), Further, the design of apparatus (100) may facilitate the self-harvesting of pre-pupal larvae, reducing manual intervention.
[0029] At operation 1112, a leachate collection vessel (116) is installed at the bottom of the horizontal barrel-shaped reactor (102). Further, the placement of larval collection trough (112), dimensions, and the orientation of the at least two slits (108) and flap (110) is configured to create pathway that aligns with the natural behaviors, ensuring that the larvae move out of the reactor (102) and into the trough.
[0030] At operation 1114, the second mesh trough (114) is configured to pass leachate from the reactor (102) to the leachate collection vessel (116). Further, a second mesh trough (114) is integrated with the leachate collection vessel (116) configured to pass leachate from the reactor (102) to the leachate collection vessel (116).
[0036] It should be noted that the apparatus (100) and method (1100) for converting bio-waste into feed, fertilizer and industrial chemicals, in any case could undergo numerous modifications and variants, all of which are covered by the same innovative concept; moreover, all of the details can be replaced by technically equivalent elements. In practice, the components used, as well as the numbers, shapes, and sizes of the components can be of any kind according to the technical requirements. The scope of protection of the invention is therefore defined by the attached claims.

Dated this 10th Day of March, 2025
Ishita Rustagi (IN-PA/4097)
Agent for Applicant
, C , Claims:CLAIMS
We Claim:
1. An apparatus (100) for converting bio-waste to feed, fertilizer and industrial chemicals, the apparatus (100) comprises:
a horizontal barrel-shaped reactor (102), wherein the horizontal barrel-shaped reactor (102) is fed with bio-waste in a ratio 1:1:1 up to a height of 10-15 cm from the bottom of the reactor (102),
wherein the bio-waste comprises food waste, abattoir waste and fruit/vegetable waste;
a lid (104) attached on an opening (106) of the horizontal barrel-shaped reactor (102) via a plurality of hinges (802), wherein a gap formed between the lid (104) and reactor (102) is configured to allow female black soldier flies (BSF) to enter within the reactor (102) for laying eggs on a first mesh trough (202);
wherein the first mesh trough (202) comprises plurality of perforations of 1mm diameter for allowing larvae to fall over the waste after the hatching of the eggs;
at least two pair of slits (108) attached with a flap (110) integrated on either side of the reactor (102) at a height of 20 cm from the bottom of reactor (102), wherein a pre-pupal stage larva is migrated through the at least two pair of slits (108) to a larval collection trough (112), via the flap (110); and
a leachate collection vessel (116) installed at the bottom of the horizontal barrel-shaped reactor (102), via inclined trough, wherein a second mesh trough (114) is integrated with the leachate collection vessel (116) configured to pass leachate from the reactor (102) to the leachate collection vessel (116).

2. The apparatus (100) for converting bio-waste to feed, fertilizer and industrial chemicals as claimed in claim 1, wherein the horizontal barrel-shaped reactor (102) is crafted with high-density polyethylene material.

3. The apparatus (100) for converting bio-waste to feed, fertilizer and industrial chemicals as claimed in claim 1, wherein the gap is formed between the lid (104) and the reactor (102) during the closed position of the lid (104).

4. The apparatus (100) for converting bio-waste to feed, fertilizer and industrial chemicals as claimed in claim 1, wherein the larval collection trough (112) is crafted and constructed in a manner that larvae does not require any artificial light to promote migration.

5. The apparatus (100) for converting bio-waste to feed, fertilizer and industrial chemicals as claimed in claim 1, wherein the opening (106) of the horizontal barrel-shaped reactor (102) is configured to fed waste within the reactor (102) and extract frass from the reactor (102).

6. The apparatus (100) for converting bio-waste to feed, fertilizer and industrial chemicals as claimed in claim 1, wherein the second mesh trough (114) is attached to the leachate collection vessel (116), via a plurality of bolts to fill the gaps between the mesh edges and the reactor (102) to prevent movement of larvae out of the reactor (102).

7. The apparatus (100) for converting bio-waste to feed, fertilizer and industrial chemicals as claimed in claim 1, wherein the horizontal barrel-shaped reactor (102) is kept ventilated room having PVC coated windows.

8. The apparatus (100) for converting bio-waste to feed, fertilizer and industrial chemicals as claimed in claim 1, wherein the larvae of pre-pupal stage are utilized of animal feeding, bio-oil extraction or etc.

9. The apparatus (100) for converting bio-waste to feed, fertilizer and industrial chemicals as claimed in claim 1, wherein the collected frass is kept for air-drying for a time interval of 1-2days that is further utilized as organic fertilizer.

10. A method (1100) comprising:
feeding, a horizontal barrel-shaped reactor (102) with a bio-waste in a ratio 1:1:1, wherein the bio-waste comprises food waste, abattoir waste and fruit/vegetable waste, at operation 1102;
attaching, a lid (104) on an opening (106) of the horizontal barrel-shaped reactor (102) via a plurality of hinges (802), at operation 1104;
allowing female black soldier flies (BSF) to enter with the reactor (102) for laying eggs on a first mesh trough (202), at operation 1106;
allowing larvae to fall over the waste after the hatching of the eggs, via plurality of perforations of 1mm diameter, at operation 1108;
migrating a pre-pupal stage larva, via at least two pair of slits (108) to a larval collection trough (112) through a flap (110), at operation 1110;
installing, leachate collection vessel (116) at the bottom of the horizontal barrel-shaped reactor (102), at operation1112; and
passing, via second mesh trough (114) leachate from the reactor (102) to the leachate collection vessel (116), at operation 1114.

Dated this 10th Day of March, 2025
Ishita Rustagi (IN-PA/4097)
Agent for Applicant