In 2011, Keppy and Ron Arnoldsen developed a vision for a small farm that wasted little, and typical plant and animal wastes produced value both for the farm and for others. Achieving this vision was a long and challenging road that required developing technologies and patents and a tremendous investment of effort on their part, as well as engaging the minds and energies of others. Many small farms create huge amounts of organic waste from their daily operations. Often, this is accumulated in large compost piles that are turned periodically and used on the farm. Sometimes these wastes are hauled away at a cost to landfills or by others to create mulch or compost. The Arnoldsens decided they could improve on these cumbersome or costly means of waste disposal and perhaps they could use the waste to create value on the farm. Their hopes were that they could eventually share this technology with other small farmers, who in turn could convert food and farm wastes into nutrients for their own use. Collectively, it might make a difference in the food waste cycle.

In this chapter, the reader will see how this need to utilize wastes and improve performance on their farm led to an innovation; the creation of a small-farm anaerobic digester and the generation of a new business and fertilizer product. By creating useful products from wastes, nutrients are sequestered to provide a fertilizer product useful for plant production technologies such as soil-less hydroponics and traditional gardening. The reader will see how this simple innovation started a quest for the Arnoldsens to improve the recycling of nutrients. Their journey is documented from idea formulation through prototype development to system refinements. The many challenges they faced and collaborations they formed along the way were important to their success. The reader will learn how they overcame these obstacles to continue inventing and improving the system used to accomplish their recycling goals. They will also learn why collaborations and partnerships are an integral component to their success. These are presented here to give the reader a better understanding of their journey and a clearer perspective of the value gained when you involve others and build a support system.

Description

The key to this innovation was the development of an anaerobic digester system that could be used to recycle farm manures and food wastes on small farms. Large farms currently use this technology but they typically install high-cost, large-scale digesters used to process vast quantities of farm wastes primarily from dairy cows and pigs. These wastes are temporarily stored in large lagoon pits or underground storage tanks. Many smaller farms cannot afford these systems and their manure quantities are not substantial enough to warrant this scale of anaerobic digester. Small farms make up a large portion of our food production industry.

In 2009, there were nearly two million small farms in the United States, roughly 90% of all farms in the country. Each year, farm animals in the U.S. produce over 335 million tons of manure. A lactating dairy cow can produce 150 pounds of manure every day, 20 broiler chickens produce over four pounds per day. Not only is this a challenge, but the potential for turning this waste into value is tremendous. Opportunity and need often combine to drive innovation.

The system of anaerobic digestion relies on bacterial decomposition in the absence of oxygen. The products that are generated in digester systems are called effluent, or sometimes digestate, containing both solid and liquid portions. A gas is generated called biogas that contains methane which is an important energy source. The Arnoldsens use it to heat pasteurize the liquid portion of the digester effluent that they use as the base for their fertilizer product, thus eliminating potentially harmful pathogens making the product safer for food production.

The story

Ron and Keppy Arnoldsen bought their 11-acre plot in Cornpropst Mills, Pennsylvania, in the late fall of 2006. Their dreams were to have a place where they could keep their horses, raise farm animals, and produce organic food. Years of hard work followed, spent installing utilities and driveways, building the barn and coops, drilling a well, and constructing high tunnel greenhouses and establishing garden beds. This labor of love was a challenge that enriched their lives and started them on their path of home food production and eventually a need to address the wastes generated. Their philosophy was to keep a small footprint on the land by recycling all of the wastes generated. On their farm, they wanted to build a device to utilize and incorporate all the resources provided by the many tenants and crops. When trying different existing approaches, they found areas for improvements especially for manure management. They wanted to create a system that was more efficient and easier to operate than compost piles or spreading of nutrients on their fields.

One day, Ron and Keppy were having a discussion over lunch about this need to repurpose wastes generated on the farm. Ron grabbed a napkin and sketched an idea he had for processing the farm wastes using a large underground section of pipe. They thought the idea would also be a benefit for odor abatement and began expanding on the engineering of such a device. After much research, discussion, and drawing, they finally agreed to pursue their innovation. The saga continued over a journey of six years and many modifications along the way. Eventually, they developed and patented their segmented anaerobic digester system, but not until it went through three major changes in the first two years of development. Some challenges left them wishing they had more engineering experience and they thought that input from other engineers might be wise. So, they looked at local programs and collaborative options for help. They also felt that surrounding themselves with others who had faith in their project, would give them motivational support.

The Arnoldsens applied to sponsor a Senior Capstone Project for Penn State’s Engineering students in a program called the Learning Factory. They put together a basic poster of their ideas for the recruiting event where students from the various engineering departments could search for their senior capstone projects. Six students from biological, agricultural, and energy engineering colleges selected them as their sponsor. They spent the rest of the semester helping the Arnoldsens in several important ways. They created the CAD drawings to accompany their patent application that detailed the specifics of the digester body and segmented sections used to process inputs. They also helped design and re-design the separator plates, as well as a warming system for the underground pipe from solar thermal heat. The last two weeks of that semester, they helped install the first prototype and erect the greenhouse enclosure around it. This collaboration yielded much insight and support for the Arnoldsens enabling them to move forward with the construction phase. The fresh input of ideas and view of the different approaches was the motivation they needed.

Another collaboration was born that same semester when four Smeal Business College finance students used the Arnoldsens project to develop a business plan for a class requirement. They suggested marketing ideas and evaluated the potential budget and cash flow. Since the Arnoldsens needed additional funding to further their efforts, they accepted loans from six friends to help manage costs, eventually paying them back at a nice interest rate. The relationships that were forged with their investors and their moral support for the project continue today.

Over the next few years, several major modifications were made to the plate designs that separated the segments within the digester body. There were many smaller changes implemented, as well as unexpected needs. That winter, the solar panel feed lines froze during an electrical outage that disabled the circulating pumps despite the use of antifreeze solution. Gas collection was inefficient due to leaks in the system from where holes were cut in the pipe during the prototype development stage. They struggled with some of these challenges and decided to support yet another group of engineering students in the Learning Factory. Once again, they hoped that further intellectual support might bring ideas for some of the needed improvements and that the additional support would help them stay focused and motivated in their long struggle.

Since they were not completely satisfied with the functional attributes and mechanical movement of the separator plates, the Arnoldsens settled on installing large drums in each segment which was an idea supported by the students that semester. So, they tested it with small 50-gallon drums and designed a device to move the drums through the pipe when full and at a heavy weight load. That semester the students reconstructed the solar panel and built a bigger biogas collection bag. With their help and renewed motivation, the prototype was mostly completed. Testing and trials for waste inputs began on this smaller drum set up and the Arnoldsens installed full-size 110 gallon drums and improved the handling system once again. They were pleased with the products the system provided including the nutrient-rich liquid portion and the well decomposed solid “compost-like” portion.

Innovations are very valuable if there is an applied benefit to the market. The Arnoldsens realized that marketing and financial planning would be keys to their success and they knew that these were areas where they could improve their expertise. Keppy decided to pursue involvement with the Ben Franklin Technology program offered at the Penn State Research Park. It was a fairly new program developed for innovators with new potential inventions to help with development research and potential funding ideas. This eight week course was very beneficial in that it brought both marketing insight and inspired even more research to improve their knowledge in the field of digester businesses around the world. It was at this point in their journey that the Arnoldsens decided to focus on marketing of the fertilizer product, rather than the digester itself.

That summer they started yet another collaboration, this time with the nonprofit group Solar Cities who specialize in bringing the technology of anaerobic digestion to others around the world using available resources in developing regions to create home-made units for cooking fuel. It turned out a valuable relationship, where both the nonprofit and the Arnoldsens reaped benefits. In 2016, they agreed to install a second digester; a single batch-type unit they made of concrete. This was beneficial to the founders of Solar Cities who could use it as a display unit in central Pennsylvania where others could see the technology in use. This second digester turned out to be valuable for the Arnoldsens in its additional generation of methane and ability to process some more of their farm wastes. Now, leaky collection pipes did not plague the amount of gas yielded. A copious amount of biogas was created that could now be put to use for testing and refining their pasteurization ideas. Probably the most important benefit of all was that this sharing of knowledge and technology forged friendships and brought more insight for both. This area of technology is still in development worldwide. The Arnoldsens received a patent for their compartmentalized anaerobic digester and they still maintain the relationships they forged over the years. Today, this underground system provides a rich liquid, made from 100% recycled materials that is used as the base for their product, a liquid fertilizer amendment they now call Fertili-Tea.

Discussion

The concept that one can recycle nutrients bound up in food wastes by combining them with farm wastes and allowing the compound to decompose was not a new concept. However, the approach that the Arnoldsens used to accomplish this goal was new. It turned out to be a valuable innovation, despite requiring several changes to the prototype and many modifications of the device. Experimentation with inputs and their ratios and the effect on the products was also necessary over the years.

The Arnoldsens faced many challenges along the way, but they were determined to make it work. Their decision to incorporate inserted drums to both contain the valuable liquid product and improve the movement of the sections in their segmented design turned out to be a good switch. This change improved the process and made handling much more efficient. Though the whole journey and development was tiring, the necessary motivation came from their deep belief in the products created through this degradation process. The Arnoldsens shared a strong belief too that the input of others was important. Over the years, they continued with persistence and continued mechanical refinements. They knew that their perseverance could pay off in the long term and that, with patience, this system would yield many benefits. They refused to give up despite the long journey they were on. They realized that change was an integral part of the innovation process and that, with perseverance, these obstacles would be temporary. Over time, small changes in both the functional aspects of the device and the inputs of wastes and additives led to valuable improvements in their products and the nutritional aspects therein.

The Arnoldsens also felt strongly about self-education. They knew that they needed to continually improve their knowledge in this field and they educated themselves at each step along the way. Much research was acquired to stay abreast of the industry and new changes in this quickly developing field of anaerobic digestion. They learned what the best practices were and studied the designs of other systems in order to advance their own ideas and provide insight into areas where improvements could be made. The scrubbing of the biogas to remove sulfur was one such example and yielded a much safer fuel source.

Collaboration and networking were the key ingredients to their success. They reached out to others and found programs that might aid their efforts. This search incorporated many facets of innovation leadership from engineering and design to funding opportunities and marketing. Their journey was one that included a deep dedication to their innovation; one that they refused to give up on, despite the many challenges. Their own partnership was probably the most important reason for their success, as there exists a special way that Ron and Keppy complemented each other in both knowledge and abilities. Ron’s mechanical knowledge and innate engineering capabilities provided the vital component needed to create, develop and advance the prototypes for the digester. Keppy’s biology background, research abilities and business senses provided them with necessary motivation in these regards. When an innovation or improvement was needed, they did the needed research and then worked together to come up with a solution or a means to accomplish their goals. Overcoming hurdles became a necessary part of their innovation process.

There were other benefits as well in the learning experiences they provided to the two Penn State University senior capstone design engineering teams and several student interns over the years as well. They participated in two finance/marketing programs at Penn State that also provided opportunities and helped the Arnoldsens to foresee markets they could target and realize ways to finance the innovation. They also networked and consulted with an international program that brings this technology to impoverished areas to facilitate cooking and heating. In the future, they hope that these small-scale anaerobic digesters can be readily available to others so that the energy generated can bring about positive change in people’s lives and this means of recycling can provide the necessary nutrients for healthy plant production.

Summary

Successful innovation requires that leaders be open to modifications and change. The Arnoldsens had to overcome many obstacles. Their investment of time and devotion to the innovation are demonstrated in the story of their six-year journey to having a marketable product. One major struggle was to keep forward momentum and make positive progress. Here are some of their final thoughts on ways to develop a successful innovation. Surround yourself with a positive support system and reach out to others. Having partners or colleagues that complement you can bring out alternative perspectives. The Arnoldsens surrounded themselves with support along the way and this was important in their success story. Remember that innovation requires much endurance and patience. The Arnoldsens are not alone in their long journey toward success. Many innovations require much time for development and this timeline can often become longer than expected. Be willing to educate yourself, be open to the ideas of others, and continue to further your expertise. Search out programs that can further your efforts from a business, engineering, or financial perspective. Believe in your idea, whether it is novel, needed, or just a better way of doing something. Try to stay positive no matter how long it takes. Positive motivation and attitudes can be contagious, inspire others to become involved, and be part of your support system. The results can be amazing!

References

Cornell University, 2017, ‘Small farm statistics’. Available at http://smallfarms.cornell.edu/about/statistics-and-information-resources/ [Accessed 25 Aug. 2017].

Danovich, T, 2014, ‘What to do with all the poo?’ Modern Farmer. Available at: http://modernfarmer.com/2014/08/manure-usa/ [Accessed 25 Aug. 2017].

USDA, 2017, ‘Farming and farm income’. Economic Research Service. Available at https://www.ers.usda.gov/data-products/ag-and-food-statistics-charting-the-essentials/farming-and-farm-income/ [Accessed 25 Aug. 2017].