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Drying system for insect farming substrate: process and uses of insects in protein flour production
A drying system for insect farming substrate is a machine that makes it possible to dry the by-products used in insect farming, using low temperatures. The insect-based food market has been widely debated in recent years, but insect flour is now a product regularly consumed by nearly 2 billion people worldwide. Entomophagy – the correct term for insect consumption – is a common practice in many countries around the world.
Thanks to their nutritional profile, dried insects represent an essential food resource for both humans and animals. Characterized by a high protein content, they are rich in vitamins and minerals while being low in fat. To achieve excellence in both taste and quality, insects are dried through a controlled process based on slow dehydration, which preserves all their nutritional properties.
In this article we will look at how edible insect drying systems work, their advantages, and the main uses and properties of dried insects turned into flour.
Drying system for insect farming substrate: what it is
Insects intended for food consumption need to be fed with organic substrates made from raw materials that would otherwise be discarded. Specifically, biomass drying systems process materials such as plant and cereal waste, wood residues, wood chips, sawdust, and bark.
RP Engineering develops and manufactures various types of dryers for substrates used in insect farming. In particular, it designs two main types of systems:
- belt drying system
- rotary drum drying system
Belt dryers: operation and advantages
Continuous belt dryers operate at temperatures between 40 and 120 ℃ and ensure uniform distribution of the material to be dried. Inside the machine, the air flow passes through the material moving from top to bottom.
Belt drying systems offer numerous advantages.
- Low temperatures. These dryers use low-temperature thermal energy (40° to 120°C)
- High product quality. Slow, low-temperature drying preserves the material’s characteristics
- Automation. RP Engineering designs fully automated systems equipped with humidity sensors
- Durability and long service life. RP Engineering dryers ensure long-lasting performance and productivity
- High capacity. These systems guarantee continuous and fast production
- Low emissions. The fine mesh of the belt filters even the smallest dust particles, ensuring very low atmospheric emissions (below 20 mg/m³, in compliance with European regulations)
Rotary drum drying systems
Rotary drum dryers are particularly suitable for drying very wet materials. Once introduced into the system, the wet material is evenly distributed through the rotating movement. Inside the machine, the product comes into contact with hot air produced by the burner and undergoes a triple pass inside the drum, where dehydration takes place.
Insect farming: a new business opportunity
Insect flour, which has been increasingly discussed in recent years, is already regularly consumed by around 2 billion people.
Insects are an excellent source of protein, vitamins, and minerals and can be used for both human and animal consumption. To preserve their nutritional properties, edible insects are also subjected to a slow drying process.
Advantages of edible dried insects
Beyond ethical considerations and personal preferences, adopting insect-based nutrition could soon become a necessity to address the global shortage of animal proteins, which are no longer sufficient to feed the world population. From a nutritional standpoint, insects offer several advantages:
- they are rich in protein (about twice as much as beef)
- they contain high levels of vitamins (especially vitamin B12) and minerals (iron, phosphorus, potassium)
- they are inexpensive to farm
- they grow quickly and have a short life cycle
- up to 80% of their body mass can be used for food purposes
Environmental benefits
Insect farming for food also offers major environmental advantages, particularly in terms of reducing:
- land use (to produce 1 kg of beef, cattle require nearly 200 m², while insects need only 15 m²)
- water consumption (insects require only 0.05% of the water needed for beef protein production)
- carbon emissions (insects produce only 1% of greenhouse gases compared to cattle)
Considering all of the above, edible insect farming represents not only a sustainable alternative for global protein supply with zero environmental impact, but also a form of circular economy, since agricultural and agro-industrial waste is used as substrate for insect larvae farming.
Insect farming: ministerial guidelines
To obtain a high-quality final food product, insects must be raised in healthy conditions using farming methods that comply with specific criteria.
The Ministry of Health has issued guidelines specifying several key points:
- Evaluate the farm location – including external boundaries – to prevent pests and parasites
- Facilities must be suitable for the species and designed to prevent insect escape at any stage
- Separate areas must be provided for farming and storage to avoid contamination
- Operators must prepare documentation on farm management, including biosecurity measures and good practices
- Official inspections are carried out under Art. 14 of Legislative Decree 134/2022 and Ministerial Decree 7.3.2023
How to start an insect farm
In practical terms, anyone starting an insect farm must:
- set up indoor rearing spaces: containers, cages, boxes, jars… all with ventilation holes
- prepare a substrate (rearing base) made from dried organic residues with a thickness of at least 2.5 cm, used as feed for larvae and insects; it must remain dry to prevent mold
- avoid overcrowding in containers
- regularly check and replace the substrate when necessary; the environment must stay dry to prevent fungi and mold
- provide water daily
- adopt proper hygiene measures to avoid infestations (regular cleaning of containers and removal of dead insects or spoiled feed)
- keep containers in a preferably dark place, with a stable temperature between 14°–20°C
- monitor insect development: once formed, pupae must be separated from larvae
separate pupae from adult insects as well
Do you want to install a drying system for insect farming substrate? Trust RP Engineering
Although still relatively little known (especially in Italy), insect farming is a highly promising business with strong future growth potential. Now is therefore the right time to invest. RP Engineering is a company specialized in the design, manufacturing, and installation of drying systems for various materials.
If you run a livestock farm, an agricultural business, or an insect farming operation, or if you want to start an industry producing insect flour with integrated farming, you should consider installing a drying system for insect farming substrate.
Contact RP Engineering by filling out the contact form.
For over 25 years, RP Engineering has been designing modular drying machines that use low-temperature thermal energy.
After analyzing each client’s specific needs, RP Engineering develops customized solutions tailored to production lines and logistics.
The service offered is “turnkey,” including both pre- and after-sales assistance.
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