Tuesday, October 24, 2017
Wednesday, October 18, 2017
Pupae Sifting Trays
A couple months ago I watched a video on Youtube showing an amazing machine that automatically sorted all stages of mealworms. I was impressed by the ingenuity of it all, and I focused my efforts on trying to figure out how in the world they were able to separate pupae from the rest of the worms.
And then I saw it..
Slotted rails!
I watched as pupae vibrated down a series of long metal rods, while the worms all fell through the slots and down into different sized containers. This was it!
Mealworm farmers have always wondered how to quickly separate their pupae. Most do it by hand (which is therapeutic to some; tedious to others), and some just leave the pupae in with the worms until they turn into beetles. But I knew there had to be a better way!
And so began my quest to build a sifting tray that was able to separate pupae like I had seen that $3,000 machine do so well. I first combed the forums and left questions in Youtube comments, trying to figure out how wide the slots needed to be. Eventually I had it narrowed down to somewhere between 3 and 4 millimeters.
I wanted to test the slot thickness before I spent lots of material to build a completed tray, so I used a 3D modeling program to design a basic grid of skinny rectangles. I ended up only having to print 2 or 3 prototypes before I zeroed in on the exact slot width I needed.
Next, I framed the base with four walls and did a test print. O.M.G. did it work! I immediately posted my results in some Mealworm Farming groups on Facebook and it was a hit. Genius! Amazing! I want one! So many positive responses I knew I was on to something good.
And so began my quest to find a way to build pupae sorting trays that were large enough to handle my needs, and possibly the needs of future customers. I visited a local Fabrication Lab to see if they had larger 3D printers. When I got there I was talked into considering other options, such as using plastic molding and laser cutting wood. I researched both options and decided that laser cutting would be the fastest and cheapest option. I then spend a day or so teaching myself how to use this new design software, and came up with a simple, yet ingenious design. I used notches in the sides of the walls and bottom that locked into place like puzzle pieces. With a bit of wood glue, they were supposedly super strong and sturdy - just what I was looking for!
I had to drive 47 miles north to a Fab Lab that had the laser cutter, and was taught the basics of how to operate the machine. After cutting and assembling my first model I made a couple minor changes (width of the notches, mainly) and created a couple videos showing them in action.
Again, I was showered with praise and requests to purchase one. So I created a Google Form survey for prospective customers. I figured this was the best way to determine the size and cost customers were hoping for. After 88 completed surveys I looked at all the data and came up with a price structure that covered the costs of building and shipping, while also paying me fairly for my time and effort.
I decided on four different sizes and prices, with the option for custom engraving and assembly. Another Google Form went out, this time allowing customers to actually place and pay for their orders.
And so begins my current situation. Right this moment I am sitting in the garage of a Fab Lab, waiting for 20 trays to finish being cut.
There have been a handful of minor obstacles that have gotten in my way (including a funeral, a wood glue debacle, and a crazy laser cutting learning curve), but I am starting to see the light at the end of this tunnel. I have always been a project-oriented person, so I am loving every moment of this, no matter how trying it seems at times. Hopefully my first batch of customers love their new sifting trays and help promote them to other mealworm farmers. I consider all of us a giant community who care about each other. We share tips, give advice, and mourn the loss of worms whenever pests take over. It's not a hugely rewarding hobby, but I wouldn't give it up for anything!
If you would like to place an order for your own Pupae Sifting Tray, please click HERE.
And then I saw it..
Slotted rails!
I watched as pupae vibrated down a series of long metal rods, while the worms all fell through the slots and down into different sized containers. This was it!
Mealworm farmers have always wondered how to quickly separate their pupae. Most do it by hand (which is therapeutic to some; tedious to others), and some just leave the pupae in with the worms until they turn into beetles. But I knew there had to be a better way!
And so began my quest to build a sifting tray that was able to separate pupae like I had seen that $3,000 machine do so well. I first combed the forums and left questions in Youtube comments, trying to figure out how wide the slots needed to be. Eventually I had it narrowed down to somewhere between 3 and 4 millimeters.
I wanted to test the slot thickness before I spent lots of material to build a completed tray, so I used a 3D modeling program to design a basic grid of skinny rectangles. I ended up only having to print 2 or 3 prototypes before I zeroed in on the exact slot width I needed.
Next, I framed the base with four walls and did a test print. O.M.G. did it work! I immediately posted my results in some Mealworm Farming groups on Facebook and it was a hit. Genius! Amazing! I want one! So many positive responses I knew I was on to something good.
And so began my quest to find a way to build pupae sorting trays that were large enough to handle my needs, and possibly the needs of future customers. I visited a local Fabrication Lab to see if they had larger 3D printers. When I got there I was talked into considering other options, such as using plastic molding and laser cutting wood. I researched both options and decided that laser cutting would be the fastest and cheapest option. I then spend a day or so teaching myself how to use this new design software, and came up with a simple, yet ingenious design. I used notches in the sides of the walls and bottom that locked into place like puzzle pieces. With a bit of wood glue, they were supposedly super strong and sturdy - just what I was looking for!
I had to drive 47 miles north to a Fab Lab that had the laser cutter, and was taught the basics of how to operate the machine. After cutting and assembling my first model I made a couple minor changes (width of the notches, mainly) and created a couple videos showing them in action.
Again, I was showered with praise and requests to purchase one. So I created a Google Form survey for prospective customers. I figured this was the best way to determine the size and cost customers were hoping for. After 88 completed surveys I looked at all the data and came up with a price structure that covered the costs of building and shipping, while also paying me fairly for my time and effort.
I decided on four different sizes and prices, with the option for custom engraving and assembly. Another Google Form went out, this time allowing customers to actually place and pay for their orders.
And so begins my current situation. Right this moment I am sitting in the garage of a Fab Lab, waiting for 20 trays to finish being cut.
There have been a handful of minor obstacles that have gotten in my way (including a funeral, a wood glue debacle, and a crazy laser cutting learning curve), but I am starting to see the light at the end of this tunnel. I have always been a project-oriented person, so I am loving every moment of this, no matter how trying it seems at times. Hopefully my first batch of customers love their new sifting trays and help promote them to other mealworm farmers. I consider all of us a giant community who care about each other. We share tips, give advice, and mourn the loss of worms whenever pests take over. It's not a hugely rewarding hobby, but I wouldn't give it up for anything!
If you would like to place an order for your own Pupae Sifting Tray, please click HERE.
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