This document describes the design and construction of a black soldier fly waste management system at Montaña de Luz orphanage in Honduras. A team of students designed and built a new wooden bin system with improved drainage, fly entry holes, and egg traps. The bin was constructed over three days in March using locally purchased wood and other materials for $352. Challenges included an ant infestation, which was addressed. The new system aims to more efficiently manage the orphanage's food waste by feeding it to black soldier fly larvae, whose pupae can then be used as animal feed.

1. Black Soldier Fly Bioconversion: Waste Management System
Montaña de Luz
Prepared by:
Kevin Everson
Thomas Gullo
Marissa Lauer
Submitted to:
Dr. Edgar Casale
Isa Fernandez-Puentes
April 29, 2016

2. 2
Table of Contents
Team Members.......................................................................................................................................4
Executive Summary.................................................................................................................................4
Background .............................................................................................................................................4
Problem Statement .................................................................................................................................5
Objectives ...............................................................................................................................................5
Final Bin Design.......................................................................................................................................6
Drainage Component...........................................................................................................................8
BSF Entry Holes and Egg Traps .............................................................................................................8
Project Work ...........................................................................................................................................8
Construction........................................................................................................................................8
Implementation of Waste and Flies .....................................................................................................8
Challenges and Limitations ..................................................................................................................8
Deliverables ............................................................................................................................................9
Bill of Materials .......................................................................................................................................9
Schedule .................................................................................................................................................9
Sustainability.........................................................................................................................................10
Cultural Connections .............................................................................................................................10
Retrospective Thoughts.........................................................................................................................10
Recommendations ................................................................................................................................11
Conclusions...........................................................................................................................................11
Acknowledgements...............................................................................................................................12
References ............................................................................................................................................12
Appendix A: Construction Photo Gallery................................................................................................13
Appendix B: Bill of Materials..................................................................................................................15

3. 3
Table of Figures
Figure 1: Final Bin Design.........................................................................................................................6
Figure 2: Outside components.................................................................................................................7
Figure 3: Inside components....................................................................................................................7

4. 4
Team Members
Kevin Everson – Project Organizer
everson.47@osu.edu – (513)-225-1238
Thomas Gullo – Construction Specialist
gullo.9@osu.edu – (614)-886-1993
Marissa Lauer – Design Coordinator
lauer.102@osu.edu – (440)-537-2913
Executive Summary
The basis of this project was to create a system to manage the organic waste at the Montaña de Luz
orphanage using the black soldier fly species. A similar system was already in place at the facility, but
certain components, including the lack of an effective drainage system and clumsy bin design, made this
system less than optimal. The team created a more sophisticated waste management system, largely
made of wood panels and beams, with the goal of reducing food waste, decreasing feed costs, and
producing usable fertilizer.
The system was designed from January to early March, and construction and installation took place over
the course of a week in March. During the first three days of the week, the system was constructed
using wood panels, wooden beams, brackets, and various other common construction components,
totalling $352.54. During the latter half of the week, the system was moved to its permanent home, and
organic waste from the kitchen, as well as black soldier fly larvae, were introduced into the bin. The
system was subsequently observed, and any roadblocks or complications were dealt with.
Within the constraints of the budget, the team wanted to create a system which was highly robust and
effective in its purpose, as well as sustainable, by adding measures to protect the wood and providing a
maintenance manual to the staff at the orphanage. While the team has a few retrospective ideas for
improvement that would make a future system even better, they still learned much about the
engineering process and about working in a developing country.
Background
Since 2000, Montaña de Luz has worked to provide a home for children in rural Honduras, in a region
east of the capital city of Tegucigalpa. While the orphanage has been able to serve a large number of
children since opening, limited resources have hindered the effectiveness of the facility to care for the
children. In order to alleviate some of the road blocks and challenges that the orphanage faces,
engineering students at Ohio State have examined the issues experienced by the staff and children at

5. 5
Montaña de Luz and created technical solutions to them. At the orphanage, a pressing matter to
consider is the manner in which they manage their waste, which is relatively simple, leaving room for
improvement in efficiency and conversion of waste. By examining the waste management system
already in place at the facility, and poring through the recent techniques and technologies in the waste
management world, such as bioconverters for fuel and basic worm composting, a more effective
solution can be reached.
Problem Statement
In all areas of the world, finding a solution to managing waste, both organic and inorganic, can be a
challenging but important task. Countless systems exist that attempt to combat this challenge, but
finding a system that works best for the particular job is critical in creating a sustainable system. Before
the group’s trip, Montaña de Luz (MdL) was using a small-scale waste management system involving
black soldier flies. Black soldier flies (BSF) are used similarly to a worm composting process, breaking
down waste and creating a nutrient-rich soil to be reused in places such as a garden. Unlike worm
composting, the BSF larvae decompose massive amounts of waste in little time and then can be
harvested as an animal feed. While the small-scale system at MdL was fully functional, the system had
room for improvement in order to efficiently manage all of the orphanage’s daily food waste. The
engineering team designed and created a larger, more robust system with a proper drainage system in
addition to other advancements for harvesting the larvae. Larvae from the bin can be then be used as
feed for animals at the orphanage. The new system was intended to have features able to control the
anaerobic bacteria and displeasing odors that come with it. Self-sustaining, inexpensive, and low-
maintenance, the improved food waste converter will be highly beneficial for the orphanage.
Objectives
The bulk of the project was a black soldier fly bin which serves to digest the majority of the facility’s
organic waste. The black soldier fly larvae consume the solid organic waste at a highly efficient rate. The
bin’s basic purpose is to contain the waste so that the larvae can readily consume it. They are known to
be able to eat twice their body weight in one day (Wikipedia, Hermetia illucens). Fortunately enough,
relatively little organic material in the bin is converted into liquid waste, or frass, that is excreted from
the larvae during the conversion process (Wikipedia, Hermetia illucens). However, the frass that does
get left behind from the flies after they consume the organic material is a concern. This liquid waste
combined with other organic waste can create a moist layer of compact mud and compost at the
bottom of the bin, which potentially leads to the growth of foul-smelling anaerobic bacteria (Wikipedia,
Hermetia illucens). For this reason, the bin has a drainage component at the bottom to clear out the
undesired liquid from the bin. Another area of concern was the manner in which the pupae (or adult
larvae) are extracted from the bin once ready to transition into adult fly form.
Because the black soldier fly larvae consume organic waste at such a high rate, the bin can be filled with
organic waste the orphanage produces daily (except for when the waste will be diverted to the worm
composting bin). The bin will also unavoidably become dirty and may produce rotting odors after
extended use, so it is recommended to be cleaned out as needed. To do this, the bin should first be
cleared out manually with shovels and/or gloves. Then, a hose should be used to thoroughly spray down

6. 6
all surfaces of the bin. This process will keep the larvae healthy and reduce the growth of anaerobic
bacteria. By incorporating this clean-out procedure, the unwanted smells caused by the anaerobic
bacteria will also be reduced. The lid which was installed on the bin is also intended to reduce the
spread of odor.
Final Bin Design
The final product delivered to MdL is pictured in Figure 1 below. The product was modeled after a
similar design posted on a BSF online forum that met all of the group’s desired design criteria (Black
Solider Fly Farming- Composting with Black Soldier Flies, n.d.).
Figure 1: Final Bin Design
The main bin section contains the organic waste from a single day’s meals, where it is consumed by the
larvae. The drainage system is located at the bottom of the bin system, where the liquid frass excreted
by the larvae can pass through and directly into the bucket below the bin. Additionally, a bucket was
placed at each end of the ramps for collection of the larvae (Figure 2). The design has a lower base of 2
feet, height of 1 foot, an upper base of 5 feet, and a depth 2 feet. Prior to the trip, it was calculated that
there would be roughly 20 pounds of food waste per day from the orphanage, based on the number of
people at the orphanage and average food waste numbers from around the world (United States
Committee for FAO).

7. 7
Figure 2: Outside components
The bin contains angled ramps from the bottom of the bin (where the flies consume the organic
material) to the top of the bin where the pupae climb and fall off into a bucket via PVC “chutes” (Figure
2 and Figure 3). At this point, the pupae in the bucket are conserved for use as livestock feed.
Figure 3: Inside components
Waste bin
Drainage
component
Pupae collection bins
Pupae exit ramps
Egg traps
Fly entry hole

8. 8
Drainage Component
This drainage component consists of a layer of galvanized mesh to support the waste in the bin and two
layers of fly screen to allow liquid to pass through. In addition, a thin sheet of tarp with a hole cut in the
middle was affixed under the fly screen to act as a funnel and direct all liquid into a bucket underneath
the bin.
BSF Entry Holes and Egg Traps
The group incorporated entry holes and egg traps to maintain black soldier fly larvae presence in the
system. The two egg traps were constructed out of corrugated cardboard and extra PVC pipe. They were
screwed to the inside panel for the females to release their eggs after entering the bin through the holes
(Figure 3).
Project Work
Construction
The construction of the BSF bin took place over the course of three days at MdL, whereas the rest of the
time was allotted for testing and sightseeing. First, the side panels and ramps of the bin were cut to size
and screwed together. The lid was also cut and multiple coats of treatment were applied to the wood.
Then, the frame of the drainage component to which the bin would sit in was constructed using the
treated lumber. The lid was attached to the bin with hinges. Holes were cut in the bin for the entry of
adult flies as well as for the PVC connections using a large drill spade. A handle was added for ease of
use as well as a cable to hold the lid open. A mesh/fly screen combination was stapled to the bottom of
the bin. Lastly, a final layer of polyurethane was added to complete the project’s construction.
Implementation of Waste and Flies
On March 17th, the BSF system was moved into its permanent home in the chicken coop. Meanwhile,
food waste from the biodigester was placed into a wheelbarrow. The team members searched through
this waste with shovels to find around one hundred larvae to kick start the system.
Challenges and Limitations
The main challenge that arose when creating this bin was an ant infestation during initial testing. The
ants were eating the food waste and potentially the larvae as well. To fix this issue, the group filled the
bottom portions of four old bleach buckets with a small brick and water (to the level of the brick) and
placed them under each leg of the system. Each leg was also sprayed each leg Raid. The next day, there
were no ants present in the system. Some other minor problems the group ran into included small
larvae accidentally falling through the mesh layers as well as incorrectly sized PVC pipes and drill bits.
Extra layers of mesh were added to prevent the larvae from falling and a trip to the local hardware store
solved the sizing issues.

9. 9
Deliverables
The main component of the project provided to MdL was the black solider fly system itself (Figure 1).
A second deliverable to MdL included a troubleshooting manual translated in both English and Spanish.
This manual was written by the creators of the bin and includes all potential issues that the workers of
MdL may face while using the bin. Additionally, the manual includes the group’s contact information so
that if any unforeseen problems arise, MdL will be able to reach out for assistance.
Bill of Materials
See Table 1 in the Appendix for the complete Bill of Materials.
The materials for the project can be divided into two categories: those which were bought domestically
and those which were bought in Honduras. Most small items were bought here in the United States: drill
bits, screws, nuts, bolts, tarp, mesh, etc. This group of items totaled $157.19. Bigger items, such as wood
panels and 2" x 4" beams could not be transported on the airplane, and were purchased near Montaña
de Luz, and these were $195.19. The total cost of the project $352.24.
Schedule
See Appendix A for chronological photographs of the construction phase.
The group planned to complete construction during the first few days of the week. The final days were
designated for testing, observation, and troubleshooting of the system.
Monday, 3/14
 Constructed the walls of the bin using wood panels and brackets
 Cut the lid of the bin from a wooden panel
Tuesday, 3/15
 Continued construction, including the frame below the bin and holes on each ramp
 Applied layers of Maderol and caulk to the walls, lid, and edges of the bin
Wednesday, 3/16
 Finalized construction, applied polyurethane, connected PVC pipes and elbows, and
connected the lid with hinges
Thursday, 3/17
 Moved the system into the chicken coop, added food waste and larvae
 Checked on the system intermittently throughout the day
Friday, 3/18

10. 10
 Cleaned the system to rid it of the ant infestations
 Added another layer of fly screen to prevent larvae falling through the system
 Created a system to prevent further ant infestations
Saturday, 3/19 - Sunday, 3/20
 Observed system in action, ensured that bleach buckets still have water
Sustainability
Sustainability was a large focus in the group’s design of the black soldier fly bin. In order to create a
highly sustainable bioconversion system, the group created a bin that required very little maintenance.
Numerous layers of Maderol and polyurethane were added to the untreated wood panels to prevent
water damage or rotting. It was important for the group to design a system that can potentially last the
orphanages decades without maintenance or repair to its core components. Next, the group found the
design to be self-sufficient due to quick BSF larvae bioconversion rates and mixing. MdL staff will not be
required to mix the waste around inside the bin. However, if MdL staff do feel that a clean-out is
necessary, the system is easy to be hosed clean. In addition to low maintenance, the system was
relatively inexpensive to create (roughly $350). The waste management system’s final product, black
soldier fly pupae, are able to act as animal feed after eliminating the orphanage’s food waste and act as
a sustainable solution to lowering animal feed costs. Lastly, the liquid released from the system can be
used as fertilizer for fruit trees and continue a nutrient cycle.
Cultural Connections
There are many unforeseen roadblocks that can arise when working in a foreign, developing country.
The main issue was that there were limited resources. For example, the electricity went off a few times,
so power tools were rendered useless for some time. When a trip to the hardware store was needed,
there were not many options or variations of a desired component, so either the only option had to be
purchased, or a makeshift alternative was needed. This lack of options and resources encouraged
improvisation and making use of scrap parts. This was beneficial in that innovation was encouraged, but
it may have impacted the quality of the final product.
Language barriers were also an issue, but when working with physical objects, it is simple to act out
what needs to be done. The professors were also helpful at translating for the students, but the
importance of communication was shown through this problem.
Retrospective Thoughts

11. 11
After the project was completed, there were a few things that could have been done differently to
improve the design, construction, and testing of the BSF bin. More research on food waste amounts
would have been beneficial, as we may have underestimated the amount of food waste that the
orphanage produces based on numbers from a website. The most accurate way to know food waste
amounts would be to ask MdL directly, yet this was never done due to believing that the workers would
not be able to provide accurate measurements. Another consideration not taken into account was
wildlife in Honduras. A large ant infestation was the biggest problem that arose, and it was never
thought to ask MdL about this. There was too much material purchased as well, and this was due to
careless calculations. Before purchasing the products, the sizes and amounts should have been double
and triple checked to help cut costs and make sure enough is purchased at the same time. Most of these
issues could have been solved with simple communication to MdL. It was difficult to get in contact with
the workers there throughout the design stages, but the information they have is the most valuable
information available. More of an effort should have been made to get in contact with them to make the
project as successful as it could be.
Recommendations
For any future modifications to the black soldier fly bin, it is recommended and asked that the team
contacts the group that created the bin before making any changes. The group has extensive prior
knowledge that a future team will not due to design, construction, and in-country experience.
Conditions, location, wildlife, and resources are just a few of the aspects of this project that are very
specific to Honduras.
Additionally, it is recommended that more wood treatment is applied to the BSF system if a team
returns to MdL in order to lengthen the life of the project. Replacing the corrugated cardboard in the fly
traps, removing unwanted trash, and monitoring the larvae population would be beneficial to the
performance of the bin as well.
Conclusions
A functional BSFL bin and manual was successfully delivered to MdL in a timely fashion such that the
orphanage can benefit fully from its potential. Once the larvae populations are thriving, there should be
gratuitous amounts of food for the chickens. This should eliminate or cut chicken feed costs for MdL.
The compost collector should help the fruit tree population thrive, and the food waste amounts should
decrease. The team will continue to check in with MdL to determine the status of the system. This
project is still in the testing stages, so if problems should arise, the team will consult with each other and
determine the next action.
Working in a foreign country has challenged this project with many hurdles, but the product was created
almost exactly as it was designed. The importance of a solid preliminary design was demonstrated,
although improvisation was needed in order to overcome the limited resources offered. Overall, the
project has been a success so far, and hopefully it will continue to function properly throughout the
years based on the sustainable design.

12. 12
Acknowledgements
Thank you Dr. Edgar Casale, Isa Fernandez-Puentes, Ruth DeYoe, Dr. Chris Ratcliff, Jorge Vallecillo, OSU
teams and the entire staff and children at Montaña de Luz.
References
Black Solider Fly Farming- Composting with Black Soldier Flies. (n.d.). Retrieved from
http://www.blacksoldierflyfarming.com/
United States Committee for FAO. (n.d.). World Food Day USA. Retrieved from
http://www.worldfooddayusa.org/
Wikipedia. (2016, March 10). Hermetia illucens. Retrieved from Wikipedia:
https://en.wikipedia.org/wiki/Hermetia_illucens

13. 13
Appendix A: Construction Photo Gallery

14. 14

15. 15
Appendix B: Bill of Materials
Table 1: Bill of Materials
Material Quantity Total Estimated Price
Purchased in the United States
PVC Pipe 4 feet $4.55
Silicone Caulk + Caulk Gun 2 bottles $22.44
Nuts and Bolts 1 box $3.97
Galvanized Mesh 1 $18
Fiberglass Fly Screen 1 $6.10
Hinges (Small) 1 pack $8.35
Brackets 8 $3.18
Plastic tarp 1 $2.98
Dowel Rod 1 $4.18
Drill Bit Set 1 $9.98
Power Saw 1 $42.48
Circular Saw Blade 1 $5.98
Trowel 1 $3.98
Gorilla Glue 1 $3.68
Staples 1 pack $2.78
Paint Brush 3 $4.18
Work Gloves 1 $5
Safety Glasses 3 $5.38
Total United States $157.19
Purchased in Honduras
Wooden Panels 4 $121.95
Severe Weather Treated Lumber 2 $18.97
5-gallon Bucket with Lid 4 $20.21
Polyurethane Spray 3 cans $19.22
Maderol 1 gallon $14.80
Total Honduras $195.19
Total $352.34