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Complete diets for laying hens are usually offered in meal form. This form initially promotes the laying hens’ natural feed intake behavior and allows them to satisfy their pecking behavior. At the same time, it can also cause difficulties, because it consists of different particles and is not a homogeneous unit. A homogeneous mixture is essential to ensure that each laying hen in the flock can meet its nutritional needs. If feed exhibits a wide particle size distribution, this can promote feed segregation during transport and selective feed intake behavior of laying hens. These two processes sometimes lead to significant differences between the composition of the feed produced and the composition of the feed that is finally ingested by the laying hens. Multi-stage sampling can be used to investigate progressing differences in feed composition. In this study, samples of different complete diets for laying hens (n = 76) were collected from ten organic farms in Germany to examine their particle size distributions (dry sieve analysis). Samples were taken at four different locations (V1 = loading, V2 = silo, V3 = at the beginning of the feed chain, V4 = at the end of the feed chain) in each farm. There was a tendency for V1 and V2 to be characterized by high proportions of particles between 1400 and 3150 µm (V1 = 61.2%, V2 = 43.5%). V3 and V4 consisted mainly of particles of size 500–800 µm and 200–400 µm, respectively. The lowest proportions across all variants were in the range above 3150 µm (V1 = 2.20%, V2 = 1.30%, V3 = 1.00%, V4 = 0.400%) and between 400 and 500 µm (V1 = 2.50%, V2 = 4.50%, V3 = 5.70%, V4 = 6.60%). The mean value comparison of the proportions of sieve mesh sizes from 200 to 1000 µm resulted in: V1 < V2 < V3 < V4; and of sieve mesh sizes between 1400 and 2000 µm in: V1 > V2 > V3 > V4. This observation can be explained by segregation of the feed during transport and a selective feeding behavior of the laying hens. However, trends were discontinuous and varied between the farms. Deviations from the guideline values were found in particular for particle sizes in the range of 1000 to 1400 µm.
Duckweeds are fast-growing and nutritious plants, which are gaining increased attention in different fields of application. Especially for animal nutrition, alternative protein sources are needed to substitute soybean meal. The current bottleneck is the standardized production of biomass, which yields stable quantities of a defined product quality. To solve this problem, an indoor vertical farm (IVF) for duckweed biomass production was developed. It consists of nine vertically stacked basins with a total production area of 25.5 m2. The nutrient solution, a modified N-medium, re-circulated within the IVF with a maximum flow rate of 10 L min−1. Nutrients were automatically added based on electrical conductivity. In contrast, ammonium was continuously supplied. A water temperature of 23 °C and a light intensity of 105 μmol m−2 s−1 with a photoperiod of 12:12 h were applied. During a 40-day production phase, a total of 35.6 kg of fresh duckweed biomass (equals 2.1 kg of dried product) was harvested from the IVF. On average, 0.9 kg day−1 of fresh biomass was produced. The dried product contained 32% crude protein (CP) and high levels of proteinogenic amino acids (e.g. lysine: 5.42 g, threonine: 3.85 g and leucine: 7.59 g/100 g CP). Biomass of this quality could be used as a protein feed alternative to soybean meal. The described IVF represents a modular model system for duckweed biomass production in a controlled environment and further innovations and upscaling processes.