From Waste to Protein
The Challenges and Opportunities of Larvae Screening in BSF Farming
By Per Albaek, CEO @ Alvibra
In this issue, Beta Buzz speaks with Per Albæk, CEO of Alvibra, about why effective larvae screening is a critical step in turning waste into valuable protein and fertiliser.
Insect farming is often described as a new frontier of the circular economy. At its heart lies a simple idea: waste materials that would otherwise be discarded can be transformed into valuable products. Within Black Soldier Fly (BSF) farming, those products include high-protein larvae for feed and nutrient-rich frass that can be returned to the soil as fertiliser.
But behind this simple concept is a highly complex reality. Waste is not uniform. The inputs coming from food processors, restaurants, or farms vary greatly in moisture content, texture, and nutrient balance.
To achieve consistent results, insect farmers must carefully process these feedstocks through grinding, heating, or mixing to create a substrate that larvae can grow on reliably.
Consistency in feed leads to consistency in larvae quality, which is critical when scaling insect farming as a dependable waste management solution.
Why Frass Matters as Much as Larvae
While larvae get most of the attention, frass, the by-product of BSF digestion is just as important in the waste management equation, and separating the frass from larvae is something Alvibra has extensive experience in, especially for large scale plants. If poorly separated from the larvae, frass can be difficult to handle and lose value as a fertiliser.
A key challenge for insect farmers is ensuring that feed is dosed correctly so that by the time larvae reach harvest size, all the substrate has been consumed and frass is produced in a clean, separable fo
This step is often overlooked, but it is essential for efficient operations. Good quality frass not only reduces waste further but also creates another income stream for farmers while supporting regenerative agriculture practices.
The Role of Screening and Separation
One of the most technically demanding parts of the BSF process is the separation of larvae from frass at harvest. At small scale, this can be managed manually, but at industrial scale, farmers need specialised screening equipment like Alvibra’s to handle large volumes of mixed material (See image 1). Getting this right is vital as poor separation leads to product loss, contamination, and reduced value of both larvae and frass.
The challenge is even greater at the start of the lifecycle, when tiny neonates hatch from eggs. At just one millimetre long and weighing less than 1/30,000 of a gram and being sticky at the same time, they must be moved, dosed, and reared with care. It requires a special dual vibrational technology like the one Alvibra possess. Precise handling of neonates helps farmers achieve high survival rates, which in turn drives the efficiency of the entire production cycle.
Waste Management in Practice
Framing BSF farming within waste management makes its wider impact clear. Food waste from dairies, farms, and restaurants can be repurposed as insect feed instead of being sent to landfill or incineration. In return, farmers and processors gain high-value outputs:
- Protein for livestock, poultry, aquaculture, and pet food.
- Frass for soil improvement and fertiliser.
- Insect oils and chitin for emerging markets in bio-based products.
This cycle demonstrates how waste is not the end of the chain but the beginning of new value creation (see Diagram 1). The success of this model, however, depends on mastering the details from substrate preparation to larvae screening and frass separation.
Looking Ahead
As the insect industry grows, so does its potential to tackle waste management challenges on a larger scale. Efficient screening, separation, and handling technologies are becoming increasingly important as farms scale up to process thousands of tonnes of waste per year.
By improving the precision of these processes, the sector can not only boost productivity but also strengthen its position as a key player in the circular economy. For waste processors, that means a future where disposal costs are reduced, valuable products are generated, and resources are continuously cycled rather than lost.
For more information about Alvibra and their various equipment contact info@alvibra.com
Enjoyed reading this article? You can read the full issue of our Beta Buzz #6: From Waste To Value publication here
