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ENCR No.9
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~;, ._ ". .PROJECT SCREW-WORM

': •

PREDESIGN CONCEPTS FOR

REARING OF 50 MILLION FLIES PER WEEK
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UNCI.ASSIFIED . AD:,.__ _ _ _ _ _ _ _ _.-Accessfon No .,_,_ _ _ _ _ __ UNC I.ASSIFIED
!.\I PlAnt■ Div, Directorate for BW :Ehgineering :'-W Plants Div, Directorate for BW Eneineering
c.nl C big em, A Cml. c, Mi. Cml. C Eng Cnd, A Cml C, }~.
PROJECT SCflEW \-!ORM. PREDESIGN COIICEPTS FOR 'IKE REAROO PREDESIGN COUCEPTS FOR 'IKE RFARilli
PROJECT SCftE\.I 'WORM.
OF 50,000,000 FI.ml PER \lEEK (U) - E. J. Kemra OF 50,000,000 FLIES PER \/EEK (U) - E. J. Kemra

E);CR NO. __L, JI.LI¥ 56, ___J!p-illus-charta-dvgs (Unclassified EliCR NO. --L, Jul¥ 56, __Jlp-illus-charts-dvgs (Unclassified

"nil■ report formal1ze11 a tentative plo.nt design for the production This report formalizes a tentative plo.nt design for the production
of irradiated •screv-wonn" flies, CRllitroga hominivorax (coq. ). of irradiated "screv-wonn" flies, Cl\llitroga hominivorax (coq.).
The fiies (actualJy in the pupal stage) are irradiated in a •The flies (actualJy in the pupal stage) are irradiated 1n a
radio-active chamber and released in the field. The release radio-active chamber and released 1n the field. The release
of the IIIIXUlllJy sterile males DlDOng the existing ratural or t.he sexually sterile males nmong the existing ra tursl
population is used as tho active mechani8111 for an eradica- population is used as tho active mechanism for an eradica-
tion program. 'lbe report is intended to be a starting tion program. 'lbe report is intended to be a starting
point or a basis frcn llhich to continue definitive drawings, point or a basis from llhich to continue definitive drawings,
design criteria, aal. cost oatilrBtes. It also points out design criteria, and cost ostilre.tes. It also points out
'lreas ot potent1allJ" grsatestreduct1on 1n cost for further areas of potentially greatestreduction in cost for further.
work 1n research acd developmsnt. work 1n research and developmsnt.
Abstract 0lrd Ro. _ _ _ _ Report Copy No _ _ __ IIICIASSJ:lo'IED A.batract O!lrd Ro. _ _ _ _ Report Copy No _ _ __ WCIASSIITED

•.

lD'-e-,,......,.........,,..,_....,,..,_...,....-,__-,;Aooe■eion No _ _ _ _ _ __ UNCIASSIFIED lD._ _ _ _ _ _ _ _ _ _ _.Acce■eion No - - - - - - - tn!CI.ASSIITED

!M PlAnt■ DiT, Directorate for BW Eneineering :\1 Plants Div, Directorate for BW Eneineering
Cml. C Ing em, A Cml. c, Mi. Cml C Eng Cnd, A Cml C, Mi.
PROJECT SCREW WORM. PREDESIGN CONCEPTS FUR 'IKE RF.ARIJll PROJECT SCIIE\I WORM.PREDESIGN COUCEPTS FOR fflE REAROO
OF 50,000,000 FLIES PER \/EEX (U) - B. J. Jtecdra OF 50,000,000 FLIES PER \/EEK (U) - E. J. Kemra

EJ-;CR NO. __L, JI.LI¥ 56, ___pp-illus-charte-dvgs (Unclassified EHCR NO. __L, Jul¥ 56, __Jlp-illus-charts-dvgs (Unclassified

"niie rsport formalises a tentative plo.nt deeii;n for tho production This report formalizes a tentative plnnt desicn for the production
or u-r,idiated •ecrev-wonn" flioa, cnllitroga hominiTorax (coq.). of irl"'ldiated "ecrev-wonn" flies, Cl\llitroga hominivorax (coq.).
The tlie■ {actualJy 1n the pupal et.ago) are irradiated 1n a The flies {actualJy in tho pupal stage) ore irradiated 1n a
J'!ldio-aot1'1'9 chair.her and releaeod 1n tho field. The relee.1111 radio-active char-.bcr and released in the field. The rel~se
or the ■exualJy sterile 111111011 OlllOng the exleting ratural oft.he sexually sterile Dl'llos runone tho existing ratural
population 111 used as tho active moohaniam fc,r an eradi011- populntion is used as the active mochnnism for on eradic:n-
tion program. The report ill intended to be a etarting tion program. The report is intended to be a st:irting
point or a bll11111 fraa llh1ch t.o continue definitive drawings, point or a basis from which to continua definitive dravings,
design criteria, and cost ostiJIBtes. It also points out design oriterio., nnd cost ootilmtcs. It also points out
11roa11 ot potentially grsateetreduotion 1n 0011t for further 1.1reas or potentially greatestrcduction 1n cost for further
work in reseorch acd developmsnt. work in reeonrch and development.
Abetraot Card Ro. _ _ _ _ Report Copy No _ _ __ IIICIASSI 1'"IED Ablltnct lard Ro. _ _ _ _ RAport Copy No _ _ _ __ l.lHCL\SCI !•1\' D

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ENG !NEER[ NG COMMAND REPORT ENCR Bo. 9

PROJECT SCREW-WORM
PREDE.S IGN CONCEPTS FOR
THE REARING OF 50 MILLION FLIES PER WEEK

by

EDWARD J. KENDRA.

RECOMMEND APPROVAL:

4CJ£~~
t,T1 Director for BW ~ineering

APPROVED,

~~~~~~~~'-PJ. I
WILLIA.M J. ~ l : . l l '
Colonel, C
Collll8nding

CHEMICAL CORPS ENGINEERING COMMUm

Arrq Chemical Center, Hlryland

July 1956

A~!lMY CHEMICAL Cr]ffEt

0
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ENGINEEH.lt'\J'G COHi•.IAND IIBPOHT ENCP. . lio. 9

PROJECT SG:HEW-WORH

CONTENTS .

Acbowledgements ••······•·•··•···•···•····•····· •
$1.IIlllll£l,cy • •• •• •• • • ••• . • • •• •• • . • . • • . • •• •• • •. •• •• • •• 0
.,,
.,
Artist's Concept, P:-elim.1.nary •···••·•••··••••·••• vi

SECTIOli I. DESIGN CRITERIA•••••••••••·•••••••••••••••••••••• 1

SECTION II. PROCESS DESC:i.UPTION FOR IRH.AD Lti.·ri...:;n SGREW-WORH
~ING PLANT •.••••••••.•••••••••••.•••••••••••• 3
1. St1JIUDELry •••••••••••••••••••• ·•••••••••••••••••• 3
2. Flow Sheet •••..•..•..•.•••••••.•••••••••• , •••
3. Raw Material Storage•••••••• · ·•·•••·••·•••••• 5
4. Incubation Room••··•·•••••·•••·•••••••••••••• 7
5. Pupation Room•••····••··•······•••••••••••••• 8
6. Radiation Building~••••••••····••·••••••••••• 9
7. Packaging and Shipping••••·•·••••••·•·••••••• 9
8. I.B.boratory ••••••••••••••••••••••••••••••••••• 10
9. Dispersal•··•·•···•·········•• • •••••·•·•·•·•• 10

SECTION III. ?-IA.TERIAL BA.IAN~-- Cl • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ll

l. Mlte~ial Flmr Sheet ••••••••••••••••••••••••••

2. Material Balance-Ove:.:-e.11 ••••••••••••••••••••• l.3 ,•
3. Material BaJ.ance-Unit ·•~·············•·••··•• J.5
4. Capacity and Rate Char~•••••···········••·•• ~ ~-· 17
SECTIOii IV. PROPOSED PLA?IT LAYOUT •••• 0 ••••• •••••••••••••••••• 18
SECTIOU V. SUGGESTE.'D CRGANIZATION CHART •••••••••• • ••••••••• 19
SECTION VI. PREDESIGN COST ESTil-1A'l'E FOR SCREW-WORM CONI'ROL
;-ffiOJECT • . .•...• • • • .••.••••••••••••...••. • •.••• 21
1. Swmna.~ • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 21
2. Buildings and Real Estate•••··•·•••····•·••• 22

ii

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3. Capital Equipment .........•.......•...••...• 23
4. Raw }ts. terial ........... . ..................•• 26
5. Supplies •................•......•..••••...•• 26
6. Utilities Expense ••.•.•..•••.•. . ••.••••.•.•. 27
7. Labor and Supervision ••.•••••••••.•••••••••• 28
8. Dispersal~ll Inclusive•••·••·•·•·•··••••••• 29
9 •. Escalation•·•·•••·••··•·•••••••••••••••••••• .31
10. Credits •...•...•.•......••••• • .••.....•...•• .31
SECTION VII. SUGGESTED PROBLEMS FOR ENGINEERING ANALYSIS •••••• .32
1.
2.
Raw l-Bterials .............................. .
Yields • •..........•.............•.••••••••.•
.32
.32
•I
J. Location of Plant in Florida•·•··••·•••••••• .32
,.
4. Reduction of Personnel•·•···•·••••••••••••••
Waste Disposal••••••••·····••••·•••••·•••·••
.32
.3.3
SECTION VIII. PROJECT ENGINEERING PLAN .34
SECTION IX. ARCHITECTURAL ELEVATIOUS OF PROPOSED PI.A:NT •••••• .36
SECTION X. DISTRIBUTION LIST ................ ............... .37

iii

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ACKNOWLEOOtNENTS

The assistance of the following Fort Detrick personnel is appreciated:

Dr. D. w. Jenkins
.Mr. Clark E. Cottrell, Jr •
.Mr. Charles R. Baldwin
Mr. William E. Gray
Mr. F.dgar B. Harrod, Jr.
Pvt. Richard A. Mohr
Mr. William C. Stauffer
Those from the u. S. Department of Agriculture, Entomology Research
Branch who gave assistance:
Dr. E. F. Knipling, Beltsville, .mryland
Dr. A. W. Lindquist, Beltsville, 11!:lryland
Mr. W. C. MicDuff'ie, Beltsville, Maryland
Dr. R. C. Bushland, Kerrville, Texas
Mr. C. L. Smith, Orlando, Florida
Mr • .M. Brandstein, Orlando, Florida
Mr. A.H. Baumhover, Orlando, Florida
.fllr. J. Graham, Orlando, Florida
.Mr. R.R. Torrent, Orlando, Florida
And from the Bureau of Entomology and Plant Quarantine:
Dr. W. G. Bruce, Washington, D. c.

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SUl'lMARY

Project "Screv-Wor~" resulted from a request by the U.S.

Department of Agriculture, Entomology Research Branch, for engineering
assistance from the BW Plants Division, Chemical Corps Engineering
Co:nmand, on the design of a pilot-plant and a large scale plant
(50 million flies per week) for rearing screw-worm flies.
This report tormlizes a tentative plant design for the production
of irradiated "screw-worm" flies, callitroga hominivorax (cqrl.).
The flies, in the pupal stage, are irradiated in a radio-active chamber
and released in the field. The release of the sexually sterile mles
·among the existing natural population is used as the active mechanism
for an eradication program. This report is intended to be a starting
point or a be.sis from which to continue definitive drawings, design
criteria, and cost estilrfltes. It also points out areas of potentially
greatest reduction in cost for further work in research and development.

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- ; SECTION I. DESIGN CRITERIA. f-.,1

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!". .. ·,. .." ··: ; • YIEID TIME TEMP HUMIDITY II
% days oF, %
r Step Cumm Step Cumm 1·
!
..
Pupae for Colony 2 I. 2 80 100
Adults in Colony 8 10 80 80
Egg laying 100 100 2 hr o.j. 100 100
' Eggs Hatched 95 95 1 1,t 80-85 100
larvae Reared 80 ., 76 · ,.. 4.5 5.5,t 95-100 95-100
Iarvae Pupated 95 72 1 . 6.5,t 80 100
Pupae Held 100 72 5 ll.5,' 80 100 I
Pupae Badia ted : ·, ·, :' ·: : . 98 : 71 1 hr . 12 Ambient ,· ,. ..... ~ . Ambient i
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Pupae Packed 100 71 1 hr 12 Ambient Ambient t
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Pupae Shipped 100 71 1 hr 12 . Ambient··, r~; Ambient i

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Product Analysis: Irradiated Males

Irradiated Females
50%
50% I.'
Packaged on 5th day of 7 day - pupation stage.

Egg laying assumptions: Femles lay only once in the process

Yield 200 eggs average

Weight per Pupae or Fly: 75 mgm = 0.075 gm •

• ..: •..... . 4 · :·; : ..• • •: ~
Number Pupae per gm: 13.J
Number Pupae per lb:
Number Pupae per bag: 130
Media per Pupae: 1.35 cc= 1.39 gm
Ratio weight of media
to weight of fly: 18.5:1
Operational Summary: J shifts ( 8 hour each), 4 cre"Ws, 7 day . ;-,
schedule; averaging /;2. hours per week,
per opera tor.
Designed production: rJ. <·: :.- ·.,,
2 year total: 5,200,000,000 flies in 40,000,000 bags
1 year total: 2,600,000.,000 flies in 20,000,000 bags
Weekly av: 50,000,000 flies 1n 385,000 bags
Isily av: 7,100,000 flies in 55,000 bags
Hourly av: 297.,000 flies 1n 2,280 bags
Average per minute: 4,950 flies in 38 bags

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SECTION iI. PROCESS DESCRIPTIOtl FOR IllRADIATED SCREW-WORJ1 REARING PLANT 1
i
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1. Summary H
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!!
The rearing of the irradiated screw-worm fly includes the hatching ii
If
of fertile eggs, the growth of the larvae on a meat-blood media, the I
irradiation of the pupae, and the packaging of the pupae in the dispersal
cont ainer. The rearing is carried out in a semi-continuous fashion
using disposable trays, tubes, and cages in carefully controlled condi-
I
tions of temperature and humidity. Media is prepared in mixing kettles
and then dispensed into trays at various stages during the larvae growth.
The self-harvesting larvae are gathered and stored in soil. The larvae
\ pupate within 24 hours, after which they are separated from the soil and
permitted to age in tubes. The dormant pupae are irradiated, using 1:1-

I radioactive source, and sent to the packaging room. The pupae are counted,
placed in bags, then into cartons ready for shipment by air to distribution
centers in an infested area. The flies emerge from the pupae just prior
to the dispersion time.

A sma.11 portion of the dormant pupae is recycled to the adult colony

room for emergence as flies for the production of eggs. These eggs are
gathered and then hatched in a laboratory incubator. The larvae are then
placed in a small quantity of meat-blood media to start the cycle again.
2. Flow Sheet Ii

~- The following flow sheet illustrates the steP-by-step

!ii ii
progression of ·P roject Screw-Worm. ;~
B• Flexibility in the operation of this plant is incorporated in
the design by the adequate live storage capacity of the conveyor racks
in the incubator room. Only three-fourths of the shelves are expected
to be utilized during a normal production schedule. Should a b;reakdovn
occur or maintenance be required, the rate could be increased to provide ,,
~l
.,
up to one-third more capacity in order to maintain the average rate. ;•
The design also includes variable speed motors for the conveyor lines.
If additional capacity is needed, the first line could be placed in
operation -for the 24-hour larvae instead of the freshly hatched tiny
larvae. The production from this line would fill the remaining one-
fourth of the shelves in the conveyor racks. Several additional stations
would be required during periods of peak operations.

f.
!
f

.,

.. .. --- ··-· ------------------

II
"
 FP.EE \/ENT

I
5 0 0 61,1:\L ·
IY\IEOIA
""'~ )(l=:. R
55 GAt, I 55 G-"L. ·
.----i ~UM ·r.J..') DP.UM

HOt-JEY
' ~ VINE S LOOC

F'DRK LIFT TRUCK _.../

PUMP

'DRAIN

AMMONIA VAPORS
E$0t::>ORS TO PUMP
FLIES: SCRUB81N6 row~R,
KERR.Vil.~!!. /
'f:!:N~T>Ol4~--====:::,
► REF'RIC:SeRATION CCMPRES'SO R
'PUMP SPAA<' TOWE.Jc:
CONVEYOR l
lo---t~EY 0~ OAT 14ULLS '
__J"--.:~~T

v 1e,RATIN6
SI F"TER PUPAE ' ·
-F.D~ -n , ~
LARVAE
~ R:>R
1>15POSA.l.. ·' _- 4 S~HO
INCUBATOR SHIP"'1NC3

~
Vll!:,RATlN0
SIF" 7'£J::
,___..._ __,PUPAE L-----1

➔~
LARVAE
¢ 5AND ~"T'f"T'r-1

Vle,R.A~-, r,.; G
5/F=-i-E.~

TUBE
c FILLER
CONVEYOP. .
DISJ:'0.5AL:
INCINEPATOR QR.
DRUM DP.YER
PROJ[CT .SCREt\t · W()RM
.
BUCKET [QU\PMt:N'T fLO,yy f~EET

.~
-•
 - - - - - - -~~----- - - -
·-··- _______,_,_~ . -::-
.

J. Raw .t-Bterial Storage

It is proposed that ground horse, beef, or goat (low fat) meat
., . be brought in refrigerated trucks from the meat packing plant. Assuming
that 1.35 milliliters of media will be required for the rearing of
one larvae, 62,208 pounds of meat will be required per week. This
figure may be on the low side, since recent indications showed that
about one and one-half milliliters were required; it was not too Yell
established 'Whether this meant per egg started or per larvae hatched.
However, it is assumed that as a result of the designed plant and
its more uniform environmental conditions, established feed times,
and controlled quantities, better media utilization 'Would result.
A one-week supply of meat could be stored in the 860-square-feet
or 8,600-cubic-feet refrigerator. The temperature would be naintained
at 40° F. using either brine-cooled coils racked against the -wall or
a unit blower systen.. The meat would be contained in reusable tote
boxes (9 in. h. by 9 in. w. by 18 in. 1.= 6.3 gals. = 55 lbs of meat)
stacked 3 feet high on 3 ft. by J ft. wooden pallets. Fach pallet
would contain 32 tote boxes containing 1,760 pounds of meat. This
would require about 35 pallets, if a one week supply was contemplated.
It is intended to store 32 pallets in the refrigerated room, 16 on the
main floor and 16 stacked. It was decided to provide a separate plat-
form level for the second tier although it my not be necessary depending
. upon the strength of the tote boxes. The tote boxes are cleaned and
replaced on the pa~lets via the supply truck. The boxes are filled
at the pa.eking house and loaded on the pallets for storage prior to
delivery. As .soon as the meat is delivered, a forked-truck operator
lifts the pallet plus tote boxes containing the ground meat from
the truck to the refrigerator room- via the loading ramp. It will
I
be assumed that the truck will back into a below-ground-level ramp.
f .. This will avoid the need for raising the entire building by 3 to 4
feet in order to accommodate the loading ramps. The lift truck hauls
1,470 pounds 9f meat (1,760 pounds on one pallet) from the refrigera-
tor room, on the loading dock, to the raised platform outside of the
media m9.keup room ready for charging the media mixer.
 - ~ - --..-~- -

i
The refrigeration system is loca ted in the utility room except \
for the hrine tank, pumps, cooling tower, and cooling condenser. This
refrigeration system also maintains the temperature of the bovine blood \
in two 2,000 gallon horizontal tanks at 40° F. The blood collected I
at the packing house is brought to the plant in 55-gallon drums, 71 per
week. A small amount of citrate, as preservative, is added to the drums
as soon as filled at the packing plant. A pump transfers the blood to
the storage tanks until ready for use. Forrelin (35.3 gals/week) is
stored in a drum as received. It would be set upon a rack and dispensed
\
in 0.84 gallon (3,180 cc.) quantities. The honey (146.9 gals./week is \
received in 55 gallon drums and also stored on racks. This is dispensed
in small quantities to the adult colony room and the packaging room.
I\
The media for the trays in the incubator room is mixed in one of
the' two 500 gallon media mixers.
. The schedule calls for one batch
L
per shift or one every four hours. \I

One batch consists of the fol.lowing: II I )

i J.
' l
Water 1,400 lbs. or 168 gallons
\'
Formalin 6.4 lbs. or 3,180 ml l
t
Blood 740 lbs. or 84 gallons ~
I.
Meat 1,470 lbs. or about 168 gallons
Total 3,610.4 lbs or · 420 gallons
\
These items are either weighed on a platform balance or measured I\
by a volumetric meter. The media is prepared by thorough mixing at I I
95° F. in the media tank kept at this temperature by hot viater (150° F.)
in the jacket. The flow of this water is controlled by the temperature
of the media. The media is dispensed by a pump to the media dispensing
room adjacent to the incubator room. The empty mixing tanks are care-
fully washed down and sterilized with free steam after every batch. i
Two operators plus the forked-truck operator are assigned for the media . I
prep area. l I
\\ I

\I
.. IIq
[\

.
\\ l
'
 7

4. Incuba. tion Hoom

All personnel working with the larvae stage of the process are
located in the media dispensing room, adjacent to the rrain incubation
room. This room will be maintained for hum.an comfort and kept as free
as possible from the incubator room odors.
For the moment, it will be assumed that a sufficient quantity of
tiny larvae from hatched ecgs are provided by the laboratory through
the double-ended incubators. The 6,300 tiny larvae in a glass petri
dish are washed onto a sma.11 disposable paper tray containing freshly
dispensed meat-blood media, measured volumetrically by an operator.
,The tray is sent down the roller conveyor to a second operator on the
first conveyor line.
These trays, containing the larvae, are placed on the rack
conveyor at the rate of 1.1 tray per minute. The design shows a
fulJ. length continuous conveyor for the first line, a]though a
much shorter line will actually be necessary. The line -was designed
for 1 tray per shelf in the rack containing 20 shelves. In this rack,
only the lower 15 shelves will be used. The trip through the incubator,
maintained at 95 to 100° F. and 95 to 100% RH, is scheduled for 24 hours.
The design allows for the possibility of changing the speed of the
conveyor line to suit the requirement as needed.
A third operator transfers the 24-hours-old larvae to one end of
an intermediate-sized tray containing more fresh media. The small

I
used tray is dropped through a funnel to a disintegrator, and carried
by a screw-type of conveyor to either a Dumpster for disposal at a
rendering plant or an incinerator or a drum dryer at the rear of the
building. The second tray is placed on a shelf of the rack in the
,: second line. The entire shelf will be used for the trays and the I I

full line utilized. The trays are handled at the rate of 1.1 per
minute allowing the operator 13.6 minutes to fill a rack. The rack
is scheduled to move at a rate of 0.14 feet per minute. Therefore, the
rack moves 1.9 feet during filling. After 24 hours, or 48 hours since
the process began, the .larvae are again transferred to a large dispos-
able tray containing fresh media. The spent media and the intermediate
tray are disposed of in a similar manner as the small tray.

f
il
. ., - --- -- ---·-- ··--··--·---- · - - -·~ ..__ -- -·-···--

The fourth operator places the large tray in the rack of the
third line for 24 hours additional incubation.
After a total of 72 hours and at the end of the third line, a
fifth operator transfers the large tray to the fourth line after
adding some additional fresh media. About half-way through the fourth
line (84 hours) the larvae begin to crawl out of the media seeking
dry, dark, and firm conditions. The self-harvest takes place by the
larvae falling from the trays into a long trough, directly underneath
the rack, at the bottom of which is located a fast moving belt
conveyor.
A sixth operator transfers the large tray to the fifth line
yhich is also equipped with a trough ~nd a fast moving conveyor.
The larvae are spray washed and then dumped in.to a chute feeding a
bucket-lift conveyor which transports them overhead, across the hall,
into the pupation room. Most of the larvae crawl out of the media
in the fifth line by the 108th hour. The rack plus the large tray
return to the media dispensing room. The tray plus spent media is
disposed of through a disintegrator and screw conveyor •
. Disposable trays are used for at least three reasons: (1) reduc-
tion of initial capital cost, (2) mi~imizing number of employees which
would be needed for the tray washing operation, and (3) to minimize the
danger of spreading disease among the flies.
5. Pupation Room
It is proposed to feed the larvae plus soil or sand to the top
of a wide conveyor. After six hours some of the larvae have pup:i.ted
and the entire mixture is dumped into one of three series of sanitary
circle sifters. These would be shaken intermittently, separating the
pupae rrom the larvae-sand mixture. The larvae continue to pupate
as they progress through these sifters during the next 18 hours. The
pupae are collected in a dispenser or counter used to fill a disposable
paper tube (12 in. 1. by 2-i in. dia.) with screened ends. Fach tube
contains 1,000 pupae. The sand is lifted by a conveyor, treated if
necessary and reused. The temperature in the room is naintained at
80° F. and 100% RH. Adequate ventilation will be provided to remove
the odor and ammonia.

.,
--....::::=c.__ --=----- ---...-:-:- -- ------==-------- --
' '

9
• L

These tubes are stored in a rack on a continuous conveyor similar

to the ones used in the incubator. F.ach rack will contain 200 tubes.
The live storage of the pupae in the tubes is scheduled for 5 days.
Two operators are used in this room. The second operator removes
the tubes at the end of the fifth day at a rate of 5 tubes per minute,
pours contents of 8 holding tubes into 1 tube for radiation, and sends
them to the radiation room on a chute.

Approximately three stationary racks with pupae in the tubes are

stored in these environmental conditions. These are held for two
additional days or until the flies begin to emerge. The tubes are then
'carried to the adult colony room in the laboratory area for restocking
the colony.
6. Radiation Building
This separated building contains 23 cobalt-60 irradiation units
similar in design to the one installed in Orlando. However, these
will be xmde with both ends open and mounted horizontally in series.
The installation will include proper sealing of the junction between
each unit. The ends of the room will be protected by an appropriate
shield. The tubes are picked up on a wire conveyor carrying through
all the units receiving a total of J6 minutes irradiation. Since the
radioactive source occupies one-half of the length of the units the
conveyor runs the tubes through in 79 minutes. It is not expected that
operators will be located in this room. Despite the safe working
conditions in the room, the only monitoring will be .through the use
of a closed-circuit industrial TV camera at the feed end of the units.
The receiver can be located in any of several rooms.
7. Packaging and Shipping

The tubes containing 8,000 irradiated pupae are emptied into a

s:rre.11 chambered funnel-dispenser. This sub-divides the pupae into
quantities of about lJO in number. They are then dropped into the
dispersal containers.

The number of packaging lines have not been determined since the
the type or shape of the container has not been determined. However,
seven operators per shift are scheduled in this area. The individual .,d
ii
j
: ____ ----- - --
------ ··---------· --=--~------- ....

10
containers need to be filled at a rate of 38 per minute. The containers
are then packed in cartons ready for shipment to the dispersal area.

8. Iabora tory
About 2% of the total production of pupae is recycled back to
the laboratory for restocking the fly colony. · These pupae are kept
an additional 2 days beyond the 5 day live storage in the pupation
I
room in order to be held at 80° F. and 100% RH. The flies emerge I

~
about the end of this time and are then transferred to the adult colonyi,room
Here the temperature is maintained at 80° F. and the RH at 80%.
One thousand pupae and flies are emptied by the technician from the .f '
}ube into a disposable cage. A. mixture of meat and honey is provided
on the first day along with water on a sponge or moist cotton. On l
the fourth day the original media is replaced by honey on oat hulls
or on bran along with water. These cages are carried on roller-tYPe
conveyors. About 4.2 caees per hour will be processed through this
room into the "egging" room. The adult flies will be 8 days old when I
they reach this room.
Fresh meat is provided on which the female flies lay their eggs.
I
Approximately 200 eggs are laid in shingle-like masses. This step requires
a naximum of two hours. The eggs are picked off and enough gathered on
a balance to total 6,300 eggs. They are placed on moist filter paper
i 11
; l
I i

and then put into a petri dish. These are placed in the double-ended
incubator and maintained at 80 to 85° F. and 100% RH for 12 to 24 hours. ! lI
The eggs hatch into tiny larvae ready to start the larvae cycle in the i : 1
incubation room. ! 1I
I ' '
I I I
•
Separate and complete facilities for n:e.intaining 20,000 adult
flies, producing 2,000,000 eggs per week are located some distance
away from the main plant. This will provide a source of new flies
or eggs in case of disease, start new strains, etc., for the produc-
tion unit.

9. Dispersal
The dispersion design and costs are contained in the "Preliminary
Statement on Operational Plan and Cost Estiirates" prepared by Entomology
Research Branchf April 19, 1956.

j il
, : I

; j

,
--------'-==---· --·- -- . - ·

11

SECTION III. MATERIAL BALANCE

This section includes four charts concerned with the material

balance of Project Screw-Worm: (1) Material Flow Sheet, (2) .?1l.terial
Balance-Overall, (3) Mlterial Balance-Unit, and (4) Capacity and
Rate Chart.

!
I
l
I
I
!
''

i
1,
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. l

I
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i'

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 ~·
-- -
--...___ - ..... ---------~-----
/!AW MATERIAL STOQA(iE

"'l'Ar , ~ :J'J I/D l'rl'' t:ll HDlrSI , l'Wpt Oil nt()ZEII;

-- ---
'°"' ,,.r
-
~~,r~
t~E'
/.(JS
1 ••

,2,208
·-

&oeo, rius., 8E£r {CIT/fATI ~ D ) I. Cli ,,,000

~ , , , ,OR lfOI.IL T COtaN1 O,lf ~~N IHOI.ASSIS
, '<>lf~IN a,,,,.
UI. f,'11~
Z70

Sf!! • WllrE,: .N ' " L/15 .

-
1,{)00 fAl.

MEDIA PRrPARATION

- .. 1--- ----.-----·--,-------.-------
- - --·--+-- -----1----- - ---
MEAT
MEO/A A
I V,X(.lt/f! HCHIY
M~OIA II li#EDIA C
,.,..TClt
MEDIA D
l t'Ol.:.mt -M-f!AT
-4-

NONO' IV:JLl/lllt ;~~ (ON/WN ()/tCIIT ~"Jt'IN

.... r lt1U, l l'tl:.WE

,------- ------ - - ·- ----- - - · -----·-·- ·----

MEDIA D!SPENSIN:j
~
~ - _.., .,,,.._
ax.:,,,,, ~NrAIIVE'll MEDIA - ·r "'t"""1AC1 l'n OIi~ (A.O HlfltEE~ r.,,'AL - DS
couwr ~~ A ,oo tt 10, 101 n,
l'OI.ONY CAl;L 8 .. ,Ote >-· ,o, 1.)7 U

. - - - - ti DnPO-t! C 4'X>O« / S,0 II, 100 I Sl,'70

j m4YS · HtOIA 8
&4GS ~ oo,vcs II '""<~ 'iiEo~oo~t,?!,~f"[.O~o~oct::1:,s~,~o[:==J--------------+
! ---!!:.~:....:::____________________,
CO/.ONl' CAl.# o zf/11./"'..,,,, ~, trn J,.7
C dn N IO• ii,-,.,..,. 91 • 1()CJ•r . - . ·· -

--- -·-
.c,

..
-----------·-
.a,.~ -- -
--
e::.- . . .
___...
100•, IOO ll It.Ii.

a:J0 ltflfl ,._ F ~ l'L'I.

40· # .,. I .a>ti tt.1t.

lffS l'lM:ID IN ~ DI Sit

,10() 'ffl/OISN
REAR/M'i ' HARVESTIN(i

TIJilEt • •S DA'd
,s-100

&DVTENTS <YOHE DISH /¥Ir T'64Y

IS T~'fS l'CIU!ACIC
I: ll N

CltAWC, Olt
PUPATION

s,
IOI INTO SAND
Olf tOIL Fn FOlf SCltFFN IN(i
P UPAE HOLOl!-14
.,., l
t.

STMT 10 ~ OCIT AT $.S Dll1S

ltEktOlfl AT 'NII. INTF,nl,CU

VU VIHAT/:,;,/ SYSTlhf ,o,c -

_ , :,-.: ,IIUff /Ill IFMllATI~ 1'1/~,U l'ltt)lrt
$()IL

-
!.
'~ Rl
--
- - •-
= - - ,, 'UDD'1XS 11114-, -
ltJ/fU, #.2 -~~ - -
/fllt!J:)OU(;TI' " ' "'" 000 -

......
l)ISPOSA/ltl nM'f1 Tr) INC/NE~
Olt DllYllll RJlt DISl"()SAI.

.. ,-/',U~ Ut./111#IC
f
., I
--··
f'IMY---~----
,_
- •

---
--
 w•
1.3
2. Mlterial Balance - Overall
\ . .'.-. Basis: 50,000,000 Pupae Shipped (1 veek 1s production)

INPUT
·'"
. '·
Quantity Volume 'Weight
... •,:•.·::~.::. : ':_..~:: ~t No, Units cc/Unit cc Gal Sp.gr. lb
To cage 707 50 .35,.350 9 •.3 1.05 81
To cage. . . . -707 200 141,400 .37.5 " .327
To tray 11,100 2,400 26,640,000 7050 " 61., 800
TOTAL 7096.8 62,208
Blood
To tray 11,100 1,200 1.3,320,000 .3525 1.06 31,000 j
j

1
TOTAL .3525 31,000 •

Hone
To cage 707 50 .35,.350 9.3 1.42 110
To cage 707 30 21,210 5.6 • 66
To Bags .385,000 1 •.3 500,000 1.32 • 1,560
TOTAL J.4,6.9 1,736
'Water
To tray 11,100 2,400 26,640,000 7050 . 1.0 58,600
TOTAL 7050 58,600
ForpBlin
To tray - 11,100 · · 12 1.34,000 .35.3 0.9172 2:70

TOTAL 35.3 2:70

GRAND TOTAL 67,467,.310 17,85.3 1.0.3 15.3,814 lb ·

.,.
.. . . -- 69,900 kg.

I I

(,
-------- - -
i:
t
 '"'
14
'.
I. L..l:
-· . 1-.
otn'PUT: Flies (In Pupae Stage) :for Shipping

50,000,000 Flies X 75 mgm/FJ.y-

·. .
(0.075 gm=
.
0.000165 lb.)
8,250 lb
@ 10 Pupae/ca. __: 5,000,000 cc = 1,320 gal . ....... ··
Waste Media 1.45,564 lb~ · . ·

.,
Ratio: Wgt of Media: Wgt of Fly Shipped: 18.6:1
I'

.,.. . ... -· .

,f' ••

·:, . ,

I
\ ..
- -- .. _, ....~---~---- ..... . .,
·. -:
..... '
•'"'I !
\
_..,...,..
- !_1'C'· i_ . i. ; ' -l : J -~
-- ·-••-.. --~-·-------------·
,,..,._.,_,...,,..~ __..... ·- ·-· . . - -
... ·
-- -· · .. . -- ···------ ~ :: ·!· :,....;
. . :, . •, ...
'' 1 ' ,t •• , • .;
r
!,
• .
\ . .
• ·•
·1 ;-. \. . ( . .- •"l r
·-' ·•• -:. . '{ , .-! J' ,_.· ·

. ·- ···--- ............ ___ ·-- ---- -·-----

·.•.

.. • . (. ,::<, -·· ..
.. ..., - ·-·-- ~ - .. ---
....... ·-- ·- - .. ---

C,

C,
 •. .. .·

•' . 15
.3 • Ml terial Balance .; Unit
Basis a ._ 50,000,000 Pupae Shipped (1 week 1s production)
.. '
INPtJT_ _ _ _ _ _ _ _ _ _ _ _ _ _ _~ - - - - - - - - ~ : -
•.

Quantity Volume Weight

To Cage No, Units gc/Unit cc Gal Sp.Gr, lb,
~t 7(1'/ .
- 50 .35,.350 9•.3 1.05 81
. ..
·..
Honey 707
I•
50 .35 ,.350 9•.3 1.42 110
TOTAL 56.l 191

Honey 707 30 21,210 5.6 1.42 66

TOTAL 5.6 66

To Cage

i {f ('i{~~(t\!
'
~t 70'1 200 141,400 .37.5 J,.05 m
TOTAL \" 327
1 ·r
1--2
-~
To Tre.;u r

II .
lt!at 11.,100 2,400 26,640,000 7050 1-. 05 61,800
Blood 11,100 11200 13,.320,000 3525 1.06 31,000
I! .

'1!:Vi;:;:~/iZft~
·.
\
; '·. .
Vater

Formlln
n,100
ll,100
2.,400 26.,640,000
12 134,000
TOTAL 17,660.3
7050
35 •.3
l.C
0.9172
58,600
270
151,670
!'j\ Ty Bagg
I
11 Honey 385,000 1 •.3 500,000 1.32 1.42 1,560
l
I TOTAL l.32 1,560
I

GRAND TOTAL 67,467,.310 17,85.3 1.0.3 153,814

...
: ,,
J;}:'.<~>:"/'t.:

r
 16
-·
----"
~
-. . I
OUTPUT: Flies (in pupae stage) for shipping ...... . : ' .' ;.

50,000,000 Flies X 75 mgm/FJ.y. (.075 gm: 0.000165 lb)

. ,~: ..
•

. :.:,.: ..i '"-'~r

.
= 8,250_lb .:J., .... - - •
'
,~
Moisture loss During . v •
I
:.. Pupation. (Assumption) 0
- ... .:· ! ·.
r·
· Waste Media 1·
145,564 lb.
TOTAL . '
153,814 .lb. ... . --. . . - ..
!
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. ~ ... ..,.•

- - ._ .........-..__....._...... .. . --·, - ... ·...,,._;

._....
·--·-· .
'-
' . , .• .. .
-+
'- . J •• • ) • . ..

' .
... : ·,•- ..
I
· L
... ~.,··. ; ·
,,, . ,. t - · .
-' ,,
.. -. ' ;, ~ .i ,
.( ·..
I. _L r ~ ,· '1

'·· '< ~. ~:· ' ,:

.., t. .. .. .

--~-. - ·- ... ..... . . -.... . .. .... . .. - -- - ·- - -- ..--- . ..._ .. - _.,. _ ----- -

•

"- {
• , •• • J

.,.,. , -•. ~-.,,. .. -\, ; . - ·

T • •
,t . j .,
-

--- - - ------ - ·- - -..- -- .--- .,,. --:I

. •-;.--. ...rE ..._
-,. ...
- '-
.. '- ... ~ ..;., _
·1 .- • . :
........1. t : - ~ -
. - -- ·-· - ---- ------ -~- .·. -~·-·• --- -------
....... -- .. . - ....,. --.. --... ···-··.,.
... . -- ·-·-·
'

--.·~--,....-
··• · · · · · - .'; . . f".. ,..._z - -....... ,.,.. , ,.._ """ --- •-
~ "\• ; I
~-·--.,., :·:.J, ;, i
\.

l
--------------~

u"· •

17
4. Ca.p!icity and Rate Chart . :

Basis: 50,000,000 Pupae Shipped (1 veek's production)

• • •.• ,~ s. ...i ~ .: r :.. ·. ·- ; >
NUMBER PER
Minute te.y 'Week Year

Egg laying 7,070 10,100,000 70,700,000 3.,700,000,000

Eggs Hatched 6,700 9,600,000 67,000,000
•Iarvae Reared
& Harvested 5,370 7,600,000 53,700,000
Iarvae Pup!! ted 5,080 7,200,000 50,soo,000
Pupae Held 5,080 7,200,000 50,000.,000
Pup!ie Radiated 5,000 7,100,000 50,000,000
Pupae Packed · 5,000 7,100,000 50,000,000
Pupae Shipped 5,000 7,100,000 50,000,000 2,600,000,~o
.)

:&gs Shipped
(1.30/bag) . .38 55,000 .385,000 20,000,000
Trays Based on
6000 latched
Eggs/Tra::r 1.1 1,590 11,100 571,000
Backs Ever:,
15/Trays/Rack 13.6 Min 106 670

l
18 .t I

SECTION IV. PROPOSED PI.ANT IAYOUT ·

~ ~.: :"' ., ' .
. '
The Proposed Pl.ant Layout for Project Screw-Worm is illustrated
in__ this section. --· . _ __J~:.'. :

.,

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PUPATION

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OAV ~ lf:T PERS ONNEi..

■ $Hll'T WORK P~HHE.L

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 .,. 19
,
I
f

SECTION V. SUGGESTED ORGANIZATION CHART

The Suggested Organization Chart, pictured in this section, clear~
indicates the size and scope of . the planned -working staff' needed to
achieve the contem.plated produc:ti.,on.~

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., '"OPERATIOIJS SE'CRETA~Y 14Dft41~TIVE ,MINTENMJC f!

H'EAD ASSISTANT fNG!>JEER.

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TOTAL 117 ~MPLOYEE-5

I
p.,\YS 11 t~PL.O'(l!ES
\ SHIFT (4 r.Z.S) 100 lft-'IP\.O_Vf.ES

I
 .r--·-· -:- ·---
.. ' .. i
t
,/

~· . 21

SECTION VI. PREDESIGN COST ESTIMATE FOR SCREW-WORM CONTROL PROJECT

, ... ,..
. .:_ 1. Slll!Uttlry · .

Ba.sis: . Two year operation; production and dispersal o~ 5,200,000,000

. ,. '• , flies
,: _. t:
·.. ·. . '•

TOTAL . COST/
ITEM COST 1000 FLIES % r
i
·· Lrexas: Building & Real Estate $59S,ooo 0.1151' .: ·. 9 I
l
Texas: Capital F.quipment 902,000 o.i7J4 · · 14 I
Texas: Rav J.Bterials 1,420,000 :· f·0.2730 ., • T ,I• • •.:• •~ -~
21 I
Te:xas: Supplies 834,000 0. 1605 12
.....
Texas: Utilities Expense 74,000 0.01.36 1

TeJCasl labor and Supervision 966,000 0.1858 .14

Florida: Dispersal all inclusive 1,913,000 0.3679 29
TOTAL $6,707,000 $1.2893 100
Escalation $ 238,000 $0.0457
Credits . $ 221,000 to.0425 •,
...f l' :

..·.,.
,:> .

...
.,' ~;".
·•··.

- - -- -.. . ------ - -
I
 ' .
22
-· .
l •
2.
• •
Building and Real Estate
UNIT TorAL COST/
COOT COOT ., .1000 FLIES
•.' ~~ji : ., !. ' : • '., I ' ; ; •• I •
.; .
' .•
-.
25,000 rt2
J
~. Buildings. '
$16 $400,000 $0.mo
]2. AYld.liary Facilities

land, fencing, road-ways

parking areas, drain-
age, etc • .
• .,I .... 180,000 0.0346
.Q• Outside Lines.
1s,ooo 0.0035
Total cost of Building
am Real Estate
$598,000 $0.1151

, .,, .
• • : • ~ \j . : C

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. ~ _:. ,, ... .. .
. ' ::, : . . __t .' . _;-c : :~:' ._,: -~r.i .. ~
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._

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- --- --... ----- - -

---- ---------
 L __

....
23
..
3. Capital ~uipment

PROCF..sS EQUIPMENT .. EQUIP . • - :- .. :··· INSTAL- TOTAL

. COST · IATIOI COST
,, •.: .- ·,:: • ,_, :.= :~\' ... ' . ' . ._

·-:,::_1,i:_-:0.:\· ,:·i;·.~':.:: 2,000 Gal. Horizontal Blood Storage

- :·•\·J,-=::. .r
Tank (64"D I 12 1L I 3/16": 1950 lb.)
304 SS for steaming 2
2
No pressure. Insulation-150 ft @$2/ft $5500 $1800 t'l300
, Ditto . 5000 1800 7300
Li.ghtnin I Agitator&Impellor for
2,000 Ge.1. 700 :100 800
Ditto 700 100 800
Pump for Blood 20 GPM 100 50 ..., 150
Pump for Blood from Drums 100 50· ,. 150
Meter f'or Bloq~ 100 50 ,. . 150
500 Gal. Media Vessel (5 1D I 4.5 1 )
· '· Jacket-304 SS Clad-Pressure 3500 .·,. : 800< '·-·_·,c: ,_··. 4300
Ditto 3500 .. •.·,: . , __ ' ' 800 .,: ·:· !:: : .- 4300
900 . · . '
Ditto
I
Lightnin Agitator
. •" • ·,.·.
· ..
900
100
' ·J,
·'.
• .
_-'-
. V-
... ,
, :
I
" ·-:
:•
:100
100
50 .
--:
·,,.
' .. - . 1000
.
< .~:-• •._
1000
150
•·
' ·. Meter for 'Water 167 Ge.1/5 Min
-,_ Pump for Media ' Foc,d Type .< :: r.,, . 100. .· ·.>',.. :,.'.-: ·::c ,·'· · 50 : ·-~ .: :.. _. · 150
. Ditto ·, ... i •. l.Jl. ·'" 1.. 100·.,_,_1...:~--·--... _. _, _., _._, . 50 J- •• : :. .1<, (': -· 150
·. ·· ··
TOR For Media Vessel 60 F-170 F
o· · o 500·.:,or. _-!(r;_ ·; ~J;.· ioo· ;!~ ,. ::, i ~ :-- :·· 600
500 .'.,•,. ..·:,;. £,,, ' : 100 :·:: _·•. ·,,.:. : 600
Ditto . . ..
Valve f'or 'Rlrm. Wat~ ,Flov_140°F • 100.,, ~ . ~~ • ·•J"' 50 _7.::'._,' •..;,, 150
100 !•¥\: • > '-' L:~, '.- , . . .co • . ·- •"•,( 1.co
I

'. Ditto ·. · .., ~'-.. - ·•· ;: ,,.,-" , "}. \ ,. i' ' •, 1 ...,.;)• o, •"'J,:,. ~ ..• . ~:. ,~ ..... · -~. J
0
Balance 1000:·lb. •~·,•:<_:: . '~ . ''··JOO V ' •• -· ' • . . ~ .... .
• ~:
.,• .. ·. _·
• ••,/:~ • • • ,..,.•
300
~ : r :. J •

· Refrig. for Blood Storage. 'n,.nk

,· ·. 5 T~n Unit . ./- Brine ._ . . .3000 1400 . 4400
:: Cooling- Coils for Above . ... 100 100·. .;•..· : ~ - 200
·. Ditto · ,, . ._ .,..,_ .. ,.- .. . ... •··.,,_ 100 .•: - .. :·. · j . 200
100
Refrig. for Meat Storage $2/cu.f't. n,ooo .,,.,. , ' •~.. .,.. IJ ·5000 - ·
·--::.' ": -' 16 000
. .
.
-
·- '
I
200
·Pallets (40) @$5 .._ . ,. 200
' Balance 25 lb~
· Conveyor Tables @$200 C . .
· ..." · ' 200
1000
·, c..:.(?.-: :;·.··.·,:: ~ ~:_·c·-/ _-:·~~
480 Racks for Conveyors ·(15 Trays) 26,000 ~-:· 26,000
120 lb ./-.150 lb Media & Tray I
20 Spares ;:..15 Trays/Rack
Conveyor SyQtem 5 I 250 Ft. Overhead
For Live Storage: $5/Pulley;4
$12/ft Steel & Chain
Conveyor 50 Ft 6"D in noor for
Disposal of Tray & Spent Media
11,200

1300
3800

700
15,000

2000
lI
'
t

r.... ,
__ _ _ _ _ ___ _ _ _ _ _ ___,..,...,= -=------ - ----·-

24 · -· .

PROCESS EQUIPMENT EQUIP INSTAL- TOI'AL

COST LATION COST

Disintegrator r or Trays & Spent Media · 300 100 400

Dempster Dumpster Bucket for Spent Media 500 500
Ditto · 500 500
Ditto Empty & Trash ·500
';: 500
Truck for Dempster . 3000 .3000
Funnel, Al. 6 ft. -wide x 125 1 200 300 500
Ditto 200 300 500
Conveyor 125 ft. at Floor ~vel 6" Wide 1200 600 1800
·))itto ( 6" -wide x 125' Long x $2 : $1500 1200 600 1800
(Motor $300)
Bucket Lift Conveyor 10 ft. High 2000 500 2500
Conveyor 25 Ft. 350 150 500
Conveyor & Screening for Pupation 16,000 5000 21,000
Lift Conveyor for Sand 2000 500 2500
Soil Treatment 2000. 500 . 2500
Sand Hopper & Feed Vibrator ·1000 300 ~· : . 1300
Counter for Pupae ,
Conveyor for Live Pupae Storage, 90 ft.
l~gg ! . . i: . -~ -Jgg
Racks for Live Pu_pa.e Storage, 180 9000 . . . 9000
-Tube Filler 1000/Tube 5.08 Min .-.- 100()__,;, ,_ , . . . . 300 _: ~-. 1300
1000 '. •·.. ,' . 400 •, . . 1400
.,::- . Conveyors to & From Radiation Roam
, :. Conveyor Thru Radiation Roam_.·._ 300 . . - '.1 100 ! ' _r.•..-., 400
·•: TV Camera in Radiation Room · 1000 . ' . 100. . . 1100
. TV Receiver .. . 400 ., ;-.... ;_, - + ~•c •·: . 400
,·. / 23 1 Radiation Chambers @ $4500 . . 104,000 .. , - 10 , 000 •..·., ll4 000 . ,
; Tube Tbru Chamber 3"D x 50 1 @ $3/ft. 200 ... 100 ,. . 300
. ·, · · Bucket Lift Conveyor · 2000 . ..,.:, ·. 5·00:. '. ~ ,.:· 2500
..,. .:~ 'h r,nr4 . . ~. ·
r Counter _..,. 200 ' . ..:.· . 100· .. . -: 300
· Honey Dispenser · 500 ,,_-\_' ~l - .,. 200 '; ._11 ) . - 700
500 ' 'I I •h \ 200 .-,. '_; ~ ~ 700
1
• • '. .
:_Excelsior Dispenser .·,,. _
: Counting Machine .. .
. Bagging Machine (Mostly by Hand)
_?00 _::·; , : -~ _. ,·. ~66 ; _, > · . _700
- ,~-.
;:~: iodQ :.· ,:. ,. 3000 - -
:. Coztveyors - No Motors · 2000 ...
Packaging - Hand
' Pallets 100 @ $5
· .. .. ·.• ':.. ..·
·-: ..:;;.;. ~·-~ ·-·~ .... .
500 ·. _ ;:,-.. ) . 500
,

-
Conveyor in Adult Colony Room· · ,. 500 · .• ~ ~ ,. I 200 700
Ditto {•. ' 500 ':'''.'· ·'. c_..:• . . 200 ...-.. _ ··. 700 ~ . . .. ~
. 500 ... :. y_;-_. .... -~ . 200 _· ~ ~~-·- .. 700
..... ... .. ., ...
~ . .. 1 •• \

__ Ditto ~' il:.~~-f-. ""•..~) .... _ ~" I ~ :.:~-= -· · ,.:_ ,,-:

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'.
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·- -·- ---·· •1 ~ - -
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•-- - ._
..,, . 25
/
,
!

PROCESS EQUIPNENT . .·. · EQUIP INSTAL- TOTAL

:..•. ; .· . ', COST LATION COST

5 Gal. Media Mix . 300 100 400

Gas Chamber for Spent Adult Flies 300 100 400
Steam Boiler Cyclotherm 8000 · 2000 10,000
Ditto 8000 2000· 10,000
•' Incul::ator 5 Sections & Racks 2000 1000 3000
Lab Benches 2350 1000 3350
Air Conditioning 12 x 3/4 Ton 3600 400 4000
" Office Furniture 6000 400 6400
Lockers 3600 400 4000
Maintenance Shop 5000 .1000 6000
Incubator Ventilation · 2500 1000 3500
_Ammonia Scrubbers~ , Bumidi;ty.· Contrql 2400 1200 · 3600
,.O:lor Removal - Carbon 3000 1000 4000
., ..... Ventilation for Pupae Room 2000 500 2500
,.··· :-.! Ventilation for Media Prep 2000 500 .2500
.. 1000 .. .
Vent.i l.ation for Laboratory plus 5000 .. ~
6ooo
10 Ton Air Cond.
. : \ Incinerator or Drum Dryer . 4000 . . 2000... 6000
: ·1 Passenge~ Car_- •
, ,4 - 2 Ton Truc'ks for Meat Hauling
·· · .. · 1350 '"
10,000
-- · ..
1350
10,000
~'.·!+ - Pickup ·Trucks
· a. Equipment Costs ::!.j
4400
$313,750
-
$56,250
-~ ,· r

$.370,000
!Jt.00
..· . ( .. . .-,! ! , .· •
.. , .;.

b. Process Piping 25,009,

~:1._:: ._:_,:; :' ( ::/.l. U ➔ .: ; .::: . :__ :· -; . 1- ;;!.

c. Izlstruments 7,000
; .- I"(' i' :·"1 \ I,·_.·. (i ~-~:-~... ·~: ~ ·,
{ ,.. ,(? , / '-. •· .. . L;;,· •, ••

d; Engineer, Construction . 200,000

: ~- ;;;::, .. > ;"'.
,.. , ,
e. -· Contingencies ·... ..
·. · . _.. ; ·. 200 000 ,
.. ., ......,. .\"
'. '·.··· ·: 100,000 .
f. Size Factor
," ... '
•.! • 1 .. ... . ... ;~'• . j

TarAL CAPITAL EQUIPMENT COSTS

I ..
r .. -
$902,ooo,
'. . ,. \, .

•.. _ . . ...' 1-
•
... : •. .,
•. t' • ~
•• !

;
........, ,
.·, .~•.\:: _ _ ,._ ' t ' l
~ .. -··:. ti:.. ;· . .. .•. .·-·.
,. .,,
. .~-·. .
•• • If,, f ·' \. ...
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- -·-~-4--
, __ _

26 -· '

4. Raw Mlterial

..' . . . 'Weight Unit Total Cost/

• ·• f lb • Cost Cost 1000 P'lies

!.• Meat, ground for cage 8,424 $0.20 $ 1680 $0.000.3

Meat, ground for cage 34,000 0.20 6800 0.001.3
Meat, ground for trays 6,469,000 0.20 1,294,000 0.2488
!?,. Blood bovine 3,224,000 0.015 48,.360 0.009.3
.,9.. ··Honey, for cage 11,440 0.37 4,240 0.0008
• r , , Honey, for cage 6,864 0.37 2,5.30 0.0005
· .·· ·.: :.· Honey, for bags 162,240 0.37 60·,000 · 0.0ll6

£• Fo:nmlin for trays 28,080 0.07 1,960 0.0004

li : <'
·· ,- . Total Bav Mlterial Costs
.••... $1,420,0~ $0.27.30
, ..,/

~-~·-~. Suppliei:~ I ' .-. r ":, -• I .•,.;.

'
'
C\~~~~:.~ ...__.. ~- ·-? .?·~-~~~;::7". ·-- ., Units : ~ . . . . ..
!.• Disposable cages 75,000 0.20 $15,000 $0~0029
·. ·. •_. , ,. -· -

/
,j;} ."Dlsposable paper dish 1,154,400 6,000 0.0012
( {10,. \... .
i , .. ~-1 .,,-.• r
-~ ::· 9.• 'Disposable trays small 1,154,400 0.01 12,000 0.0023 .
; .. - : ' •, .-, .
,., .. · ·rifsposable trays
f',( ),) ,,in,termedia te 1,154,400 0.0.3 .35 ,ooo: > ·.,.~_·. o.0067
... .. .. ~-
, -. - Disposable trays , .......
.: •.::.. .::.'J.arge··-- - · · ·- · ~ · · · 1~154,400 581 000 O.Oll2
g_; Disposable holding
. ·:, ..
::.~~:.: tubes · . - ~ • · .. 5,28.3,200 263,000 0.0505
.!!.• Dispersal containers 40,000,000 0.01 400,000 o.r:mo
t_. Miscellaneous supplies .30,000 0.005s
i.• Travel - Texas 15.000 0,0029
Total cost of supplies $8.34,000
 .. -i • .,.

6. Utilities Expense
$15,000
M
!~ $, ~.")..0/gal 500
. ,· .
.R• Water," cooling gai-..·t: 5,000,000
.[.', .J ~\ ~-- ,~
'.r. .-. . . ,· . ,:i --::·.... .. -~ :,_. :2. '· --· _... · ·· - -·· .
M ' : : !. : : '
.£• Water, processing, . 1.00/gal' · 1,000,
._1~ .. . labs, lockers, gal. 1,000,000
{ . :., .
.l
~. Fuel oil for hot 0.13/gal
water & heat, gal. 50, 000

. §.•. Electricity, pm,er 0.02 36,000

1
Kw-hr 1,800,000

i• Electricity, light- ,· '. 0.02 ... ·.-~ 12,000

·. ing !&-Hr .
3,ooo" · ,·:. ·-
g. Telephone
-~-~- .r .,- ..,: .J - · . . .... :. '

$74,00() $0.0136 ~
TOTAL . :... ' : ~- ; ; • • •· .'. . · v -. _·}

,0 ,•·. ~ .
. .. ' i: .

·, ....
. ) .. _
('\( -.
... J ... .. .·.l.

rn.J
c·.
.'
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s.

t• .. . · •

.:.: .(r.:.,J , J C.: .:\ c;-r; :.i ...1-·r '; : _!:_L~'~j;._ft

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•,

... -· -- - - -- ·
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28 ..
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lf
'

7. labor apd Supervision

,,- •\
. . ···.
•'
I
\
··'
l
.l
Annual . Total Cost Cost/ \·
Emulozees Number Salar;r Per Two Years 1000 Fl!e§ i
I
i
\
Plant 1-hnager GS-14 1 $10,320 $20,640 $0.0040 \
Operations Head Engr.GS-13 1 8,990 17,980 0.0035 \
·...:~~~·j:·;·~.- .·.:· .:
Colony- Supervi~or
Ent. GS-11 1 6,390 12,780 0.0024
"'
Entomologist GS-9 1 5,440 10,880 0.0021
Technicians . GS-7 •'·
13 4,525 117,650 0.0226
Shift Supervisors GS-9 4 5,440 43,520 0.0084
Operators YB 76 3,500 532,000 0.1023 I
I

Mlintenance Engr. GS-11 1 6,390 12,780 0.0024 I

. :-; .'.:° \S"!?~
I
.. ' < . Stationary Engr. YB 4 4,500 J6,000 0.0069
\
Mechanics Da.y YB 5 4,500 45,000 0.0086

Shift Mechanics YB 4 4,500 J6,ooo 0.0069

Janitor WB 1 3,000 6,000 0.0012
Truck Driver WB 1 4,000 8,000 0.0015
Secretary GS-5 1 3,670 7,340 0.0014
:~}{(~ ~l~?-3:t Administrative Asst. GS-12 1 7,570 15,140 0.0029
Clerks GS-5 2 3,670 14,680 0.0028
1
,l.'3% 29.610 0.0058

TOTAL 117 $4,120 t966,000 $0.1858 i

~
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 29

8. Dispersal - All Inclusive

_____
.,,
'
From report by

Entomology Research Branch

April 19, 1956

····• !!;• Salaries.

Program Direction
"
Entomologist GS-14 1 $10,320 $20,640 $0.0040
Entomologist GS-1.3 1 8,990 17,980 0.0035
Secretary GS-5 1 3,670 7,3/IJ 0.0014
Fly Detection - . J:'
.,
•
I'
•• l .

Entomologist GS-12 1
· Entomologist · - GS-9 2 5,440 21,760 ~-:-:, 0.0042
Z.. .: . Agent-Field. Aid __ GS-7 · 25 4,525 226,250 .!)"/.0.0435
I. Administrative Office
· ·- ...... _. _ _____ ., .

~ Assistant (Florida) GS-9 1 5,440 10,880 :_,,..., .0.0021,

.. . -=· .:;..: .! .:".:: . -~ ·. :: ~t. " ..._'1

Clerk- Typist (Florida) G3-4 1 3,4,15 ..· 6,83Q.,

. . .... ..-•-\/. 0.0014
;

~- Fly. Dispersal Project

•• I ., • 'I, ., I•• • • .- ':"') •• I

Aircraft Specialist . GS-12 1 7,570 · · .,' 15,140: ·_ 0. 0029

~ ~~ : -:<.--: . . - __, . .... ~- ,_._· ... -~ ---·--
- . ___ .,___ ....... __.. ·---·---·: . :. . -· __ _,. .-
. Aircraft Specialist GS-11 1 -,r, • 12,780
6,390. . ! .......... 0.0024
t ;(:\ ~_ ."- .. ·r _, · .. ,. ,.... . .
Aircra.f't Specialist GS-7 7 4,525.. ... 63,.350 0.0122
,_. • ._, h ,.._ _ -·-. ., .
• ';, '. - ..r ...

Truck Driver GS-5 4 3,670 29,360 0.0056 !

. ' I
Increases /.'YI, 13.050 0.0026

46 $460,500 $0.088"1 i. lI
I !
I

i, J
J
---- -------:-'.'. - -- -
...:.: - :

30
•. .
;e. Office and Working Space - Florida, $32,000 19,0062
" ,

TOIAL OFFICE $32,000 to.0062

I . .. . . : .·. .
S• Supplies and F.guipment.
Passenger Cars (Hq) 3 $1,.330 $ 4,000 $0.0008
Pickup Truck 1 1,100 1,100 0.0002
Trucks (Fly Dispersal) 4 2,500 10,000 0.0019
Pickup Truck (Survey) 25 1,100 27,500 0.0053
"
Automatic Dispersal Devices · 12,000 0.0023
for Airplanes
'·,, . Air Conditioners for Fly- 4,400 0.0008
holding Rooms & Trucks
... ~~ -~J'

Ge.s, Oil & Maintenance .39,000 0.0075

of Automotive Equipnent .· ,:--·c.::·!.• .

Miscellaneous .
.
·. 45,000 .-._ .- -o.0086
.:.
. Travel
.:,
.
.. ' Florida
.
('
,... . -. .. -~.. 50.000 :.---:~ .. 0.0096
TOIAL SUPPLIF.S $193,000 · ,.- $0.0370

.!.. ·, ·-· .•

•. , .. . ..J. ~ .. : .
.30 ' Airplan~s@ $10/hr' to
cover 60 sectors, est. 50,000 sq. miles
Air Shipment of Pupae :.·--:: :.. · ... .:· .

Texas-Florida 227.500 0,944

.:. -~: .- . \
.. ' .. . i i_•. • • I . . .... : ,:_ ,J) ,-. -; · '. . ~ I,,
TOTAL CONTRACTS $1,227,500 $0.2360
TOTAL DISPERSAL $1,913,000 $0.3679
. .....
1 • ,• I
..
·"'

I
 ... .
.31
9. Escalation
Present rate of rise as indicated in Engineering News-Report is .3.~%
per year. Ir construction begins one year from nO\l and operations begin a
.. ~ ,1·'... ... ·.,., • • ,- , ... :.!. ,_•.. :•....d l.,4 •' '.. \).>.~,:,') ,) .. i ;.... •., ·· . .
year and a half from now the following additional costs can be expected: ·· ·

Additional Cost Cost/1000 Flies

•.
Building and Real Estate $22,000 $0.0042
., Capital Equipment .32,000 0.0061
) "-.

Operations ll5,000 0.0222

Raw Materials .. ·. -~-
Supplies
Labor & Supervision
. i . :. ··, ; . :. . .. ,, . . .:;~~ :
Florida Dispersal 69,000 0,0132

<",~;t;:;~:~~f~'.~'.('.:~::EJ+,~;:::··2i:;~s :J~.: ,:; .~':-· ,~:i:.~ ~, ;. :·:~:-;

TOTAL ESCALI\TION $238,000 $0.0457
'· . ~- ·. : ,' .

1
!:•' Waste . Media: - assuwf-naterial could be dried to 20% of original"·...,~
-~--. _·: :.:..:_: weight by the use of a drum dryer. Disposable ·t rays 'will ·be ll!ixed in with

.. ., ...
~ _, but vill not -be considered in' the weight:.-., .. r.!:;,;_.U ·i
., . <. .• ,~ .·..l.,,;·; ;_., ._,; :_. •.

Weight of ,Wet Media 15,1.4.0,000 lb. :. -. ., ,. , . ... .. -· ...

,.. ...... . , . . . . . ~/
,,

Weight
. . .
of Dried
, ...
Media 3,028,000 lb
.. ··.,;.: 1; •. ,I ' ti!.\ '- \._. • ~•• , ." •,' • ~ . . . ~i ·' ..i'J .! lf. .... ; i . - _:,·.

Value @ 3¢ per lb. $90,000 .. ....: .,.• .... $0.0173

~. ·: Resale , Value of :Equipment . 31,000 __ o.0060
. . . •,. . Us:illg 10% of Original Price ·' •. 1 •

·,. ... .. ; : i. ) ... ~ ·•. • :·,_., ·,

Resale of Building 100,000 0.0192

Using 25% Realized at
.. End of Project
.I

TOTAL CREDITS $221,000 _:' $0.0425

 32
V
.. .
SECTION VII. SUGGESTED PROBLE:t1S FOR ENGINEERING ANALYSIS

( .

li. Rav Mlterials·

. r . ,_r_. .
!• Cost ot groUDd meat is $0.2488 per 1000 rues, contributing
'1~20% to the total cost of project or 46-47% to the operating cost.
B• Suggestions for improvement in cost include:
Substitutions such as meat extracts, soy bean meal, etc;
Fillers such as sawdustg oat hulls;
Better utilization of material by feeding only that
amount actually utilized by the larvae;
Better utilization by spraying on t h e ~ ;
Better utilization by feeding from the underside;
. r ...

Use of chemicals to reduce decanposition; ·

2. Yields
Largest loss in the production is in the rearing step. In this
step 67s,000g000 batched eggs per week are fed in the incubator roam -.;
which nets 53g700s,000 larvae per week or 801' recovery. Each 1$ gain in
yie~. would decrease the operating cost of the plant by about $10,000.

• • I
3.. Location of Plant in Florida
• ·•
~:i.·. ·-:~. ·~ ' .~v
' ···

Balancing flight transportation coat versus adequate building ~·.::::

design plus transpor'"..ation of raw material cost. ·
. ', ~ . '
, • . ·.. . ' : -· : :i : <.
4- Reduction of Persoill'l.81
·., :· . , · ..
Reduction of number of personnel by mechanizing the
£!:•
_p ackaging operation. :~ ;~ ( ·: ,. , -. . .
B• The design includes the utilization o:f 7 employees · per
shift. Reduction of one employee per .shift reduces cost .by $28,000 tar
direct labor over a tvo year period.
. : . : ,. _; :, ,, ~ .- I •

.
- -~· .. - - .
• :· . .- . 'T.,. : ·. .... ,
'!1 -- • •
.. ;

., .l

...

'·

"
 -· . .3.3

5. Waste Disposal
r, _Either of two method.a aould. ~ used for disposal of th~ spent · ...
nutrient. Burning in an incinerator vould result in a small volume of
ash !or disposal. If a market is available for a fertilizer mixed vi.th
paper pulp, then drum drying would be the method of disposal.

. . . .... ..

,,

"
 34 ... .
SECTION VIII. PROJECT ENGINEERING PIAN

This section contains a Phase Schedule and Budget Requirements

Chart'.!C· for Project Screw-Worm.
: ,:_ ...._, ., :_· __' __, ' .::.: ,,
··
·. · ·~;.../ . •.., ; ,,:· •- . ~ · <.' J
·1, . • ~. ·... .:. . ~1;-{,: _ '.''},
. ! , ..,,... 1•-:. -,. t ..... ; .

J . 1. ... ,.., • • ~.~ ... :. : t,r -~•/ . .. ). ,._,- ••• ' . . ·:

,;

" .

-
 '

BW PUNTS DIVISION
.
PROJECT SCREW-WORM
.-~
..
PHASE SCHEDULE & BUDGET REQUIREMENTS

CAIENDAR YEAR 1956 1957 1958-

A M J J A s 0 N D J F M A M J J A s 0 N D J F M

PHASE NO. & TITLE

Phase I ~

Technical Liaison ..
-<><:: KX ~
and Appraisals ,_
•;

Phase II
Selection of Process
and Process Design
/
~ - -- - ....,_ ....,.,
~

-- · -
·'
Phase III
~ RS
'J
- - ....
......
Plant Design ~ ....... -
"'v'

Phase IV
.,-..;,;
~ K.x... ~ ~~ ~
PJ.a~t Qonstruction
 36 ..
SECTION IX. ARCHITECTURAL ELEVATIONS OF PROPOSED PIAN!'

The Architectural Elevations of the Proposed Plant for Project.

Sorev-Worm are illustrated in this section.

! ,:, .. .

·,.

L. .·, ....
'1

. ''
:'·~
.
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L£~T /;.LG VAT/ON RIGUT t;;u;:;:v.L.\T/{)N

- 0£PARTNEHT OF TW~ UM'Y

CHENICAL ~
o,m o, N00UCT10II DIIM -
P\MTIOICillDN-CAMPKTaCII.,--_-
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.

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37
DISTRIBUTION
No, Copies
1 Chief Chemical Officer
Addressees
I
'·
l

l
Deputy Chief Chemical Officer for Scientific
Activities
Assistant Chief Chemical Officer for Planning_,
and Doctrine
I
J1
:3 Commanding General, .MA.TCOM j
1 Commanding General, RADCOM !
1 Commanding Officer, TNG COMO
1 President, Cml C Board
'l c.o. Cm1 C Field Requirements Group ✓
1 C. O. CWL
1 ->C. O. CWL, Attn: Dir/Medical Research·]•
:3 . -;::,c. O. CWL, Attn: Technical Library _
4 C. o. Ft. Detrick
• 1 C. O. Dugway Proving Ground
1 C. o. Pine Bluff Arsenal
l c. o. Rocky Mountain Arsenal
1 Secretary Cml C Technical Committee
1 C. O. ENCOM .
1 Attn: Deputy for Engineering
t 1 Attn: Dir/Prod Engr
1 Attn: Dir/Facilities
1 Attn: Dir/ Plants and Processes
1 Attn: Dir/ml Engr;
·l Attn: Dir/Engr. Documents
l Attn: Chief, Program M:lnagement
1 Attn: Library
1 Attn: z.hil and Records
1 Operations Research Group, OCCmlO
5 ASTIA.✓

.
'
10 USDA. Agricultural Research Service
Attn: Dr. E. F. Knipling
1 ' 'Chief; ,E:ntcimollogy··lh'mlch; Allied Sciences Division
Attn: Dr. D. W. Jenkins
6 Chief, BW Plants Division

.,
,..

~-- . -