Full-Circle Farming

More Markets, More Buyers, More Profits

Nothing goes to waste on Bill Couser's Iowa farm. The 5,200-head cattle feeder uses his corn crop for feed and fuel, and recycles manure from the redesigned feedlot into fertilizer. A system of berms, settlement basins and bromegrass Vegetative Treatment Areas manage feedlot runoff. (DTN/Progressive Farmer photo by Bob Elbert)

Bill Couser sees farming as a full circle. If it comes off the farm, it can go back into the farm. And in just about every case, it can make money or save money for the operation in the process.

Start with the corn the Nevada, Iowa, producer grows. He hauls the grain to an ethanol plant. From there, he gets dried distillers grains (DDGs), which he brings home to feed to cattle in the family's on-farm feedlot. The manure from the cattle fertilizes several thousand acres of crops. And that's just the tip of the cow at this 5,200-head capacity feedlot.

FINDING BETTER WAYS

Improvement and adaption takes expertise and partnerships. To that end, the 59-year-old farmer/feeder has been working with Iowa State University and the Iowa Department of Natural Resources to bring new, innovative practices to his operation.

Changes are well thought out, with a goal of fitting every piece into that circle of farming Couser talks about.

One change includes the Cousers' new cattle facility. Built in 2009, it took the place of an old, outdoor feedyard that dated all the way back to 1889.

The new facility includes two monoslope feed barns along with two outdoor feedyards. A monoslope building has a roof truss higher on the front side, sloping toward the back. Couser's monoslope barn has no front wall and a partial 6-foot back wall. The facility faces south so the sun shines to the back wall in winter, providing warmth.

A 6-foot-long curtain can be lowered during extreme weather. Most of the time, the facility remains open to allow air circulation and ventilation. The interior is shaded during the summer, keeping animals cool.

The monoslope directs rainfall away from feeding areas and allows for more capacity without compromising the Vegetative Treatment Area (VTA) system put into place to handle runoff.

P[L1] D[0x0] M[300x250] OOP[F] ADUNIT[] T[]

Protecting the feeding area preserves the value of manure, which Couser uses as fertilizer on his corn crop. Since the manure is protected from rain, it isn't diluted. Cornstalks are used as bedding in the buildings. The mixture of stalks and manure provides the fertilizer for a 200-bushel-per-acre corn crop, with additional nitrogen added as the corn develops early in the growing season. Couser's goal is to raise an acre of corn for every feedlot animal.

The new facility has also meant better gains. Couser said depending on the group of animals, cattle average 12% improved feed conversion and 5% to 15% better average daily gains in the monoslope building compared to outdoor pens.

VEGETATION CUTS RUNOFF

Every feedlot deals with runoff and Couser's is no different. Looking for cost-effective and efficient strategies to reduce runoff, he partnered with National Resources Conservation Service, the Iowa Department of Natural Resources, ISU and the EPA. A pilot system came out of the partnership.

The system uses a series of berms, settlement basins and bromegrass VTAs to treat feedlot runoff to an acceptable standard. Based on studies and monitoring, the VTAs reduced the mass of total solids, nitrogen and phosphorus runoff by at least 75%.

Couser gets maximum use of the VTA by harvesting the bromegrass and using it as hay for his cattle. He is also transforming corn husks, stalks and cobs into feed, fuel and bedding.

CORN TO STOVER

"I've tried to put on my thinking cap and come up with several products from an acre of grain," Couser said. He decided that stover was a proven and effective way to get the most out of his corn crop.

"We can greatly improve the feed value of cornstalks by rehydrating them with calcium hydroxide [slaked lime] to make the lignin more digestible," he said.

In cattle-feeding trials, adding slaked lime to corn stover rendered the plant material sufficiently digestible to constitute up to 25% of cattle rations. That's after the treated stover is combined with wet distillers grains and solubles (WDGS.)

WDGS is a protein-rich feed ingredient and a coproduct of corn ethanol production. The treatment process involves combining ground or chopped stover with the lime solution, then storing the treated stover in an oxygen-free container (typically a plastic "ag bag" or a bunker) for approximately a week.

Fifty pounds of calcium hydroxide will treat a 1,200-pound bale of stover. The calcium hydroxide solution loosens the chemical bonds between the stover's less-digestible lignins and its more digestible components. Relaxing these bonds enables natural enzymes in a cow's front stomach to effectively digest the stover.

BIOMASS HARVESTING

In an effort to market additional products from each acre, Couser is working with John Deere on a prototype biomass harvester.

In addition to providing additional income, removing most of the fodder helps soils warm in early spring and prevents difficulties with stalks and cobs for the corn planter. He leaves behind 30% of plant material to maintain organic matter in the soil. With corn yields of 200 bushels per acre, excess crop residue can be an issue at planting.

MARKETING OPTIONS

The Lincolnway Energy ethanol plant is a key part of the Couser operation and is located just 3.5 miles down the road. He serves on the board of directors.

The plant produces 50 million gallons of ethanol a year, as well as corn oil and distillers byproducts for animal feed.

Couser pointed out he now markets three primary commodities from a corn acre: 1) corn for grain sales, ethanol or feed; 2) bales of cobs, shucks and leaves for feed or energy production; 3) bales of cornstalks for feed, bedding or energy.

"My goal is to provide options for farmers so we aren't locked into selling our corn to the ethanol plant or feeding our corn to cattle," he said. "We have several choices to help us make the most money from each acre."

(VM/CZ)

P[] D[728x170] M[320x75] OOP[F] ADUNIT[] T[]
P[L2] D[728x90] M[320x50] OOP[F] ADUNIT[] T[]
P[R1] D[300x250] M[300x250] OOP[F] ADUNIT[] T[]
P[R2] D[300x600] M[320x50] OOP[F] ADUNIT[] T[]
DIM[1x3] LBL[article-box] SEL[] IDX[] TMPL[standalone] T[]
P[R3] D[300x250] M[0x0] OOP[F] ADUNIT[] T[]