WO2025224672A1

WO2025224672A1 - A green waste processing method

Info

Publication number: WO2025224672A1
Application number: PCT/IB2025/054288
Authority: WO
Inventors: Patty ABOU-JAOUDÉ; Suaad Amin Mohamed YOUSIF; Rodrigo ANSELMO PEREIRA DO NASCIMENTO; Iannis DE SALVADOR E LIMA
Original assignee: Ecofeed Innovations Holding Ltd
Current assignee: Ecofeed Innovations Holding Ltd
Priority date: 2024-04-26
Filing date: 2025-04-24
Publication date: 2025-10-30
Anticipated expiration: 2026-10-26
Also published as: GB2641878A; GB202405861D0

Abstract

A green waste processing method is disclosed. The method comprises: preparing the green waste material, forming a green waste derived mixture, and thermo-processing the green waste derived mixture. Preparing the green waste material comprises: separating the green waste material into non-wood material and wood material; pre-grinding the separated non-wood material and controlling the hydration level of the separated non-wood material to a non-wood hydration ratio; and pre-grinding the separated wood material and controlling the hydration level of the separated wood material to a wood hydration ratio. Forming the mixture comprises: mixing the pre-ground non-wood material and pre-ground wood material together in a non-wood/wood ratio; and grinding the pre-ground non-wood material and pre-ground wood material. Thermo-processing the mixture comprises: pre-conditioning the mixture; and heating the mixture, under a pressure, to a temperature to produce a cooked green waste product.

Description

A GREEN WASTE PROCESSING METHOD

Technical Field

The disclosed inventions relate to green waste processing methods. Specifically, the disclosed inventions relate to methods of processing green waste material to form a cooked green waste derived product and apparatuses for performing the methods.

Background

Large amounts of green waste are generated globally from economic activities such as fruit and vegetable cultivation, landscaping, public park maintenance and private garden management. Managing this green waste is economically costly and can also be environmentally damaging since the green waste is often simply disposed of in landfills and the like where the green waste can decompose thereby contaminating ground water and causing unpleasant odours.

Often green waste is removed to recycling sites where the decomposing remains of the green waste are transformed into vegetable compost or biofertilizer. In other, more unsatisfactory options, the green waste is incinerated leading to unwanted carbon emissions.

Summary

In one aspect of the invention, a green waste processing method is disclosed. The method uses green waste material and comprises: preparing the green waste material, forming a green waste derived mixture, and thermo-processing the green waste derived mixture. Preparing the green waste material comprises: separating the green waste material into non-wood material and wood material; pre-grinding the separated non-wood material and controlling the hydration level of the separated non-wood material to a pre-determined non-wood hydration ratio; and pre-grinding the separated wood material and controlling the hydration level of the separated wood material to a pre-determined wood hydration ratio. Forming the green waste derived mixture comprises: mixing the pre-ground non-wood material and pre-ground wood material together in a predetermined non-wood/wood ratio; and grinding the pre-ground non-wood material and preground wood material. Thermo-processing the green waste derived mixture comprises: preconditioning the green waste derived mixture; and heating the green waste derived mixture, under a pre-determined pressure, to a pre-determined temperature to produce a cooked green waste product. In certain examples, the pre-determined non-wood hydration ratio and/or the pre-determined wood hydration ratio is a maximum of approximately 14%. Controlling the hydration level of the separated non-wood material may comprise de-hydrating or drying the non-wood material. Controlling the hydration level of the separated wood material may comprise de-hydrating or drying the wood material.

Pre-grinding the separated non-wood material may comprise grinding the separated non-wood material into pieces having a maximum size of approximately 40mm. Pre-grinding the separated wood material may comprise grinding the separated wood material into pieces having a maximum size of approximately 40mm.

In certain examples, separating the classified green waste material supply into non-wood material and wood material is based on a classification of the green waste material supply into the non-wood material class and the wood material class. Preparing the green waste material supply may comprise classifying the green waste material supply into the non-wood material class and the wood material class.

Classifying the green waste material supply may comprise using machine vision to identify non- wood material for classification into the non-wood material class and/or to identify wood material for classification into the wood material class.

In certain examples, preparing the green waste material comprises applying a fungicide to the green waste material supply. In certain examples, preparing the green waste material comprises applying a pesticide to the green waste material supply. The pesticide may comprise one or more of: a fungicide, a herbicide, an insecticide, and a nematicide. In certain examples, the pesticide comprises propionic acid. For example, the pesticide may comprise ammonium dipropionate.

The pesticide may be applied to the green waste material after or before separation of the green waste material supply into non-wood material and wood material supply. In certain examples, the pesticide may be applied to the separated non-wood material during pre-grinding of the non- wood material. In certain examples, the pesticide may be applied to the separated wood material during pre-grinding of the wood material. In certain examples, the pesticide may be applied to the separated non-wood material during drying of the non-wood material. In certain examples, the pesticide may be applied to the separated wood material during drying of the wood material.

The method may comprise storing the pre-ground non-wood material and/or pre-ground wood material before forming the green waste derived mixture. The pesticide may be applied to the pre-ground non-wood material before storing the pre-ground non-wood material. The pesticide may be applied to the pre-ground wood material before storing the pre-ground wood material.

In certain examples, preparing the green waste may comprise conducting a laboratory test on each of one or more samples.

The samples may be selected from a group comprising: one or more non-wood samples, drawn from the pre-ground non-wood material, and one or more wood sample, drawn from the preground wood material. The group may comprise: one or more additional constituent samples, drawn from one or more additional constituents to be mixed with the with the pre-ground non- wood material and the pre-ground wood material, as described herein.

Conducting the laboratory test may comprise determining one or more selected properties of the one or more samples. In certain examples, conducting the laboratory test comprises determining the hydration ratio of the one or more samples and/or the particle size of the one or more samples. Conducting the laboratory test may comprise determining the nutritional content of the one or more samples. Determining the nutritional content may comprise determining one or more of: the water content, the micronutrient content, the macronutrient content, and the starch content of the one or more samples.

In certain examples, the method comprises determining the pre-determined non-wood/wood ratio based on the laboratory test.

Forming the green waste derived mixture may comprise selecting a non-wood material portion and a wood material portion, according to the pre-determined non-wood/wood ratio. Forming the green waste derived mixture may comprise adding the selected non-wood material portion and the selected wood material portion to a mixing apparatus.

In certain examples, forming the green waste derived mixture comprises mixing the pre-ground non-wood material and pre-ground wood material at the same time as grinding the pre-ground non-wood material and pre-ground wood material.

In other examples, forming the green waste derived mixture may comprise mixing the pre-ground non-wood material and pre-ground wood material and then grinding the pre-ground non-wood material and pre-ground wood material. In certain examples, forming the green waste derived mixture comprises mixing one or more additional constituents with the pre-ground non-wood material and pre-ground wood material.

The additional constituents may be mixed with the pre-ground non-wood material and preground wood material at the same time as grinding the pre-ground non-wood material and preground wood material, before grinding the pre-ground non-wood material and pre-ground wood material, or after grinding the pre-ground non-wood material and pre-ground wood material.

In certain examples, at least one of the additional constituents comprises starch and/or a starchy ingredient.

At least one of the additional constituents may comprise a starchy cereal grain. The additional constituents may comprise one or more of: sorghum, rye, wheat, rice, maize, oats, millet, and barley.

In certain examples, at least one of the additional constituents comprises a source of protein and/or a protein ingredient.

The additional constituents may comprise a conservative compound to prevent the green waste derived mixture decomposing.

The method may comprise pre-testing one or more of the additional constituents to determine the nutritional content of the additional constituents. The pre-testing may comprise determining one or more of: the water content, the micronutrient content, the macronutrient content, and the starch content of the additional ingredients. For example, pre-testing one or more of the additional constituents before the additional constituents are delivered for mixing with the preground non-wood material and pre-ground wood material.

The method may comprise determining the proportion of additional constituents mixed with the pre-ground non-wood material and pre-ground wood material based on the results of pre-test and/or the laboratory tests. The method may comprise measuring the amount of the one or more additional constituents to be mixed with the pre-ground non-wood material and pre-ground wood. The method may comprise monitoring the proportion of additional constituents being mixed with the pre-ground non-wood material and pre-ground wood material.

In certain examples, forming the green waste derived mixture comprises monitoring a non- wood/wood ratio of the green waste derived mixture during mixing. Monitoring the non-wood/wood ratio of the green waste derived mixture may comprise using machine vision to sample one or more properties of the green waste derived mixture during mixing. For example, machine vision may be used to sample the light wavelengths in an image of the green waste derived mixture during mixing. In certain cases, machine vision may be used to determine whether the correct selected non-wood material portion and the correct selected wood material portion are being added to a mixing apparatus.

Forming the green waste derived mixture may comprise measuring the amount of pre-ground non-wood material and/or pre-ground wood material being added to the mixture during mixing.

Forming the green waste derived mixture may comprise determining whether the non- wood/wood ratio corresponds to the pre-determined non-wood/wood ratio and, in response to a lack of correspondence, adjusting the amount of pre-ground non-wood material and/or preground wood material being added to the mixture.

In certain examples, forming the green waste derived mixture comprises grinding the pre-ground non-wood material and pre-ground wood material into particles having a maximum size of no more than 1.5 mm to 3 mm. Forming the green waste derived mixture may comprise grinding the additional constituents into particles having a maximum size of no more than 1.5 mm to 3 mm. The particles may have a maximum size of no more than approximately 2 mm.

In certain examples, the method comprises storing the green waste derived mixture before thermo-processing the green waste derived mixture.

Pre-conditioning the green waste derived mixture may comprise injecting steam into, or steaming, the green waste derived mixture to hydrate the green waste derived mixture.

Pre-conditioning the green waste derived mixture may comprise pre-heating the green waste derived mixture.

Pre-conditioning the green waste derived mixture may comprise dosing the green waste derived mixture with water.

In certain examples, the pre-determined temperature is between approximately 95°C and approximately 160 °C. In some examples, the pre-determined temperature may be approximately 135 °C. In certain examples, the pre-determined pressure is between approximately 25 and approximately 75 bar.

In certain examples, heating the green waste derived mixture comprises feeding the green waste derived mixture into a pressurised heated barrel and forcing the cooked green waste product out through a nozzle of the heated barrel. The cooked green waste product may be extruded from the nozzle. The heated barrel may comprise a helical screw that, on activation, forces the green waste derived mixture through the heated barrel to the nozzle.

In certain examples, the method comprises injecting steam into the pressurised heated barrel.

The cooked green waste derived mixture may be processed following extrusion from the barrel. In certain examples, the extruded cooked green waste derived mixture is chopped or cut immediately following extrusion. In certain examples, the extruded cooked green waste derived mixture may be allowed to extrude into long strands in the manner of straw. In certain examples, the extruded cooked green waste derived mixture may be allowed to extrude into long strands that are coiled or allowed to randomly bunch, bundle or cluster following extrusion.

In certain examples, the cooked green waste product is extruded from the nozzle as kibble.

The cooked green waste product may be formed into pellets by compression and, optionally, a liquid compression aid is applied to the pallets prior to the pellets being compressed.

In certain examples, following thermo-processing, the cooked green waste product is delivered to a dryer.

In certain examples, following thermo-processing and/or drying, the cooked green waste product is packaged.

In another aspect of the invention, a cultivation substrate is provided. The cultivation substrate comprises cooked green waste product produced according to any of the methods described herein.

In another aspect of the invention, animal feed is provided. The animal feed comprises cooked green waste product produced according to any of the methods described herein.

In another aspect of the invention, animal bedding is provided. The animal bedding comprises cooked green waste product produced according to any of the methods described herein. In another aspect of the invention, a preparation system for preparing green waste material is provided. The preparation system comprises: a separation station and one or more pre-grinding stations.

In some examples, the preparation system comprises one or more drying stations. In some examples, the preparation system comprises a sampling station. The preparation system may also comprise one or more storages for storing pre-ground non-wood material, pre-ground wood material, and/or pre-ground additional constituents. The preparation system may comprise one or more controllers.

In another aspect of the invention, a mixture forming system for forming a green waste derived mixture is provided. The mixture forming system comprises: a mixer and a grinder. The mixture forming system may comprise a mixture storage where the green waste derived mixture may be temporarily stored. The mixture forming system may comprise one or more controllers.

In another aspect of the invention, a thermo-processing system for cooking a green waste derived mixture is provided. The thermo-processing system comprises a pre-conditioner and a pressurised cooker. The thermo-processing system may comprise a dryer to dry cooked green waste product. The thermo-processing system may comprise one or more controllers.

In another aspect of the invention, a green waste processing system is provided. The green waste processing system may comprise one or more of: any of the preparation systems as described herein; any of the mixture forming systems as described herein; and any of the thermo-processing systems as described herein. The green waste processing system may comprise one or more controllers.

Brief Description of the Drawings

Further features of the disclosure are described hereinafter, by way of non-limiting examples of the invention, with reference to and as illustrated in the accompanying drawings, in which:

Figure 1 is a flowchart of a green waste processing method using green waste material according to one example, as disclosed here in.

Figure 2 is a flowchart of a green waste processing method using green waste material according to one example, as disclosed here in. Figure 3 is a flowchart of a green waste processing method using green waste material according to one example, as disclosed here in.

Figure 4 is a flowchart of a green waste processing method using green waste material according to one example, as disclosed here in.

Figure 5 is a flowchart of a green waste processing method using green waste material according to one example, as disclosed here in.

Figure 6 schematically illustrates an example of a green waste processing system as described herein.

Figure 7 schematically illustrates an example of a green waste material preparation system, as described herein.

Figure 8 is a schematic diagram illustrating another example of a green waste material preparation system, as described herein.

Figure 9 schematically illustrates an example of a green waste derived mixture forming system, as described herein.

Figure 10 is a schematic diagram illustrating another example of a green waste derived mixture forming system, as described herein.

Figure 11 schematically illustrates an example of a thermo-processing system, as described herein.

Figure 12 is a schematic diagram illustrating another example of a thermo-processing system, as described herein.

Figure 13 is a schematic diagram of an example green waste processing system, as described herein.

Figure 14 is a graph showing gas generated from an in vitro fermentation test for a cooked green waste product produced according to the methods described herein.

Figure 15 is a graph showing gas generated from an in vitro fermentation test for a comparison composition as described herein. Detailed Description

In this description, the term “green waste” shall be interpreted to mean organic plant-based waste that is decomposable or can rot. Green waste shall be interpreted to include plant waste that includes wood and other plant materials that are not considered wood (non-wood material). “Wood” should be interpreted to include the structural tissue of plants such as roots, trunks, and branches, and in some cases, stems. Wood material forms the support function in a plant and is strong due to the nature of the cellulose fibres forming a matrix with polymeric lignin. Other plant materials included in green waste are the tissues of plants that are part of the “shoot system” of plants; that is, the leaves, stems, flowers, fruits of plants, which may also be described as “foliage”. Depending on, amongst other things, the season of harvest, the type of plant, or the age of the green waste, stems may be considered wood or not considered wood. Green waste should be considered to include a higher concentration of nitrogen. Green waste does not include older harvested materials that have been specifically left to dry out, such as straw, hay or dried leaves although some amounts of these materials may be present in the green waste materials processed as described herein without impacting the effectiveness of those processes. Dried leaves and the like have a higher content of carbon in comparison with the nitrogen-rich green waste.

The Applicant has considered that green waste may comprise garden, parks and landscaping refuse such as grass clippings, weeds, leaves, pine straw, fruits, dense vegetation, tree prunings, tree branches, roots and trunks, ornamental plant waste, flowers, and plant cover. The Applicant has considered that the green waste may comprise forest residues and farm/crop residues, for instance as may be respectively derived from forest management activities and farming management activities such as crop harvesting in which such residues would otherwise be discarded.

In one particular example, considered by the Applicant, waste generated by the cultivation of the date palm tree (phoenix dactylifera) is considered a particular target for use in the methods described herein. For example, date palm fruit, fronds, leaves, stems, stalks, branches, roots and trunks may be particularly processable according to the methods described herein. Other palm trees may be used in the methods described herein. For example, palm trees of the genus Phoenix may be particular target for use in the methods described herein. The North Africa, Middle East and South Asia regions are particular regions where the Applicant considers that the methods described herein may find particular utility. In this description, the terms “hydration level” and “level of hydration” shall be interpreted to as referring to the average total water content in a particular portion of green waste, or a stream of green waste, relative to the total mass of that green waste. The term “hydration ratio” shall be interpreted to as referring to the percentage of water mass to total green waste mass in a particular portion of green waste, or a stream of green waste.

In this description, the term “cooked green waste product” is the result of applying the processes and methods described herein to a portion or stream of green waste material. Cooked green waste product is more digestible by animals than green waste material that has not been subject to the methods and processes described herein. Cooked green waste product also has a longer shelf life than green waste material that has not been subject to the methods and processes described herein. Cooked green waste product can be used as a substitute for previously used animal feeds and/or to replace commonly used animal bedding and cover such as straw and hay. Cooked green waste product can also be used as a cultivation bed or substrate for certain agricultural uses. For example, cooked green waste product can also be used as a cultivation bed for fungi, such as edible mushrooms.

In this description, the term “machine vision” shall be interpreted to mean the capturing of one or more images, the automatic processing of those images to extract certain information, and the defining of certain actions based on the extracted information. The defined certain actions can then be executed by a system incorporating the machine vision and/or other systems that cooperate with the system incorporating the machine vision. The images may be a stream of images that are continuously processed to result in a continuous output of defined actions corresponding to the captured images.

The Applicant has conceived methods and systems that convert material that would otherwise be disposed of as waste and instead processes the material into economically viable products. Furthermore, the use of waste through the methods described herein reduces the environmental impact of the waste and also the economic activity associated with generating that waste in the first place. Large amounts of green waste can be produced in certain geographical areas, so finding an economically viable use for this material is considered attractive. This is especially true if the use of the green waste can help reduce costs by replacing existing, more costly, materials presently used in industry. Moreover, the methods and systems described herein permit green waste to be processed immediately as soon as the waste is generated; there is no need to pre-process the waste before use in the methods - for instance, there is no need to dry the waste before use and the waste can be used when freshly generated. The use of green waste, as described herein, is particularly beneficial since the green waste is a source of fibre and is nutritious - for instance, when using the cooked green waste product as described herein as animal feed or as cultivation substrates. The use of additives such as antioxidants, conservation agents and other plant-based materials such as starchy grains and vegetable sources help to produce a nutritionally balanced and stable product that is easily transported, stored and used in the applications described herein. Similarly, protein-based additives may help produce a product that meets certain nutritional needs.

In general, the constituents of plants can be divided into cellular content (lipids, nitrogenous compounds, fats, starch, and other water-soluble compounds) and cell walls (insoluble protein, hemicellulose, cellulose, and lignin). Herbivorous animals, who mainly consume products derived from plants, have a specially adapted gastrointestinal tract that can accommodate a diet comprising high levels of fibre; specifically, the gastrointestinal tract has dilated segments that are necessary for the microorganisms needed to be able to decompose cellulose (cellulose, hemicellulose, and others) present in the plants they ingest. Amongst these herbivore species are horses, cattle, camelids, buffaloes, sheep, goats, and rabbits. Such herbivore animals, whether being farmed, employed as working animals, or kept as house pets (husbandry), require large quantities of food that is rich in vegetable fibre. Global demand for animal products, such as in meeting human nutritional needs, continues to grow and, along with it, the demand for animal feed. Meeting this demand is challenging as, for example, herbivorous animals also consume some foods that are part of the human diet. For instance, 13% of the grain used by humans globally is consumed by herbivorous animals and the amount of grain required to produce 1 kg of beef is estimated between 3 kg and 20 kg, depending on the particular study. It is generally accepted that the animal production will have to be steadily increased over the first half of this century in order to meet the global demand for animal products. Increasing this supply will be accompanied by heavier land use along with associated environmental damage and resource depletion. The Applicant believes that the methods disclosed herein will contribute to lessening the impact of this growth in demand for animal products by providing alternative source of animal feed and by removing waste from the usual waste disposal methods. In particular, the animal feed produced according to the methods described herein will be high in fibre and nutritious.

Many economically important animals also have carefully managed bedding arrangements. Animal bedding is used to support animals when resting as well as to generally maintain good health and well-being of the animals. Such animal bedding is often frequently replenished for hygiene and sanitary reasons and, accordingly, large amounts of the animal bedding material are required. One source of animal bedding are wood shavings, which are comfortable and easy to maintain with good absorbent characteristics. Dry and clean wood shavings are considered good bedding for horses, for example. It is accepted, however, that conventional beddings like wood shavings are responsible for numerous respiratory diseases by promoting the creation of a microclimate with many of suspended small particles, which, together with the accumulation of ammonia - produced from the urea present in horse urine - cause inflammatory issues for the respiratory system. Furthermore, conventional beddings like wood shavings are responsible for hoof problems in some animals as humid environments, which can be promoted by conventional beddings, cause brittle hooves. Moreover, there is an increased incidence of infectious microorganisms (bacterial and/or fungal) in stables with sawdust and wood shaving beddings lacking a preferred level of hygiene. The Applicant believes that the methods disclosed herein will provide a viable alternative animal bedding product that reduces the respiratory problems and infection issues that are prevalent when using conventional animal beddings.

In another agricultural industry, edible mushrooms have been growing in importance in recent years in respect of recycling agricultural and agro-industrial waste. Mushroom cultivation can be carried out under natural non-aseptic conditions or under axenic conditions. In the case of axenic cultivation, a substrate is subjected to sterilization and aseptic cultivation techniques are used until total colonization of the substrate by the mushroom is achieved. It is notable that substrates subjected to sterilization processes to provide axenic conditions have higher production potential than non-aseptic substrates. One sterilization process is pasteurisation; for example, pasteurisation for the edible Agaricus mushrooms involves raising the temperature of compost substrate to approximately 62°C to sanitise the compost, eliminate some harmful microorganisms and, at the same time, complete the composting process. This process involves the costly use of heaters, air filters, and ventilation systems. The Applicant believes that the methods disclosed herein will be useful in removing some or all of these sterilization and aseptic conditioning techniques by providing an alternative source of cultivation substrates. Specifically, the cultivation substrates described herein may be utilised directly on delivery from a supplier without needing to implement further time-consuming sterilisation techniques. In particular, the processing of the green waste according to the methods described herein is heated to such a temperature during processing that the cooked green waste product is sterile and free of pathogens.

All of these industries use costly and resource hungry materials which make for higher costs for consumers. Furthermore, the resources used are often obtained from a single cultivation source and do not have a diversified supply chain. The Applicant believes that using the methods described herein can help with the issues experienced in these agricultural industries and, at the same time, reduce the environmental impact of generated green waste, increase food security and independence for humans, and reduce the land required for agricultural use such as for producing hay, wood, and/or grains. Certain examples of methods of green waste processing will now be described. The example methods will be described with respect to Figures 1 to 5. The example methods may be executed in any of the example systems described herein. For instance, the example methods may be executed in any of the preparation systems, mixture forming systems, and/or the thermoprocessing systems, as described herein and illustrated in any of the Figures. In certain examples, the example methods may be performed by any of the one or more controllers of the example systems described here in.

An example of a green waste processing method 10, developed by the Applicant, is shown in the flowchart of Figure 1. The method comprises a preparation phase 1000, a mixture forming phase 2000, and a thermo-processing phase 3000. Certain parts of the method may be performed between of these phases and be considered as part of one or other of the phases of the method. For instance, a mixture formed according to the mixture forming phase 2000 may be stored prior to use in the thermo-processing phase 3000; the storing of the mixture may be considered a part of the mixture forming phase 2000 or the thermo-processing phase 3000.

Referring to Figure 1 , at block 1010, during the preparation phase 1000, in which green waste material is prepared for later use in the mixture forming phase 2000 and the thermo-processing phase 3000, the method comprises separating the green waste material into non-wood material and wood material.

Separation of the green waste material into non-wood material and wood material may be performed by hand, for instance, by removing wood material from a stream of green waste material moving along a conveyor. For instance, the green waste material may be visually surveyed to separate the non-wood material and wood material. In some examples, further separation of the green waste material may be performed by visual inspection, for example to separate flowers, colourful leaves and other plant matter that may require analysis before further processing. In some cases, specific plant species may be selected for removal from the non- wood material and/or wood material streams or for processing separately according to the methods described herein. Specific plant species may be selected for separate analysis prior to processing.

In other examples, the separation of the green waste material into non-wood material and wood material may be performed by machine, for instance by using a machine to identify the wood material and the non-wood material and then automatically separating the different materials. Once separated, the non-wood material is, at block 1020, pre-ground into pieces of a certain size. Similarly, the wood material is, at block 1040, pre-ground into pieces of a certain size. The pre-grinding of the non-wood material and the wood material permits the processing of the green waste material into a more manageable size. By pre-grinding the non-wood material and the wood material, the hydration level of the separated non-wood material and wood material can be more easily controlled. For instance, large pieces of non-wood materials, such as large leafy stalks, may not dry in an even manner or predictable manner if they remain in their original state.

In certain examples of the method, the separated non-wood material is pre-ground into pieces having a maximum size of approximately 40 mm. In certain examples of the method, the separated wood material is pre-ground into pieces having a maximum size of approximately 40 mm. The Applicant has found that pieces sized at 40 mm provided the best management and drying size for pieces of the non-wood material and wood material. It was also found that the size of 40 mm was suitable for storing the pre-ground non-wood material and the pre-ground wood material.

At block 1030, the hydration level of the pre-ground non-wood material is controlled. The hydration level of the pre-ground non-wood material is controlled such that the hydration level meets a predetermined non-wood hydration ratio. That is, the hydration level of the non-wood material is limited to a certain percentage of water in the total mass of the non-wood material. Similarly, at block 1050, the hydration level of the pre-ground wood material is controlled. The hydration level of the pre-ground wood material is controlled such that the hydration level meets a predetermined wood hydration ratio. That is the hydration level of the wood material is limited to a certain percentage of water in the total mass of wood material. Controlling the hydration level of the non-wood material and the wood material is important for later processing of the non- wood material and the wood material. For example, having a suitable hydration level of the non- wood material and the wood material can help with the grinding and mixing process during the mixture forming phase of the method. Furthermore, the hydration level is important for maintaining the quality of the non-wood and wood material during storage, for instance to avoid rotting. Decomposed green waste material is not suitable for processing. The Applicant has found that controlling the hydration level prevents issues at the mixture forming phase and the thermo-processing phase by permitting blending of the right proportions of non-wood material, wood material, and/or additional constituents prior to initiating the thermo-processing. For instance, controlling the hydration level means that stored non-wood material and/or wood material can be used in the mixture formation phase with a homogenous composition and hydration level leading to a consistent and predictable cooked green waste product. Furthermore, controlling the hydration level means that the non-wood material and/or wood material can be handled and stored without presenting any hygiene or environmental issues due to decomposition. As the mixture forming phase is performed using measurements based on hydration-controlled constituents (i.e., the non-wood and wood material with dry additional constituents) the dosing of the constituents can also be consistent and predictable. The Applicant has found that green waste material can have very high hydration levels prior to processing using method 10. For instance, a high hydration ratio of around 50% can often be expected for freshly produced green waste material.

Once the hydration level of the non-wood material and the wood material has been controlled to the desired level, the pre-ground non-wood material and the pre-ground wood material can then be stored for any suitable length of time until required for use later in the process. Storing the pre-ground non-wood material and the pre-ground wood material can be beneficial since it allows the for the control of the flow of non-wood and wood material during processing. For instance, just the right amount of non-wood material and/or wood material can be released to the mixture forming phase 2000 from storage, which avoids any wastage of material and/or manufacturing time. Storage of non-wood and/or wood materials can address issues with raw material availability - for instance, equal volumes of green waste material may not be available for processing every day, week, or month. Some green waste streams or species may only be available at certain times of the year. Alternatively, in some examples the pre-ground non-wood material and the pre-ground wood material can be passed directly to the mixture forming phase 2000 once dehydration level has been controlled.

In certain examples, controlling the hydration level of the pre-ground non-wood material comprises de-hydrating the non-wood material. Similarly, controlling the hydration level of the pre-ground wood material may comprise de-hydrating the wood material. Drying machines may be used to dehydrate the pre-ground non-wood material and/or the pre-ground wood material. For example, a cold air dryer may be used in which cold air is circulated over the non-wood material and/or the wood material. In other examples, hot air maybe used to dehydrate the non- wood material and/or the wood material. In certain examples, the pre-ground non-wood material and/or the pre-ground wood material may be passed through the dryers on conveyors. In other examples, the pre-ground non-wood material and/or the pre-ground wood material may be distributed on racks or on the ground in large drying facilities and allowed to dry naturally over time. This may be particularly useful in environments where there is little rainfall and/or the atmosphere is usually of particularly low humidity. For example, the pre-ground non-wood material and/or the pre-ground wood material may be spread out in the open to be dried in the sun. This option may be particularly energy efficient.

The Applicant has found that the pre-determined non-wood hydration ratio should be no more then approximately 14%. Similarly, it has been found that the pre-determined wood hydration ratio should be no more then approximately 14%. That is, the water content of both the preground non-wood material and the pre-ground wood material should be no more than 14% of the total mass. This maximum level of water content, or hydration, has been found to provide the best results when processing the pre-ground non-wood material and pre-ground wood material during the mixture forming phase 2000 and the thermo-processing phase 3000. In certain examples the predetermined non-wood hydration ratio and/or the predetermined wood hydration ratio may be even lower than 14%. For instance, this may occur in environments where the green waste is processed in very humid conditions where the pre-ground non-wood material and pre-ground wood material are expected to absorb water before further processing in the mixture forming phase 2000 and the thermo-processing phase 3000.

In certain examples, preparing the green waste material will also include the application of a pesticide to the green waste material. For instance, a fungicide, a herbicide, an insecticide and/or, a nematicide may be applied to the green waste material. For example, the pesticide may comprise propionic acid. The pesticide may comprise ammonium dipropionate. The pesticide may comprise ammonium dipropionate comprising 63% propionic acid. One example of a suitable pesticide is Mold-Zap® (Alltech/USA).

The pesticide may be applied to the green waste material at any suitable time in the preparation phase 1000. For example, the pesticide may be applied to the green waste material after separation of the green waste material supply into non-wood material and wood material. The pesticide may be applied to the separated non-wood material and/or wood material prior to pregrinding. The pesticide may be applied to the separated non-wood material during pre-grinding of the non-wood material. The pesticide may be applied to the separated wood material during pre-grinding of the wood material. In other examples, the pesticide may be applied to the preground non-wood material and/or the pre-ground wood material following pre-grinding. For example, the pesticide may be applied during the hydration control of the pre-ground non-wood material and/or the pre-ground wood material. For example, the pesticide may be sprayed onto the pre-ground non-wood material and/or the pre-ground wood material when laid out in the open or on racks to dry. Where the pre-ground non-wood material and/or the pre-ground wood material is stored, the pesticide may be applied before storing or after storing of the pre-ground non-wood material and/or the pre-ground wood material. In some other examples, the pesticide may be applied to the green waste material after the preparation phase 1000.

The use of a pesticide can be dependent on the ultimate intended use of the cooked green waste product. For example, if the cooked green waste product is to be used as a cultivation substrate for fungiculture, then no pesticide would be applied. On the other hand, for using the cooked green waste product finding use as herbivore food, a certain amount of pesticide may be applied. For example, the quantity of pesticide used on the product may be in the range of 0.0% to 0.4%.

Referring again to Figure 1 , at block 2010, during the mixture forming phase 1000, in which a green waste derived mixture is formed for later use in the thermo-processing phase 3000, the method comprises mixing the pre-ground non-wood material and pre-ground wood material together in a pre-determined non-wood/wood ratio. Mixing may comprise selecting a non-wood material portion and a wood material portion, according to the pre-determined non-wood/wood ratio, and then adding the selected non-wood material portion and the selected wood material portion to a mixing apparatus so that the desired non-wood/wood material ratio is present in the green waste derived mixture. As discussed further below, the method may also comprise, determining the pre-determined non-wood/wood ratio based on the results of the laboratory testing described herein.

At block 2020, the pre-ground non-wood material and pre-ground wood material are further ground to a desired particle size that is suitable for use in the thermo-processing phase 3000 of the method 10. In certain examples, mixing the pre-ground non-wood material and pre-ground wood material occurs at the same time as grinding the pre-ground non-wood material and preground wood material. For instance, the mixing and grinding may occur together in one mixer. Alternatively, mixing the pre-ground non-wood material and pre-ground wood material may be performed before grinding the pre-ground non-wood material and pre-ground wood material. Alternatively still, grinding the pre-ground non-wood material and pre-ground wood material may be performed before mixing the pre-ground non-wood material and pre-ground wood material.

In certain examples of the method 10, forming the green waste derived mixture comprises mixing one or more additional constituents or additives with the pre-ground non-wood material and preground wood material. The additional constituents may be mixed with the pre-ground non-wood material and pre-ground wood material at the same time as grinding the pre-ground non-wood material and pre-ground wood material, before grinding the pre-ground non-wood material and pre-ground wood material, or after grinding the pre-ground non-wood material and pre-ground wood material.

The use of additional constituents may be beneficial for the management or later processing of the green waste derived mixture. In certain cases, at least one of the additional constituents comprises starch and/or a starchy ingredient. The use of starch and/or starchy ingredients can be helpful when heating the green waste derived mixture under pressure. For instance, the use of starch and/or a starchy ingredients can help bind the green waste derived mixture together when cooking and also help augment the nutritional content of the cooked green waste product. For example, the additional constituents may comprise a starchy cereal grain such as one or more of: sorghum, rye, wheat, rice, maize (corn), oats, millet, and barley. The use of, or the amount of, starch and/or starchy ingredients may be varied depending on the ultimate use of the cooked green waste product. For example, a higher proportion of starchy ingredients may be used for producing animal feed product and lower proportions for other uses.

Other possible additional constituents that can be added when forming the green waste derived mixture comprise a conservative compound to prevent the green waste derived mixture decomposing. The use of a conservative compound can assist with prolonging the shelf life of the cooked green waste product.

In some examples, the conservative compound may comprise an antioxidant. One possible antioxidant found suitable by the Applicant is Silvafeed® ATX, which is a natural antioxidant considered suitable for nutritional applications. Another possible antioxidant found suitable by the Applicant is BANOX® 100. In other examples, the additional constituents may comprise flavourings, fragrances, and/or nutritional supplements and the like. For instance, liquid flavouring may be added during forming green waste derived mixture.

The method may comprise pre-testing the additional constituents to determine the nutritional content of the additional constituents. The pre-testing may comprise determining one or more of: the water content, the micronutrient content, the macronutrient content, and the starch content of the additional ingredients. The pre-testing may be performed before the additional constituents are delivered for processing under the method 10. The pre-testing may be in addition to the laboratory testing described herein. The method may comprise determining the proportion of additional constituents to be mixed with the pre-ground non-wood material and preground wood material based on the results of pre-test. The method may also comprise, or comprise, determining the proportion of additional constituents to be mixed with the pre-ground non-wood material and pre-ground wood material based on the results of the laboratory testing described herein. The method may comprise measuring the amount of additional constituents to be mixed with the pre-ground non-wood material and pre-ground wood. The method may comprise monitoring the actual proportion of additional constituents being mixed with the preground non-wood material and pre-ground wood material to ensure that the actual proportion of additional constituents corresponds to the determined proportion of additional constituents.

In certain examples, the pre-ground non-wood material and pre-ground wood material may be ground into particles having a maximum size of no more than 1.5 mm to 3 mm. In some examples, the particles may have a maximum size of no more than approximately 2 mm. Where added, the additional constituents may also be ground into particles having a maximum size of no more than 1 .5 mm to 3 mm or, in some cases, a maximum size of no more than approximately 2 mm. In certain examples, making the particles smaller than 1.5 mm to 2 mm can be possible but will incur a greater processing cost. Particles larger than 3 mm can cause difficulties with thermo-processing the green waste derived mixture.

In certain examples, the method may comprise storing the green waste derived mixture before thermo-processing the green waste derived mixture. Again, this can be beneficial as storing the mixture can assist with managing the processing of green waste in an efficient manner.

Referring once again to Figure 1 , at block 3010, during the thermo-processing phase 3000, in which a cooked green waste product is produced from the green waste derived mixture, the method comprises pre-conditioning the green waste derived mixture before the green waste derived mixture is heated under pressure. Pre-conditioning the green waste derived mixture has been found by the Applicant to improve the composition and quality of the ultimate cooked green waste product. For instance, pre-conditioning the green waste derived mixture results in improved cooking of the green waste derived mixture so that more nutritional content is absorbed in the digestive system of animals that eat the cooked green waste product. Furthermore, preconditioning the green waste derived mixture improves the cooking process such that the cooked green waste product is easier to digest for an animal. Pre-conditioning the green waste derived mixture may comprise controlling the temperature and/or hydration level of the green waste derived mixture.

Pre-conditioning the green waste derived mixture may comprise pre-heating the green waste derived mixture. Pre-heating the green waste derived mixture results in a staged increase in the temperature of the mixture before heating under pressure, which the Applicant believes leads to an improved cooking process. Pre-conditioning the green waste derived mixture may comprise pre-hydrating the green waste derived mixture. In one example, pre-conditioning the green waste derived mixture comprises injecting steam into, or steaming, the green waste derived mixture to hydrate the green waste derived mixture. Injection of steam may be continuous during pre-conditioning or, in other examples, steam may be periodically injected. The Applicant considers that injecting steam is particularly useful because the green waste derived mixture is both heated and hydrated at the same time. In other examples, the green waste derived mixture may be dosed with water. For instance, water may be added to a pre-conditioning vessel. Preconditioning the green waste derived mixture may increase the hydration level of the green waste derived mixture. The increase in temperature and/or the increase in hydration of the green waste derived mixture may initiate a cooking process in the green waste derived mixture. In some cases, certain flavourings, fragrances, and/or nutritional supplements and the like may be added to the green waste derived mixture during pre-conditioning. At block 3020, the green waste derived mixture is heated to a pre-determined temperature, while a pre-determined pressure is exerted on the green waste derived mixture at the same time. The heating and pressurising cooks the green waste derived mixture thereby producing a cooked green waste product.

The Applicant considers that cooked green waste product can find many uses. For instance, a cultivation substrate comprising the cooked green waste product may be produced according to any of the methods described herein. In one example, a fungi cultivation substrate for fungiculture comprising the cooked green waste product may be produced according to any of the methods described herein.

In another example, an animal feed comprising the cooked green waste product may be produced according to any of the methods described herein. In another example, animal bedding comprising the cooked green waste product may be produced according to any of the methods described herein. Such uses may be particularly environmentally beneficial since the methods described herein use matter that would otherwise need disposal as unusable waste.

The Applicant has found that the pre-determined temperature should be set between approximately 95°C and approximately 160°C for best results. In certain examples, the predetermined temperature can set at around 135°C. The Applicant has also found that the predetermined pressure should be set between approximately 25 bar and approximately 75 bar. The cooked green waste product can be further processed once thermo-processing has been completed.

Turning now to the flowchart of Figure 2, the method, during the preparation phase 1000, may comprise, at block 1012, classifying the green waste material supply into a non-wood material class and a wood material class. On the basis of the classification of the green waste material into the non-wood material class and the wood material class, at block 1014, separation of the classified green waste material supply into non-wood material and wood material may be performed.

Classifying the green waste material supply in this manner may be particularly useful where the separation is to be performed automatically by a system or machine. In certain examples, classifying the green waste material may comprise using machine vision to identify non-wood material for classification into the non-wood material class and/or to identify wood material for classification into the wood material class. For instance, machine vision may be used to assess one or more properties of a stream or batch of green waste material that is to be separated. The properties may consist of colours, heat patterns, size, shape, or any combination of such properties. In other examples, properties such as the weight or hydration level of the green waste material may be assessed to determine the relevant class to which a particular component of the green waste material belongs.

The flowchart of Figure 3 shows that the method, during the preparation phase 1000, may comprise, at block 1060, drawing one or more samples from the materials that will be mixed and ground during the mixture forming phase 2000. The one or more samples may be selected from: one or more samples taken from the non-wood material and/or one or more samples taken from the wood material. The one or more samples may also be selected from one or more samples taken from the additional constituents.

The one or more samples may be drawn from the separated non-wood and wood materials after the pre-grinding is performed. The one or more samples may be drawn from the separated non- wood and wood materials after the hydration of the pre-ground non-wood and wood materials is controlled. The one or more samples may be drawn at any suitable time during the preparation of the green waste material. In some examples, the one or more samples can be drawn immediately before the green waste derived mixture is formed in the mixture forming phase 2000.

Once the one or more samples have been drawn, at block 1062, a laboratory test is performed on each of the one or more samples. Conducting the laboratory test may comprise determining one or more selected properties of each of the one or more samples. In some examples, conducting the laboratory test comprises determining the hydration ratio of each of the one or more samples. In some examples, conducting the laboratory test comprises determining the particle size of each of the one or more samples. The laboratory test may be used to determine the nutritional content of each of the one or more samples. The nutritional content of concern may comprise one or more of: the water content, the micronutrient content, the macronutrient content, and the starch content of the one or more samples. Other samples may be drawn at any stage of the method 10 to monitor the quality of the green waste during processing under the method 10.

The laboratory test(s) may be used to determine the proportions of the various constituents that will be mixed together in the mixture forming phase 2000. For instance, the nutritional content of the cooked green waste product can be carefully controlled by utilising the laboratory test(s). In other examples, the strength, elasticity, and/or brittleness of the cooked green waste product can be carefully controlled by utilising the laboratory test(s). Determining the pre-determined non-wood/wood ratio based on the laboratory test may be beneficial due to imparting control over the nutritional content of the cooked green waste product, for instance. Using the results of the laboratory tests can ensure that the right variety of the ingredients are mixed and ground, for instance for each batch of green waste derived mixture that is to be formed or for the stream of green waste derived mixture that is to be formed, before thermo-processing.

Turning now to the flowchart of Figure 4, the method, during the mixture forming phase 2000 may comprise, at block 2012, monitoring an actual non-wood/wood ratio in the green waste derived mixture during the mixing of the pre-ground wood material add the pre-ground non-wood material. At block 2014, the method may comprise determining whether the actual non- wood/wood ratio corresponds to the pre-determined non-wood/wood ratio and, in response to a lack of correspondence, adjusting the amount of pre-ground non-wood material and/or preground wood material being added to the mixture. Real time adjustment of the amount of preground non-wood material and/or pre-ground wood material being added to the mixture during mixing may be beneficial in that more exact control of the nutritional content or other properties of the cooked green waste product can be achieved. The monitoring may be performed simultaneously with the adding of the pre-ground non-wood material and/or pre-ground wood material to the forming mixture. In certain examples, forming the green waste derived mixture may comprise measuring the amount of pre-ground non-wood material and/or pre-ground wood material being added to the mixture during mixing. In this way the amounts of pre-ground non- wood material and/or pre-ground wood material being added to the mixture can be controlled.

In some instances, monitoring the actual non-wood/wood ratio of the green waste derived mixture may comprise using machine vision to sample one or more properties of the green waste derived mixture during mixing. For instance, machine vision may be used to assess one or more properties of a stream or batch of green waste derived mixture as mixing is performed. The properties may consist of colours, heat patterns, size, shape, or any combination of such properties. The properties may then be assessed to determine the status of the green waste derived mixture with respect to desired property states. For instance, on the basis of the state of one or more properties of the green waste derived mixture, the amount of pre-ground non-wood material, pre-ground wood material, and/or additional constituents being added to the forming mixture may be adjusted so as to change the properties of the green waste derived mixture to bring those properties closer to the desired state.

The flowchart of Figure 5 shows one possible method for heating and pressurising the green waste derived mixture. At block 3022, the green waste derived mixture is fed into, and forced under pressure through, a heated barrel thereby cooking the green waste derived mixture. The green waste derived mixture is forced out of the heated barrel by the applied pressure. The result is a cooked green waste product that is extruded from a nozzle of the heated barrel. Extruding materials through a heated barrel has been used for various materials such as plastics, rubbers, and metal alloys. In one example, the heated barrel may comprise a helical screw that, on activation, forces the green waste derived mixture through the heated barrel to the nozzle. Other mechanisms may be used to generate the pressure, such as a plunger. The Applicant has found that the heating the barrel to a pre-determined temperature around 135°C gives good results in the cooking process. However, heating the barrel to a pre-determined temperature to between approximately 95°C and approximately 160°C works well.

In certain examples, the cooked green waste product is extruded from the nozzle to form kibble. Kibble may be a particularly desirable form since it is useful as an animal feed. In other examples, the cooked green waste product may be formed into pellets by compressing the extruded product. For example, the kibble produced during extrusion can be further processed to form pellets from the kibble. In some examples, a liquid compression aid may be applied to the extruded product prior to the pellets being formed. Pelletisation can be useful in some examples since the higher density of the product means that the product can be easier and cheaper to transport.

In one example, the method comprises injecting steam into the pressurised heated barrel. The applicant has found that injecting steam into the pressurised heated barrel assists with maintaining the quality and composition of the cooked green waste product. Injecting steam into, the barrel helps to hydrate the green waste derived mixture during cooking. The Applicant considers that injecting steam is particularly useful because the green waste derived mixture is both heated and hydrated at the same time and because the steam is able to permeate through the green waste derived mixture during cooking. Injection of steam into the heated barrel may be continuous during processing of the green waste derived mixture or, in other examples, steam may be periodically injected into the heated barrel.

Blocks 3030, 3040, and 3050 set out optional post-processing examples for the cooked green waste product after thermo-processing. At block 3030, the extruded cooked green waste may be further processed. In certain examples, the extruded cooked green waste derived mixture is chopped or cut immediately following extrusion. In other examples, the extruded cooked green waste derived mixture may be allowed to extrude into long strands to form straw or hay-like material. In certain examples, the extruded cooked green waste derived mixture may be allowed to extrude into long strands that are coiled or allowed to randomly bunch, bundle or cluster following extrusion. For instance, a form of wool or padding may be formed from the extruded strands. At block 3040, the extruded cut green waste arrived mixture is passed through a dryer. The trial may be heated air dryer. The dryer may comprise cold air dryer, for instance, a cold air dryer in which air is circulated by a fan or the like above the cooked green waste product. Drying the cooked green waste product at this stage controls the hydration level of the cooked green waste product before it is used, packaged, or stored for later use.

Add block 3050, the dried cooked green waste product is packaged. Packaging may take any suitable form dependent on the ultimate final planned use of the green waste product. For instance, where they cooked green waste product is to be used as animal feed, the cooked green waste product maybe packaged in plastic bags or sacks suitable for transporting the product.

Figures 6 to 13 illustrate some examples of systems in which the methods described herein may be implemented. A green waste processing system 400 is shown in Figure 6. The green waste processing system 400 may be set out in any suitable facility or factory. In the example shown, the green waste processing system 400 comprises a preparation system 100, a mixture forming system 200, and a thermo-processing system 300. It will be understood that the preparation system 100, the mixture forming system 200, and the thermo-processing system 300 may each be provided independently of one another and not as a part of a green waste processing system 400. For instance, certain method implementers may only implement one or two phases of the method 10, for example by operating only one or two of the preparation system 100, the mixture forming system 200, and the thermo-processing system 300.

The green waste processing system 400 may comprise other elements that facilitate the implementation of any of the methods described here in. For example, the green waste processing system may comprise a non-wood, wood, and additive storage area 420. Alternatively, storage facilities may be provided within, for example the preparation system 100 and/or the mixture forming system 200. The green waste processing system 400 may also comprise a product packaging and package storage area 430 where the cooked green waste product may be packaged for later delivery to customers. The cooked green waste product may also be stored in its packaged state. The green waste processing system 400 may also comprise a pre-sort area 410 where arriving green waste is surveyed to check that it is suitable for processing in the preparation system 100. For example, the arriving green waste may be surveyed to check for items such as stones, metal parts, or rubbish, for example, old tyres or the like, that are present in the delivered green waste and cannot be processed by the preparation system 100. The green waste processing system 400 may also comprise a facility control centre 450 in which management of the green waste processing system 400 is controlled. For example, the preparation system 100, the mixture forming system 200, and the thermo-processing system 300 may each be controlled from the control centre 450. The control centre 450 may comprise one or more controllers as described herein that are configured to control the operations of the green waste processing system 400. In use, the preparation system 100, the mixture forming system 200, and the thermo-processing system 300 may be controlled by the one or more controllers of the control centre 450 and each be operated independently or in concert with one another. The one or more controllers may be communicatively coupled with the preparation system 100, the mixture forming system 200, and/or the thermo-processing system 300 to cause operation of the same. In some examples, the controllers may be co-located with the preparation system 100, the mixture forming system 200, and/or the thermo-processing system 300.

Turning now to Figure 7, which illustrates an example of a preparation system 100 in which the preparation phase 1000 of the method 10 may be implemented. Green waste is delivered to a separation station where the green waste is separated into non-wood material and wood material. The separated non-wood material and wood material is then delivered to one or more pre-grinding stations. For instance, a single pre-grinding station may be used to pre-grind the separated non-wood and wood material. In other examples, dedicated pre-grinding stations may be provided for each of the non-wood material and wood material.

From the pre-grinding station(s) the pre-ground non-wood and pre-ground wood material is delivered to one or more drying stations where the hydration level of the materials is controlled, as described above. Again, a single drying station may be used to dry these separated non- wood and wood material or, alternatively, dedicated drying stations may be provided for each of the pre-ground non-wood and pre-ground wood materials.

The preparation system 100 also comprises a sampling station where samples drawn from the non-wood material and wood material can be tested. In certain examples, as shown in Figure 7 the sampling station involves drawing testing samples following hydration control for each of the pre-ground non-wood and the pre-ground wood material. However, it will be understood that the sampling station may test samples that have been drawn following pre-grinding but before drying is performed.

The preparation system may also comprise one or more storages as shown in Figure 7. In addition to storage for non-wood material and storage for wood material, there may also be provided a storage for additives or additional constituents that are to be added to the mixture during the mixture forming phase 2000. Figure 8 is a schematic diagram of another example of a preparation system 100. Figure 8 shows just one possible arrangement conceived by the Applicant for managing the preparation phase 1000 of the method 10 in a processing facility. It will be understood that other equipment arrangements can be provided.

In Figure 8, green waste material is delivered to a separation station 102 where the green waste material can be sorted, or identified, into non-wood and wood material for separation S and then pre-grinding. In one example, a machine vision system 104 may be used to survey the contents of the green waste material as it is processed at the separation station 102. For instance, the machine vision system 104 may capture images of the green waste material as it passes through the sorting area of the separation station 102.

From the separation station 102, the green waste material is separated into non-wood material and wood material streams or batches. The non-wood material is pre-ground at a pre-grinding station 110. Once pre-ground, the non-wood material is then moved to a dryer 112 where the hydration level of the pre-ground non-wood material is controlled. Samples T may be drawn from the pre-ground non-wood material before or after drying. In the same way, the wood material is pre-ground at a pre-grinding station 120. Once pre-ground, the wood material is then moved to a dryer 122 where the hydration level of the pre-ground wood material is controlled. Samples T may also be drawn from the pre-ground wood material before or after drying and moved to the laboratory 130 for testing.

The properties of the samples T are moved to, and tested at, laboratory 130. Data indicative of the properties of the samples T, which result from the tests on the samples T, can be stored for later use in the method 10, for instance after storing of the pre-ground non-wood and pre-ground wood material.

As shown in Figure 8, in certain examples, the preparation system 100 may comprise storages 114, 124 where the non-wood and wood materials can be temporarily stored until required for use in the mixture forming phase 2000 of the method 10. The non-wood and wood materials may be stored separately, as indicated in Figure 8.

In certain examples, any of the preparation systems 100 may comprise a controller, such as the controller 150 shown in Figure 8. The controller may be solely dedicated to controlling the functions of the preparation system 100 or control may be provided by a controller of the green waste processing system 400. The controller may be configured to control the operation of the separation station, the pre-grinding station(s), and/or the dryer(s). The controller may also be communicatively coupled to the machine vision system 104 and configured to manage data representing the images obtained from the machine vision system 104. The controller may also be configured to manage data representing the properties of the non-wood material, wood material, and/or additives as derived from testing samples in the laboratory. The controller may be communicatively coupled to one or more other controllers of the green waste processing system 10.

Figure 9 illustrates an example of a mixture forming system 200 in which the mixture forming phase 2000 of the method 10 may be implemented. In the example shown, the mixture forming system 200 comprises a mixer and a grinder. Pre-ground non-wood material and pre-ground wood material are delivered to the mixer where they are mixed together to begin forming the green waste derived mixture. Additives or additional constituents, where used, may also be delivered to the mixer in some examples. Once mixed, the partially formed green waste derived mixture is ground in the grinder to complete formation of the green waste derived mixture.

In certain examples, the mixture forming system 200 may comprise a mixture storage where the green waste derived mixture may be temporarily stored until required for use in the thermoprocessing phase 3000 of the method 10. In other examples, the green waste derived mixture may be immediately transferred for processing in the thermo-processing phase 3000 of the method 10.

Referring to Figure 10, which shows a schematic diagram of another example of a mixture forming system 200. Figure 10 is just one possible arrangement conceived by the Applicant for mixing and grinding the non-wood and wood materials during the mixture forming phase 2000. It will be understood that other arrangements are conceivable.

In Figure 10 a combined mixer and grinder 230 is shown. Pre-ground non-wood material and pre-ground wood material are introduced to the combined mixer and grinder 230. In the example shown in Figure 10, the pre-ground non-wood material is introduced via conveyor 210 and the pre-ground wood material is introduced via conveyor 220. The conveyors 210, 220 are controllable such that streams of non-wood material and wood material may be delivered in a stop-start manner. Similarly, if the non-wood material and the wood material are to be delivered in batches, then the batches can be introduced via the conveyors 210, 220.

Additional constituents or additives can be introduced into the combined mixer and grinder 230 from a supply source, such as hopper 202. The introduced contents of the combined mixer and grinder 230 are mixed and ground together by a set of grinding wheels 232. Other arrangements inside the combined mixer and grinder are conceivable. For instance, a mixing blade and separate grinding wheels may be provided in some embodiments. Once ground and mixed, the formed green waste derived mixture is removed from the combined mixer and grinder 230 via output conveyor 234.

In one example, a machine vision system 204 may be used to survey the contents of the combined mixer and grinder as the introduced contents is mixed and ground. For instance, the machine vision system 204 may capture images of the introduced contents during mixing and grinding.

In certain examples, any of the mixture forming systems 200 may comprise a controller, such as the controller 250 shown in Figure 10. The controller may be solely dedicated to controlling the functions of the mixture forming system 200 or control may be provided by a controller of the green waste processing system 400. The controller may be configured to control the operation of inputs, such as the conveyers 210, 220, grinding elements, such as the grinding wheels 232, mixing elements, and/or outputs, such as the conveyor 230. The controller may also be communicatively coupled to the machine vision system 204 and configured to manage data representing the images obtained from the machine vision system 204. The controller may be communicatively coupled to one or more other controllers of the green waste processing system 10.

Figure 11 illustrates an example of a thermo-processing system 300 in which the thermoprocessing phase 3000 of the method 10 may be implemented. In the example shown, the thermo-processing system 300 comprises a pre-conditioner and a pressurised cooker. Green waste derived mixture is delivered to the pre-conditioner where the mixture is pre-conditioned as described herein. Once pre-conditioned the green waste derived mixture is heated under pressure to complete formation of the cooked green waste product. In certain examples, the cooked green waste product may be delivered to a dryer where the cooked green waste product is dehydrated to control the hydration level of the cooked green product. Controlling the hydration of the cooked green product can improve the shelf life of the cooked green product and can also help with storage and transport costs.

Referring now to Figure 12, which shows a schematic diagram of another example of a thermoprocessing system 300. Figure 12 is just one possible arrangement conceived by the Applicant for thermo-processing the green waste derived mixture during the thermo-processing phase 3000. It will be understood that other equipment arrangements are conceivable to achieve suitable thermo-processing. Thermo-processing is initiated, in the example shown in Figure 12, by introducing the green waste derived mixture into a pre-conditioner 310. In this example, steam is injected into the preconditioner 310 to pre-condition the green waste derived mixture. The steam is injected via an inlet 312, which may comprise a valve that is closeable, in use, to control the injection of steam into the pre-conditioner 310.

Once pre-conditioned, the green waste derived mixture is fed into a heated extruder barrel 320. The green waste arrive mixture is forced through the heated barrel 320 using a helical screw 322, which applies a significant force (for example, between 25 bar and 75 bar) to the green waste derived mixture to force it along the barrel 320 and out through the barrel nozzle 328. As the green waste derived mixture is forced through the barrel 320, the mixture is further heated by the heated barrel. The heated barrel 320 comprises heating elements 324 that are arranged sequentially lengthwise along the heated barrel 320.

The helical screw 322 is configured so that the pressure, or force, applied to the green waste derived mixture can be varied. Varying the force applied to the green waste derived mixture can control the speed at which the green waste arrive mixture is extruded from the nozzle, which can assist with controlling the length or form of the product - for instance, products extruded at a different rate may have different porosities. As with all extrusion methods, the nozzle of the heated barrel may be shaped according to the desired final cross-section of the cooked green waste product. In other words, different extrusion dies may be deployed dependent on the desired final shape of the cooked product. In one example, a nozzle is provided having an opening varying from 10 mm to 20 mm, Sizes of nozzles used by the Applicant include 12 mm and 16 mm. These are useful for the majority of kibble products that are to be produced. The density of the extruded cooked green waste product can be varied by varying the constituents in the green waste derived mixture. Specifically, in one example it is possible to change the amount of fibre in the green waste derived mixture in order to control the density of the cooked green waste product.

The heated barrel 320 may also be configured such that the lengthwise temperature profile of the heated barrel 326 can be varied. For instance, heating elements 324 that are located closer to the nozzle end of the heated barrel may be set at a lower temperature than heating elements that are located further from the nozzle end of the heated barrel 320. Controlling temperature in this manner may provide a better cooking result and/or prevent burning, for instance.

In certain examples, the heated barrel 320 also comprises a steam inlet 326 through which steam is injectable into the heated barrel 320. Injecting steam into the heated barrel 320 allows the temperature and the hydration of the green waste arrived mixture to be augmented and controlled during cooking. The injected steam may permit a finer control over the final composition and quality of the cooked green waste product than if the cooking process solely relied on the heating and pressurising of the green waste derived mixture. The steam inlet 326 may comprise a valve that is closeable, in use, to control the injection of the steam into the heated barrel 320.

Once extruded, the cooked green waste product may be post- processed. For instance, a reciprocating or rotating cutter or blade 330 may be placed immediately adjacent to the nozzle 328 of the heated barrel 320. Activating the blade 330 allows the cooked green waste product to be chopped into smaller pieces. Smaller pieces of product may be useful for such applications as animal feed and the like. In other examples, the cooked green waste product maybe extruded to form bundles or long string-like strands that can be used in other applications such as animal bedding or cultivation beds or substrates for fungi.

In the example shown in Figure 12, the post- processed green waste product drops onto a conveyor 332 where a cooling and drying process begins. The cooked green waste product is delivered from the conveyor 332 into an air dryer 340. Dryer 340 comprises one or more fans 342 which are operable to circulate cool air over the cooked green waste product to dehydrate the product. The cooked green waste product passes through the dryer on a conveyor 344. In another example, the dryer may comprise a hot air dryer or dehumidifier. From the conveyor 344 the post- processed cooked green waste product may be packaged for storage and/or delivery to customers.

In another example of dryer tested by the Applicant, cooling and drying of the cooked green waste product is performed using a pneumatic transportation system. In this instance, compressed air is used to move the cooked green waste product via closed at a relatively low velocity, which, in the process of transport, permits the cooked green waste product to cool and dry whilst being transported. Conveniently, the cooling and drying can occur as the cooked green waste product is moved to storage for packaging or directly to a packaging station.

As mentioned above, the example methods described above may be performed in any of the example systems described herein and illustrated in any of the Figures. For example, the method(s) described above may be performed in the example green waste processing system 400 shown in Figure 13. The green waste-processing system 400 may further comprise a controller 500. In use, the controller 500 may control functions of the green waste-processing system 400. The controller 500 may be located in the facility control centre 450 described above. For example, the controller 500 may control the separation of the non-wood material and the wood material in the preparation system 100, the forming of the green waste derived mixture in the mixture forming system 200, and/or the thermo-processing of the green waste derived mixture in the thermo-processing system 300. the controller 500 may be configured to manage data representing the images obtained from the machine vision system 104 and/or the data representing the images obtained from the machine vision system 204. For instance, the data from the representing the images obtained from the machine vision system 204 may be used by the controller to control the non-wood and wood materials being introduced during mixing and grinding in the mixture forming system 200. The controller may also be configured to manage data representing the properties of the non-wood material, wood material, and/or additives as derived from testing samples in the laboratory.

It will be understood that, instead of the controller 500 being provided to control the functions of the green waste-processing system 400, there may be separate controllers, such as those described above, provided for each of the preparation system 100, the mixture forming system 200, and/or the thermo-processing system 300. The controller 500 may be communicatively connected 530 with each of the preparation system 100, the mixture forming system 200, and/or the thermo-processing system 300. The controller 500 may be electrically connected by way of communication cabling. However, it will be appreciated that a wireless communication protocol could be used instead.

The controller 500 may comprise a processor 510. The processor 510 may carry out any of the processes or methods described herein or instruct they be carried out in the green wasteprocessing system 400. The controller 500 may comprise a storage module 520. The storage module 520 may comprise a non-transitory storage medium. The non-transitory machine- readable storage medium 520 may be encoded with instructions executable by the processor 510.

Any of the example processes or methods described herein may be encoded in machine readable form on the non-transitory storage medium. For example, the example processes or methods above may be in the form of a computer program comprising computer program code. For example, the non-transitory machine-readable storage medium may be encoded with instructions for performing all, or any of, the blocks described herein. For example, the processor 510 may retrieve and execute the encoded instructions and perform any of the blocks described herein or instruct another device, such as the preparation system 100, the mixture forming system 200, and/or the thermo-processing system 300, to perform any of the blocks described herein. The processor 510 may retrieve and execute encoded instructions and perform additional blocks relating to other functions of the green waste processing system 400. EXAMPLES

The Applicant has conducted a number of tests to identify suitable amounts of the constituents that may be used to form cooked green waste product.

Table 1 : First Composition

A first composition is set out in Table 1 , above, which is one of the compositions tested by the Applicant and found to be suitable.

For example, an animal feed, produced according to the methods described herein, may comprise: at least one source of fibre based on green waste, in the proportion from 30.00% to 99.00% by weight; at least one source of anti-catalysts based on a blend of polyphenols, or butylated hydroxytoluene, in the proportion of 0.00% to 4.00% by weight; at least one source of propionic acid-based preservatives, in the proportion of 0.01 % to 4.00% by weight; and at least one source of starchy cereals, based on maize (corn), sorghum, rice, wheat, rye and/or oats, in the proportion of 1.00% to 70.00% by weight. In another example animal feed, produced according to the methods described herein, may comprise: at least one source of fibre based on green waste, in the proportion from 30.00% to 99.00% by weight; at least one source of anticatalysts based on a blend of polyphenols, or butylated hydroxytoluene, in the proportion of 0.00% to 4.00% by weight; at least one source of propionic acid-based preservatives, in the proportion of 0.00% to 4.00% by weight; and at least one source of starchy cereals, based on maize (corn), sorghum, rice, wheat, rye and/or oats, in the proportion of 1.00% to 70.00% by weight.

For example, a fungiculture substrate, produced according to the methods described herein, may comprise: at least one source of fibre based on green waste, in the proportion from 30.00% to 99.00% by weight; at least one source of anti-catalysts based on a blend of polyphenols, or butylated hydroxytoluene, in the proportion of 0.00 % to 4.00% by weight; at least one source of propionic acid-based preservatives, in the proportion of 0.00% to 4.00% by weight; and at least one source of starchy cereals, based on maize, sorghum, rice, wheat, rye and/or oats, in the proportion of 1.00% to 70.00% by weight. For example, animal bedding, produced according to the methods described herein, may comprise: at least one source of fibre based on green waste, in the proportion from 30.00% to 99.00% by weight; at least one source of anti-catalysts based on a blend of polyphenols, or butylated hydroxytoluene, in the proportion of 0.01% to 4.00% by weight; at least one source of propionic acid-based preservatives, in the proportion of 0.00% to 4.00% by weight; and at least one source of starchy cereals, based on maize, sorghum, rice, wheat, rye and/or oats, in the proportion of 1.00% to 70.00% by weight.

Table 2: Second Composition, Animal Feed

A second composition is set out in Table 2, above, which is one of the compositions tested by the Applicant and found to be suitable for animal feed. The green waste provides a source of fibre.

Table 3: Third Composition, Fungiculture Substrate

A third composition is set out in Table 3, above, which is one of the compositions tested by the Applicant and found to be suitable for fungiculture substrate. Note that no propionic acid is used in this composition.

Table 4: Fourth Composition, Animal Bedding A fourth composition is set out in Table 4, above, which is one of the compositions tested by the Applicant and found to be suitable for animal bedding.

Table 5: Fifth Composition

A fifth composition is set out in Table 5, above, which is another composition tested by the Applicant and found to be suitable for use in the methods described herein.

The Applicant sourced raw material used in this composition mainly from vegetation remains from renovation and pruning of gardens and landscaping. The composition was mixed with conservative and anti-catalyst additives and other sources of starch (corn, sorghum, wheat, rice, rye, cassava, barley and oats). The composition may or may not contain protein sources (soybean meal, cottonseed meal, canola meal, sunflower meal, peanut meal, distilled grain meal and/or urea).

In an example use of the fifth composition, the Applicant has considered the use of the composition as a food for herbivores. Accordingly, there may be provided a animal feed, such as a food for herbivores, produced according to the methods described herein, and comprising: at least one source of fibre, based on green waste material (such as garden and landscaping remains), in the proportion of 10.00% to 99.00% by weight; at least one source of anti-catalysts based on a blend of polyphenols or butylated hydroxytoluene, in the proportion of 0.00% to 4.00% by weight; at least one source of preservatives based on propionic acid, in the proportion of 0.00% to 4.00% by weight; at least one source of starchy cereals, based on maize, sorghum, rice, wheat, rye and oats, in the proportion of 1.00% to 90.00% by weight; and at least one source of protein, based on soybean meal, cottonseed meal, canola meal, sunflower meal, peanut meal, distilled grain meal and/or urea in the proportion of 0.00% to 50.00%.

In another example use of the fifth composition, the Applicant has considered the use of the composition as a substrate for fungiculture. Accordingly, there may be provided a substrate for fungiculture, produced according to the methods described herein, and comprising: at least one source of fibre, based on green waste material (such as garden and landscaping remains), in the proportion of 10.00% to 99.00% by weight; at least one source of anti-catalysts based on a blend of polyphenols or butylated hydroxytoluene, in the proportion of 0.00% to 4.00% by weight; at least one source of preservatives based on propionic acid, in the proportion of 0.00% to 4.00% by weight; at least one source of starchy cereals, based on maize, sorghum, rice, wheat, rye and oats, in the proportion of 1.00% to 90.00% by weight; and at least one source of protein, based on soybean meal, cottonseed meal, canola meal, sunflower meal, peanut meal, distilled grain meal and/or urea in the proportion of 0.00% to 50.00%.

In another example use of the fifth composition, the Applicant has considered the use of the composition as an animal bedding. Accordingly, there may be provided an animal bedding, produced according to the methods described herein, and comprising: at least one source of fibre, based on green waste material (such as garden and landscaping remains), in the proportion of 10.00% to 99.00% by weight; at least one source of anti-catalysts based on a blend of polyphenols or butylated hydroxytoluene, in the proportion of 0.00% to 4.00% by weight; at least one source of preservatives based on propionic acid, in the proportion of 0.00% to 4.00% by weight; at least one source of starchy cereals, based on maize, sorghum, rice, wheat, rye and oats, in the proportion of 1.00% to 90.00% by weight; and at least one source of protein, based on soybean meal, cottonseed meal, canola meal, sunflower meal, peanut meal, distilled grain meal and/or urea in the proportion of 0.00% to 50.00%.

Specific examples of the composition detailed in Table 5, which have been prepared and found suitable are shown in Tables 5A, 5B, and 5C below. Each of Tables 5A, 5B, and 5C shows the percentage amounts, for the use of at least one of the components mentioned in Table 5, as a source of fibre, source of anti-catalysts, source of preservatives, other starch sources and sources of protein.

Table 5A:

The Applicant has considered that the composition of Table 5A has been prepared and found suitable as a fibrous food for herbivores. The Applicant considers that any suitable green waste, as described herein, could be used in this composition. Table 5B:

The Applicant has considered that the composition of Table 5B has been prepared and found suitable as a substrate for fungiculture. The Applicant considers that any suitable green waste, as described herein, could be used in this composition

Table 5C:

The Applicant has considered that the composition of Table 5C has been prepared and found suitable as an animal bedding. The Applicant considers that any suitable green waste, as described herein, could be used in this composition

Table 6: Sixth Composition - A specific woody and non-woody composition Table 6 shows one specific example of a green waste composition that was used to produce a cooked green waste product. The green waste composition included both woody and non-woody green waste materials. The cooked green waste product was produced according to the methods described herein. The composition shown in Table 6 is substantially in accordance with the composition detailed in Table 2. The composition shown in Table 6 was utilised in the tests for the nutritional analysis reproduced in tables 6A and 6B.

Processing Comparisons and Results

In one set of tests to confirm the suitability of the green waste processing methods described herein, the Applicant prepared a composition that was substantially according to that set out in Table 6 and in accordance with the methods described herein - that is, the composition was processed by forming the green waste derived mixture and then the green waste derived mixture was thermo-processed. In preparation for these tests, the green waste derived mixture was fed into a pressurised heated barrel. The resulting cooked green waste product was then nutritionally analysed to determine nutritional content. The results of the nutritional analysis of the resulting cooked green waste product are shown in Table 6A.

In the same set of tests, the Applicant prepared a comparison composition that was prepared with substantially the same starting constituent materials and formed into a green waste derived mixture but not subjected to the thermos-processing of the method described herein. The green waste derived mixture was not subjected to the pre-conditioning and pressurised heating of the described method. The resulting comparison composition was then nutritionally analysed to determine nutritional content. The results of the nutritional analysis of the resulting comparison composition are shown in Table 6B.

When Tables 6A and 6B are compared, it is evident that the additional processing steps set out in the methods described herein are not detrimental to the overall nutritional content of the cooked green waste product. In fact, there is very little variance in nutritional values between cooked green waste product and the comparison composition. Furthermore, at least some of those differences may be attributed to natural variances in the nutrition contained in the source green waste, which will unsurprisingly vary somewhat given the source green waste is harvested from the natural environment. For instance, some result variance can be expected due to variance between batches and physical handling of the samples.

Thus, T ables 6A and 6B show that the nutritional value of the green waste material supply is not degraded by being subjected to the green waste processing methods described herein. Specifically, the nutritional content of the green waste derived mixture does not change between pre- or post-thermal processing. Furthermore, Table 6A serves to illustrate that the nutritional elements present in the green waste derived mixture ensure that the resulting cooked green waste product is suitable for animal consumption.

Table 6A: Nutritional Content Analysis - Cooked Green Waste Product

Table 6B: Nutritional Content Analysis - Comparison Composition

In Vitro Fermentation Testing The Applicant also performed in vitro fermentation testing on certain examples of cooked green waste product. In vitro fermentation testing involves collecting rumen chemicals from an animal’s rumen and using those in a laboratory test.

In one set of tests, the in vitro testing used rumen fluid to ferment feed samples under controlled laboratory conditions thereby simulating the rumen environment and allowing the evaluation of both digestibility and the efficiency of certain feed ingredients. The in vitro testing measures gas production and dry matter degradation, amongst other factors such as remaining residues. The results indicated that cooked green waste product is highly digestible and is comparable to other feeds such as corn silage. Table 7 and Figure 14 show the results from analyses of cooked green waste product produced according to the methods described herein and subjected to in vitro fermentation testing.

Table 7: Bromatological comparison between Cooked Green Waste Product and Corn Silage

Table 7 shows one specific example of a composition of cooked green waste product (CGWP) in comparison with corn silage, which is a common animal feed. The cooked green waste product samples used in the testing were substantially in accordance with Table 6. Accordingly, the cooked green waste product samples used in this example were substantially in accordance with the composition of Table 2. Table 7 illustrates that the bromatological composition of a cooked green waste product, produced according to the methods described herein, is comparable to corn silage in terms of nutritional content and in terms of digestibility for animals such as herbivores.

Referring to the last two rows of Table 7, the degradability of samples significantly increases its digestibility - especially in the hours following feeding/supply, that is from 0 to 24 hours - which directly contributes to an animal's caloric demand. As Table 7 shows, the degradability of the example cooked green waste product has proven to be similar to corn silage, confirming safe feed consumption of the cooked green waste product. Furthermore, digestibility in the first 6 hours is high, which is an important period for energy and nutrient digestion before the next feeding cycle.

Figure 14 illustrates the gas pool generated during fermentation (in mL/g of dry feed matter) against time for a composition of cooked green waste product (CGWP) that is substantially in accordance with Table 6. In Figure 14, the total gas pool generated from the in vitro fermentation test for the cooked green waste product is shown. Also shown are the fast and slow generated portions of generated gas that make up the total gas pool. The fast generated portions of gas represent the digestibility of proteins, starch, amino acids and sugars, i.e., non-fibre parts of the cooked green waste product. On the other hand, the slow generated portions of gas represent the digestibility of fibre parts of the cooked green waste product. Reference curves are also shown, which illustrate the total gas, and the fast and slow generated portions, for a reference feed. The reference feed refers to a feed that generates ideal values for gas generation, that is the reference feed has pre-defined goals for gas generation.

Figure 15 illustrates the gas pool generated during fermentation against time for a comparison composition that is substantially in accordance with a (non-thermo-processed) composition of Table 6, i.e., a composition that has not been thermo-processed according to the methods described herein. In Figure 15, the total gas pool generated from the in vitro fermentation test is shown along with the fast and slow generated portions of generated gas. Again, the fast and slow generated portions of gas respectively represent the digestibility of the non-fibre parts and fibre parts of the comparison composition parts. Reference curves (for a reference feed) are shown for the total gas and the fast generated portions.

Figure 14 shows that the total gas pool generated during fermentation for the composition follows the expected curve, producing 163.65 mL/g (mL gas per gram of dry matter) over a 48-hour period. In contrast, the comparison composition, used to produce the results shown in Figure 15, and which had not been subjected to the thermo-processing of the method described herein, produced a lower amount of gas at 146.93 mL/g. Thus, the composition of cooked green waste product has greater digestibility. Moreover, as can be seen from a comparison between Figures 14 and 15, the fast generated portions of gas curves, which represents the digestibility of proteins, amino acids and sugars, and the like, is lower in Figure 15 than that of the equivalent in Figure 14, especially in the crucial 6 to 12-hour window. Thus, by comparing the results of the tests on the cooked green waste product and the comparison composition that were used to produce Figures 14 and 15, it is evident that the cooked green waste product produces higher levels of gas and therefore is generating more rumen digestion activity. The result illustrated in Figure 14 also indicates that the cooked green waste product meets a suitable standard for being used as animal feed.

The Applicant also performed further in vitro fermentation testing on certain samples of cooked green waste product, which were prepared in accordance with the methods described herein - that is, the composition was processed by forming the green waste derived mixture and then the green waste derived mixture was thermo-processed. In this instance, the green waste derived mixture was fed into a pressurised heated barrel. The samples of cooked green waste product used in the further testing were substantially in accordance with Table 2.

The further fermentation testing differed from the initial in vitro testing and involves providing the cooked green waste product feed to ruminal fluids that have been extracted from a rumen of a live animal. Samples are then withdrawn from the ruminal fluid at regular intervals over a certain period. The samples are then nutritionally analysed to measure digestion progress, i.e., by measuring the amount of feed that has been consumed during digestion.

As with the testing performed to generate the results of Tables 6A and 6B above, the further fermentation testing was also performed on a comparison composition. Again, the Applicant prepared a comparison composition that was prepared with substantially the same starting constituent materials as those that were used to produce the samples of cooked green waste product. Again, the comparison composition was then formed into a comparison green waste derived mixture but not subjected to the thermo-processing of the method described herein. Samples of the resulting comparison composition were then tested in the same manner as for the cooked green waste product, i.e., at the same intervals as for the cooked green waste product thereby permitted a direct comparison of digestibility of the cooked green waste product with the comparison composition,

The results of the nutritional analysis of the periodically removed samples for both the cooked green waste product and the comparison composition are shown in Table 8.

Table 8: Dry Matter Digestibility Comparison Table 8 shows measurements for in vitro dry matter digestibility (IVDMD) at certain time intervals over a 72-hour period. IVDMD is indicated as a percentage of nutrients consumed after the respective period. Thus, Table 8 indicates the amount of nutrients consumed after 6 hours, 12 hours, 24 hours, 48 hours and 72 hours. Three samples are assessed at each in interval and the results averaged to produce an average in vitro dry matter digestibility value. The tests were performed for both the cooked green waste product (CGWP) and the comparison composition.

When the results for the cooked green waste product (CGWP) and the comparison composition are compared, it is evident that the additional processing steps set out in the methods described herein aid digestion in a live animal for cooked green waste. In particular, Table 8 shows that digestibility is higher at each interval. Moreover, there is significantly higher digestibility evident at the earlier intervals when the samples were drawn from the animals’ rumen. This is important because the 6 hour and 12-hour intervals represent the period immediately after feeding in animal management. In agricultural settings, many animals are fed every 8 to 12 hours, so the most important digestive period to appreciate with animal feed production is to understand how much energy and nutrients are digested by an animal in the immediate period after eating and before the next feeding session, for example within the next 12-hour window or even 8-hour window. Table 8 thus shows that the cooked green waste is product much more digested than comparison composition, especially over the first 12 hours of the test.

The in vitro fermentation testing performed by the Applicant shows that the feed (cooked green waste product) produced according to the methods described herein is highly digestible. Furthermore, the feed is a safe and nutritional food for animals, in particular ruminant animals.

It will be understood that the above embodiment descriptions are given by way of example only and that various modifications may be made by those skilled in the art. Although various embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the scope of this invention. It is to be understood that any feature described in relation to one example may be used alone, or in combination with other features described, and may also be used in combination with any features of any other of the examples, or any combination of any other examples.

Claims

1. A green waste processing method using a green waste material supply, the method comprising: preparing the green waste material supply, wherein preparing the green waste material supply comprises: separating the green waste material supply into non-wood material and wood material; pre-grinding the separated non-wood material and controlling the hydration level of the separated non-wood material to a pre-determined non-wood hydration ratio; and pre-grinding the separated wood material and controlling the hydration level of the separated wood material to a pre-determined wood hydration ratio; forming a green waste derived mixture, wherein forming the mixture comprises: mixing the pre-ground non-wood material and pre-ground wood material together in a pre-determined non-wood/wood ratio; and grinding the pre-ground non-wood material and pre-ground wood material; and thermo-processing the green waste derived mixture, wherein the thermo-processing comprises: pre-conditioning the green waste derived mixture; and heating the green waste derived mixture, under a pre-determined pressure, to a pre-determined temperature to produce a cooked green waste product.

2. The method of claim 1 , wherein the pre-determined non-wood hydration ratio and/or the pre-determined wood hydration ratio is a maximum of approximately 14%.

3. The method of claim 1 or claim 2, wherein pre-grinding the separated non-wood material comprises grinding the separated non-wood material into pieces having a maximum size of approximately 40mm and/or wherein pre-grinding the separated wood material comprises grinding the separated wood material into pieces having a maximum size of approximately 40mm.

4. The method of any one of claims 1 to 3, wherein separating the classified green waste material supply into non-wood material and wood material is based on a classification of the green waste material supply into the non-wood material class and the wood material class and wherein preparing the green waste material supply comprises: classifying the green waste material supply into the non-wood material class and the wood material class.

5. The method of any one of claims 1 to 4, wherein preparing the green waste material supply comprises applying a fungicide to the green waste material supply.

6. The method of any one of claims 1 to 5, wherein the method comprises storing the preground non-wood material and/or pre-ground wood material before forming the green waste derived mixture.

7. The method of any one of claims 1 to 6, wherein preparing the green waste comprises conducting a laboratory test on each of one or more samples selected from: a non-wood sample, drawn from the pre-ground non-wood material, and a wood sample, drawn from the pre-ground wood material.

8. The method of claim 7, wherein conducting the laboratory test comprises determining the hydration ratio of the one or more samples and/or the particle size of the one or more samples.

9. The method of claim 7 or claim 8, wherein the method comprises determining the predetermined non-wood/wood ratio based on the laboratory test.

10. The method of any one of claims 1 to 9, wherein the forming the green waste derived mixture comprises mixing the pre-ground non-wood material and pre-ground wood material at the same time as grinding the pre-ground non-wood material and pre-ground wood material.

11. The method of any one of claims 1 to 11 , wherein the forming the green waste derived mixture comprises mixing one or more additional constituents with the pre-ground non- wood material and pre-ground wood material.

12. The method of claim 11, wherein at least one of the additional constituents comprises starch and/or a starchy ingredient.

13. The method of claim 11 or claim 12, wherein the additional constituents comprise one or more of: sorghum, rye, wheat, rice, maize (corn), oats, millet, and barley.

14. The method of any one of claims 11 to 13, wherein the additional constituents comprise a conservative compound to prevent the green waste derived mixture decomposing.

15. The method of any one of claims 1 to 14, wherein forming the green waste derived mixture comprises monitoring a non-wood/wood ratio of the green waste derived mixture during mixing.

16. The method of any one of claims 1 to 15, wherein forming the green waste derived mixture comprises grinding the pre-ground non-wood material and pre-ground wood material into particles having a maximum size of no more than 1.5 mm to 3 mm.

17. The method of any one of claims 1 to 16, wherein pre-conditioning the green waste derived mixture comprises injecting steam into, or steaming, the green waste derived mixture to hydrate the green waste derived mixture.

18. The method of any one of claims 1 to 17, wherein the pre-determined temperature is between approximately 95°C and approximately 160 °C and/or wherein the predetermined pressure is between approximately 25 and approximately 75 bar.

19. The method of any one of claims 1 to 18, wherein heating the green waste derived mixture comprises feeding the green waste derived mixture into a pressurised heated barrel and forcing the cooked green waste product out through a nozzle of the heated barrel.

20. The method of claim 19, wherein the method comprises injecting steam into the pressurised heated barrel.

21. The method of claim 19 or claim 20, wherein the cooked green waste product is extruded from the nozzle as kibble.

22. The method of any one of claims 1 to 21 , wherein, following thermo-processing, the cooked green waste product is delivered to a dryer.

23. A cultivation substrate, the cultivation substrate comprising cooked green waste product produced according to the method of any one of claims 1 to 22.

24. An animal feed, the animal feed comprising cooked green waste product produced according to the method of any one of claims 1 to 22.

25. Animal bedding, the animal bedding comprising cooked green waste product produced according to the method of any one of claims 1 to 22.