The technology addresses a persistent and underappreciated problem in livestock production. Rice husk, an abundant by-product of rice milling, is widely used as poultry bedding because it is cheap, lightweight, and absorbs moisture well. But during storage and use, bedding accumulates organic matter, fecal residues, and moisture that support microbial growth. Contaminated bedding can act as a long-term environmental reservoir for foodborne pathogens, facilitating transmission between production cycles and throughout the poultry supply chain. Conventional sanitation relies on chemical disinfectants such as quaternary ammonium compounds, aldehyde-based treatments, and oxidizing agents, yet these often penetrate bulk biomass poorly, work unevenly in porous substrates, and lose effectiveness under high organic loading, while raising concerns about residues, worker exposure, and environmental impact.

The new system, described in the journal Cleaner Engineering and Technology, is a trailer-mounted, mobile processing platform designed for continuous on-site operation. Its core components include an insulated sanitization chamber, a screw-assisted biomass transport mechanism that lifts and cascades rice husk particles through the treatment zone, an LPG-fueled gas burner generating hot air at 350 to 400 degrees Celsius, a hot-air mixing chamber, forced-air and recirculation blowers, and a cyclone dust separation unit. The screw-assisted cascading design is central to the system’s performance: by continuously lifting and redistributing particles, it repeatedly exposes fresh surfaces to the heated airflow, minimizing localized cold spots and thermal dead zones within the porous biomass bed.

A key engineering innovation is the airflow recirculation architecture. Rather than exhausting heated air after a single pass, the system captures hot air exiting the chamber, passes it through cyclone separators to remove suspended dust, and redirects it back into the heating circuit. This recirculation loop achieved an efficiency of approximately 86.7 percent, substantially improving thermal retention, stabilizing chamber temperature under transient loading, and reducing fuel consumption. Under steady-state conditions, the sanitization chamber held temperatures of roughly 115 to 125 degrees Celsius while rice husk exited at 95 to 100 degrees Celsius, with chamber temperature variation held to about plus or minus 2.1 degrees Celsius.

Residence time proved to be a critical operating variable. By tuning screw rotational frequency between 50 and 60 hertz, the researchers achieved residence times of 15 to 17 minutes, which they identified as the optimal window balancing microbial inactivation against throughput. At these settings the system processed 2.0 to 2.5 tonnes of rice husk per hour with thermal utilization efficiency peaking near 87.6 percent. Shorter residence times below 10 minutes risked ineffective sanitization, while longer exposures reduced productivity without meaningful gains. Statistical analysis confirmed that both temperature and residence time significantly influenced microbial reduction, with their interaction significant at p less than 0.01.

The microbiological validation was unusually rigorous for an industrial study. Throughout three years of routine monitoring, approximately 67 samples per month were collected from production lots of about 15 tonnes each, and formal annual validations compared 50 samples before treatment with 50 after. All analyses were performed at an ISO/IEC 17025-accredited laboratory, using selective enrichment, culture on Xylose Lysine Deoxycholate agar, and confirmatory identification by MALDI-TOF mass spectrometry. Under optimized conditions, contamination frequency fell from 16 percent to 4 percent, an estimated 75 percent reduction in positive detections. In controlled laboratory experiments, log reductions of total bacterial count reached 6.2 to 6.4 log CFU per gram at 120 to 125 degrees Celsius, corresponding to inactivation efficiencies above 99.999 percent, and Salmonella was not detected under any tested condition.

Perhaps the most instructive finding concerned moisture. Feedstock water content emerged as a dominant constraint on performance, contributing an estimated 18.6 percent of the relative influence on lethality. At moisture levels of 8 to 11 percent, the system achieved log reductions of about 6.3, but at 18 to 20 percent moisture the reduction fell to roughly 2.7 log, a level the authors classified as ineffective. The explanation is thermodynamic: water evaporation consumes latent heat, diverting thermal energy away from microbial destruction and buffering the biomass temperature. Field validation during rainy conditions confirmed the pattern, with positive detections rising to 9 percent at high moisture and 14 percent when high moisture was combined with shortened residence time. The researchers argue that industrial thermal sanitization must therefore be governed by integrated heat-and-moisture frameworks rather than temperature-only criteria, and they recommend real-time moisture sensing and adaptive residence-time control as future upgrades.

The economics are compelling. Total treatment cost was estimated at 0.0083 US dollars per kilogram of rice husk, compared with 0.014 to 0.021 dollars for conventional centralized chemical sterilization, an operating cost reduction of roughly 40 to 60 percent and a benefit-cost ratio of 4.6. LPG consumption averaged 8.3 kilograms per tonne of treated biomass, translating to a fuel cost of about 0.0052 dollars per kilogram. The savings arose from multiple vectors: complete elimination of disinfectant procurement, which alone accounted for 38.4 percent of total savings; removal of dedicated chemical storage warehouses; simplified single-stage logistics replacing multi-stage transport to centralized facilities; and reduced transportation emissions from on-site processing. Over three years, cumulative savings exceeded 0.30 million US dollars, averaging about 100,000 dollars annually.

From a sustainability standpoint, the system embodies cleaner production and circular economy principles. By using thermal energy as the sole sanitizing agent, it removes chemical residues from bedding that might otherwise accumulate in soils when spent litter is applied as fertilizer, and it eliminates occupational exposure to formaldehyde and related compounds. The life-cycle analysis, conducted through a life-cycle thinking approach rather than a formal ISO 14040/14044 assessment, attributed 34.8 percent of sustainability benefits to chemical elimination, 26.5 percent to biomass reuse and valorization, and 11.6 percent to avoided transportation. The technology effectively upcycles a low-value agricultural residue into a standardized sanitary product, closing a resource loop that links rice milling, poultry farming, and eventual nutrient recycling through spent bedding.

The authors are careful to note limitations. The microbiological outcomes reflect the tested operating conditions and should not be read as evidence of complete pathogen elimination under all field scenarios, and the sustainability percentages are relative indicators rather than quantified greenhouse gas reductions. Future work will pursue a full cradle-to-grave life cycle assessment, quantitative microbial inactivation modeling using D-value and z-value kinetics, computational fluid dynamics optimization of the reactor, and predictive process control. Still, the demonstrated combination of scale, reliability, and economics marks a significant step. A system that processes nearly 8,000 tonnes of abrasive, silica-rich biomass over three years with greater than 95 percent availability shows that continuous thermal sanitization has moved beyond the pilot stage, offering poultry producers a practical blueprint for biosecurity that is simultaneously cleaner, cheaper, and more circular than the chemical status quo.

Subject of Research: Industrial-scale continuous thermal sanitization of rice husk bedding for chemical-free poultry biosecurity

Article Title: Industrial-scale continuous thermal sanitization of rice husk bedding for cleaner poultry production: Resource valorization, biosecurity improvement, and sustainability assessment

Article References: Sangpradit, K., Thoetrattanakiat, S., Sookyoo, W., Intarasuk, A., & Samseemoung, G. (2026). Industrial-scale continuous thermal sanitization of rice husk bedding for cleaner poultry production: Resource valorization, biosecurity improvement, and sustainability assessment. Cleaner Engineering and Technology, 34, Article 101304. https://doi.org/10.1016/j.clet.2026.101304

Image Credits: AI Generated

DOI: 10.1016/j.clet.2026.101304

Keywords: rice husk, poultry bedding, thermal sanitization, biosecurity, cleaner production, circular economy, pathogen inactivation, agricultural waste valorization, hot-air heating, Salmonella, LPG energy efficiency, sustainable livestock production