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The biochemical reactions of aerobic microbial respiration (AMR) suggest that silage temperature (Tsi) rise, oxygen (O2) consumption and carbon dioxide (CO2) emission may be equally useful as indicators of silage deterioration during feed-out, but only temperature has been used extensively to assess aerobic stability. Here we extend the study of aerobic stability to incorporate AMR of silage by developing a novel experimental cell integrated with multiple sensors. Silage samples, ensiled from a triticale crop, were made in twelve air-tight barrels (60 L), packed to bulk densities of 190 or 250 kg m−3 dry matter (DM). Tsi and O2 measurements were co-located at 15- and 30-cm behind the working face. CO2 was measured as flux across the working face. The experimental period of aerobic exposure was 7 days. We provide the first reports of: (i) distinct aerobic responses of these parameters, showing that Tsi varied with CO2 in phase but with O2 out-of phase; (ii) CO2 flux was dominated initially by anaerobic discharge and subsequently by aerobic products; (iii) linear relationships between aerobic reheating and both O2 consumption (0.994 ≥ R2 ≥ 0.815, P

The microbiome in silage may vary substantially from the onset to the completion of fermentation. Improved additives and inoculants are being developed to accelerate the ensiling process, to enhance fermentation quality, and to delay spoilage during feed-out. However, current methods for preselecting and characterizing these amendments are time-consuming and costly. Here, we have developed a multi-sensor mini-bioreactor (MSMB) to track microbial fermentation in situ and additionally presented a mathematical model for the optimal assessment among candidate inoculants based on the Bolza equation, a fundamental formula in optimal control theory. Three sensors [pH, CO2, and ethanol (EtOH)] provided data for assessment, with four additional sensors (O2, gas pressure, temperature, and atmospheric pressure) to monitor/control the fermentation environment. This advanced MSMB is demonstrated with an experimental method for evaluating three typical species of lactic acid bacteria (LAB), Lentilactobacillus buchneri (LB) alone, and LB mixed with Lactiplantibacillus plantarum (LBLP) or with Enterococcus faecium (LBEF), all cultured in De Man, Rogosa, and Sharpe (MRS) broth. The fermentation process was monitored in situ over 48 h with these candidate microbial strains using the MSMB. The experimental results combine acidification characteristics with production of CO2 and EtOH, optimal assessment of the microbes, analysis of the metabolic sensitivity to pH, and partitioning of the contribution of each species to fermentation. These new data demonstrate that the MSMB associated with the novel rapid data-processing method may expedite development of microbial amendments for silage additives.

The aim of this study was to develop a new experimental setup to determine parallel the emissions of greenhouse gases (GHG) and volatile organic compounds (VOCs) from silage during the opening as well as the subsequent aerobic storage phase of the complete bale without wrapping film. For this purpose, a special silage respiration chamber was used in which a silage bale could be examined. The gas analysis (CO2, methanol, ethanol, ethyl acetate) of inlet, ambient and outlet air of the silage respiration chamber was carried out by photoacoustic spectroscopy. The gas samples taken inside the bale were analysed by gas chromatography for CO2, O2, CH4, and N2O. Three silage bales (grass and lucerne) as the smallest silage unit commonly used in practice were examined. The emission behaviour of the bales was recorded during experimental periods up to 55 days. The results allow a differentiation of the outgassing processes. On the one hand, gases produced during the anaerobic ensiling process (CO2, CH4, N2O) are released once in a large amount during the first experimental hours after opening the silage. On the other hand, a continuous outgassing process takes place, which is particularly true for the VOCs ethanol, methanol, and ethyl acetate, whereby VOC emissions increase with rising ambient air temperatures. In this study, the emissions during the first 600 experimental hours from the grass silage bale and lucerne silage bale were 2313 g and 2612 g CO2, 17.6 g and 145.2 g methanol, 132.3 g and 675.9 g ethanol, 55.1 g and 66.2 g ethyl acetate, respectively. Nevertheless, the focus of this study was on the technical recording of gas concentrations inside the silage bale itself and the emissions in the ambient air of the bale. For a better interpretation of the data, additional factors should be considered in further investigations.

Silage quality and aerobic stability are sometimes insufficient. If management requirements are not met, or to improve silage quality, additives are often used. The objective of this study is to investigate the effects of different factors on silage during aerobic conditions. Whole-crop forage maize was harvested and 24 buckets (65 L) were filled and assigned to one of four treatment groups: (1) control (no treatment); (2) chemical additive (sodium benzoate, potassium sorbate, sodium acetate); (3) a mixed biological inoculant containing Lactobacillus buchneri, L. plantarum, and Pediococcus acidilacti; and (4) a mixed biological inoculant containing L. buchneri, L. plantarum, and L. rhamnosus. An untreated variation was also ensiled. Two different densities were adjusted during ensiling. After opening, the temperature was measured for seven days and O2 and CO2 concentrations were analysed. The findings show that the chemical additive very effectively prevented silage from reheating and deteriorating. Aerobic reheating of silage was also successfully inhibited through biological additives and high density.

Biogas plants are the most complex systems and are heavily studied in the field of renewable energy. A biogas system is mainly influenced by biological and technical parameters that strongly interact with each other. One recommended practice when operating a biogas plant is the recirculation of the substrate from the second fermenter into the first fermenter, which extends the recirculation amount (RA) and, in turn, the recirculation rate (RR). This technique should be applied to support and secure the biogas process. In this investigation, the RA was varied, starting with the recommended “best practice” of 10.0 m3/d (RR 40%). Every ten days, the RA was reduced in steps of 1.5 m3/d, with 5.5 m3/d (RR 27%) being the final value. The basic question to be addressed concerns to what extent the RR influences the methane yield and thereby influence the efficiency of a manure-based biogas plant in practice. Diverting the “best practice” to a RR of 27% stabilised the fermentation process and lead to significantly higher methane yields with smaller standard deviations. In addition, with a reduced RR, the standard optimal acid concentration within the biogas substrate was approximately reached.

Carbon dioxide (CO2) is a principal byproduct of various chemical, biological and biochemical processes. CO2 has been measured using various advanced sensors, but a limiting technical challenge has been resolving independent streams of CO2 produced by processes occurring simultaneously. The magnitude and kinetics of each stream may be chemically, biologically or/and physically informative, but such partitioning has received little attention and successful case studies remain rare. In silage production, CO2 flux, an important indicator of aerobic deterioration, microbial activity or oxidative rate of silage, derives from two different pools: gas accumulated in the pores during the early anaerobic phase, and current real-time production of CO2 as oxygenated air enters the silage across the exposed face after opening for feed-out. The former is regarded as a noise confounding the signal and the latter reflects current degradation of the silage. Using a self-developed automatic sensor system with novel signal decomposition, we successfully partitioned CO2 flux into two independent streams derived from the two distinct pools in maize silage, following two independent processes: a physical venting of stored gas through a tortuous diffusive pathway, and a biochemical process generating gas in real time. Three silage samples, treated with a chemical or a biological additive, or left untreated, were tested. The signal decomposition found two best-fit functions (0.8034 ≤ R2 ≤ 0.9036), a quadratic CO2 discharge function and an exponential CO2 production function, for characterizing these distinct processes. These results demonstrate chemical sensor with powerful data-processing capability to resolve the complexity of dual-pool CO2 emission.

Oxygen (O2) concentration inside the substrate is an important measurement for silage-research and-practical management. In the laboratory gas chromatography is commonly employed for O2 measurement. Among sensor-based techniques, accurate and reliable in situ measurement is rare because of high levels of carbon dioxide (CO2) generated by the introduction of O2 in the silage. The presented study focused on assessing three types of commercial O2 sensors, including Clark oxygen electrodes (COE), galvanic oxygen cell (GOC) sensors and the Dräger chip measurement system (DCMS). Laboratory cross calibration of O2 versus CO2 (each 0–15 vol.%) was made for the COE and the GOC sensors. All calibration results verified that O2 measurements for both sensors were insensitive to CO2. For the O2 in situ measurement in silage, all O2 sensors were first tested in two sealed barrels (diameter 35.7 cm; height: 60 cm) to monitor the O2 depletion with respect to the ensiling process (Test-A). The second test (Test-B) simulated the silage unloading process by recording the O2 penetration dynamics in three additional barrels, two covered by dry ice (0.6 kg or 1.2 kg of each) on the top surface and one without. Based on a general comparison of the experimental data, we conclude that each of these in situ sensor monitoring techniques for O2 concentration in silage exhibit individual advantages and limitations.