Composter Automates Rotating Drum Operation

Composter automates rotating drum operation with the newly automated PLC Control Panel with Soft Touch Screen by XACT Systems.  The user friendly soft touch screen on the front of the control panel was designed for the BioReactor Composting System in order to give the operator easy access to a wide variety of critical data.  Data which is vital to the successful composting of solid organic waste.

Although composting is not a complicated process it is a fairly precise process in terms of balancing the few factors that impact it.  The control panel has been developed to provide more accurate monitoring of these factors to ensure the best results.  A quick reminder as to what those few factors are:  Carbon-Nitrogen ratio, moisture content, oxygen, operating temperatures, and particle size.  For a more detailed description of the parameters for successful composting, please follow this link to the XACT Composting System website page describing them.

In addition, the data collected from the monitoring can be sent to the operator’s cell phone or computer 24/7.  By making the data “portable”, the operator can be tracking the BioReactor’s operation while eating lunch!

These added features compound the benefits that the XACT BioReactor System already has.

  1. The BioReactor has the fastest decomposition time—it can compost organic waste in as little as 4 days. Compare this to traditional methods that can take upwards of a year!
  2. Odor control is also ensured by the continual rotation of the drum, which causes the organic material to tumble around inside.  This tumbling action ensures all the particles of the waste are exposed to oxygen at all times which is vital to a highly aerobic composting process and therefore an odor-free process.
  3. Pathogen and virus destruction are the foundations of our composting system. XACT In-Vessel Organics Composting follows the guidelines set down by the EPA to ensure pathogen and virus kill.
  4. Less manpower is required because the rotating vessel does all the work—one man can operate the entire process especially when the composter automates rotating drum operation.
  5. The XACT BioReactor uses a very, very low horsepower electric motor to operate.
  6. The vessel can be insulated which helps retain the high operating temperatures of 130°F+ (55°C+) required (this is the EPA standard for pathogen kill—3 days at 130°F). Because of the insulation, the XACT vessel does not need to be housed in a building, but the compost should be stored under cover.
  7. The process is natural and typically requires no added heat.
  8. Less land is required with the BioReactor rotating drum because the decomposition process occurs within the vessel, and less feedstock piles are required because material is processed so fast.
  9. Site requirements are minimal because of the compact size of the system, and because what little condensates are present are completely captured.
  10. Fantastic compost is the result because changeable weather conditions are not a consideration, and all the factors needed for great decomposition are optimized and controlled.

To learn more about how the composter automates rotating drum operation with the new control panel is super easy.  Just contact us by Cell: 613-391-1445 or email info@xactsystemscomposting.com.  Many many thanks!  D

composter automates rotating drum operation with control panel and soft screen

The Soft Touch Screen on the PLC Control Panel allows for easy access to data such as processing temperature, starting/stopping, correct loading (capacity), door opening/closing and more!

Solid Organic Waste Management Facility

XACT Systems’ BioReactors will compost tons of solid organics daily at this new state-of-the-art solid organic waste management facility located in Goa, India.  In the final stages of completion, this massive facility will treat the solid organics waste of just the north half of the city.  The waste material coming into the plant is classified as MSW.

Solid organic waste mangement facility in Goa, India

These are the administration buildings of the North Goa facility.

Solid Organice Waste Management Facility

These 3 BioReactors are part of a comprehensive solid organic processing facility. The BioReactor Composting System by XACT Systems Inc. handles all the composting portion of the waste management treatment.

The treatments of the organics coming into the plant consist of fermentation processing (digester), and compost processing by the BioReactor Composting System.  In addition, the facility features bio-filters, transport truck weigh scales, bag openers, screeners, sorting stations, magnetic separators, balers, conveying systems and shredders.

This solid organic waste management facility design will be duplicated time and again.  The next facility to be built will be located in the south of Goa, India

SFC Environmental Technologies PVT Ltd. is the engineering firm behind this impressive facility.  They chose XACT Systems’ to be the supplier of the composting equipment.  Because of the heavy-duty and 24/7 performance redundancy design of the BioReactor, it was

Solid Organic Waste Management Facility

SFC designed and engineered this modern compost processing plant. It is but one portion of the entire solid organic waste management facility. At the end of the building, the ends of the 3 BioReactors are visible.

an obvious choice.  Plus, the accelerated processing, cleanliness and 70% fill capacity of this composter pushed the invessel rotating drum BioReactor to the top of SFC’s composter list.  It is very exciting for both XACT Systems and SFC Environmental Technologies to see this project nearing completion.  The next time we show pictures of this site, all the brown clay earth showing will be covered in green vegetation because the finished compost will applied to the grounds.  Compost makes as an excellent soil amendment and supports plant growth in harsh, dry conditions in a remarkable way.

For those of you who cannot get to Goa India to see this site, XACT Systems has many BioReactors working in North America and elsewhere.  Please feel free to contact us at anytime if you wish to arrange for a site visit.

If you want to meet with us, consider going to the US Composting Council Conference in Los Angeles, California, USA, on January 23-25.  You can find us at Booth 514. (Click on the link below to get more details about the conference venue etc).   Please feel free to stop by or call ahead (call
Glenn McConkey at 6123-391-1445) and arrange a private meeting to discuss you particular project.  Many thanks,  Doreen

www.uscompostingcouncil.org

 

 

Composting Technology Saudi Arabia & Middle East

The composting technology by XACT Systems was introduced to the agricultural market in Saudi Arabia just last week.  The International Trade Exhibition for Agriculture, Water and Agro-Industry proved to be an excellent venue to show The BioReactor to the Middle East ag-business community.  XACT Systems’ partner in Saudi Arabia is Tamimi Global C0. Ltd.

composting technology Saudi Arabia & Middle East

The BioReactor composting technology will provide sustainable organic waste management solutions to Saudi Arabia farming and food processing operations. Tamimi Global Co. Ltd. represents XACT Systems throughout the Middle East.

Tamimi is a top tier company that has provided product and services to the Saudi market for decades.  Now, with their new mandate in their Waste Management Division to provide more innovative and sustainable solutions, Tamimi is blazing the trail in the Middle East once again.

Composting Technology Saudi Arabia & Middle East

Tamimi chose the BioReactor, which is an modern in-vessel rotating drum, to be the composting technology that leads them into a better future.  The company’s core business is in the food services sector.  One of the services they provide are meals to the personnel of work camps.  These work camps can reach populations of 10,000 workers.  This volume of food service produces as serious volume of food waste that requires a serious organic waste management solution.  The BioReactor is just such a solution.

The BioReactor is a work horse!

It is ruggedly engineered and built to withstand the 24/7/365 operational requirement of the waste management industry.  Because solid waste never stops being produced, therefore, it never stops needing to be processed.

composting technology Saudi Arabia & Middle East

This BioReactor is composting food waste. The footprint required for the composter is very small because the composting processing happens very quickly.

The BioReactor drum slowly rotates.  It quickly turns organic waste (no more than 4 to 7 days) into compost.  It  tightly controls the parameters of the composting process. In other words, this composter makes an ideal environment for the oxygen-loving bacteria to thrive and decompose the material in a highly aerobic process. The BioReactor will compost large volumes of organic waste quickly.  And will do so without the occurrence of hazardous leachates or foul odors.

Indeed, the compost bears no resemblance to the waste from which it was produced.  This compost has tremendous economic value if sold in bags or bulk because it makes an excellent soil amendment.  The compost has a high level of organic matter and nutrient content. The compost no longer has harmful bacteria in it to cause disease so it can be spread on land close to water sources.

By adopting the ground-breaking BioReactor Composting System, Tamimi is now able to provide a sustainable cycle of complementary food services-from meal preparation to organic waste recycling.  The ability to divert the organic waste from landfills has tremendous environmental and economic advantages.   The finished compost can be land applied to the fields that grow the food crops in the first place.  It makes an excellent soil amendment because it introduces much needed organic matter back into the soil.

 

Compost Slaughterhouse Renderings & Carcasses

Compost Slaughterhouse Renderings & Carcasses completely using the BioReactor by XACT Systems.  It makes sense for an organic beef operation to choose to compost the renderings from its slaughter house because this method of organic waste management jives with the overall objectives and philosophy of the organic meat industry.

This BioReactor Composting System is designed to compost slaughterhouse renderings & carcasses. (The carcasses have to be small or cut up) It can also handle other organic wastes such as manure, spoiled feed etc.

This site layout illustrates the complete composting process of the organic waste material from the mixer, the BioReactor to the short term curing piles.

This type of composting system (using multiple rotating vessels) can be scaled to any size to handle any volume of waste material/amendments.  The BioReactor is available in many sizes.  The smallest BioReactor is 5′ diameter x 10′ long while the largest is 10′ diameter x 60′ long (1.5 m diameter x 3m long) to 3m diameter x 18 m long).

Site Layout Description

In this particular scenario, the entire operation is inside (this is not always necessary for all facilities).  In order to compost slaughterhouse renderings & carcasses, the waste/amendments are loaded into a mixer.  The purpose of this initial step is to blend the various waste materials into a homogenous mixture.  This mixture is then discharged onto a conveyor and conveyed up to the infeed opening which is located in the upper quadrant of the end of the BioReactor.  The BioReactor has fixed ends.  A consequence of this unique feature allows the vessel to big filled to 70% capacity.

Another unique feature of the BioReactor are the Blending Bars.  The rotating drum turns SLOWLY and this rotation with the help of the Blending Bars causes the mixture to tumble inside.  This tumbling action greatly facilitates the aerobic composting process.  There is ample oxygen available to the naturally occurring aerobic bacteria and they thrive–multiplying their population exponentially–and decomposing the waste material at a phenomenal speed.

In addition, the high temperatures (thermophilic) required to compost any waste successfully are easily maintained by the BioReactor using the Negative Ventilation Fan.  This fan is located at the discharge end of the BioReactor and can be ducted into a BioFilter if odour control is an issue.

When ready for discharge, the discharge door/auger opens/unloads the compost onto an incline conveyor.  Then the compost is piled and stored for a short term curing period.  Skid steers are used to handle the piles as needed.

Typically, the length of time from start to finish is under 30 days.  To learn more about various possibilities of a composting operation check out www.xactsystemscomposting.com

 

Composting Septic Sludge

Composting Septic Sludge Tests Prove Successful

Composting septic sludge in 5 days AND making compost that is pathogen free is possible with the BioReactor by XACT Systems Inc.   In this testing project, the septic sludge is combined with other materials in order to make a balanced recipe of organics with a C:N ratio in the ideal range (20:1 to 30:1).  This is the vital first step in composting solid organic waste quickly and making compost that is pathogen free.  The second step is to compost this proper mixture in the BioReactor which is an in vessel rotating drum composter.  The composter rotates slowly and constantly.  The rotation tumbles the waste material inside the drum and exposes all of the material to the ambient oxygen.  The aerobic bacteria which naturally reside in the organic waste will decompose it.  The fact that all the bacteria are getting all the oxygen they need to do a great job of breaking down the material means that the waste will compost quickly and with little or no odor.  The innovative features of this 5′ diameter x 10′ long BioReactor allow the temperatures of the composting process to hit temperatures of 145 degrees Fahrenheit  to 170 degrees Fahrenheit and maintain it there.  Once these high temperatures are achieved, the septic sludge is exposed to this heat for 72 hours (as per the protocol stated by the EPA standard for pathogen kill in a composting process). After 5 days, the compost is discharged and it looks and smells like dirt.  It will make an excellent soil amendment and be a valuable revenue stream for this composting operation.

When composting septic sludge at 170 degrees for 5 days, pathogen free compost is guaranteed.

Composting Septic Sludge is made easy in the BioReactor. The processing temperatures are running between 145 degrees and 170 degrees.

Composting septic sludge with a rotating drum composter.

This BioReactor is 5′ diameter and 10′ long and is currently composting septic sludge.

XACT Systems Inc.

XACT Systems Inc. offers sincere congratulations to our partner in India, SFC Environmental Technologies Pvt. Ltd., which has been awarded contracts for 2 more large scale solid waste handling facilities in India.  

XACT Systems Inc.

Indian officials proudly unveil the solid waste management facility designed and built by SFC Environmental Technologies Pvt. Ltd in Mumbai, India

These new facilities are mandated to compost 310 tons of solid organic waste per day. The composting technology that SFC has specified for these 2 operations is XACT Systems Inc. BioReactor Composting System from Canada.  A total of 12 BioReactors  will be built and installed by SFC, and each BioReactor will be 10′ diameter by 60′ long (3m x 18m). SFC has earned this contract on the heels of very recently and successfully completing 2 other large scale solid organic waste management projects in India that also featured XACT’s BioReator composting technology.

New XACT Systems’ Composting Technology Videos Just Posted To YouTube

Composting Technology Videos

Rotation Speed & Odor Control
https://www.youtube.com/watch?v=-zlt8hOoDt8
The successful odor-free composting process of organic waste in the BioReactor is dependent upon a few factors.  One of these is the rotation speed of the drum itself.  The BioReactor by XACT Systems Inc. rotates very very slowly as shown in this video.  This allows the material inside the composter to gently tumble.  In turn, this gentle tumbling allows each and every particle of the waste material to be exposed to the oxygen present in the ambient air.  The oxygen-loving bacteria which naturally occur in the waste are therefore “knee deep” in the oxygen and thus thriving, multiplying and decomposing (eating) the waste material at a highly accelerated rate.  The by-products of such highly aerobic decomposition is simply water vapour (H20) and carbon dioxide C02.  Neither of these gases are odorous, noxious or harmful. So, by using the BioReactor Technology to compost organic waste, you can do so quickly and in a virtually odor-free manner.
Discharged Compost is Virtually Odorless!  
https://www.youtube.com/watch?v=BdZgBOqTJWI
 The composting process in the BioReactor is highly aerobic due to the ventilation systems and slow tumbling action of the organic waste inside the BioReactor.  As a result the compost upon discharge, is odor-free.  Typical composting time varies from 3 to 7 days depending on the waste material to be composted
composting technology videos

Advanced composting technology such as the BioReactor can produce compost that is virtually odor-free.

Dewater Dairy Manure 
https://www.youtube.com/watch?v=HggJ3PWIY9Q
 Composting dairy manure in XACT Systems BioReactor typically requires that the manure be dewatered prior to loading into the composter.  The optimum moisture content of any organic waste to be composted is approximately 65%
Please click on any of the links above to view the new composting technology videos.  Many thanks.  D

 

How Many Farming Operations Have Manure Composting Technology on Their Farm Improvement Plan?

Manure composting technology has proven economic and  environmental advantages.  XACT Systems’ Manure Composting Technology — The BioReactor is proving to be a wise choice by farmers in all animal farming operations including dairy, beef, horse, poultry and fish.  How many farmers think that composting manure is a good manure management strategy?  If so, how many farms are now using manure composting technology?

manure composting technology

Viewed here from the in-feed end, this BioReactor is composting dewatered dairy manure in just 4 days.

Economic Advantages of XACT’s Manure Composting Technology:

Environmental Advantages of XACT’s Manure Composting Technology:

1700 Cow Dairy Composts Dewatered Manure for Bedding

The XACT BioReactor on this dairy operation is 10’ diameter by 60’ long. It has to turn 45 to 50 tons of dewatered cow manure 240 times per day, 365 days per year.  After taking a look at the robust mechanical characteristics of the XACT BioReactor drum and the heavy duty drive system, this dairy operation was confident in the ability of the XACT system to handle the staggering weights of waste material to be processed daily. Check out all the specs for the BioReactor by clicking on xactsystemscomposting.com/bioreactor/.

Dewatered cow manure is fed into the vessel by a conveyor. Because the infeed opening is located in the upper quadrant of the stationary infeed end, the BioReactor can be filled to 70% capacity. Remarkably, a 7.5 hp variable speed drive turns the BioReactor and its load.

After a 4-day retention period in the vessel, the discharged compost is taken back to the barn to be used as bedding for the herd. Upon discharge the compost is pathogen free, weed seed free, insect larvae free, and odorless. At this point the compost is about 50% moisture, and therefore as it gets blown into the stalls there is minimal airborne dust. Most importantly, the cows love it as it provides exceptional comfort.

Please share your thoughts about composting manure.  Many thanks, D.

 

Manure Composting Equipment at Pete and Gerry’s Organic Egg Farm

industrial composting technology for composting manure, mortalities,  litter, egg processing waste

This BioReactor is 6′ diameter by 30′ long and is able to compost manure as well as many other forms of organic waste.

Manure composting equipment at Pete and Gerry’s Organic Egg Farm, supplied by XACT Systems Inc., allows these innovative organic farmers to manage their poultry manure with the same approach/philosophy as they apply to all their farming practises: reducing pollution, maintaining healthy soil, and conserving water and other precious resources.

Pete & Gerry’s Organic Eggs has been farming for four generations. They are totally committed to producing the highest-quality, freshest eggs possible. Organic eggs means that no antibiotics, pesticides, herbicides, fungicides, GMO or animal by-products are used.   In addition, Pete & Gerry’s is a values-led company, dedicated to humane treatment of animals–no cages–with free range barns.  The company is a champion of small family farms believing that these kinds of farms are the best stewards of environmental sustainability.

The manure composting equipment chosen for the job is the BioReactor Composting System built by XACT Systems Inc.

manure composting equipment

Organic poultry farm composts poultry manure to determine viability of producing and marketing compost made from manure of the organic laying hen farm. The BioReactor discharges the finished compost onto a conveyor.

Always looking to the future, Pete & Gerry’s wanted to test an idea they have for producing compost from the poultry manure.  They want to capitalize on the marketing potential of this specialized compost–possibly as an organic soil amendment.   The BioReactor is 6′ diameter by 30′ long (1.8m x 9 m) and has a total processing capacity of 22 cubic yards (16 cubic metres).

This pilot project to test XACT’s manure composting equipment and producing great compost is just nicely underway and so far the results are promising.  Stay tuned for more updates as the trial continues.

 

Composting Multiple Organic Waste Streams Separately? No Big Deal

Composting Multiple Organic Waste Streams Separately?  No Big Deal

Composting multiple organic waste streams separately is no big deal.  Do so with a very small footprint and in just 6-7 days–so now there is something to talk about!   This is all  possible with the BioReactor Composting Technology by XACT Systems.

Composting multiple organic waste streams separately? No big deal

Two full size BioReactors are composting 2 waste streams at an integrated processing plant. The 3rd smaller BioReactor is processing other waste streams on a trial basis.

This installation is operating with 3 BioReactors in order to quickly compost multiple waste streams (slaughterhouse sludge, hatchery waste, wood chips).  2 of the composters are permanently situated and each is composting a different organic waste. The smaller third composter is temporarily in place to conduct trials of various other organic waste streams.   As you can see, these vessels are housed under a single roof.  The land requirement for this composting system is pretty small compared to other methods of composting which would require a large acreage to compost the same amount of waste.

How the BioReactor Composting Technology Works:

The BioReactor  is an in vessel rotating drum that provides the perfect environment for the composting process to take place which means that the composting process happens very, very fast.   Small Land Requirement:   These larger 2 units are 10′ x 60′ (3m x 18m). Heat:  The continual rotation of the BioReactor controls the temperatures of the composting process in optimal range.  Oxygen:  Plus, ALL the tumbling waste material is exposed to the oxygen in the air at all times, so decomposition process is completely aerobic.  Capacity:  The BioReactors can process large volumes of waste per day…in this case each vessel is processing 22 tons per day.

Composting Multiple Organic Waste Streams Separately? No big deal

This Composting Facility with the BioReactor Composting System and curing area is located in Brazil.

Composting multiple organic waste streams separately? No big deal–so please get in touch by phone (613-399-5686) or email to learn more!

http://www.intecnial.com.br

Tel: 1-613-399-5686   •   Or: 1-613-391-1445   •   Email: info@xactsystemscomposting.com