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

BioReactor Composting Technology

BioReactor Composting Technology Features at the 2015 National Farm Machinery Show in Louisville KY

Are you attending National Farm Machinery Show new week?  If so, stop in at the XACT Systems booth located in the PAVILION booth number 000827 and learn how to successfully compost DAIRY MANURE (and other solid organic waste) with the awesome BioReactor Composting Technology.

Composting dairy manure (dewatered) with

The BioReactor Composting Technology makes compost for bedding from dewatered dairy manure

Compost Bedding Made By the BioReactor Composting Technology

the BioReactor is a winning solution to manure management in 3 ways.  The resulting fibrous material makes an excellent & safe BEDDING material which cab replace other costly materials.  Plus by converting manure into QUALITY compost you can capitalize on in the lucrative retail and wholesale market of organic fertilizer/soil amendments.

And finally, because traditional methods of managing manure are under legislative scrutiny, are creating health hazards and odor problems in the surrounding communities, and are causing damage to the environment, the BioReactor Composting Technology allows you to treat your huge volumes of dairy manure with technological innovation.

The BioReactor Composting Technology is the Solution!

The BioReactor Composting Technology is a rotating drum that converts dewatered dairy

Composting manure for bedding a dairy herd using the BioReactor Composting Technology

The rotating drum composting technology–better known as the XACT BioReactor- is ideal for fast composting, ease of operation, and trouble free service.

manure into compost.  This in-vessel composting system is designed to successfully process manure by tightly controlling the parameters of the composting process.  In other words, the BioReactor makes an ideal environment for the oxygen-loving bacteria to thrive and decompose the manure. The BioReactor will process large volumes of manure quickly, and will do so without the occurrence of hazardous leaches.

Independent test results have proven that the BioReactor composting technology will compost dewatered dairy manure in 4 days (or less), and will produce a light fluffy compost that is PATHOGEN FREE (including e-coli), odor-free, weed-seed free, insect larvae-fee and mature. Indeed, the compost bears no resemblance to the waste from which it was produced.

This compost has tremendous value if sold in bags or bulk because it makes an excellent

In-vessel composting technology for composting organic solid waste

BioReactor Composting System with In-feed and Discharge Conveyors, BioFilter & Future Expansion Capability.

soil amendment due to its organic matter and nutrient content. Indeed, the compost no longer has harmful bacteria in it to cause disease so it can be spread on land close to water sources.

Site layouts are our speciality, and we would be happy to work with you to design a BioReactor Composting Solution specific for your farm needs.   The BioReactor is available in a variety of sizes (the largest is 10′ diameter x 60′ long), and the size of machine required is determined by the volume of dairy manure produced per day.  Note:  a herd will utilize only 30% of the compost produced by that herd for bedding–the remainder is available for other purposes (selling or land application).

If you are planning to go to the National Farm Machinery Show  in Louisville, KY February 11 to 14, 2015, please consider visiting us at booth 000827 in the PAVILION.    Hope to see you there!

Are You Attending the International Poultry Expo in Atlanta This Week?

Are You Attending the International Poultry Expo in Atlanta This Week?

If so, stop in at the Farmer Automatic booth in Hall C booth number C13007 and learn how to successfully compost all poultry waste.   There, you will find us, XACT Systems Inc. and the awesome BioReactor.

Compost poultry litter and much more with the BioReactor composting technology by XACT

BioReactor Composting System with In-feed and Discharge Conveyors, BioFilter & Future Expansion Capability.

When you compost poultry litter and all your other poultry waste with the BioReactor, you will realize economic benefits (always a good thing),  and environmental benefits.  Converting waste into quality compost allows you to capitalize on the nutrient value of the waste.  Because traditional methods of managing these wastes are incurring high costs, are creating health hazards and odor problems in the surrounding communities, and are causing damage to the environment, there is a need to treat these huge volumes of organic waste with technological innovation.

The BioReactor Composting System

The BioReactor Composting System is a rotating drum that converts any solid organic waste into compost.  It complies with the fundamentals of composting* regulations by tightly controlling the parameters of the composting process. The BioReactor makes an ideal environment for the oxygen-loving bacteria to thrive and decompose the material. The BioReactor will process large volumes of organic waste quickly, and will do so without the occurrence of hazardous leachates.

On Wednesday, January 28th, XACT Systems will make a presentation  describing 2 separate pilot projects that were conducted on poultry farms composting various types of poultry waste. One test took place in Brazil and the other in New York State. The test results proved that the BioReactor composting system will compost organic poultry waste in 7 days (or less), and will produce a light fluffy compost that is pathogen-free (including salmonella and coliforms), odor-free, weed-seed free, insect larvae-fee and mature. Indeed, the compost bears no resemblance to the waste from which it was produced.

This compost has tremendous value if sold in bags or bulk because it makes an excellent soil amendment due to its organic matter and nutrient content. Indeed, the compost no longer has harmful bacteria in it to cause disease so can be spread on land close to water sources. Because the BioReactor is situated on site, the cost of hauling poultry waste is eliminated. Depending on the facility’s situation, the compost can be used on site or sold to others.

* Composting is defined as a process of biological decomposition of biodegradable organic fraction of the waste, carried out by a diverse population of organisms under controlled aerobic conditions and other parameters (ratio of carbon: nitrogen, moisture, temperature, pH, particle size, porosity, homogeneity of the mixture).

If you are planning to go to the International Poultry Expo (IPPE) in Atlanta January 27-29, 2015, please consider attending the presentation and visiting us at booth C13007.  We will be at the Farmer Automatic booth in Hall C…again the booth number is C13007.  Hope to see you there!

Food Waste Composted with the In-Vessel Composter by XACT

Composting Food Waste Generated by 8,000 Room Resort in Cancun

Food waste composting

Food waste from the kitchens and dining rooms is collected separately and taken to the on-site composter for fast composting.

Food waste composted with the in vessel composter by XACT is solving the organic waste problem of an 8,000 room hotel in Cancun, Mexico.  The Cancun Palace Resort generates 2500 tons of organic waste per year, and wanted/needed to reduce their high waste haulage costs and landfill tipping fees.  In addition, the hotel management wanted to take meaningful action to reduce their GHG emissions.

The Palace Resort was able to solve both objectives effectively by choosing the BioReactor by XACT Systems to compost their organic waste.    As an added bonus, the Cancun Palace Hotel’s corporate image is enhanced by their responsible waste management initiative.  Plus the benefits don’t stop there!  The Return On Investment (ROI) is only 18 months making the investment in the BioReactor Composting System a savvy decision in all respects.

Food Waste and Garden Waste are the Feedstocks

The BioReactor is composting food waste from the kitchens and dining rooms as well as green and brown gardening residue.  The waste is processed in the in-vessel composter for 5 days.  Upon discharge, the compost is pathogen-free, weed seed-free and virtually odorless.

Composting in the BioReactor Is Followed by Vermicomposting

Composting Food Waste

The BioReactor is 8′ diameter by 40′ long. The food waste, green and brown plant residue are composted in the vessel in 5 days.

The next step in the operation is for the compost to be placed in the worm bins for further decomposition.  Vermicompost is process of decomposition of organic waste using worms.  The castings (or worm manure) have a high saturation of water soluble nutrients (readily plant available) and makes an excellent organic fertilizer and soil conditioner.  The Cancun Palace Resort uses the castings in their own nursery, gardens, flower beds, and on the golf course.

In-Vessel Composters to Compost Palm Fruit Bundles

These in-vessel composters of XACT Systems are being manufactured in our Mexico plant, and will be composting the spent fruit bundles from palm oil production.  After the oil has been extracted from the fruit, the tons and tons of fruit bundle waste will be loaded into the XACT in-vessel composter and converted into rich earthy compost.  The compost will be a terrific soil amendment because it adds organic matter and nutrients back into the soil.  The soil is healthier thus the crops are healthier, more resistant to disease, and will produce higher yields.  So, not only will the XACT BioReactor solve the organic waste problem, it is also improving  crop production.

This link will take you to a document describing research done in 2006 regarding palm oil production and composting the spent fruit bundles.

http://www.biomass-asia-workshop.jp/biomassws/03workshop/material/tanaka.pdf

Actually, the in-vessel composter by XACT can compost any solid organic waste.  In this case, fruit bundles will be composted, but the BioReactor can also compost other agricultural waste such as green waste, spoiled feed, manure and mortalities.  In the  commercial sector, the BioReactor quickly composts food waste, fish waste, paper, leaf and yard waste, grass clippings and so on.

Composting palm fruit bundles

The production of palm oil creates tons of fruit bundle waste which needs to be sustainably managed. The operation where these 2 BioReactors by XACT will be going have wisely chosen to compost their waste. The finished compost can then be spread on the land to enhance future crop production.

Composting agricultural waste.

In-Vessel composters engineered by XACT Systems are ruggedly built to handle tons and tons of waste. The BioReactors turn slowly and in a 4 to 7 day period will compost raw organic waste into rich fluffy compost. These 2 composters are going to a palm oil production facility. They will be used to compost the spent fruit bundles from which the oil is extracted.

 

 

Each BioReactor is 10′ diameter x 40′ long.  The drum turns very slowly while the ends of the drum remain stationary.  This allows for the filling capacity to reach 70% of the volume of the vessel. The typical daily operation of a BioReactor begins by unloading a specific portion of the compost using the discharge door followed by loading the daily volume of waste material in to the BioReactor at the in-feed end.  The waste material remains in the BioReactor 3 to 7 days depending on the properties of the waste material.

Once this installation gets up and running, I will get pictures and post them so that you can see how well the operation is working.  Until then…check out our website for more information on some of our other installations.  Many thanks for your interest today!

In-Vessel Composting System is Put Through Its Paces and Performs Well

Our In-Vessel Composting System Is Being Put Through Its Paces and Performs Well

XACT’s in-vessel composting system is being put to the test in a pilot project using various solid organic materials and amendments.  One of the tests included small animal/bird mortalities as a feedstock.  Recently, one of the superb composts produced used the following feedstocks:

Composting food waste and other organic solid waste with the Compact BioReactor.

In-Vessel Composting System Using XACT Systems’ BioReactor for a
Pilot Project to Test Various Organic Waste Including Food Waste.

This project has been implemented  to confirm the BioReactor’s performance and to determine best practises for the composting process protocols  and feedstocks.  This in-vessel composting system is comprised of a 5′ diameter  x 10′ long vessel, a mixer and conveyor and is situated in a hoop building.  It has been running tests for approximately 6 months trouble free.  Satisfied with the pilot project results, this company is ready to take on the full “meal deal” and   get started commercially on a large scale with a 1060 BioReactor.

The Value of Pilot Projects

Pilot projects allow a facility to:

An in-vessel composting system, such as the Compact BioReactor, lend itself perfectly for pilot projects:

  1. The system is totally self-contained.  Typically, a mixer and conveyor come with the rotating drum in order to facilitate blending and loading.
  2. The BioReactor composting system comes completely wired and ready to go….just plug and play! (3 phase or single phase options)
  3. This composting system comes equipped with variable speed return air fan.
  4. The friction drive systems has extremely low energy requirements.
  5. The system is very quiet and pristine.
  6. The Compact composting system can be place on a flat bed trailer and moved from site to site.

 

 

 

XACT Systems Composter Seminar at the Waste Expo 2015

The Waste Expo 2015 in Atlanta features a seminar afternoon on the 29th of April.   In the 1:00 pm slot will be a presentation showing the advantages of XACT Systems’ in-vessel composter (BioReactor) and the various installations we have around the world .  This presentation will take place on Tuesday (the first day of the show) in the Organic Waste Management section.

Booth 5440.  Look for this logo in the Organic Management section at the Waste Expo 2015

Look for this logo in Booth 5440 in the Organic Management section at the Waste Expo 2015

XACT SYSTEMS BOOTH

Our booth 5440 is also located in this section….just keep a lookout for our logo.  So if you would like to discuss your particular composting project as well as learn about the BioReactor technology and installations around the world, please stop by.

COMPOST SAMPLES

We will have samples of compost made from food waste, other organic waste and amendments in the BioReactor in just 4 to 5 days.  Come see it for yourself so that you can appreciate its potential dollar value, soil value, and plant value.  For those of you looking for free passes to the show, simply get in touch with me and I will see that you get all that you need.  www.xactsystemscomposting.com.  Remember the Waste Expo 2015 begins on April 29th and runs for 3 days.  Hope to see you there!  Many thanks, D

XACT Systems In-Vessel Composting System Exhibits at Waste Expo 2014 in Atlanta, GA

The BioReactor is an In-vessel, rotating drum composting technology by XACT Systems.

The BioReactor is an In-vessel, rotating drum composting technology by XACT Systems.

The Waste Expo 2014 in Atlanta, Georgia will showcase XACT Systems BioReactor later this month. The dates of the show are April 29 – May 1. You are welcome to check out the latest innovations of the BioReactor Composting System by coming to our booth # 5440 which is located in the Organics Waste Management section of the show. The BioReactor will compost food waste, biosolids, yard waste, wood waste and more. Check out our website for a complete listing of the types of solid organic waste that can be composted successfully with our in-vessel rotating drum composting technology. wwww.xactsystemscomposting.com. Hope to see you there!
Free Passes
If you would like a free pass into the show (and save yourself some bucks), please get in touch with me as I have plenty of free passes to share….phone #’s and email address are listed below.  Many thanks.  D

Food Waste Composting: Fast, Easy, Minimal Odor

Food Waste Composting with XACT Systems BioReactor is Fast, Easy, Minimal Odor

…but you don’t have to take my word for it!  Here is a letter we just received from the operations manager of Alaska Waste describing their operation and their experience with the BioReactor composting food waste and horse manure.

“At the Alaska Waste headquarters in Anchorage, Alaska, we use the XACT composting system that allows us to produce just over 1 million pounds of raw, immature compost annually. We began production in January 2009 and have been able to consistently produce quality compost at a rate of 30yd3  per 5 day work week with only one technician and one cleaning laborer. The technician drives the green waste collection route as well as grinds/mixes the compost ingredients, offloads and stockpiles the raw compost, and maintains the equipment. The cleaning laborer is required due to the fact our operation is indoors and located in midtown Anchorage, which demands minimal odor. We receive our brown waste from environmentally conscience companies looking for an alternative to the local landfill.

The XACT system has required only preventative maintenance with no extended lost production repairs. In fact, most of our maintenance and safety concerns are related to the conveyers that are responsible for the loading and offloading of the vessel. If properly maintained the XACT system will last for decades of continuous operation. It is a simple and very efficient means to producing high grade compost in considerably less time than traditional methods.”

This BioReactor is composting food waste.

This BioReactor is composting food waste.

Exhaust Duct at Discharge End of the In vessel Composter.
Exhaust Duct at Discharge End of the Invessel Composter.

 

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