Composter Rotating Drum Technology

 

Composter Rotating Drum Technology is Destined For China

 

This Model 515 BioReactor Composting System (BCS) will be utilized as a Demo Unit For Pilot

Composter Rotating Drum Technology

This BCS offers a “plug and play” opportunity to test various feedstocks and amendments, and blending combinations at the job site.

Projects in all market sectors based in China. It is equipped with the essential components and complete automation features required for most composting facilities….essential that is if the goal is to obtain high quality mature compost in 4 to 7 days!

The Model 515 BioReactor Composter Rotating Drum Technology

The BioReactor is a rotating drum composter that has a load capacity of 70% of the total volume of the drum. This composter is 5’ diameter x 15’ long. It features a fixed, spring-loaded in-feed end with an opening for loading; a fixed, spring-loaded output end with an automated discharge auger or door; a rotating vessel supported by 4 trunnion wheels, a Friction Drive (.75 HP motor), and a negative ventilation fan.

The Mixer

A mixer is needed in order to pre-blend all the feedstocks so that a homogenous mixture of all the materials is obtained. This Mixer is equipped with cutting blades to slash the feedstocks in order to

Composter Rotating Drum Technology

The blades on the rotating vertical auger slash into the organic waste material thus breaking it into smaller pieces. This slashing action is especially critical and necessary when whole vegetables or fruit are present.

reduce the particle size. The capacity of the mixer used on the Model 515 BCS is 50 cubic feet and has a:

The Conveyor

The BCS is equipped with a heavy-duty automated incline conveyor fortified with a cleated belt. The cleated belt prevents the pre-blended organic waste from sliding back down the conveyor as it is being automatically loaded into the BioReactor.

The Control Panel

The control panel monitors the composting process and controls the function of the mixer, the conveyor and the BioReactor. This is accomplished by the Timer/PLC Control on the Control Panel. Complete control of the system is thus at the finger tips of the operator.

 

 

 

 

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.

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

 

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!

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

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