In early 2024, a poultry farm in Ohio's agricultural heartland faced a double crisis. The 50,000-chicken operation produced 12 tons of chicken manure daily, a byproduct that was becoming increasingly burdensome. Landfill tipping fees had increased 35% over the past two years, eroding profits.
The farm's management team explored various options, from hiring a third-party waste hauler to investing in basic compost bins, but none offered a long-term solution. Transport costs alone reached $18,000 per month, and makeshift compost piles often failed to reach the proper temperature, resulting in inconsistent quality and persistent odor issues. That's when they sought a customized solution from our team.
After an on-site assessment, we recommended a medium-sized trough aerobic compost turning system, supplemented by a high-speed pulverizer and a double-deck vibrating screen. Key to their challenges lay two customized modifications: a closed fermenter with an integrated biofiltration system and a network of temperature monitoring sensors. A biofilter filled with activated carbon and specialized microorganisms neutralizes foul-smelling gases before they are released, while sensors ensure the compost reaches a stable 65-70°C—hot enough to kill pathogens and weed seeds, meeting OEPA guidelines for organic fertilizers.
Installation began in March 2024, with our engineers working alongside farm staff to ensure minimal disruption to daily operations. The three-week setup involved adjusting the compost turner speed based on manure moisture levels (optimized for 60-65% moisture) and calibrating the screener to produce a uniform 3mm particle size—ideal for easy application by local farmers.
By September 2024, after only six months of operation, the results were truly remarkable. The $18,000 monthly waste hauling costs were completely eliminated. Even more impressively, the farm began selling its OEPA-certified organic fertilizer to 15 local organic vegetable farms and eight garden centers within a 50-mile radius. They say, "We didn't just buy equipment—we invested in a business model. The system has not only paid for itself, but more importantly, it turned a liability into an asset. Our customers love the feeling that they are supporting a circular economy, and we're proud to tell the story of how their vegetables were grown using nutrients from our farm. The 18-month payback period was better than we expected, and we're already considering expanding the line to process an additional five tons of manure per day."
