Perfect Application for Composting
ACT has been extremely successful in helping large, high volume Poultry growers improve their farm’s operation with our innovative and robust Forced Air Composting System. Via work with independent growers and coordination with the Dept. of Agriculture (NRCS) and with the blessing of integrator partners such as Tysons, Mountaire, and Prestige, we have been able to bring our high performance, and cost effective composting solutions to meet the Mortality Management requirements of today’s progressive Poultry grower.
With ACT’s origin in North Carolina and the high concentration of poultry producers in our state, our Poultry Mortality Composting Solution has been widely deployed and proven across growers of all sizes. The large number of successful installations into such a tight-knit community of growers and integrators is testimony to the cost-savings and performance we deliver to the grower. The combined weight of the mortalities and scope of larger farms make these truly industrial, heavy use sites, and showcase the performance of our Forced-Air composting systems. Our installations include entry-level configurations, up to farms that are processing over 750,000 pounds of mortality waste per year, so our systems can scale to a robust, industrial level.
Individual Kit Options
Most of our Poultry mortality systems feature our robust, custom turnkey solutions built for rugged, daily use with standard farm equipment. ACT also offers a “kit” option specifically engineered for Poultry applications, and customized for government agricultural “Cost Share” incentives. This option is available for growers to do their own site installations, or for farms that have existing composting processes that need a high performance, cost reducing upgrade. These kit options include all the necessary components to build and operate an industrial duty composting operation, utilizing the ACT Forced Air Systems for more efficient, lower cost, and more environmentally responsible composting.
- Reduces farm BioSecurity risk: No rendering trucks visiting farm
- Inexpensive + clean: Eliminates fossil fuel costs & mess of incineration systems
- Safe, environmentally sound: Farm compost process approved by EPA, NRCS
- Accommodates spikes in mortalities: Very scalable on daily needs
- Adjusts to seasons: Fully operational in sub-freezing environments
- Closed loop system: No runoff waste
- Custom Kit Option: Designed specifically for Poultry growers
- Industrial use: Designed for industrial use with standard farm equipment
- Solution approved: For Tyson, Prestige, Sanderson, Pilgrim Pride, Mountaire grower networks
- Possible funding: Approved for NRCS “Cost Share” funding
Sizing & Configuration Options
To begin to gauge the physical site configuration and composting components necessary to process your estimated amounts of feedstock (the organic material you need to process), we utilize our proven history at real-world customer sites to help size a system that is tailored to your need. Our custom Forced Air delivery system, and Closed Loop Leachate control systems are integrated into every design option. Our systems operate from a BIN unit that is constructed to industrial standards for duty and functionality with standard farm or industrial equipment. BINS serve as housing for the ACT Forced Air and Closed Loop Leachate Control systems, the feedstock being composted, and thus serve as “management units” that are monitored and recorded daily for performance and environmental compliance. The size and number of BINS needed is directly correlated to the amount of waste being processed, and the type and variety of organic matter needing to be processed. A great virtue to doing business with ACT, is that we have 3 major implementation options to our core BIN design that allow us to configure the best system for your budget and application. Not only do we have these 3 major designs to work from, but we are able to both scale and customize each customer’s installation utilizing these designs in modular fashion.
INDUSTRIAL HEAVY USE (Turnkey): These systems are almost always custom designed, and function “on-site” at a farm, food service location, or industrial site adjacent to the origin of the feedstock. These systems provide solutions for applications where there are daily or routine heavy requirements for treatment, as measured by quantity. Our systems can scale to practically any volume of feedstock. Typically, the systems utilize custom concrete bins and appropriate shelter and work pad areas. Solutions here are going to include Agricultural uses for animal mortalities at swine, poultry, cattle, fish, or other farms where there is a steady requirement for processing. These systems are scaled to work with normal farm/industrial equipment, and are robust with 20+ years expected lifetime utility.
INDUSTRIAL MODERATE USE (Turnkey): In some composting applications, there is a need for a serious, industrial solution, but the predictability of waste matter in volume is very unpredictable. For these applications, ACT has modular solutions that can be scaled to meet peak demands, but configured with lower start-up investment budgets. A great example of this configuration is our Dept. of Transportation/Roadkill Application. Image you are a state agency tasked with rendering the carcasses of dead animals on the state highway system; you may go days without any animals to process, and then get an influx of animals all at one time, perhaps due to variances based on seasonal animal behavior. Our insulated, metal container configurations allow for easy deployment with less site preparation and construction, and typically utilizing a smaller site footprint. Once these systems are loaded with feedstock and our recipe for processing, they are no less potent for processing to a completed process, our “Waste to Dirt in Days” than our larger installations. TIP: This configuration may likely avoid “Capital Budget” definitions by many organizations and thus, offer advantages for budgeting, funding, and speedy approval processes.
INDUSTRIAL “KIT” OPTION (Customer Install): For situations where customers would like to utilize ACT’s forced air technology, bin architecture, and composting management experience (or as a means to gain access to our solutions at the lowest possible cost), we have designed a “kit” solution option. In the kit option, the user will be responsible for the bin and site construction; ACT will provide a kit package that will include all of the industrial duty components that go into our turnkey solutions, just packaged for a customer install. Included in these kits are:
- ACT proprietary Forced Air piping and Blower Fan Unit
- Schematics for bin layout and hosting of the ACT hardware components
- Sized to scale for Application Specific environments and waste volume needs
- All fitting, connectors, electrical components for installation
- Detailed Architectural & Engineering Drawings for site facility buildings (if required)
- Installation DVD and Site Operators Guidebook
- Industrial duty 10 foot, split-level doors for bins
- Instructional Recipe for Composting regime & Site Maintenance
- Shippable kit to any destination
- Industrial quality, made in USA
In this package, ACT provides detailed architectural and engineering drawings on how to construct the bins themselves as well as the structure to cover the bins and house the components necessary for operation of the composting operation. This would include specs on the working pad area, dry storage area for raw materials, and other design elements. Site designs and all components are engineered for industrial duty, daily use and are standardized for operation with standard farm or industrial equipment if necessary. Building designs are established to meet codes of up to 130 mph wind, and live load of 30 PSF for roofing. Each customer must establish service for electrical and water to the site, as well as be responsible for all construction and environmental permits. Bin design is organized around a 10′ wide x 12′ long x 6’ high configuration capable of processing approximately 10,000 pounds of waste material when fully loaded. Each bin becomes a “management unit” for processing so the user can maximize performance and in order to comply with environmental regulations.