Reduces costs by mechanizing wood chip composting - Deodorization and Composting equipment - Miraie

CASE STUDY

Construction example

2021.11.01 PLANT WOOD CHIPS

Reduces costs by mechanizing wood chip composting

Place:Ibaraki Prefecture
Processed Material
and Amount:
Wood chips, pruned branches, fallen leaves, etc. 20,000 tons/year
Overview:The largest facility in the region for composting wood chips, etc. Turn over work is reduced and low cost composting with high pressure aeration is realized.

Measures and Effects

Increased processing volume by expanding facilities/equipment: Processing volume was increased from 50,000 to 70,000 tons per year by expanding facilities.
Increased processing volume by improving aeration:By improving the aeration method from conventional systems, it shortened the fermentation period and realized efficient processing in a smaller area.
Reduced cost by saving labor:By reducing turn over cost, it reduced heavy equipment costs (¥18,000,000/machine) + running costs (¥9,000,000/year) × 1 person = ¥27,000,000/year.
Raised compost quality by improving aeration:By improving the aeration method, it improved the quality of compost.
Expanded compost sales channels by packaging compost in bags:Some of the fertilizer is packaged in bags, expanding the scope of users.

Company K is a recycling company in Ibaraki Prefecture which composts wood chips and cut grass.

They have long operated a composting facility that processes tens of thousands of tons of waste annually, and have now built a new plant to increase their processing capacity.

Their new composting plant can accept pruned branches and leaves, cut grass, and trees, and has a processing capacity of 20,000 tons per year. The processing procedure is as follows:

(1)Crushed materials are deposited in the fermentation tank.
(2)Water is sprayed regularly on the compost while it is aerated and turned over by EasyJet.
(3)The compost is aged in the aging yard. Composting is completed in 3 months.
(4)Some of the compost is screened, then automatically bagged by a bagging robot. 

They decided to introduce EasyJet for the purpose of shortening the processing period and processing 20,000 tons of waste per year by doing compost reliably year round.

While general wood chip composting does not produce foul odors, the wood chips decompose slowly because the material mostly contains cellulose, so the fermentation period is extremely long (Generally taking 1 to 3 years to mature). 

Therefore, the greatest costs incurred are the increased deposition area due to the long fermentation period, the cost of purchasing heavy equipment for turn over work, and operation costs.

Using EasyJet, the fermentation period can be shortened by more than half, and turn over work can be reduced, which is expected to produce great economic benefits. 

While this also depends on the scale of processing, the number of operation staff can be reduced to approximately half that of conventional systems.

Reducing operation staff by one person contributes greatly to profits, because costs can be reduced by ¥10,000,000 to ¥15,000,000 for the purchase cost of each heavy machine, as well as ¥9,000,000 in personnel and fuel costs per year.

We will use our wealth of know-how to select the optimal machinery and make proposals that help improve your profits. Feel free to contact us for consultation.