Reduced bedding cost for sawdust pigsties (Introduced to: Pig Farm M Co. (200 sows, 2,200 pigs total) - Deodorization and Composting equipment - Miraie

CASE STUDY

Construction example

2021.10.16 EASYJET

Reduced bedding cost for sawdust pigsties (Introduced to: Pig Farm M Co. (200 sows, 2,200 pigs total)

Processed MaterialPig manure
OverviewCut costs by reducing the amount of auxiliary materials used in sawdust pigsties.
Raise fermentation temperature 1By revising the composting process, the fermentation temperature now rises stably.
Raise fermentation temperature 2By introducing high pressure aeration, it became possible to raise the temperature even in winter.
Reduce costBy using return compost as part of the auxiliary material (bedding), they achieved an annual cost reduction of ¥4,800,000.

Rapidly rising prices of sawdust and wood chips made the cost of purchasing sawdust (bedding) for the sawdust pigsty a major pig farming business burden.

Here we introduce a case in which EasyJet was introduced to aerobically ferment and reuse used sawdust, helping to decrease the cost of buying sawdust. 

This pig farm has 200 sows, and raises them in sawdust pigsties.

They had piled up used sawdust in the compost shed (using blower aeration). However, they faced several issues, including the fact that the fermentation temperature did not rise (winter: 40˚ C, other seasons: 50 to 70˚ C), moisture did not fall much (when compost was reused, the pigsty filled with sludge and became muddy).

Therefore, we made a proposal saying “How about you introduce EasyJet in just one tank of the compost shed to raise fermentation temperature, then remove moisture with blowers?” Then we did the following construction.

Bedding mixed with manure discharged from the sawdust pigsty is first deposited into the EasyJet tank. Oxygen is supplied to every part of the materials with high pressure aeration, so the fermentation temperature rises in a short period. Once the temperature rises, the materials are moved to the blower tank, which removes moisture with air from the blower. Before introduction, there was concern that the amount of air from the blower would not be adequate, so we added another blower.

As a result of this, after introduction the initial fermentation temperature (in the EasyJet tank) exceeded 70˚ C even in winter. It became possible to keep the temperature at 60 to 70˚ C even in the blower tank.

Moisture content has dropped considerably after fermentation, so it is adequate for reuse as a bedding.

In this way, by installing EasyJet only in spots where fermentation is difficult, it is possible to increase the efficiency of compost production while reducing introduction costs. 

In cases like this, where the purpose is to remove moisture, it is highly effective to raise the temperature with EasyJet in the initial stage and remove moisture with blowers in the middle and late stages.

The cost benefit for this customer is as follows.

  • Cost of buying sawdust: 10 ton truck-load (30 m3) = ¥50,000 (¥1,667/m3)
  • Return compost produced: 57 m3/week
  • Benefits: ¥1,667 × 56 m3/week × 52 weeks = ¥4,850,000/year reduction

As such, they managed to realize a tremendous cost benefit.

Improving manure processing capacity made a great impact on the environment and disease prevention on the farm, so we recommend taking measures soon.

EasyJet can also be installed in existing fermentation facilities, so please contact us for consultation.

Before introduction, we did preliminary composting tests in-house, and made a proposal for a plant based on the test data.