Wood scrap composting cost reduced with mechanization (Introduced to: Company K) - Deodorization and Composting equipment - Miraie

CASE STUDY

Construction example

2021.10.12 EASYJET

Wood scrap composting cost reduced with mechanization (Introduced to: Company K)

PlaceIbaraki Prefecture
Processed Material and AmountWood chips, pruned branches, fallen leaves, etc. 20,000 tons/year
OverviewThe largest facility in the region for composting wood chips, etc. Reduces turn over work and realizes low cost composting with high pressure aeration.

Measures and Effects

Increase processing amount 1By expanding the facility, the amount was increased from 50,000 tons per year to 70,000 tons per year.
Increase processing volume 2By improving the aeration method from conventional systems, it shortened the fermentation period and realized efficient processing in a smaller area.
Reduce costBy reducing turn over work, it reduced heavy equipment costs (¥18,000,000/machine) + running costs (¥9,000,000/year) × 1 person = ¥27,000,000/year.
Raise compost qualityBy improving the aeration method, they improved the quality of compost.
Expand compost sales channelsSome of the compost 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 by EasyJet and turned over.
(3)Aging in the aging yard. Composting is completed in 3 months in total
(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.