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Let's make chicken manure

gm-en-full-nutrient-recovery-pdf

GM-EN-Full-nutrient-recovery.pdf

Chicken manure

Pellet fuel is an alternative to renewable energy sources made from recycled biomass such as wood waste (wood chips and sawdust), wastepaper, agricultural residues (straws, corn stalks, and other residual crops). Raw biomass is usually collected for recycling and pre-treated before being manufactured into pellet fuels to increase its burn efficiency. Pellet fuel is made uniformly in terms of size, shape, moisture, density, and energy content so it is easy to transport, store and feed into heat and power generation units.

Pellet fuel

Dorset GM (Green Machines) is specialized in designing and manufacturing solutions for processing organic waste.

No loss of valuable nutrients in end product

Clean water is extracted suitable for for use or discharge

Modular system reduces investment costs lower vulnerability to interruptions

No emissions due to vacuum process

  Save costs with very low energy consumption

Consistent and reliable as it does not rely on any biological process

Traditionally, liquid manure processing can lose some important nutrients. An efficient full nutrient recovery system ensures that nutrient N-P-K are not lost while processing but remain in the end product while allowing easy operation.


<h2>Economic, full nutrient recovery while processing liquid slurry</h2>
Dorset’s Arnold Vacuum Evaporator is designed for processing liquid fraction with low dry matter content. Its end products are clean water and thick fraction. The system is modular, providing a complete solution for the processing of liquid slurry in 4 steps.

First, the separator moves the solids to the dryer, and the liquid to the vacuum evaporator without any flocculants. Its special configuration of the heat exchanger prevents clogging and allows easy operation. The solids from separation and the concentrate from evaporation can be dried separately or together. The system then, turns the product in a compact good-looking organic fertilizer pellet suitable for storage, long distance transport and export certification procedures.

Alternatively, a simple version of the evaporation system is also available as a standalone product. It can be used for stripping ammonia from liquids, with the end product being ammonium sulphate or ammonia water.

Evaporator for manure fertilizer

Process

Biomass

Chemical

Feed

Continuous

Drying technologies are used to remove moisture from your product. Energy or heat can be supplied directly by blowing hot air or gas, through a product, or indirectly by using a heating medium. Choosing drying equipment depends on your product feed and the required flow of your commercial or industrial production line.

Evaporation equipment is used to reduce or remove the moisture content of a mixture. Considerations for choosing suitable evaporation equipment include the moisture content in the mixture, the boiling point of the solvent, heat sensitivity of the product, and the amount of material to be processed. Evaporators are used for applications such as obtaining fruit and vegetable concentrates in the food industry, concentrating aromas and herbal extracts in the cosmetics industry, and to isolate active ingredients in the pharmaceutical industry.

Evaporating

Extracts from plant material, such as seeds, leaves, flowers, roots, and bark provide essential oils and active ingredients used in the pharmaceutical and food industries. The three most commonly used methods of extraction are steam distillation, cold press extraction, and solvent extraction. Considerations for selecting suitable extraction equipment include the type of plant material to be processed, heat sensitivity of the extract, and volume of production. Extraction equipment is applied in the pharmaceutical industry for extracting active compounds from medicinal plants or herbs. It is also used for the recovery of essential oils, oleoresins, aromas, natural extracts, and proteins in the food industry.

Extraction

If a raw material was recently part of a living organism, it makes good biomass. Organic substance that has otherwise little use for you such as inedible plant cuts, sawdust or recycled cooking oil, offers a path to carbon neutral energy generation. With the right process, you can transform biomass materials into a range of valuable energy sources.

Due to their potential hazardous nature, chemicals are classified for proper identification and safety during production. Chemical classification depends on their properties, structures and functions. In the chemical industry, you can regard them as basic chemicals such as acids, chemical products to produce plastic materials and finished chemicals for use in cosmetology. As a manufacturer or engineer, you want to know their reactivity when using chemical process equipment.

Chemicals

We continuously talk to suppliers of feed processing technologies that have important know-how on how to create the smarter, better, and greener feed products we need to kickstart a better tomorrow. Are you into making animal feed or pet food and looking for ways to improve your production process? Let’s navigate the world of feed production technologies together!

Made from natural sources, organic fertilizer has become a popular solution to providing nutrients to plants and soil. Commonly, organic fertilizers are produced by using animal manures and agricultural residues and by-products. These readily biodegradable materials make organic fertilizers a better nutrient source than chemical fertilizers (or sometimes called synthetic fertilizers). It is therefore widely used in the production of organic foods.

Organic fertilizer

liquid

solid

dorset-fertilizer_lr-pdf

Dorset-Fertilizer_LR.pdf

Can deliver the full package including the required engineering work, service afterwards, storage etc.

Energy efficient and sustainable solution

Produces green chemical fertilizers

Manure fertilizer needs to be made marketable by making them visually attractive, with high level of hygiene frequently required for export. A full processing line can provide a cost-efficient, start-to-end solution to form pellets, which are uniform with smooth surface and high stability of the granulate, ready for transporting.


<h2>Reliable, standardised system focused on processing poultry manure</h2>
Dorset’s Pelleting line is a fully equipped standardised pelleting line, dedicated for volumes of 400 Kg/H or 800 Kg/H. It is a full processing line, mounted on a steel platform. It includes all the parts required for pelleting dry poultry manure: a crusher, dosing system, pellet press, dust sieve, cyclone, sanitation and a cooling system.

Most wastewater treatment plants processing slurry use techniques that result in waste streams which by itself have little or no value and are difficult to process further. However, this pelleting line for manure fertilizer combines these substances for effective and configurable production of green chemical fertilizer. This results in a customer specific supply of fertilizer to the end-user.

Pelleting line for manure fertilizer

Continuous milling is a flow production method used to grind materials without interruption. It is often used in the production of foods, cosmetics, pharmaceuticals, chemicals, and minerals. The material to be processed flows in at one end and the milled output flows out at the other in a continuous process. By choosing the right combination of milling technology and processing power you can obtain the desired particle size distribution in an uninterrupted stream.

Continuous milling solutions

A pellet mill is a type of mill used to make small, round, compressed, pellets from powdered materials. Selection of a suitable pellet mill requires consideration of the desired pellets size and shape, nature of the material to be processed, ease of cleaning, and the scale and mode of pellet production. In the animal feed and pet food industries, pellet presses are used to combine various nutritional ingredients into each pellet. In biomass combustion, a pellet mill is used to increase bulk density and provide a consistent, easy-to-handle input product made from raw materials such as sawdust.

Pellet mills

Using pelleting presses allow you to compact your material granules into a homogenous mass by pushing powder into a pellet die hole and applying pressure with a roller. The compressed material is then cut down to size in equal measurements. Used for numerous applications, pellets vary in consistency and may require further temperature control to achieve the required solidity. In order to improve pellet quality, conditioners are an important part of the pelleting press process. This step treats the powders and raw materials hydrothermally, before being pressed, in order to achieve high quality pellets.

Pelleting Presses

You may press finely sized powders together into dosages and quantities using compaction machines. The process separates the fed material into predefined measurements and packs the powders into blocks according to the specified density and shape to accommodate different end products.

Pelleting

Have you ever wondered why the names of plastics always start with poly like polyethylene? The reason is that plastics are nothing more than synthetic or semisynthetic materials made from chains of molecules, called polymers, linked together. Plastics' main feature is the malleability to be easily molded and extruded into different shapes such as bottles or tubes. When heated, plastics can soften and be reshaped (thermoplastics) or they can solidify and never be reshaped again (thermosets).

Plastics

gm-en-dorset-drying-system-pdf

GM-EN-Dorset-Drying-System.pdf

Plant waste

Lowers costs of energy consumption

Does not require pre-treatment of digestate

Low cost of maintenance

Fully automatic, eliminating costs of manual labour

Low dust generation through low speed

The drying of poultry manure digestate requires careful and consistent moisture level control. A sustainable and cost-efficient solution which uses the residual heat at biogas installations can be used to dry wet digestate, then converted to dry and valuable biomass or used as an organic fertilizer or litter in stable boxes.


<h2>Save energy consumption with a cost effective and sustainable dryer for digestate</h2>
The Dorset drying system uses the residual heat produced at biogas installations for the drying of manure and digestate remaining after anaerobic processes. It can be used year-round and is a cost-efficient alternative to the emergency cooler. The electricity consumption on this system is relatively low. It also keeps the airflow through the product extremely low, to prevent dust from being generated.

One of the primary technical advantages of the belt dryer for digestate is its smooth coated perforated steel plates. Its sturdy belt permits a thick layer of manure (15 – 18 cm) to be evenly distributed across the full width of the plates, ensuring a highly efficient drying process. The efficiency of the belt allows the dryer to be constructed in a compact configuration.

The dryer operates fully automatically and requires no manual input. It can be monitored remotely if required. It can help you achieve various end products depending on the input and the techniques used.

Belt dryer for digestate

Belt dryers are suitable for continuous drying and cooling applications. They use heated air or an inert drying gas to remove the moisture, as the product passes through a drying chamber, on a perforated belt. Belt dryers are suitable for industries producing pelletized or granular, dry bulk products.

Belt dryers

Quality control procedures dictate that each bag must reach the consumer in perfect condition. Random sampling procedures do not guarantee the quality of each bag. An important step in choosing the right bag inspection equipment is identifying the critical quality control checks that ensure quality. These checks may include scanning for foreign objects, testing the bag seal, and ensuring that each bag contains the labeled amount of product. Bag inspection equipment is widely used in the food, pharmaceutical, and chemical industries to check the bag seal and guard the product against drying and deteriorating from exposure to the environment.

Bag inspection technology

A belt conveyor system uses pulleys or drums to keep an endless loop of conveying belts in continuous motion. Considerations for choosing a suitable belt conveying system include the physical form of the product, processing requirements, and the desired speed and volume of transportation. Belt conveying systems find numerous applications in the food, pharmaceutical, and chemical industries such as filling and packaging operations. In the biomass industry, these systems are used for moving biomass feedstock to the boiler. In the mineral industry, conveying belts process and transport granular and crushed minerals.

Conveyor belts

Homogenization is the process of reducing particle size in mixtures to improve the consistency, uniformity, and stability of the product. The choice of a homogenizer depends on the nature of the product, desired particle size, the physical state of the ingredients, and pressure requirements during the process. Homogenization is widely used in the biotech industry for cell lysis and in the pharmaceutical industry for emulsification of creams and ointments; it also finds applications in the cosmetics and food industries for improving consistency and uniformity of various products.

Industrial homogenizers

Bagging is the process of packing measured portions of a product into bags that protect it from spoilage, enable easy and safe transportation, and secure the product against tampering and pilferage. The choice of a bagging solution depends on the desired mass or volume per bag, the flow characteristics of the product, and bag construction and design. Bags vary in size from small sachets to bulk flexible containers.

The fermentation process stimulates enzymatic activity in organic substrates to transform their chemical composition. Fermentation is aided by storying the biomaterials in anaerobic environments, allowing the microorganisms to decompose their nutrient structures. The process is integral to some of the most popular products throughout time such as wine, beer, cheese, and kimchi. But besides the food sector, fermentation is also an important stage in the industrial manufacturing of chemicals, pharmaceuticals, and biofuels.

Industrial mixing is used to combine a heterogeneous mix of two or more solid, liquid or gaseous ingredients into a homogenous product. The choice of a suitable mixing solution depends on the physical state of the ingredients and the desired mixing process; the sensitivity of the ingredients and process temperature and pressure requirements are also important factors.

Sterilization is a key procedure across many manufacturing processes. Sterilization processes and methods are found in food, healthcare, pharma as well as in the medical field. Specialized equipment is used to kill harmful microorganisms from containers before you fill them up with your goods. Most sterilization equipment employs high temperature pressurized steam to completely eliminate bacteria and disinfect surfaces from any spores. Other methods include radiation sterilization or the use of chemicals such as hydrogen peroxide for disinfection.

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Processing steps involved in chicken-manure making

Bag inspection technology

Belt dryers

Conveyor belts

Industrial homogenizers

Pelleting Presses

Bag inspection technology

Belt dryers

Conveyor belts

Industrial homogenizers

Pelleting Presses

Bag inspection technology

Belt dryers

Conveyor belts

Industrial homogenizers

Pelleting Presses

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