Compost Production

The primary objective of founding the company was to satisfy the increasing demand for high quality compost.

Compost production has developed dynamically since the very beginning. Our company has developed numerous composting innovations and new processes successfully combining them with the most advanced Dutch technology. Compost production capacity: 1,500 tons/week phase II compost.

Composting Plant

Own development and Dutch technology, phase II compost production capacity of 1,500 tons/week, 80,000 tons/year closed circulation indoor plant with 15 heat treatment units.

Our Own Developments and Methods

which are successfully used even today

·         Major focus is put on the selection and treatment of the raw materials. We work with raw materials of selected quality and store 20,000 tons of straw in 3 large stack-yards.

·         The capacity of the preparation unit is 60 large bales/hour; it mixes the additives and liquid manure in proportion to the quantity of the straw using a built-in automatic control unit. So a homogeneous mixture of standard characteristics and suitable moisture content is always produced.

·         The sprinkling towers specially developed by us continuously ensure the desired water content in the compost during the preparation phase, which in turn guarantees optimal microbiological activity.

·         The whole process is strictly controlled by a quality control laboratory and a computerised process control system completed with a correction system ensuring intervention if necessary. So, any problems occurring in the process can be detected and corrected. This reliability is a guarantee for standard quality.

·         In the specially dimensioned heat treatment units, our own air units and controlling elements also contribute to the high production yield.

·         Our developments were motivated by the need to eliminate fluctuation of the quality of indoor compost and to maintain the increased production capacity also under average production conditions.

·         One major advantage of the completely automated fermenting chamber system is that the bacterial processes occurring in the material during the preparation phase are fully controlled and perfectly completed.

·         The high level of control is also ensured by the highly reliable, precision air ventilation and air control systems installed in the breathing floor systems.

·         A highly reliable computer-controlled registration system has been developed for the breathing floor preparation process, the bunkers and the fermentation chambers, using PLCs.

·         In addition, a modernised PLC control system is used for the heat treatment units.

·         A centralised digital control system controlling all the major processes has been installed.

Biofermented Indoor Compost

High Fertility

Environmentally Friendly

Easy-to-use

Standard, High Quality Mushrooms

A complex production process has been developed in order to address environmental and economic problems, the technical unit of which is the biofermenter.

The biofermenter developed by us performs the biological processes of preparation in a precise and controlled manner, eliminating all the disadvantages. Reproducible high average production yield and constant selectivity may be ensured while reducing the generation of air emissions by 90%.

No post-concentration technology is used, that is, no protein or formalin is added. Therefore, the mushrooms as a finished product are really a natural product.

New Indoor Biofermenting Technology Bioferm “know-how”

·         Using the patented equipment involves a new process in which preparation is substituted by biofermenting.

·         This is a know-how process developed by our company and has been perfectly operating for two years. The system has been adapted to all varieties of compost production.

·         As follows from the properties of the basic mixture, it is microbiologically highly unstable. In other words, depending on the physical or chemical conditions (temperature, pH, air oxygen concentration, ammonia concentration), the processes may be directed towards any microbiological decomposition, including acidic fermentation, alcoholic fermentation, ketone-aldehyde fermentation, putrefaction or composting.

·         The starting material in the biofermenter is subjected to physical and chemical conditions under which the microbiological processes of composting become dominant in the mixture.

·         In the biofermenter, nutrients are placed onto a forced path in order to prevent disadvantageous biological decomposition processes from becoming dominant and to facilitate the composting processes, i.e. biomass synthesis.

·         With a high level of control in the biofermenter, losses are minimised; i.e. biomass is produced with a high yield and a low loss ratio, because decomposition and synthesis processes are in a harmonious balance. Since all the required physical parameters can be precisely controlled in the biofermenter, the processes take place in an optimal manner with minimal loss. Consequently, the fertility of the generated compost will be maximised while the variability is minimised.

·         Exclusion of the disadvantageous processes is important both economically and for the protection of the environment. The main groups of “stinking” bacteria that generate mercaptan, bisulphides, odorous aldehydes, ketones and acids may be suppressed and the harmful populations minimised.

·         In comparison with traditional compost production, odour generation will be reduced by 90% to 95% when the same quantity of compost is processed.

·         .Softening of the cellulose and adsorption of the biomass generated in the suspension by the straw are highly characteristic of the process. So, the texture is optimised.

·         .In this way, the biofermenter may be simply used for fermentation only or for pre-bunkering after fermentation, or may be used for preparation, fermentation and pre-bunkering in a completely closed process.

·         .In this mode of operation, efficient production technology and the production of compost of reproducible high quality is also ensured in a closed, brief process, which, by virtue of its selectivity, has the particular advantage of easy use under non-optimised growing conditions.

The development was awarded

the Grand Prize for Innovation of the Ministry of Agriculture and Rural Development.

Quality Assurance

Concept

Technique

Control

For financially viable growing, the only alternative for the growers is to ensure constant, standard high quality.

·         Variability of indoor compost is reported as being a characteristic feature of the indoor technology. Especially in the period between spring and autumn, this is a major problem.

·         Standard, high quality production has been realised using a conceptional technology solution. The fermentation chambers equipped with special engineering systems ensure controlled bacterial curing, which is a prerequisite of our standard quality.

·         The fermentation chambers and the completely closed circulation bunker system with the top-feeding unit represent the most advanced and required method of producing constantly high fertility compost. As such, it is a unique process in Central Europe.

·         Both the quality control system and the potential for intervention serve to ensure an optimal standard throughout the whole process.

Environmental protection

We have always been aware of environmental considerations and have been pioneering in improving and managing the environment.

·         Since the beginning of compost production, process wastewater has been treated in a closed wastewater recirculation system.

·         By controlled preparation on a large breathing floor and a completely closed fermentation chamber and bunker system, the release of odorous substances, such as sulphur compounds, mercaptans and hydrogen sulphide is minimised.

·         Using this technological system accelerates the processes. Therefore, the quantity of simultaneously processed material is reduced to one third compared to traditional processes.

·         80% of all the curing processes occur in a completely closed system, from where the volume of gas released is low and proportional to the volume of air fed into the system. This gas stream is then transported using our own-developed equipment into a 36-m-high chimney for suitable dilution.

·         The features listed above, i.e. the completely closed bunker system, the suitably sized precision engineering systems, the breathing floor equipped with an automated control system, the exhaust system and the 36-m-high chimney together ensure compliance with EU-compliant environmental requirements.

·         With this innovation, the problem of odour emissions from the composting plant has been suitably addressed within the framework of a high quality compost production process. Currently, the technology is in compliance with the relevant provisions of the Environmental Act, that is, compost may be produced in a financially viable fashion using the best available level of technology and with the lowest environmental impact.