Discover how BC Organics’ manure digester is revolutionizing dairy farming and protecting the environment. Can this technology make agriculture more sustainable?
Dairy farming is evolving, and at Wiese Brothers Farms, that evolution is grounded in sustainability and innovative technology. By transforming what was once considered waste into valuable resources, dairy farmers like Dan Wiese are setting new standards in environmental stewardship. “When my family first started dairy farming, we treated our manure as an inconvenience, but in the last 15 years, we’ve valued our manure for what it is and treat it as a nutrient source,” Wiese shares. This paradigm shift is part of a larger collaboration with BC Organics, a ground-breaking anaerobic digester in Brown County, Wisconsin, which is helping dairy producers meet their environmental goals while improving the sustainability of agriculture in the region.
Introduction to BC Organics: Leading the Way in Manure Digestion
Imagine transforming what was once considered waste into a resource-packed powerhouse. That’s exactly what BC Organics has achieved through its close partnership with 11 dairy farms in Wisconsin. Capable of processing an astounding 900,000 gallons of manure daily, this anaerobic digester system stands as a marvel of modern agricultural technology.
Every day, BC Organics produces 1.6 million British thermal units (Btus) of renewable natural gas, equating to around 11,000 gallons of gasoline when used as compressed natural gas. That’s not all—thanks to its unique water filtration technology, the plant also generates over 400,000 gallons of clean water daily. Additionally, the system creates 135 tons of fiber bedding each day, which participating farms can reuse, closing the loop on sustainability.
What truly sets BC Organics apart is its state-of-the-art water filtration technology. By leveraging a series of advanced filtration steps—including ultrafiltration, superfiltration, forward osmosis, and reverse osmosis—the plant effectively converts digested manure into nutrient-rich concentrates and crystal-clear water. This comprehensive approach ensures that approximately 45 gallons of clean water are returned for every 100 gallons of raw manure processed.
Overall, the BC Organics project is not just about mitigating waste, but about transforming it into valuable resources that contribute significantly to environmental sustainability and the economic vitality of the local farming community.
The Technology Behind the Transformation: Filtration Systems at BC Organics
Imagine raw manure looking like a thick chocolate milkshake. The magic begins with ultrafiltration, which removes suspended solids from the mix. Next, the material enters the superfiltration stage, where finer organic matter is filtered out.
Following that, forward osmosis and reverse osmosis come into play, working together to refine the liquid further, transforming it into clean, drinkable water. This intricate system not only separates nutrients but also ensures that every drop of water is as pure as possible.
As a final step, the filtered water undergoes an ultraviolet light treatment. This crucial process disinfects the water, ensuring it’s safe for reuse as irrigation water or for discharge into nearby streams. Altogether, these steps make BC Organics’ filtration technology a groundbreaking approach in nutrient management and environmental stewardship.
Benefits for Partner Farms: Environmental Gains and Efficiency Improvements
- Reduction in Water Hauling and Application Volume: By filtering out a significant portion of the water content from the manure, BC Organics’ technology allows partner farms to transport drier material. This means fewer trips to the fields and less water being hauled, which translates to notable savings on fuel and labor costs.
- Environmental Benefits: The anaerobic digestion and water filtration processes significantly reduce noise and odor associated with manure management. Moreover, fewer truck hauls contribute to decreased road wear and lower emissions, fostering a cleaner and quieter rural environment.
- Improved Nutrient Management and Application: The concentration of nutrients in the remaining manure is enhanced, allowing for more precise application. This improves crop uptake and reduces the risk of nutrient runoff, making farms more sustainable and compliant with environmental regulations.
- Potential for Carbon Negative Operations: By integrating cover crops and no-till farming practices, alongside the advanced manure management techniques, partner farms have the potential to become carbon negative. This is a substantial step toward mitigating climate change impacts.
- Return of Solids as Bedding Material: The separated solids, dried using rotary dryers, are returned to the farms as high-quality fiber bedding. This not only saves on bedding costs but also closes the loop in a sustainable nutrient cycle, further enhancing the farm’s efficiency and environmental footprint.
Project Authorization and Goals: Feasibility Study on Phosphorus Runoff and Sustainability Improvements for Agriculture in Brown County
The project was authorized in fall 2017 following a feasibility study that evaluated phosphorus runoff into the Fox River watershed. Specifically,its goal was to examine anaerobic digestion with water treatment for the possibility of improving the sustainability of agriculture in Brown County.
Dynamic Renewables broke ground on the project in summer 2022 and commissioned the facility this winter.
“In ways that agriculture was affecting the watershed, the biggest pieces were to reduce the manure volume and control nutrients, which allows lower manure application rates, reduced tillage, reduced compaction and a greater use of cover crops,” Nemke says. “All of these things together help decrease the potential of phosphorus entering the surface water.”
The Community Benefits: Cleaner Water and Reduced Truck Traffic
Reduced truck traffic alone is a significant advantage of the BC Organics project. With less need to transport massive amounts of liquid manure, partner farms are seeing a notable decline in road congestion, noise, and the wear and tear on local infrastructure. Another substantial benefit is the reduction in odor, which directly improves the quality of life for local residents.
Wiese Brothers Farms, along with the other participating farms, now uses fewer trucks, allowing them to focus more on sustainable farming practices. Instead of hauling water-laden manure, they can concentrate on spreading nutrient-dense material, paving the way for more efficient and eco-friendly agricultural operations.
The implementation of water filtration systems means that the water returning to the environment is cleaner than before. This not only benefits local waterways but also aids in the reduction of phosphorus runoff, which has been a significant concern for the health of the Fox River watershed. Clean water is essential for both agricultural and residential communities, and BC Organics ensures that the project’s water output supports this vital resource.
Imagine a future where farmland is enriched, waterways are cleaner, and rural roadways are less congested. This is the reality BC Organics is working towards, creating a sustainable synergy between dairy farming and environmental stewardship.
Reducing Phosphorus Runoff: A Closer Look at the Environmental Benefits
Phosphorus runoff is a significant environmental concern, particularly in regions with dense agricultural activities. Excess phosphorus in water bodies can lead to harmful algal blooms, which deplete oxygen levels and threaten aquatic life. By incorporating advanced technologies like the anaerobic digester at BC Organics, farms can dramatically reduce the amount of phosphorus introduced into waterways.
The anaerobic digestion process at BC Organics converts manure into biogas, which can be used as a renewable energysource, and separates valuable nutrients for reuse. This process is instrumental in isolating phosphorus-rich concentrations, allowing farms to make precise applications where needed and minimizing excess runoff.
Furthermore, the subsequent filtration stages ensure that the water leaving the facility is substantially cleaner. The filtration technology employed involves several layers, including ultrafiltration, superfiltration, forward osmosis, and reverse osmosis. This thorough process reduces the phosphorus content before the water is either reused for irrigation or safely discharged, contributing to cleaner local waterways and reduced algal bloom risk.
An added benefit is that the resultant water is often cleaner than the natural bodies it is reintroduced into, creating a ripple effect of positive environmental impact. Scott Crosby from Digested Organics points out, “After the filtration process, the clean water discharged into the environment is cleaner than the water already there.” This added advantage boosts the ecological health of the surrounding area.
The commitment to reducing phosphorus runoff aligns with the broader goals of sustainable farming practices in Brown County. By lowering the potential for nutrient overload, farms not only protect the environment but also adhere to increasingly stringent environmental regulations. This proactive approach positions the participating farms as leaders in agricultural sustainability, setting a high standard for others to follow.
The Future of Dairy Farming: Sustainable Practices and Environmental Stewardship
For dairy farms like Wiese Brothers and Gerrits, the shift towards sustainability is not just a trend but a necessity for the continuity of their operations. The implementation of advanced manure management and filtration technology facilitates a holistic approach to farming, where waste is transformed into valuable resources.
As you observe the evolution in farming practices, you’ll notice a significant focus on reducing environmental impactwhile enhancing farm efficiency. For instance, the ability to convert raw manure into clean water and nutrient-rich concentrates means less reliance on synthetic fertilizers and a reduction in pollution.
Importantly, introducing such technologies allows for the integration of cover crops and no-till practices. These methods are crucial in preserving soil health, reducing erosion, and promoting biodiversity. Both Wiese and Gerrits emphasize the importance of being proactive in adopting practices that ensure the longevity of their land and resources.
Moreover, the partnership with Dynamic Renewables showcases a collaborative effort that benefits not just individual farms but the wider community. By collectively processing manure through BC Organics, the partner farms significantly reduce truck traffic, noise, and odor, creating a more harmonious environment for neighboring communities.
Ultimately, the goal extends beyond immediate gains. It’s about setting a precedent for future farming generations, emphasizing the ethos of environmental stewardship. As Wiese reflects on the farm’s journey and ongoing initiatives, he underscores an essential truth: “To sustain farming here in the next five years, we have to innovate and embrace these environmentally-friendly technologies. It’s closer than we think, and it’s crucial for our survival.”
Time, as they say, will tell. The path set by BC Organics and its partner farms is a promising beacon of what sustainable agriculture can achieve, blending economic viability with environmental care.
The Bottom Line
Ultimately, BC Organics stands as a testament to the dairy industry‘s potential for innovation and environmental stewardship. By transforming manure from a waste product into a valuable resource, the project not only supports sustainable farming practices but also delivers significant environmental benefits such as reduced phosphorus runoff and cleaner water. This collective effort by forward-thinking farmers sets a compelling example for agricultural operations nationwide, underscoring the importance of leveraging technology for a greener, more sustainable future.
Key Takeaway: BC Organics showcases the power of innovation in the dairy industry by converting manure into valuable resources, supporting sustainable agriculture, and delivering environmental benefits like reduced phosphorus runoff and cleaner water. This initiative highlights the critical role technology plays in promoting a sustainable future for farming.
