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The closed-loop automated complex by OrganicPROM is an advanced solution for large-scale organic waste processing. This standard project, with a waste processing capacity of up to 230 tons per day, integrates bioreactors, packaging lines, and monitoring systems into a unified infrastructure. The complex is designed for maximum efficiency, full process automation, and environmental safety, with scalability and adaptability to regional needs.
Integrated Infrastructure for Industrial-Scale Waste Processing
- Scalability: The standard project includes 23 bioreactors, each processing up to 10,000 kg of waste per day. The facility’s capacity can be scaled proportionally to the number of bioreactors, providing flexibility and adaptability to various waste processing volumes.
- Process Integration: All stages, from raw material intake to the production of finished fertilizers, are integrated into a single automated system.
- Environmental Efficiency: The complete closed-loop processing minimizes waste, produces natural fertilizers, and reduces the environmental footprint.
- Digital Transformation: Process management utilizes AI and IoT technologies, ensuring high precision and minimal human intervention.
Key Advantages of the Complex
Complex Structure
Controls incoming raw materials, registers, and weighs transport vehicles.
Initial quality and characteristic assessment of incoming raw materials.
Automatic removal of foreign objects (e.g., film, packaging, glass, plastic) to protect equipment and ensure raw material purity.
Prepares raw materials for processing by shredding and evenly distributing them across lines and workshops.
Handles food waste from catering facilities, restaurants, cafés, and social institutions.
Specialized line for processing fats, bones, and blood.
Optimizes processing of fish-origin waste.
Handles unique waste types, including plant by-products (cake, husk, leaves, stems), mineralized and adsorptive materials, as well as protein and organic mixes.
Cleans and standardizes raw materials before the final stages.
Adds nutrients to create fertilizers with specific characteristics.
Produces fertilizers with unique formulas to adjust soil pH and restore microflora according to plant needs.
Forms granules, packs, and labels finished products.
Stores products before shipment.
Quality control of processes and products, development of new premixes and starters.
Washes and disinfects containers.
Cleans, washes, and services special equipment.
Ensures uninterrupted equipment operation.
Every workshop utilizes automated conveyors for waste loading and finished product unloading. Bioreactors are grouped and managed using AI and IoT. All processes are automated, including temperature, humidity, and cycle time control, which minimizes human intervention and boosts productivity.
Special attention is given to environmental safety and gas-air emission filtration. The complex operates as a closed circuit where sealed containers enter and all processes occur within this loop—from unloading to the serviced equipment's exit with the final product.
For gas-air mixture purification, a photocatalytic ozonation technology is used, which breaks down toxic impurities and microorganisms into safe components, ensuring an eco-friendly process.
These complexes are designed to be located close to population centers, where the main generation of food production and consumption waste occurs, further optimizing the logistics chain for centralized waste collection.
Special attention is given to environmental safety and gas-air emission filtration. The complex operates as a closed circuit where sealed containers enter and all processes occur within this loop—from unloading to the serviced equipment's exit with the final product.
For gas-air mixture purification, a photocatalytic ozonation technology is used, which breaks down toxic impurities and microorganisms into safe components, ensuring an eco-friendly process.
These complexes are designed to be located close to population centers, where the main generation of food production and consumption waste occurs, further optimizing the logistics chain for centralized waste collection.
Integration and Automation
The complex is equipped with:
- Specialized Equipment: For centralized waste collection and delivery.
- Custom Containers: Adapted for transportation and loading into bioreactors.
- Intelligent Accounting and Monitoring Systems: Integrated into a unified digital platform.
Infrastructure Support
The closed-loop automated complex by OrganicPROM is a groundbreaking solution for businesses and regions striving for sustainable development. By combining innovative technologies, environmental safety, and economic benefits, our project sets a new standard for organic waste processing, laying the foundation for a circular economy.
Conclusion
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