Anaerobic digesters for dairy farms have seen a resurgence in the past 20 years. This trend is due to the role digesters play in reducing odor and greenhouse gas (GHG) emissions and minimizing manure pathogens. Digester technologies also allow dairy producers to add a new revenue source and participate in developing carbon markets.
According to the EPA, as of January 2023, there were 343 manure-based anaerobic digestion systems in the U.S., with nearly 100 more in progress.
While investing in an anaerobic digester can have many advantages, dairy farmers have much to consider as they embark on these projects.
“There is excitement about building digesters, making renewable natural gas and so on,” says dairy producer Lynn Boadwine, who has integrated four digesters onto his Baltic, South Dakota, farm. However, he notes that anticipation and excitement wane as the reality of working through this complicated process sets in.
Use the following tips to help ensure your anaerobic digester journey is successful.
1. Plan, plan, plan
Crafting and negotiating the contract for an anaerobic digester project is one of the most significant – and most difficult – steps in the process, second only to breaking ground.
“The difficulty is in the beginning with the contracts,” Boadwine says. “Always read those contracts. Go through them line by line.”
Work to ensure the contract protects your dairy business and outlines who is responsible for each step and component of the process and facilities. Consult with an attorney well-versed in agriculture and projects of this nature.
Throughout the planning and building process, consider hidden costs like legal fees, regulatory challenges, project delays and more. Even if they do not affect your capital investment, these costs can add up and impact the digester partnership and its future.
Other considerations during the planning process include:
- Learning from other farms that have partnered in anaerobic digester projects.
- Finding and hiring experienced project coordinators who understand dairy operations and bridge the gap between the digester developer and your dairy.
- Requesting a timeline for all project phases, from signing the contract to commissioning, and set start and completion dates to help keep the project moving.
According to the EPA, as of January 2023, there were 343 manure-based anaerobic digestion systems in the U.S., with nearly 100 more in progress. Photo courtesy of McLanahan.
According to the EPA, as of January 2023, there were 343 manure-based anaerobic digestion systems in the U.S., with nearly 100 more in progress. Photo courtesy of McLanahan.
2. Make a construction game plan
After months and sometimes years of planning, breaking ground on your digester site is a thrilling moment. Most decisions have been made, and most of the day-to-day needs have been handed off to the development team.
Yet, it is extremely important you do not take a back seat in this project phase. Failing to communicate plans, address issues in a timely way or find cooperative solutions will quickly lead to the demise of even the best-designed system.
Work to ensure digester construction does not interfere with normal dairy functions. Communication between the digester development and dairy teams is critical to help meet this goal. If communication is not your strong suit, it is essential to partner with someone who can facilitate meetings and outcomes on your behalf.
Set clear expectations. Outline access and usage of farm resources, such as water, electricity, equipment and more, to reduce misunderstandings while ensuring the farm team and the digester team have access to the resources and tools they need. Set up weekly project meetings to help facilitate communication.
Additionally:
- Designate a dedicated shipping address for any materials related to the digester.
- Work to ensure traffic flow doesn’t disrupt dairy operations and communicate with neighbors about the increased traffic.
3. Manage service and follow-up
Any digester project aims for 100% uptime. It is essential to understand the type of system you are installing and be prepared for potential impacts on your dairy’s daily operation. Consider who will be responsible for keeping the system running after installation – whether a dedicated member of your farm team, a contractor or a combination of personnel.
4. Use your resources
Rely on your peer networks and key partners to help navigate your anaerobic digester project. These partners should include a team with deep industry knowledge, technical expertise and a history of tackling challenges resulting in positive outcomes for their customers. Always ask for references.
Understand and embrace the fact that dairy farms are unique in form and function from municipal and other commercial operations. Farm experience matters, so it is important to work with contractors who have firsthand knowledge of dairy farms and digesters in addition to being reliable and responsive. Strive to connect with a trusted dealer or vendor with dairy experience who can prevent your farm from becoming a test case.
5. Manage sand
Digesters are engineered to handle organic matter, but sand-bedded dairies can also take advantage of anaerobic digestion. By implementing a sand-manure separation system, dairies can remove as much of the sand as possible from the manure stream ahead of the digester. Plus, dairies can further benefit from being able to reuse the reclaimed sand.
Although switching from sand to fiber when installing an anaerobic digester is not a prerequisite, you must have a plan and equipment in place to prevent sand-laden manure from entering the digester inflow stream.
Dairies that have navigated these projects recommend keeping an inventory of spare parts on-site to support your system. Include parts for your entire manure system – anything that keeps manure flowing to the digester and prevents disruption to your herd’s routine.
Also keep in mind sand separation continues to evolve, and expectations for higher sand recovery will only increase. Just as digester development companies continue to evolve their processes and offerings, so do manure-handling systems.
6. Plan for long-term success
Throughout a digester project development, implementation and operations processes, keep the long-term plans for your business in mind. There are different digester project development models to meet your needs, whether you plan to add more cows, invest in additional locations or expand herd size. Find the one that works best for you, your farm and plans for your dairy operations.
To learn more about tackling a digester project on your dairy, check out this e-book.
References omitted but are available upon request by sending an email to the editor.
