Proven Results in Manure Management & Resource Recovery

See how Loway Equipment helps dairy farms and cooperatives turn waste into profit through advanced high-pressure dewatering technology.

Case Study 01: The Circular Economy Model

Integrated Manure Management System: Transforming Waste into Sterile Bedding & Bio-Fuel

Project Overview:

• Scale: 5,000 Head Dairy Farm
• Daily Capacity: 300 Tons of Raw Manure
• Equipment: Loway High-Pressure Belt Filter Press Series (Heavy-Duty)

The Challenge:
The client was operating under significant financial pressure due to the rising cost of sand bedding and strict local environmental discharge limits. With raw manure moisture at 85%, traditional screw presses could not lower the moisture enough for immediate reuse, leading to massive stockpiles and odor issues. They required a solution that could turn this liability into a sterile, usable asset.

Our Technical Solution:
Loway Equipment engineered a comprehensive “Flocculation + High-Pressure Filtration” line.

Pre-treatment: Automated removal of large debris to protect downstream equipment.
Deep Dewatering: We deployed our signature 8-roller system. By applying hydraulic pressure up to 200kg, we mechanically forced out capillary water that standard machines miss.
Thermal Process Integration: The output solids (50% moisture) are immediately fed into a 65°C+ high-temperature aerobic fermentation system. This 24-hour cycle ensures the complete elimination of pathogens like E. coli and Salmonella.

Operational & Economic Impact:

Bedding Self-Sufficiency: The farm now produces 120 tons of hygienic bedding daily. The material is fluffy, highly absorbent, and has improved cow lying time and comfort.

Energy Generation: Excess solids are mixed with straw (7:3 ratio) to create biomass pellets with a calorific value of 14MJ/kg, replacing 1,200 tons of coal annually for the farm’s heating boilers.

ROI Verification: With $570k in annual combined savings and revenue, the project achieved a full ROI in 1.8 years.

Case Study 02: The Efficiency Model

Reducing OpEx by 40% for Mega-Farm Operations via Managed Services

Project Overview:

• Scale: 6,870 Head Stock (Industrial Scale)
• Model: Third-Party Managed Service (BOO Model)
• Key KPI: Cost per ton & Discharge Compliance

The Challenge:
For this mega-farm, logistical efficiency was paramount. Traditional manure handling was labor-intensive and costly ($8.00+/ton). The client needed a “hands-off” solution that guaranteed compliance and bedding supply without distracting from their core business of milk production.

Our Technical Solution:
The facility utilizes Loway’s High-Pressure technology as a Secondary Dewatering Stage.

Operational & Economic Impact:

Dramatic Cost Reduction: Total processing cost was driven down to ~$4.90/ton, a 40% reduction compared to the previous operational model.

Environmental Compliance: The system achieved a true “Zero Discharge” loop. 100% of the solids are reused as bedding or fertilizer, and the filtrate is recycled, reducing the farm’s carbon footprint by 3,000 tons/year.

Reliability: The equipment has maintained an uptime of >98%, ensuring the farm never faces a waste backlog.

Case Study 03: The Cooperative Model

Centralized Processing Hub: Driving Community Wealth through Bio-Resources

Project Overview:

Structure: Regional Cooperative serving 3 distinct farms (3,200 Head Total)
Focus: Commercial Organic Fertilizer & Fuel Production

The Challenge:
Individual small-to-mid-sized farms often lack the capital for advanced waste treatment. This cooperative needed a centralized, robust machine capable of handling varying manure consistencies from different sources while producing high-value commercial products to subsidize operational costs.

Our Technical Solution:
We installed a rugged, high-throughput Loway Belt Filter Press designed for versatility.

Adaptive Controls: The system can adjust belt speed and pressure to handle fluctuations in influent sludge consistency.
Product Versatility: The dewatered cake (50% moisture) is the perfect baseline for two product lines: 1. Premium Fertilizer: Mixed with humic acid and trace elements to create N-P-K granules. 2. Bio-Fuel: Compressed into high-density fuel rods for local heating.

Operational & Economic Impact:

Community Revenue: The project generates substantial income from selling 5,000 tons of organic fertilizer and 3,000 tons of fuel rods annually.

Rural Development: The facility created jobs and an income stream for 30+ local households involved in the logistics and production chain.

Sustainability: By centralizing treatment, the region eliminated illegal dumping and significantly improved local soil and water quality.

Performance Matrix: Project Outcomes at a Glance

Key Metric	Case A: Circular Economy	Case B: Efficiency Model	Case C: Cooperative Model
Farm Scale	5,000 Head	6,870 Head	3,200 Head (3 Farms)
Challenge	High Bedding Costs	Management Overhead	Waste Disposal
Solution	Integrated Bedding/Fuel Line	Managed Service (BOO)	Centralized Hub
Moisture Result	Reduced to 48-52%	Stabilized at 50%	Stabilized at 50%
Daily Output	120 Tons Bedding + Fuel	150 Tons Bedding	Fertilizer + Fuel Rods
Economic Value	~$570k / Year (Savings + Revenue)	40% Cost Reduction	~$390k / Year (Profit + Wages)
ROI Period	1.8 Years	Immediate (OpEx Savings)	2.2 Years

Do these challenges sound familiar? Whether you manage a single farm or a regional cooperative, Loway Equipment has the engineering expertise to turn your waste management liability into a profitable asset.