Renewable Energy Production

Biogas Utilisation
Biogas produced in the AD plant consists of methane (60%–70%), plus carbon dioxide and trace levels of other gases (hydrogen, nitrogen and oxygen). Prior to energy generation, the biogas is treated to reduce its moisture content and remove impurities.

Each kilogram of Chemical Oxygen Demand (COD) removed from the feedstock yields approximately 0.35 m3 of methane. This plant can remove 3,000 kilos of COD per day.

The biogas is fed to the CHP engine, which generates renewable electricity for use in the dairy and supply to the national grid. Out- put is about 40% electricity, 40% recovered heat and 20% heat losses. Some heat is used to maintain the digester temperature. The balance is transferred to the dairy for use in our production processes.

Energy Efficiency
The CHP system (supplied by Ener-G) generates 2,150 MW of electricity and 1,685 MW of heat per annum. This dramatically reduces reliance on fossil fuels for our energy needs. As dairy output increases a larger CHP unit will be installed. Maximum anticipated output is 2,600 MW of electricity.

Surplus heat is being used in the dairy production process. It is supplied through a heat exchanger and has replaced heat that was previously generated by oil burning boilers.

Production of renewable energy is supported by the Government, through the Feed in Tariff system (FIT). FIT's provide a cash subsidy for each kW of low carbon electricity. The on-site energy production process used here can be replicated elsewhere in the food industry, with a range of feedstocks.

Carbon Reduction
There is concern about the "carbon footprint" of food production. The carbon footprint of a business is the total amount of "greenhouse gases" produced, directly and indirectly, during production and waste treatment activities, usually expressed in tons of carbon dioxide (CO2) per year.

BV Dairy will cut its carbon footprint by about 60% - reducing its output of carbon by about 1200 tonnes per year. This equates to the environmental impact of planting 120,000 trees.

As a pioneer of liquid digestion, using Clearfleau's technology, BV Dairy will reduce its overall impact on the environment, whilst cutting production costs, as expected of food processors by Government, consumers and major retailers. Companies that buy dairy ingredients from BV Dairy will also cut their carbon footprint.