Food waste process overview

1. DEPACKAGING PROCESS
OVERVIEW

2. Product Arrival
Products can arrive in one of many different ways. When dealing with pre-
consumer food, a storage area will generally always be required. Only Loose and
in bags products can directly discharge from truck into Twister
BOXES PLASTIC TOTES PLASTIC WRAPPED
PALLETS LOOSE AND IN BAGS
REQUIRES FRONT
LOADER AND
TEMPORARY
STORAGE AREA TO
UNLOAD
REQUIRES FRONT
LOADER AND
TEMPORARY
STORAGE AREA TO
UNLOAD
REQUIRES FRONT
LOADER AND
TEMPORARY
STORAGE AREA TO
UNLOAD
CAN DISCHARGE
DIRECT FROM TRUCK
BIN WASHER ALSO REQUIRED

3. Truck Types
The Twister has a 6m3 integrated hopper. To take full advantage
of this hopper. Most Trucks will exceed the hopper capacity of
the Twister and will therefore require some intermediary
storage or face a long discharge time if dumping directly into
the Twister.
In that case a front loader will be required.

4. STORAGE BAYS 1. Bays can allow you to sort waste types
in order to run separate batches. This can
be useful in case if for example you want to
process only aluminum cans and want a
clean reject stream to send aluminum to the
material recovery facility.
2. Some countries prohibit storing loose waste
in bays and in this case, you may need a
bunker or top loader so that when trucks
arrive with waste in bulk that you can
immediately dispose of it in a screw bunker
or Top loader
3. A Storage Bay will always be required in the
case some goods arrive in pallets or bins.

5. BIN WASHER
When receiving goods in bins, you will be
required to wash these bins prior to sending
them back on the truck.
Drycake can offer you a bin washing system
to address this

6. FRONT LOADER
A solution that uses only bays and a Front Loader is certainly the lowest capex
cost, but has some opex costs. An operator is required to load the Twister
regularly, and bays are required to stock the waste materials before loading.
Some potential issues
1. Some countries prohibit the storage on floor, this is relevant for trucks
that come in with Food Waste in bags and/or loose; in this case, really
relevant for trucks that come in with Food Waste in bags and or loose and
in this case a screw bunker or top loader can help meet this regulatory
requirement. However, in some or most of the waste is coming in pallets
or bins you would need a storage area or bay for this kind of waste just to
be able to unload the truck.
2. Emptying the goods directly from the pallet or bin into the screw bunker
may pose problems when trying to recuperate a non-mixed form of
rejects. For example you want to process only aluminum cans and want a
clean reject stream to send aluminum to the material recovery facility.
3. Even when dealing with mono products, if the quantities are sufficient a
bunker may be ideal if you want the freedom to load all of the material
from the storage bay in big batches without having to wait on the Twister
to process the waste
The Advantage of a pure top
loader system is that since the
product accumulation in the
Twister hopper is smaller than
working in batches of different
products ,it's easier to manage

7. Loading Pit Installing the Twister directly provides a
footprint benefit and eliminates the need of a
waste storage area and a front loader
operator, but of course involves some
excavation civil works.
The limitation is that only truck can be
accepted at a time, and generally you are
limited by the Twister processing time.
A Storage area will still be required for pallet
and bin goods, but the speed of loading those
goods into the Twister will be must faster ass
the loader is working at ground level
Loading Schedule
1. Truck at a time.
2. Longer unloading time for
larger trucks

8. Bigger Hoppers
While the Twister is provided with a 6m3 hopper standard, it
can also be supplied with a 10m3 hopper.
Moreover bigger hoppers, such as 30m3 are also available. If
the Trucks are on an upper floor, you can have the Trucks
discharge by gravity while the goods on pallets or bin are
loaded from the ground.
The bigger hopper area provides you the further benefit of
loading in bigger batches rather than waiting for processing
time.
Of course the bigger the hopper, the longer you must wait for
processing time.

9. Chain Conveyor Chain Conveyors can be built with large hopper like receiving
area that are ground level or ramp level to make it easier to
accumulate material before dumping into the Twister hopper.
The Twister hopper, equipped with a level sensor would
activate the chain conveyor as needed, and can even dump on
a distributing conveyor to feed two twisters.
A chain conveyor is unlikely to break the product before
entering the Twister but will also have issues with product
runoff and can have some issues with uneven tightening on
both side of units, causing downtime.
As with any hopper
designed to accumulate
material to simplify feeding,
segregation of the products
feeding the Twister is
harder

10. LOADING SCREW BUNKER
A Loading Bunker is an expensive solution to be able to
discharge from a truck at floor grade, but doesn’t offer the
same kind of capacity as a typical bunker, still it is a solution
that some customers might find meet their needs

11. SCREW BUNKER
The Screw Bunker is a good solution and is available in
volumes from
• 20m3/30 m3 / 40 m3 / 50 m3 / 80 m3 / 100 m3 / 150 m3.
• Above or sunk into the ground
• Hydraulically controlled bin lids
• Splash shields
• Air ventilation connection holes
• Draining systems
• Mixers
• Heated coils
• Loading cells
A Single Screw Bunker can feed 1 or 2 Twister in a left/right
configuration.
The value of a below ground bunker is that trucks can easily
discharge directly into the bunker but this of course means
you need a building made on two levels, or a ramp can be
built so that it can be built on a single level
With 4+1 motorized screws(4x 7.5Kw), the total
power of a bunker is greater than a top
loader(10kw), and of course the maintenance is
done below grade. However the installation is
self-standing

12. TOPLOADER
The TOPLOADER is an alternative to the Screw Bunker
and can be offered up to 150m3. 10kw power only
The Top loader can feed two Twister in a left/right
configuration. Furthermore, it can be built entirely out
of steel to avoid civil works and meet regulatory
requirements around a floor.
The main advantage of a Toploader is that the
maintenance is done above grade on a maintenance
platform, and that the Toploader can be designed to
inspect and remove nonconforming products in the
stacking process.

13. FEEDING OF TWISTER HOPPER
FOOD WASTE
REJECTS
ORGANICS

14. TOPLOADER LOADING BY TRUCK

15. FEEDING OF TWISTER BUNKER
The material dumps into the Bunker and a
bottom
Extraction screw feeds into the Twister.
Each Bunker can feed up to two twister

16. Liquid Addition
Operation of the Twister can be made in both Wet or Dry
operation. This means that a product can be processed by the
Twister without liquid addition. The Twister can also be supplied
with an organics discharge system to pump or convey liquid or
dry organics.
The need to operate Wet or Dry, as well as the desired outlet
humidity of the Twister Organics, is determined by the
downstream biogas or composting system technology and/or the
distance and means of transport to such facilities.
Product Liquid Addition
OFMSW Liquid Addition Required
SSO Liquid Addition May be Required
Liquid Additon Value
Water Not Recommended, last resort
Hygenizer/Hydrolizer Acidity to break down carboard
Liquid Digestate Acidity to break down carboard
Twister Perfomance
Drop off
>20% DS Organics
Liquid Addition on
Rated Capacity
None!
Our rated capacities are based
on a certain fluidity of the
outlet organic soup. The
addition of liquid does not
negatively impact throughput.

17. Automatic Liquid Addition
Item Description Size Control
1 Leachate(working cycle) 2” Automatic with
Motorized actuated
valve and flowmeter
2 Reuse or Fresh
Water(washing cycle)
1” Automatic wash end of
cycle
Liquid Addition is automatic by means of a motorized valve and flowmeter

18. ORGANIC SOUP MANAGEMENT
In function of the final destination and the plant layout, you may prefer to use a
conveyor, pump or both
Our Conveyors are designed to transport organics both solid or liquid organics,
however it can be beneficial when working with pure liquid, such as milk
products to pump rather than convey.

19. ORGAHOPPER WET+DRY
Vac Truck
Connection
Dry
Discharge
Biopulp(Soup)
from Twister
Reversible
Screw
Liquid Discharge
Pump Connection
The Orgahopper Wet+Dry is designed to be installed under a
Twister and should always be considered the best solution for
Organics management

20. Two Twisters
ORGAHOPPER-Dual: WET+DRY
Some customer will ask to discharge from organics from Twister
into a common conveyor. In this case a double screw conveyor
can be installed to convey the combined organics of two
twisters into an inclined screw.
Note: There is a drain available on
the horizontal conveyor and an
option for a drain or bypass on the
inclined conveyor to give the option
to pump

21. Macerate Organics
1. Should Organics be macerated?
2. Where/When should they be macerated?
After a Depackagers, the organics can come out like a thick
pulp. Macerating the organics can improve the efficiency of
the biogas production. It is therefore always recommended to
macerate the organics. Solutions are proposed by Vogelsang or
Boerger.

22. Seditank Glass RemovalMacerate Before seditank Better
Sedimentation
Macerate After
Seditank
Less wear on
macerator
The Settled grit is removed from the
bottom of the grit channel with a
horizontal grit screw
An inclined shafted screw then conveys
and dewaters the collected grit
The Grit Discharges down a chute in a grit
bin
Conveyor Inlet
Pump Inlet
Seditank Organic Outlet Tank

23. Seditank Organic Outlet
Organics from the Seditank Overflow into a Tank from which
the organics are pumped to the Hygenizer/Hydrolizer

24. Seditank Plastifloat: Residual Plastics Removal
The Seditank can be equipped with a
plastics removal system.
The plastics that will will be removed will
be full of organics so they will need to be
passed through the twister again or a
screen as to not lose organics

25. SSO/OFMSW OPERATING SCHEDULE
TSS10 TSS10 TSS10 TSS10 TSS10 TSS20 TSS20 TSS20 TSS20 TSS20 TSS20 TSS20 TSS20 TSS20 TSS20
Tons per year 50 100 500 1,000 5,000 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000 100,000
Operating Weeks 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50
Tons per week 1 2 10 20 100 200 400 600 800 1000 1200 1400 1600 1800 2000
Operating days 1 1 3 4 5 5 5 5 5 5 5 5 5 5 5
Tons per day 1.0 2.0 3 5 20 40 80 120 160 200 240 280 320 360 400
Recommended Twister
Model TSS10 TSS10 TSS10 TSS10 TSS10 TSS20 TSS20 TSS20 TSS20 TSS20 TSS20 TSS20 TSS20 TSS20 TSS20
Minimum Throughput t/h 1 1 1 1 1 3 3 3 3 3 3 3 3 3 3
Storage Time days before
processing <1 is good 1.0 0.5 0.3 0.2 0.1 0.1 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Average Througput t/h 3 3 3 3 3 10 10 10 10 10 10 10 10 10 10
# of Twisters 1 1 1 1 1 1 1 1 2 3 3 3 4 4 4
Operating time per day
hours 0.33 0.67 1.11 1.67 6.67 4.00 8.00 12.00 8.00 6.67 8.00 9.33 8.00 9.00 10.00
Operating hours with 1
machine broken <18 =good plant down
plant
down
plant
down
plant
down
plant
down plant down plant down
plant
down 16 10 12 14 11 12 13
Density of inlet product
(typical) t/m3 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Here we present a scope of supply based on tons/per year,
The tables across all three pages are meant to be read together
Icon on the right has complete excel

26. STORAGE
Tons per year 50 100 500 1,000 5,000 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000 100,000
Raw Storage as % of daily
Tonnage 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%
Storage Bay+ Bunker Size
m3 (max bunker size is
150m3) 2.00 4.00 6.67 10.00 40.00 80.00 160.00 240.00 320.00 400.00 480.00 560.00 640.00 720.00 800.00
Twister Hopper + Bunker
recommendation
No, Twister
hopper only,
throw in until
processing
No,
Twister
hopper
only,
throw in
until
processing
No
Standard
Twister
with 6m3
hopper
No
Standard
Twister
with 10m3
hopper
Twister
fed by
40m3
bunker or
Standatd
Twister
with 40m3
storage
area
Twister fed
by 80m3
bunker or
Standatd
Twister with
80m3
storage area
Twister fed
by 150m3
bunker or
Standatd
Twister with
150m3
storage area
2 Twisters
fed each
by one
120m3
bunker or
storage
area
2 Twisters
fed each
by one
150m3
bunker or
storage
area
2 Twisters
fed each
by one
150m3
bunker or
storage
area
3 Twisters
fed each
by one
150m3
bunker or
storage
area
3 Twisters
fed each
by one
150m3
bunker +
storage
area
4 Twisters
fed each
by one
150m3
bunker +
Some
storage
area in
bays
4 Twisters
fed each
by one
150m3
bunker +
Some
storage
area in
bays
4 Twisters
fed each
by one
150m3
bunker o+
Some
storage
area in
bays
Max Bunker Size m3 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150
# of Twisters if all of the
Raw Storage must be in
bunkers 0.01 0.03 0.04 0.07 0.27 0.53 1.07 1.60 2.13 2.67 3.20 3.73 4.27 4.80 5.33

27. ORGANICS MANAGEMENT
Tons per year 50 100 500 1,000 5,000 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000 100,000
Organic Matter 85% 85% 85% 85% 85% 85% 85% 85% 85% 85% 85% 85% 85% 85% 85%
Organic Outlet tons/day 0.85 1.70 2.83 4.25 17.00 34.00 68.00102.00 136.00 170.00 204.00 238.00 272.00 306.00 340.00
Density t/m3 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98
Organics m3/day 0.87 1.73 2.89 4.34 17.35 34.69 69.39 104.08 138.78 173.47 208.16 242.86 277.55 312.24 346.94
Organics m3/day Liquid
Addition Ratio 1:1 1.87 3.73 6.22 9.34 37.35 74.69 149.39 224.08 298.78 373.47 448.16 522.86 597.55 672.24 746.94
Organics m3/h 0.62 2.49 5.60 5.60 5.60 18.67 18.67 18.67 37.35 56.02 56.02 56.02 74.69 74.69 74.69
Conveyor or Pump or Bin Bin Conveyor Conveyor Conveyor Conveyor Conveyor
Organics m3/day Liquid
Addition Ratio 2:1 2.87 5.73 9.56 14.34 57.35 114.69 229.39 344.08 458.78 573.47 688.16 802.86 917.55 1032.24 1146.94
Organics m3/h 0.96 3.82 8.60 8.60 8.60 28.67 28.67 28.67 57.35 86.02 86.02 86.02114.69 114.69 114.69
Conveyor or Pump or Bin Bin
Conveyor
or Pump
Conveyor
or Pump
Conveyor
or Pump
Conveyor
or Pump
Conveyor or
Pump
Conveyor or
Pump
Conveyor
or Pump
Conveyor
or Pump
Conveyor
or Pump
Conveyor
or Pump
Conveyor
or Pump
Conveyor
or Pump
Conveyor
or Pump
Conveyor
or Pump