James River Correctional CenterDepartment of Agribusiness and

Enterprises

S.V. Pruett, Warden

Grade A Dairy 305 Day Milk: 30,872 pounds

Milk Processing Plant: 12,600 Gallons Processed per Week

Commercial cow-calf operation & sire proving program: 1300 cross bred brood cow herd

In Vessel ComposterJRCC State Farm, Virginia

Beef Pastures

• Once cattle is taken off field, manure is spread across the fields with a pasture “drag”

• This incorporates the manure into the field for fertilization

• This procedure disturbs breeding sites of flies

Why Recycle Food Waste?

                                    

Why Compost Food Waste?

• Environmentally friendly – food waste does not go into landfills

• Cost to remove waste from JRCC, JRWC, DMCC and PCC over $200,000 per year

• DOC pays by the pound to remove waste from facilities

• Food waste is the largest contributor to the dumpster – from kitchen waste and inmate plate waste

History of Composter

• Canadian technology – Wright Environmental Management, Inc.

• 4 years for development, budgeting and construction phases

• JRCC is pilot program for DOC

• All DOC institutions will eventually have a composter on site

• In Vessel composters can be found in New York DOC facilities

• 55 composters are located in Canada, the United Kingdom and USA

• The largest composter to date is located at Walt Disney world in Florida

Costs

• Equipment cost was $175,000

• DOC total cost was $600,000 due to additional DEQ regulations and requirements

• Anticipated cost of next unit: $300,000

Construction

• Concrete pad with four drains• DEQ required a total containment system • There are no written regulations for In-

Vessel composting – additional precautions taken, which raised costs

• Environmental engineer hired on contract to address certain aspects of construction

Wood Chips

• Made from dried crushed wood pallets

• Chips should be free of water, and kept dry at all times

• Size of chip is important – too fine of a chip will clog conveyor

Why Wood Chips?

• Wood gives off carbon – energy source• Microorganisms require 1 part nitrogen to

30 parts carbon for growth and activity• Oxygen: 12% for aerobic conditions• Final products of decomposition: CO2,

H2O, NH3, nitrates and cell biomass• Keep the system aerobic: faster

decomposition, less smell, more heat

Requirements of “Bugs”“FAT TOM”

• F: Food (Nutrients)

• A: Acidity (pH neutral at 6-8)

• T: Temperature (131 degrees F. )

• T: Time (Minimum 72 hours)

• O: Oxygen (Aeration)

• M: Moisture (40%-70%)

Operation of Composter

• One operator – 2 inmates

• 5 days per week

• Unit is made of stainless steel

• Two cycles: 14 or 28 days

• Unit holds 2000-4000 pounds of waste/day

Procedure

• Food waste is saved in 62 gallon containers

• Food waste is mixed 60 wood/40 food, 55% - 65% moisture by weight

• Mixture is dumped into hopper

Challenges to Composting

• Water in waste containers must be limited to 60% or less

• Food waste bins vary in composition of food types and water

• Excess water in food clogs the conveyor unit

• Non food trash placed into bins• Training of food staff

• Wood chips: if too fine or wet can clog conveyor system. Chips often contain too much water, or are the wrong size

• Once clogged – operator must climb into composter to unclog

• Shaker unit clogs – chips hard to separate out

• Unit can freeze in winter• Slight smell

Aeration and Water Addition

• Water from the food is drained into the bottom of the unit, then pumped back up onto the food daily

• 7 days into cycle mixture is at center of unit. Spinners aerate mixture and add fresh water

• Water is also used to decrease temperatures if mixture gets too hot

Bunker System

• 3 bunkers allow for rotation of mulch• 1st bunker holds mulch for 30 days • Transferred to 2nd and 3rd bunker

after 30 day holding, and aerated• Temperatures taken daily• If temperature is within 20 degrees F.

of outside temperature, then mulch is ready for use. Testing occurs.

Monitoring

• Temperatures of mixture in composter taken daily

• Compost must maintain a temperature of 131 degrees F. for a minimum of 72 hours

• Pathogen testing

• pH testing

Validation of System

• Microbiological and pH tests are performed by DEQ

• Unannounced quarterly inspections completed by DEQ

• Licensing is required to operate unit

• Operator must be licensed

Uses for Mulch

• Flower beds

• Mulch helps to keep weeds and bugs out of garden

• Mulch keeps dirt from packing which allows air to reach the plant root

Use on Fields

• Spread 6 inches deep on fields

• Disc mulch into field dirt

• Can be used on crops for cattle such as barley, soybean and corn.

PLEASE Recycle !