Cornish Cheese Co invests in Anaerobic Digestion

Cornish Cheese Co invests in Anaerobic Digestion

Harnessing Green Energy: The Start Of Our Journey To Net Zero

In an era where sustainability is no longer optional, businesses like ours are seeking innovative ways to reduce reliance on traditional energy sources. For us, the drive towards sustainability gained momentum as electricity prices surged, doubling the cost of power from the grid as well as other costs across the business which have been challenging but we were conscious of being proactive about solving these problems and not just passing on huge costs on to our customers. Reducing grid dependency became not just a financial necessity but a promising path to a greener future. After exploring various energy solutions, we ultimately chose anaerobic digestion, a technology that BioFactory has made viable for smaller farms.

Evaluating Sustainable Energy Options: Solar, Wind, and Beyond

Our journey began by considering solar energy, which was already part of our strategy, with a system capable of generating 50,000 kWh. However, expanding this approach would require substantial investment in battery storage, an area where prices have yet to align with performance. Wind energy was also considered, but our location within an Area of Outstanding Natural Beauty (AONB) made planning approval complex and time-consuming.

Then, we turned our attention to anaerobic digestion (AD), a promising but typically costly solution requiring a significant amount of waste for ongoing operations. Conventional AD plants are costly and suited to larger farms, often beyond the reach of smaller enterprises like ours. This is when we discovered BioFactory, a company committed to making AD technology more accessible for smaller operations.

Introducing BioFactory: AD Technology for Small Farms

BioFactory identified the gap in the market for smaller farms with limited capital and waste volume. In essence, anaerobic digestion captures gases released from organic waste (like cow manure) and converts them into energy. BioFactory’s system filters these gases, allowing a motor to generate electricity, while the heat generated naturally warms water within the system.

When we reached out to BioFactory and explored their system, we quickly saw its potential: a small AD plant on our farm could produce over 250,000 kWh annually. This energy, derived from hot water and electricity, would cover about 75% of our dairy’s current consumption. Our long-term goal is to supplement this with solar energy, pushing us closer to net-zero emissions.

Adding Whey to the Mix: Supercharging Gas Production

Beyond the benefits of manure, we realized we had another valuable byproduct at our disposal: whey from our cheesemaking. Studies have shown whey can enhance gas production in AD systems, likely due to its high sugar content. This “rocket fuel” effect on the manure is an exciting prospect, as the projected energy output of 250,000 kWh was calculated using only manure. By incorporating whey, we anticipate generating even more energy. We plan to test, monitor and share the results!

Environmental Impact: Capturing Methane for a Cleaner Planet

Methane is one of the most potent greenhouse gases, primarily emitted by livestock on large-scale farms. While small UK herds are not the main contributors, every effort to capture methane and convert it to green energy is a win for the environment. Capturing methane from manure not only prevents it from entering the atmosphere but also produces nutrient-rich manure that is easier and more economical for farmers to spread.

Funding the Future: Securing Support for Our Micro AD Project

As a smaller business, investing in AD technology was a substantial financial commitment. Toward the end of 2023, we applied for national grants designed to support businesses working toward net-zero goals. After months of preparing our proposal, we were thrilled to receive funding approval in July 2024 from the Cornwall & Isles of Scilly Growth Hub Net Zero Scheme.

Our Roadmap and Commitment to Transparency

We anticipate installing the AD system by late November 2024, and we’re eager to start testing it immediately. The effect of whey on gas production remains a variable we’re excited to explore, and we’ll be monitoring our progress monthly to document any boosts in energy generation.

As the first cheesemaker in the UK to deploy a Micro AD Plant, we’re committed to sharing our journey openly. Our goal is to demonstrate to other small businesses that affordable, scalable, and sustainable solutions are within reach. By investing in green technology, we’re not only curbing operational costs but also contributing to a healthier planet—one step closer to a sustainable future for all.