From Manure to Money: Systematic Compost Quality

Image rights: © Midwest Organics – Andy Klink / Viably – Gerrett Lapsys

 

 

McHenry, a small town located 40 miles outside of Chicago in the US state of Illinois, is home to the 51 acre plant of Midwest Organics Recycling. Now known as a professional composting facility with growing demand, the operation began over 20 years ago with a simple question: What should be done with all the manure from your own dairy farm?

A full-grown cow produces up to one ton of manure per month – a considerable amount. The founding family‘s answer was as pragmatic as it was forward-looking: turn the organic material into high-quality compost – initially for their own use, and later for sale.

In the meantime, the input is no longer limited to cow manure. Green waste, horse bedding, leaves and food waste are also processed. Around 120,000 cubic yards of biomass are processed into approximately 60,000 cubic yards of compost each year. Around 70% is sold to gardening and landscaping companies and private gardeners, while 30% is used on the farm‘s own fields.

 

 

Image: Technology and support at the highest level – Andy Klink (left) from Midwest Organics relies on Komptech and Viably.

Bildnachweis: Midwest Organics – Andy Klink / Viably – Gerrett Lapsys

 

 

TURNING POINT: WHEN THE CRAMBO CAME

Things didn’t always run smoothly. In the early years, the team used a high-speed grinder that regularly caused problems and did not process the material optimally: “The material was shredded too finely, leaving fine material too little room for airflow in the windrows under humid conditions – they got too wet too fast and became unusable,” says Andy Klink, Midwest Organics’ site manager for over ten years.

The turning point came when the grinder finally broke down. Garrett Lapsys, Viably‘s regional sales manager for Komptech machines, had already been in regular contact. When the breakdown happened, Viably quickly provided a Crambo as a temporary replacement.

 

„We used to spend hours removing contaminants. Today, the Hurrikan does it – better and faster.“

Andy Klink,
Site manager at
Midwest Organics Recycling

 

“The Crambo was a real game changer,” recalls Andy. Not only did its energy efficiency and durability impress the team, but its low-speed shredding system was a perfect fit for the input material. The Crambo produced a structured output that allowed for more stable windrows and required less frequent turning. This not only saves working time but also increases the quality of the end product. The machine also had significantly lower fuel consumption. “With the Crambo, we not only saved a lot of fuel but also drastically cut maintenance and repair costs,” Andy emphasizes.

 

 

Image: The Crambo ensures that Midwest Organics has structured input material that enables stable windrows.

Image rights: Midwest Organics – Andy Klink / Viably – Gerrett Lapsys

 

 

STEP BY STEP TO THE IDEAL SETUP

What began with a temporary machine developed into a long-term partnership. Further machines followed: a Multistar star screen, a Hurrikan wind sifting machine, a drum screen – and finally a Topturn windrow turner. The Multistar in particular impressed with its ability to deliver a constant throughput, even with very moist material. In combination with the Hurrikan, the proportion of contaminants in the end product was drastically reduced – a clear improvement compared to before. “We used to spend hours walking through the windrows with waste tongs,” says Andy. “Today, the Hurrikan takes care of that – clean, safe and, above all, time-saving.” The combination of screening, wind sifting and structure-preserving shredding increased the efficiency of the plant.

For additional flexibility, a drum screen was added – particularly suitable for changing materials or specific fractions. Finally, the line was completed with the Topturn windrow turner. “The Topturn delivers clean windrows, ventilates reliably and is easy to operate,” summarizes Andy – a clear win for the entire team.

 

 

Image: Clean, safe, time-saving: the Hurricane wind sifter efficiently removes contaminants from compost.

Image rights: Midwest Organics – Andy Klink / Viably – Gerrett Lapsys

 

 

PARTNERSHIP WITH REAL ADDED VALUE

Today, Midwest Organics has a machine line that has grown over the years and in which everything fits together seamlessly. Other suppliers were soon no longer an option for the company. Andy Klink summarizes: “With their well thought-out and efficient design, the Komptech machines prove that they know the customer‘s wishes and requirements and align their products accordingly.”

But it‘s not just the technology that counts: The support provided by Viably and Komptech also plays a key role for Andy Klink. “Service, availability, spare parts supply – it all works. And our staff gets along great with the machines. For us, it‘s not just efficiency that counts, but also ease of use.”

 

„I get a technician on the phone when I need one – and machines that simply work. That‘s what makes the collaboration so valuable for us.“

Andy Klink,
Site manager at
Midwest Organics Recycling

 

For Komptech, Midwest Organics is a prime example of how well thought-out machine technology and close customer relationships lead to sustainable efficiency. Or as Andy Klink puts it: “Our work contributes to a healthy and intact environment. And the Komptech machines help us to do our work well and efficiently”.

 

 

 

This is the online version of the article “From Manure to Money: Systematic Compost Quality” from the Komptech magazine Opportunity / Issue No. 4 (2025) ↗

Image rights: All images © Komptech GmbH where not otherwise indicated.

No liability accepted for changes or errors.