AUTOMATED PROCESS FLOW
From segregated waste to biomethane, renewable energy and biofertiliser, supported by real time monitoring and control.
Two layers working together: the plant and the system that monitors it
An AeroShakti installation has a physical plant and a digital layer. The plant converts segregated organic waste into biomethane, renewable energy and nutrient rich biofertiliser. Alongside this, a remote monitoring system tracks key parameters such as feedstock volumes, temperatures, gas production and digester health in real time, allowing our team to supervise operations and ensure stable performance.
These two layers work as one. Our operations team monitors the data round the clock, provides guidance to on site teams and takes corrective action wherever needed, so your plant runs safely, efficiently and with minimal downtime.
How waste becomes energy
From the moment organic waste arrives at our facility to the point it leaves as biomethane, renewable energy and biofertiliser, the process follows a series of carefully controlled stages.
Organic Waste Collection
Segregated organic waste is collected from source and delivered to our facility. Each load is weighed, recorded and inspected before being accepted.
Shredding and Mixing
The accepted organic waste is shredded and mixed to create a uniform feedstock with the right particle size and moisture content for efficient digestion.
Feedstock Conditioning
The mixed feedstock is conditioned to achieve the right consistency and remove any undesirable materials, ensuring a stable and reliable digestion process.
Anaerobic Digester
The conditioned feedstock is pumped into sealed digesters where naturally occurring microorganisms break it down in the absence of oxygen to produce biomethane and a nutrient rich digestate.
Biomethane Cleaning
The raw biogas produced in the digester is cleaned and purified to remove moisture, carbon dioxide and other impurities, upgrading it to high quality biomethane.
Gas Storage
The purified biomethane is stored in a buffer system at controlled pressure to ensure a steady and reliable supply for end use.
Compression
Depending on the end use, the biomethane is compressed to the required pressure for pipeline injection, storage or use as compressed biomethane for vehicles.
Flare System
A safety flare system is in place to burn any excess gas in a controlled manner, ensuring safe and compliant operation at all times.
End Use Applications
The biomethane is supplied for electricity generation, heat or cooking fuel, or upgraded to bio CNG for use in transport and industrial applications.
Digestate Handling
The remaining digestate is processed through solid liquid separation to produce a nutrient rich biofertiliser and treated liquid for safe discharge or reuse.
Quality Monitoring
Throughout the process, key parameters such as temperature, gas composition and digestate quality are continuously monitored to ensure optimal performance, compliance and consistent output.
The physical process flow. Tap or click to open it full size.
How the plant is watched
Our plants are supported by a remote monitoring system that tracks key parameters in real time, helping us maintain stable operations and respond quickly to any changes.
AeroShakti Plant
The plant includes feed preparation equipment, anaerobic digesters, biomethane handling and related equipment, all connected to a remote monitoring system that tracks performance and alerts the team if any parameter goes out of range.
Digester Health Checker
Dedicated sensors continuously monitor digester temperature, pH level, gas production and other key parameters to ensure the digestion process remains healthy and stable.
Command Centre
Our operations team monitors all plants remotely. They track real time performance, receive alerts and interpret the data to understand what the numbers mean for each specific site.
Secure Cloud Server
All plant data is securely stored on a cloud server, giving us a continuous and accurate record of operations that can be accessed anytime for analysis and reporting.
On Site Team and Support
Our on site team receives clear instructions from the operations team and takes preventive action based on the data. This helps us address any issues early and keep the plant running smoothly.
Live Dashboard
Plant specific information is available on a live dashboard, so our operators and your team can view key data, track trends and get a complete picture of performance from their location.
The preventive action loop
The flow is not one way. Readings and alerts travel from the plant to the command centre and back to the site team, so adjustments are made before a small issue turns into a bigger problem. This continuous feedback loop helps maintain stable operations and maximise biomethane and biofertiliser output.
The automated monitoring flow. Tap or click to open it full size.
Where would you like to go next?
Get Started with AeroShakti
A simple way to start turning your organic waste into renewable energy.
CONNECT
Whether you are a hotel, hospital, residential community, institution, airport, food manufacturer or municipality, our team will assess your organic waste stream and recommend the most effective waste-to-green-energy solution. Every enquiry begins with a consultation focused on sustainability, operational efficiency and long-term value.
DESIGN
Our experts evaluate your waste generation, available space and operational requirements to design a customised collection and processing solution. From container placement and collection schedules to regulatory compliance and commissioning, we ensure a seamless implementation tailored to your facility.
BENEFIT
Your organic waste is transformed through advanced biomethanation into renewable biogas, green electricity and nutrient-rich organic fertiliser, reducing landfill dependence, lowering your carbon footprint and returning measurable value to your operation.
Ready to implement biogas solutions? Reach us for a free consultation.
Send us your waste volumes and location. You get an indicative plant size, expected gas output and a payback range within three working days.