Zone 5 - Digestate Management Equipments - Capacity, specification & price ranges
Equipment specifications and indicative price ranges for Zone 5 — the digestate management stage of a CBG plant — covering the seven items that separate, store, dry, and filter digestate into marketable Fermented Organic Manure (FOM).
| Equipment | Capacity / Throughput | Key Specifications | Price Range (Approx. INR) |
| Screw Press Separator | 5 - 10 m3/hr | SS 304 Screen; Adjustable dryness; 5-7.5 HP motor | ₹6,00,000 – ₹10,00,000 |
| Digestate Transfer Pump | 10 - 15 m3/hr | Non-clog centrifugal or Helical rotor; 5 HP | ₹2,00,000 – ₹4,00,000 |
| Liquid Fertilizer Tank | 100 - 200 m3 | RCC with HDPE lining or Glass-fused Steel | ₹5,00,000 – ₹10,00,000 |
| Solid Drying & Packing | 2 - 5 Tons/day | Manual or Semi-auto bagging machine; weighing scale | ₹3,00,000 – ₹6,00,000 |
| Slow-Speed Agitator | For Liquid Tank | 3 - 5 HP; Prevents settling in storage | ₹2,00,000 – ₹4,00,000 |
| LFOM Filtration Unit | 5 m^3/hr | Sand and Carbon filters for drip-irrigation grade | ₹3,00,000 – ₹6,00,000 |
| Hydraulic System | For Separator | Controls the "plug" pressure for moisture control | ₹1,00,000 – ₹2,00,000 |
| TOTAL ZONE 5 ESTIMATE | Organic Fertilizer Stage | Zero-Waste Compliance | ₹22L – ₹42 Lakhs |
Beyond definitions
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How to read this table
- Price ranges are indicative for Indian-market procurement; actual quotes will vary with make and installation scope.
- The final row (TOTAL ZONE 5 ESTIMATE) is the sum of all items above — not an additional line item.
- Tank capacity (m³) refers to liquid volume; throughput rates (m³ per hour) refer to flow through the separator or pump per hour.
- SS 304 screen in the screw press refers to food-grade stainless steel — required for digestate applications where corrosion and hygiene matter.
About this table
Zone 5 is the organic fertiliser production stage of a Compressed Biogas (CBG) plant. The digestate exiting the digester — a nutrient-rich slurry containing nitrogen, phosphorus, and potassium — must be separated into a solid fraction (baggable FOM) and a liquid fraction (suitable for drip or sprinkler irrigation) before it can be sold or distributed to farmers. This table lists the seven core equipment items that accomplish that separation and preparation, with technical specifications and indicative Indian-market prices.
The Screw Press Separator is the workhorse of the zone — it handles 5–10 m³ per hour of digestate slurry, pushing it through an SS 304 screen to press out liquid while the solid cake exits at the discharge end with roughly 25–35% dry matter. A Digestate Transfer Pump (helical rotor or non-clog centrifugal type, 5 HP) feeds the separator from the digester discharge sump. The Liquid Fertilizer Tank at 100–200 m³ capacity stores the liquid FOM fraction — this tank must be covered and agitated by a Slow-Speed Agitator to prevent nutrient settling and ammonia loss.
For operations supplying liquid FOM to drip irrigation systems, the LFOM Filtration Unit using sand and carbon filters upgrades the liquid to drip-irrigation grade, preventing nozzle clogging. The Solid Drying and Packing equipment — a semi-automatic or manual bagging system — handles the solid FOM fraction at 2–5 tonnes per day. The Hydraulic System controlling screw press plug pressure is a small but essential sub-system that determines the moisture content of the pressed solid cake.
Together, Zone 5 equipment costs an estimated ₹22–42 lakh for a 10 TPD plant — a meaningful portion of the overall plant budget, and one that generates a direct revenue stream through FOM sales that partially offsets operating costs.
Key insights
- The Screw Press Separator is the central item in Zone 5 — every other piece of equipment either feeds it, receives its outputs, or supports its operation.
- The Liquid Fertilizer Tank must be equipped with a slow-speed agitator to prevent settling and ammonia evaporation from stored liquid FOM.
- The LFOM Filtration Unit is only needed for drip-irrigation-grade liquid FOM supply — operations using flood or sprinkler irrigation can omit it and reduce zone cost.
- Zone 5 total equipment cost of ₹22–42 lakh is recoverable through FOM sales revenue, making digestate management a genuine secondary revenue stream within the CBG project.
Methodology & sources
Price ranges are indicative for Indian-market procurement as of 2024–2025, at 10 TPD plant scale. Prices exclude GST and civil works. The hydraulic system is often supplied as part of the screw press package — confirm with your separator vendor whether it is included or quoted separately. Actual screw press selection depends on feedstock type and target cake dry matter percentage.
Related data tables
Bio-CNG Production Yield & Output - Quantity Breakdown (Based on 10 TPD Input)
Daily digestate output split into solid Fermented Organic Manure (FOM) and liquid FOM for four feedstock types in a 10 TPD Bio-CNG plant — the numbers a developer needs to plan digestate storage and off-take.
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