dairy farm stepped hearth high capacity incinerator

Large scale dairy farmers in need of a solution

Alsafi Danone is one of the largest integrated dairy farms in the world. Controlling fallen stock and bio-security is critical to the upkeep of a healthy productive herd.


Riyadh, Saudi Arabia

Client overview

Alsafi Danone, are the largest integrated dairy farm in the world. They first opened in 1979 and have has since expanded to a herd of over 37,000 cows who produce 700, 000 litres of milk every day. They are widely recognised as one of the leading, high-quality dairy producer and has been rewarded with an ISO 9002 certification along with a string of awards.


An incinerator is needed

Cattle have one of the lowest fatality rates in farmed livestock, however a farm the size of Alsafi Danone required a machine with a minimum throughput of up to 6 cattle per day,  whilst having the additional provisional capacity to allow for future expansion of the facility.

The importance of incineration

Originally, incineration was not the main waste disposal option. Carcasses were dismembered by a third party company and sent to a burial in the local area. As the site expanded, groundwater contamination for the livestock and for the local human population became a concern. Fluids from dismembering and burial had the potential to interact with the water sources on site.

Whilst fluid trails from transportation vehicles did not fit into the company’s image or it bio security ethos.

High Capacity stepped hearth dairy farm incinerator

Which incinerator?

The machine implemented was Addfield-Techtrol Pyrotec AP1000 incinerator. A robust, large scale, stepped hearth machine made up of three major components:

Waste loading: A large reception loading hopper and an automatic ram charging system that can continually load large cattle carcasses throughout the day.

Primary Combustion:  A stepped hearth incineration chamber, with multi-point air injection and hydraulic sweeping rams that are capable of burn rates of up to 1000kg/hr for animal-by-products.

Automatic De-Ashing: The sterile inert ash that is generated,  is then automatically removed from the incinerator and deposited into a ash holding zone.

Self contained high capacity incinerator

Advantages of using Addfield incinerators

There are a number of benefits of using the Addfield-Techtrol range of incinerators. The key identifiers for the AP-1000 include:

  • A stepped hearth refractory, allows for the fast and effective breakdown of waste. The system incorporates two hearth rams to push residue and stoke the waste.
  • The AP-1000 is fitted with an induced hot hearth system. Two burners underneath the refractory aid the full destruction of the waste, by eliminating cold spots below the waste.
  • A natural draft in the chimney produces a ‘pull effect’ vortex in the primary and secondary chamber. This encourages combustion air to be drawn through the waste load improving combustion.

Class leading fuel efficiency, innovative design combined with robust and reliable craftsmanship. The AP1000.


Animal Pathological waste incinerator with stepped hearth diagram

From Concept to Completion - Addfield Offer Turnkey Solutions