0%
+380 96 858 0107 info@pro-energy.com.ua
EN
UA
+380 44 227 7119 info@pro-energy.com.ua
EN
UA
Home SolutionsBiogas & Biomethane Biogas plant for a dairy factory

Biogas plant
for a dairy factory

Instead of waste disposal — energy independence and profit. A biogas plant is a solution that allows you to reduce fuel costs to zero.

Without a biogas plant:

  • Daily costs of whey disposal.
  • High dependence on gas and electricity prices.
  • Informal waste disposal — environmental risks.
  • The high cost of drying or concentrating whey.
  • Product prices are rising due to energy costs.

With this, you get:

  • Complete utilisation of the whey at no cost.
  • A self-generated energy source — biogas.
  • A biogas plant — an effective solution for waste treatment.
  • Replacing natural gas with our own biogas.
  • The cost price of dairy products is falling.

When should you contact us?

01

Your plant produces whey in significant quantities

02

You are looking for an alternative to natural gas for your boilers

03

You are already using whey drying and want to reduce costs

04

You are interested in energy independence, reducing CO₂ emissions and decarbonising production

About raw materials

The main feedstock for the biogas plant at the dairy is whey, as well as other by-products: milk residues, fat fractions, fugate, sludge, sewage sludge, and substandard products (yoghurts, kefir, cheese products).

Raw milk has a high content of organic matter (lactose, proteins, fats), which ensures a high biogas yield. Liquid streams with high COD (whey, effluents) are typically treated in high-load UASB/EGSB reactors, which offer a compact design and high performance.

Where fats, curd, or returned product are present, CSTR reactors are used, as they ensure stable operation with heterogeneous feedstock and control of the fermentation process.

Prior to feeding into the reactor, the material undergoes buffering, averaging, temperature and pH control, and, where necessary, grinding and homogenisation.

Biogas is used to replace natural gas in boiler rooms or in combined heat and power (CHP) systems to provide electricity and heat for the company’s own needs.

Biogas plant for a dairy factory - photo — pro-energy.com.ua

Would you like to find out how to convert whey into biogas?

Book a free consultation, and our managers will provide comprehensive information regarding your questions.

Options for collaboration:

  1. Joint financing and the establishment of a joint venture.
  2. Grant co-financing (from the EU or international funds).
  3. Development with subsequent buyback.
  4. Equipment-backed loans through Ukrainian banks.
  5. Contract for the supply of raw materials to the investor’s power stations.

Ways to recoup the investment:

  • Replacement of natural gas
  • Reducing the cost of whey disposal
  • The use of heat in manufacturing
  • Reduced drying costs
  • Increasing energy independence

Biogas technologies for dairy factories

For dairy plants, we recommend focusing biogas production as much as possible on the processing of all possible organic waste. This allows for an increase in biogas yield and a reduction in the cost of biogas production; therefore, the optimal solution is to use CSTR-type reactors with preliminary homogenisation, grinding and buffering. This approach enables efficient processing of both liquid streams (whey, process effluents with high COD) and more complex raw materials — fat fractions, curd, returned or substandard products. Prior to feeding into the reactor, homogenisation, temperature and pH control are applied, and where necessary, grinding and separation are carried out to ensure stable dosing.

The gas is purified to remove H₂S and moisture. Raw milk typically has a low hydrogen sulphide content, so sorption filters are used. Dehumidification is essential for the reliable operation of gas equipment.

The gas is then used for combined heat and power (CHP) generation, with simultaneous production of heat for industrial processes (washing, water heating, steam).

We integrate all components into the SCADA and commercial metering systems, monitoring feedstock supply, fermentation parameters, biogas composition and consumption, electricity and heat production, and internal consumption. In the case of biomethane production, additional metering of gas flow, pressure, temperature and quality is implemented in accordance with the requirements of the transfer point or internal consumer — depending on the chosen business model (CHP, boiler house or biomethane).

Click on the image to enlarge
Your single partner for effective solutions

A systematic approach
from Pro-Energy

We provide a range of engineering and consulting services for project implementation. From concept to efficient operation of the plant using your raw materials and location.

More about the systematic approach

Our services:

Concept development and feasibility study
Project development and permits
Development of project documentation
Supply of technological equipment
Construction and installation
Start-up and commissioning works
Service maintenance

Biogas projects implemented

Generation of feed-in energy at an agricultural enterprise

Chernihiv region
The plant was put into operation: February 2022
More details
Biogas plant for a dairy factory - photo 1 — pro-energy.com.ua
Project completed

Biomethane plant with a capacity of 750 Nm3/h of raw biogas

Khmelnytskyi region
Year of implementation: December 2023
More details
Biogas plant for a dairy factory - photo 2 — pro-energy.com.ua
Project completed

Biomethane plant with a capacity of 600 Nm3/h of raw biogas

Ukraine, Chernihiv region
Commissioned: 2023
More details
Biogas plant for a dairy factory - photo 3 — pro-energy.com.ua
Project completed

Why choose Pro-Energy?

We are committed to long-term partnerships!

More About us
advantage item

Many years of experience

We have been successfully operating in the bioenergy sector since 2014. We have the knowledge, experience and understanding of the specifics of working in the Ukrainian market.

advantage item

Unique partnerships

We have reliable partners. Therefore, we can offer solutions that will allow each project to reach its full potential.

advantage item

Reliable technologies

We use technologies with 90% availability for stable operation of installations, which guarantees efficiency and return on investment.

advantage item

Stable work

We do not leave our customers alone after commissioning the facility. We provide 24/7 technical support and remain available under any circumstances.

More About us

Ready to discuss the implementation of your project?

Leave a request for a free consultation.





    Frequently asked questions

    Is sweet whey suitable for biogas production?


    Yes, whey is one of the best feedstocks for biogas production due to its high organic content and availability. Biogas plants operate efficiently using whey without any pre-treatment.

    Does it make sense to build a biogas plant if you already have a dryer?

    Yes. Drying whey consumes a lot of energy, and the market for it is unstable. In contrast, a biogas plant generates energy and enables you to reduce energy dependence, as well as lower production costs.

    What type of reactor is suitable for whey?


    For liquid streams (whey, process effluents), high-load UASB/EGSB reactors are the optimal choice, as they offer a compact design and high performance. If the feedstock contains fats, protein residues, or returned product, CSTR reactors are used to ensure stable operation with heterogeneous feedstock.

    How much biogas can be produced from whey?


    On average, 20 to 30 m³ of biogas can be produced from 1 m³ of whey, depending on its composition and freshness. The fresher the whey, the greater the biogas yield.

    Does the whey need to be purified or prepared before feeding?


    The whey does not require complex mechanical preparation; however, buffering, composition stabilisation, and temperature and pH control are essential. This helps to prevent unstable bioreactor operation and ensures a predictable biogas yield.

    Can biogas be used at the dairy itself?


    Yes, biogas can be fed directly into steam or water-heating boilers that previously ran on natural gas or fuel oil. This is one of the key advantages of the solution.

    What is the payback period for a biogas plant at a dairy? 


    On average, 3–5 years, depending on the scale of production and the cost of energy. However, it may be shorter if gas costs are high and whey volumes are substantial.

    Are there any examples of such plants in Ukraine?


    Yes. We have implemented solutions at several dairy processing plants. Book a free consultation, and we will tell you about our experience in this field.