Three kilometres of manure pumping with significantly lower energy consumption

How do you pump cattle manure over a distance of three kilometres – without using enormous amounts of energy?

That was the challenge at Fair Oaks Farms in Indiana, USA, where an LSM peristaltic hose pump demonstrated that it is indeed possible.

Fair Oaks Farms is one of the largest cattle farms in the USA, with approximately 36,000 dairy cows across eight locations. The manure from the farms is used in a large biogas plant, but one of the farms was located approximately three kilometres from the plant.

More than ten years ago, a 6" pipeline was installed between the barn and the biogas plant. Several different pumping solutions were tested, but none provided the desired reliability or capacity. The final option was a high-pressure pump of approximately 300 hp – a solution with very high energy consumption that did not fit with the economics or energy balance of the biogas production.

LSM offered an alternative solution

Through LSM Pumper's US division, we established contact with the manager of the biogas plant. We offered Fair Oaks the opportunity to test a specially reinforced LSM125 hose pump on a rental basis, allowing the system to be tested under real operating conditions.

The pump was installed in August 2022.

The result surprised everyone. The specially adapted LSM125 was able to pump the manure across the entire three-kilometre distance – powered by a motor of just 22 kW.

Following the successful test, Fair Oaks decided to purchase the pump.

Continuous optimisation

Following the initial installation, the solution has been further developed. Among other things, a booster pump has been installed halfway along the pipeline, increasing capacity by approximately 40%, while energy consumption remains very low.

The successful installation has also provided the basis for further expansion. Fair Oaks is now working on installing two additional LSM 150 hose pumps, allowing manure from two more farms to be pumped directly to the biogas plant over a distance of more than 4 km. The aim is to reduce the need for transportation by tractors and slurry tankers and thereby create more efficient and sustainable logistics.

In addition, they have installed three LSM 100 pumps to pump manure through the heat exchanger.

 Part of one of the largest farms in the USA

Fair Oaks Farms covers approximately 14,000 hectares across eight locations and produces milk from around 36,000 cows. The manure is collected in a central lagoon, where three LSM100 hose pumps operate continuously, pumping the biomass through a heat exchanger and into the biogas reactors.

In addition to agricultural production, Fair Oaks also operates a hotel, restaurant, visitor centre and petrol station. Around 500,000 guests visit the business each year, which also produces approximately 80,000 m³ of biogas per day.

Proven technology with international interest

The Fair Oaks project has demonstrated that long-distance pumping of cattle manure is a realistic solution – even over several kilometres and with significantly lower energy consumption than traditional alternatives.

The experience has already generated considerable interest, and LSM Pumper is currently working on several similar projects in the USA. At the same time, we are seeing increasing international demand for solutions that can make biomass transportation more energy-efficient and reduce the need for heavy internal transport.

Project facts

• Customer: Fair Oaks Farms, Indiana, USA

• Pump: LSM125 hose pump

• Capacity: 200 GPM

• Application: Pumping cattle manure to a biogas plant

• Motor power: 22 kW

• Result: Reliable long-distance pumping with significantly lower energy consumption