Case: Meyer Biogas saves around 200 kWh per day with the RotaCut macerator

17 September 2026 | VOGELSANG

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Long-fibred feedstocks, floating layers and high energy consumption limited operations at Meyer Biogas. After converting to a liquid feeding system with a RotaCut® RCX macerator, the biomass became more homogeneous and the main pump more reliable. According to owner Søren Meyer, the solution saves approximately 200 kWh per day.

The biogas plant needed to handle more feedstocks

Søren Meyer operates Meyer Biogas GmbH & Co. KG in Germany as part of the family farm, which specialises in pig and bull beef production.

The biogas plant was commissioned in November 2011 and produces approximately 2.3 million m³ of biogas per year. It consists of two digesters operating in parallel and a final storage tank.

Initially, the plant was primarily fed with maize silage and liquid manure, supplemented by CCM and rye flour. The biomass was fed into the digesters using a walking floor and two screw conveyors.

Once the plant was operating reliably, Søren Meyer wanted to reduce feedstock costs. One objective was to replace maize silage, CCM and rye flour with a higher proportion of green rye and liquid manure.

Long-fibred feedstocks caused feeding problems

The existing solid matter feeding system and agitators could only handle limited quantities of green rye. Long fibres placed additional strain on the feeding system and agitators, while floating layers formed in the digesters.

This restricted the choice of feedstocks and increased the workload, energy consumption and servicing requirements.

To use more green rye and liquid manure, Meyer Biogas needed a solution that could turn the demanding feedstocks into a homogeneous, pumpable suspension before the biomass entered the digesters.

Liquid feeding with the RotaCut RCX macerator

Following technical advice and an assessment of the biogas plant, Søren Meyer decided to convert to a liquid feeding system. The solution consists of a large walking floor, a solid matter feeder and a downstream RotaCut RCX macerator. The system was commissioned in May 2016.

During the liquid feeding process, the solid feedstocks are mixed with liquid. The RotaCut macerator reduces coarse and long-fibred components, making the biomass easier to pump and mix.

The integrated heavy material separator also removes stones and metal parts before they can enter the digesters and place additional strain on pumps, agitators and other equipment.

The result is a more homogeneous organic suspension and more reliable feeding into the biogas plant.

Lower energy consumption and reduced wear

Following the conversion, floating layers were eliminated, even though the proportion of demanding feedstocks increased significantly. The main pump operates more reliably and with less wear, while the load on the agitators has been reduced.

The more homogeneous biomass has lowered both the energy consumption and servicing requirements of the agitators. According to Søren Meyer, Meyer Biogas saves approximately 200 kWh per day. This corresponds to annual energy cost savings of around €12,000.

Taking the energy savings, lower servicing requirements and greater feedstock flexibility into account, Søren Meyer expects a payback period of approximately four years.

“I chose Vogelsang because the combination of the liquid feeding system and the RotaCut macerator ensures trouble-free operation and a more efficient biogas plant.”, Søren Meyer, owner and operator, Meyer Biogas GmbH & Co. KG

Results for Meyer Biogas:

According to Søren Meyer, energy savings of approximately 200 kWh per day
Annual energy cost savings of around €12,000
Expected payback period of approximately four years
No floating layers in the digesters
More reliable operation and reduced wear on the main pump
Lower energy consumption and servicing requirements for the agitators
Ability to use a higher proportion of demanding feedstocks
Removal of stones and metal parts before they reach the digesters

Learn more about the RotaCut macerator and Vogelsang’s solutions for reliable and energy-efficient biomass feeding. Visit Vogelsang at Agromek 2026 in Hall K, stand K8000.