Case: More than 10 years of continuous operation without blockages

16 September 2026 | VOGELSANG

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Coarse materials and fibres in the organic biomass caused weekly blockages in Agrinord’s recirculation system. After a RotaCut® RC 5000pro macerator was installed, the blockages were eliminated. The plant has since operated for more than 10 years without shutdowns caused by clogging.

Processing 76,600 tonnes of organic waste per year

Agrinord Srl operates a biological waste treatment plant with biogas production in Isola della Scala, Italy. The plant processes approximately 76,600 tonnes of organic waste each year.

The material includes separately collected household organic waste, vegetable residues, biomass and sludge from households and the agro-industrial sector. The biogas is used to generate electricity, covering the plant’s own energy requirements while surplus power is supplied to the grid.

Blockages required weekly cleaning

Following the initial treatment, the material is pumped into two 50 m³ storage tanks. It is continuously recirculated at a capacity of 20–30 m³ per hour before being transferred to the reactor’s recirculation system and heat exchanger.

Coarse components, vegetable residues and fibrous material repeatedly blocked the pipes and pumps. As a result, the operator had to clean the entire recirculation system every week. This required considerable working time and caused production losses due to unplanned downtime.

The RotaCut macerator protects the pumps

To solve the problem, Agrinord installed a RotaCut RC 5000pro macerator in the recirculation line.

The RotaCut macerator reduces fibrous materials and coarse components before they reach downstream pumps and equipment. At the same time, heavy foreign matter is separated from the medium. This creates a more homogeneous biomass and reduces the risk of blockages in the recirculation system.

Following installation, the blockage problems were eliminated. The RotaCut macerator and centrifugal pump have now operated continuously, 24 hours a day, for more than 10 years.

Lower costs and more stable operation

Stable recirculation has removed the need for the previous weekly cleaning shutdowns. Agrinord has therefore reduced its cleaning and maintenance costs, as well as the financial losses previously caused by interruptions to operation.

The QuickService concept also allows the plant’s own employees to carry out routine servicing quickly and easily.

Results for Agrinord:

More than 10 years of continuous operation without shutdowns caused by blockages
No weekly cleaning of the recirculation system
Reliable processing of approximately 76,600 tonnes of organic waste per year
Effective reduction of coarse and fibrous materials
Improved protection of pumps and downstream equipment
Lower cleaning and maintenance costs
Routine servicing can be carried out by the plant’s own employees

Learn more about the RotaCut macerator and Vogelsang’s solutions for efficient biomass processing at biogas plants. Visit Vogelsang at Agromek 2026 in Hall K, stand K8000.