Power Need
By the early 2000s the dairy herd on Wanner’s Pride-N-Joy Farm had grown well beyond its original size, raising concerns about odor, greenhouse gas (GHG) emissions, and energy costs. They needed a solution that could generate reliable low-cost electricity, make the neighbors happy by reducing odors, and use an abundant on-site resource: cow manure.
Solution
In 2007, Wanner Farm installed an anaerobic digester that breaks down manure and produces methane-rich biogas. This gas powers a Cat® G342C engine, which runs 24/7. Waste warms the digester and heats the milking parlor and shop during cold months. They also use Cat AMP, a real-time monitoring and forecasting tool, to optimize energy costs.
Results
All that manure gets turned into green. During half the year, the CHP system generates more electricity than the farm uses, so surplus power is sold back to the grid. Annual electricity savings have grown from about $35,000 to roughly $50,000 today. Using the biogas system results in reduced GHG emissions, healthier soil, and ready power during outages.
The Wanner family has farmed the rolling hills of southeastern Lancaster County, Pennsylvania, for eight generations. They’ve transformed their operations with a methane digester and repurposed Cat genset in a Combined Heat and Power (CHP) system. It converts manure from 800 cows into renewable electricity, heats livestock and working areas, and eliminates methane emissions.
They also use Cat AMP, a real-time monitoring and forecasting tool that tracks CHP system performance, utility pricing, and peak energy events, helping reduce costs and improve energy planning. This innovative approach preserves the farm’s 185-year legacy while positioning it as a model for sustainable agriculture.
What benefits do the Cat G342C CHP system and Cat AMP provide?
120 kWh
Continuous power output
$50,000/year
Approximate electricity cost savings
800
Number of cows supplying manure
Actual results may vary based on conditions and other factors.
Cat industrial and commercial gas generator sets, at ratings from 100 to 4,500 ekW (100 to 4,500 kVA), operate on natural gas and a wide range of other gaseous fuels including biogas, landfill gas, coal gas and propane..
Learn MoreUnlock cost savings, grid resilience, and operational control with Cat® AMP for smarter energy asset management.
Learn MoreLearn how Cat biogas generator sets provide economical and sustainable power for agricultural farms, waste water treatment, landfills, and other industries.
Learn MoreCat® Combined Heat and Power (CHP) systems can lower operating costs and emissions. Ask a Cat dealer how Cat cogen systems can increase efficiency up to 90%.
Learn MoreBiogas is a renewable fuel made from organic waste like manure. Microorganisms break down this waste in a sealed tank (anaerobic digestion), producing methane-rich gas. A biogas generator then uses that gas to make electricity. The generator also gives off heat, which can be captured and reused through a CHP system (Combined Heat and Power) to warm buildings or water.
Biogas generator sets offer a reliable, on-site energy solution that can help reduce a site’s total greenhouse gas emissions, lower operational and energy costs, and create new revenue opportunities. With a higher reliability rate than solar or wind, biogas systems also enhance resiliency, as it is often produced and consumed on the same site.
CHP, or Combined Heat and Power, is an extremely efficient system that generates power on your site with cogeneration – producing electricity and thermal energy at the same time. CHP systems capture heat produced by generator sets and use that thermal energy for industrial processes, which can include space heating, water heating, drying, and producing low-pressure steam.
CHP systems can reach up to 80% efficiency and reduce both the cost and emissions of your facility by using the heat captured, rather than wasting it like traditional power plants do. Using this waste heat can eliminate the need for boilers and other heating systems that would require costly fuel or grid power.
Using a Distributed Energy Resource Management System (DERMS) solution like Cat AMP allows you to monitor, control, and optimize your energy assets. By optimizing your energy use, or avoiding peak energy charges, you can lower your overall energy costs. Cat AMP can manage it all for you.
