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Case Study
Covered lagoon digester and biogas destruction system for one of the world's largest pork processing facilities, eliminating methane emissions from high-volume swine processing wastewater.
The Challenge
Smithfield's Tar Heel facility is the world's largest pork processing plant, slaughtering over 32,000 hogs per day and generating enormous volumes of high-strength organic wastewater. The open lagoon system was producing an estimated 55,000 tCO2e per year in methane emissions, drawing regulatory scrutiny from NCDEQ and community complaints from neighboring Bladen County residents.
Our Approach
EFI designed and installed a covered lagoon digester system with dual enclosed flares, continuous H2S scrubbing, and cloud-based monitoring across the facility's primary and secondary wastewater lagoons. The system captures and destroys methane from processing wastewater while maintaining the existing treatment flow. A redundant flare configuration ensures 99%+ uptime for carbon credit verification.
Outcomes
“At our scale, environmental compliance isn't optional — it's existential. EFI delivered a system that handles the volume of the world's largest pork plant and turned a regulatory liability into a revenue stream.”
VP Environmental Affairs, Smithfield Foods
Related Work
Poultry / Food Processing
Food Processing / Agriculture
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