Our factory in Khokana (near Bhaisepati) has completed three years since the start of its operations in January 2014 and is again in full swing for the 2017 season. During the past three years, the waste collection and production processes have come to full maturity and the sales results have greatly improved by increased customer trust and satisfaction.
Biocomp Nepal undertakes 95% of its organic waste collection itself. Using two trucks – one tipper and one with a fixed and covered flatbed – and two teams of waste collectors, we undertake daily trips to over a dozen organic waste dispatch points in the Kathmandu Valley. During these trips, our Waste Supply Officers monitor the intake process and ensure the correct ratios of green and brown waste are being collected and loaded.
At the west side, the factory contains a large open air composting space, fitted with PCC concrete floors and duct work. At the start of the process, the intake and sorting area is utilised for receiving the green waste and for mixing brown waste and organic additives. Two electric waste graders are used for grading the waste to small particles and mix brown waste in predefined ratios. Our mini dumper then takes the waste to the composting or “green” zone, which is fitted with duct work to collect the percolate liquid. A purpose designed compost turner turns the waste every two to three days in order to aerate the process. After two to three months of composting and volume reduction, the stacks are moved to the maturation or “brown” zone. After another final two to three weeks of drying, the finished rough compost is relocated to the storage and production building for further processing.
At the east side of the factory, several buildings support the production process. The production building is utilised for screening and packing the compost, and for temporary storage. The garage building has four compartments and houses our rolling equipment. Two offices, staff changing rooms and a security guard house complete this front side of the compound. The buildings have been fitted with western style bathrooms and toilets. A water tower with two tanks provides shower water to the staff rooms as well as drinking water to the various buildings. As of January 2016, the Sales & Marketing and Accounts departments are located in the factory office as well. For this purpose, a broadband internet connection has been installed by connection through optical fibre cable.
The production process is largely mechanised around a rotating sieving machine with a medium-large mesh size. In front of the sieving machine, a 12-ton collector bucket is filled after which a conveyor belt transports the rough compost into the sieving machine. The sieved product is removed by manual labour, after which it gets manually checked for any impurities to be removed. Subsequently, the compost is being packed in 2 and 25 kg bags and temporarily stored until the moment of dispatch. The production building is accessible through large shutter doors which facilitates easy loading into small or medium size vans. Large trucks can be parked at the top of the Sainbu hill and will be loaded by shuttling our mid size truck. Typically, the compost is transported in 16-ton cargo loads, which require no more than three shuttles up and down the hill.
During 2015, the sales record of Biocomp Nepal has shown extensive growth. The total sales volume increased by over 1200% compared to 2014 and we now serve customers all over Nepal, from Kailali and Jumla in the west to Itahari and Morang in the east. Starting with nurseries at the beginning of 2014, we now deliver wholesale volumes of organic compost to agents, dealers, farmer cooperations and government institutions. In 2016 we will further introduce a diversification of our product range, starting with organic fertiliser which can be applied to crops directly or mixed with our compost.