Composting Case Study: Transforming Animal Waste Into Sustainable Solutions

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HOW ACE COMPOSTING & ANCO EQUIPMENT & SERVICES REVOLUTIONIZED PIG MORTALITY MANAGEMENT

When Roc Rutledge of ACE Composting set out to develop a more efficient, sustainable way to process dead-on-arrival (DOA) pigs, he faced a significant challenge. Traditional composting methods were slow, inefficient, and labor-intensive, limiting the scalability of his operation. After years of trial and error, Roc sought a high-performance solution—and found it in ANCO Equipment and Services.

By integrating ANCO’s Duracut Rendering Shredder and a high-performance Mixer, ACE Composting dramatically increased efficiency, reduced processing time, and improved compost quality—all while reducing environmental impact.

The Challenge

ACE Composting needed to handle 14,000 lbs. of DOA pigs per day, ensuring the
material was:

Shredded efficiently to accelerate decomposition
Mixed with carbon-rich materials (straw & corn stalks) to absorb liquids and maintain compost balance
Processed within two hours to prevent backlogs and maintain efficiency
Clean and biosecure to meet industry and environmental standards

Despite having 20 years of composting experience, Roc needed a faster, more effective solution to meet the growing commercial demand for sustainable mortality management.

The ANCO Solution

ANCO custom-engineered a streamlined composting system, integrating the

Duracut Rendering Shredder and a mixer to create a seamless process:

1. Shredding & Mixing for Optimal Decomposition

The ANCO Duracut Shredder efficiently processes pigs into small, uniform pieces, dramatically reducing bone size and accelerating decomposition.
The material moves directly from the shredder into the mixer, minimizing handling and contamination risks.
Augers feed wheat straw and corn stalks into the mixer, absorbing excess liquid and maintaining the ideal carbon-to-nitrogen ratio (25-30:1).

“The ANCO shredder breaks everything down smaller—smaller bones, smaller parts—which means it composts faster. The old way took almost twice as long.”

– Roc Rutledge, ACE Composting

2. Automating Efficiency & Biosecurity

A one-control-box system allows remote monitoring and automation, optimizing feed rates and preventing overloads.
Safety interlocks adjust the system automatically if an issue arises, preventing breakdowns.
A self-cleaning mechanism uses straw in the final phase to remove liquid residue, keeping the system clean and ready for the next cycle.

“I’ve been composting for 20 years, but this system changed the game—it’s faster, cleaner, and more efficient.”

– Roc Rutledge

3. Turning Waste into Sustainable Compost

The processed material is combined with active compost microbes to initiate decomposition.
Maintains 132°F+ temperatures in the first few days to ensure pathogen elimination.
Turned 4-5 times to regulate oxygen levels, preventing overheating (which can exceed 400°F and cause combustion).
No liquid runoff, no environmental contamination—just clean, sustainable composting.

THE RESULTS: FASTER PROCESSING, HIGHER EFFICIENCY, & FUTURE GROWTH

Processing Time Cut in Half – The entire operation runs in under 2 hours, minimizing downtime.
Reduced Environmental Impact – No liquid waste, improved biosecurity, and sustainable resource management.
Cost Savings & Revenue Potential – Eliminated expensive disposal costs and created a valuable compost product.
Scalability for Expansion – By the end of the year, ACE Composting will expand into cattle mortality management, processing up to 50,000 lbs. per day.

“I’m figuring out ways to offset since agriculture is up and down with prices—this is just another way to stabilize my farming practice.”

– Roc Rutledge, ACE Composting

FUTURE PLANS & INDUSTRY TRENDS

Expanding into other livestock composting, scaling from 50,000 lbs. per day to 100,000 lbs. max capacity.
Planning to sell compost commercially as production increases, staying local with potential for pelletizing and shipping.
Consulting for other ranchers, sharing expertise in sustainable mortality management.
Addressing industry-wide biosecurity concerns, as many mortality disposal methods involve trucks moving between farms—posing contamination risks.

“Right now, I’m the only one doing composting this way—but I see the industry moving toward this model.” – Roc Rutledge

– Roc Rutledge, ACE Composting

WHY IT MATTERS

ACE Composting’s success proves that mortality waste doesn’t have to be a burden—it can be a resource. By partnering with ANCO Equipment & Services, Roc transformed a costly, inefficient process into a scalable, profitable solution.

This case study highlights how ANCO’s rendering technology can adapt beyond traditional applications, creating sustainable waste solutions that benefit the environment and drive business growth.

Want to explore how ANCO can customize a composting or rendering solution for your operation?
Contact us today!