Deep Stacks vs. Windrows: Revolutionizing Compost and Mulch Operations

• 
• 
• 
• 

Share this article

• 
• 
• 

The Overarching Advantages of Deep Stacks in Compost Manufacturing

Deep stacks provide numerous benefits that make composting operations more efficient and productive:

• Space Efficiency – Deep stacks maximize vertical space utilization, reducing the required ground area compared to windrows. This is crucial for sites with limited space or high land costs.
• Reduced Moisture Loss – The compact nature of deep stacks minimizes exposure to air, improving moisture retention and reducing the need for frequent watering.
• Temperature Control – The larger volume of material promotes natural heat generation, maintaining optimal temperatures for efficient decomposition.
• Enhanced Microbial Activity – The controlled environment within deep stacks fosters microbial activity, accelerating the breakdown of organic material.
• Reduced Turning Frequency – Thanks to better heat retention and aeration, deep stacks require less frequent turning, cutting labor and equipment costs.
• Higher Yield and Consistency – Deep stacking enables faster processing of larger volumes, yielding a uniform and high-quality compost product.

A Deep Dive into the Benefits of Deep Stacking

Space Efficiency: Maximizing Your Footprint

Deep stacking significantly reduces land requirements—by up to 40%—compared to windrows for the same volume of material. This is especially beneficial in urban composting sites or areas with high land costs. Additionally, deep stacks minimize the need for extensive buffer zones, thanks to lower odor emissions and runoff, optimizing land use and reducing costs.

Reduced Moisture Loss: Conserving Resources

Deep stacks retain 20-30% more moisture than windrows, particularly in hot, dry climates. The outer layers act as a natural barrier, reducing evaporation and shielding the inner material from direct sunlight and wind. This leads to lower water consumption and decreased labor costs for watering, making operations more sustainable and cost-effective.

Temperature Control: Fueling Decomposition

Maintaining optimal temperatures is critical in composting, and deep stacks excel in this area. The outer layers insulate the inner core, ensuring stable temperatures for thermophilic composting. This controlled heat accelerates decomposition, eliminates pathogens and weed seeds, and enhances the overall quality of the final product.

Enhanced Microbial Activity: The Engine of Composting

The warm, moist environment of deep stacks creates an ideal setting for microbial activity, which is essential for breaking down organic matter. Thermophilic microbes thrive in deep stacks, leading to faster and more efficient composting while ensuring a richer and more stable end product.

Reduced Turning Frequency: Saving Time and Labor

Windrow composting requires frequent turning to maintain oxygen flow and prevent anaerobic conditions. Deep stacks, on the other hand, allow for improved thermal stratification and natural gas exchange, reducing the need for mechanical aeration. This results in significant savings in labor, fuel, and equipment maintenance.

Higher Yield and Consistency: A Superior Product

Deep stacks create an optimal environment for decomposition, leading to a more uniform, high-quality compost product. The stable conditions result in compost with consistent texture, nutrient levels, and higher nitrogen retention. This reduces the need for extensive screening and quality control, ensuring a higher percentage of usable compost.

Bakke Ag Services Maximizes Efficiency and Space with EDGE Deep Stacking Technology

The benefits of deep stacking are not just theoretical—they are transforming real-world composting operations like California-based Bakke Ag Services. When Bakke Ag sought to improve the efficiency of their composting process, they invested in the EDGE FTS75 Mulch Master, a decision that revolutionized their operations. By moving from traditional windrows to deep stacking, Bakke Ag Services achieved an impressive 60% reduction in space requirements, allowing them to maximize their footprint and significantly cut down on operational costs.

“The EDGE FTS75 Mulch Master is extremely diverse,” says Ian Baake. “We can handle raw product with ease—it never jams, never holds up. Its stacking capability is very good, creating a tidy tepee-shaped pile that drastically diminishes fire risk.” This space-saving technology, combined with enhanced moisture retention, reduced turning frequency, and exceptional material blending, has made deep stacking not just a method, but a competitive advantage for Bakke Ag Services.

Bakke Ag further adds, “The EDGE FTS75 Mulch Master is a low-cost machine that gives us a high rate of return. Its space-saving technology, reliability, and efficiencies are, in my opinion, unmatched, and I firmly believe that this machine will never become obsolete in our industry – you are not going to find a better, more efficient, and productive machine anywhere. If we are not using this technology as an industry, then we probably are not doing it right.”

The EDGE FTS Mulch Master: The Ultimate Deep Stacking Solution

Key Features of the EDGE FTS Mulch Master:

• High Output Capacity – Handles large volumes of material with ease, reducing processing times.
• Variable Speed Feed System – Ensures even and controlled material flow for consistent deep stacks.
• Enhanced Aeration and Mixing – Promotes uniform decomposition by thoroughly blending organic material.
• Adjustable Conveyor Heights – Allows operators to create taller, more efficient deep stacks with minimal effort.
• Reduced Fuel and Labor Costs – Optimizes workflow by minimizing handling and reducing the need for additional equipment.

By integrating the EDGE FTS Mulch Master, composting and mulch operations can fully leverage the benefits of deep stacking. This machine not only enhances efficiency but also improves the quality and yield of compost, making it a game-changer for the industry.

Deep stacking is revolutionizing composting and mulch operations, offering unparalleled advantages in space efficiency, moisture retention, temperature control, microbial activity, reduced turning frequency, and product consistency. By adopting deep stacking and investing in the EDGE FTS Mulch Master, compost operators can significantly enhance productivity, reduce costs, and produce superior-quality compost and mulch.

Discover how the EDGE FTS Mulch Master is revolutionizing composting operations—click here to read the full customer success story.

ABOUT EDGE INNOVATE

EDGE Innovate develops, manufacturers and markets sophisticated technologies for shredding, stacking, screening and sorting of primary and secondary raw materials in production processes and recycling. Our Material handling and recycling range is made up of reliable, durable and cost saving products with a wide range of mobile stockpilers, tracked stackers, tracked and mobile feeders, trommels, slow-speed waste shredders, picking stations, material classifiers, roll-sizers and truck off-loaders. Our product range allows our customers; to shred, screen, separate, stockpile and size a vast array of materials

Keep up to date with EDGE’s news and events by following us on social media:

Facebook | Twitter | LinkedIn | Instagram