Bio-Tunnel Composting System
Thermarex’s bio-tunnel composting system converts sludge and organic waste into high-quality compost through controlled aerobic fermentation — automated, modular and scalable to your plant capacity.
How the Bio-Tunnel Composting System Works
Sludge and organic waste are enclosed in insulated tunnels where aerobic fermentation runs under controlled conditions. Forced aeration and automated turning hold oxygen and temperature at optimal levels, speeding microbial breakdown. The closed design controls odor and yields a stable, pathogen-reduced product for agricultural or land application.
Controlled Aerobic Environment
Insulated tunnel chambers keep temperature, humidity and oxygen within set limits through the fermentation cycle.
Automated Turning
Mechanical turners redistribute material for even aeration, heat and decomposition across the batch.
Biofilter & Odor Control
Exhaust air passes through a biofilter before release, containing odor and meeting emission requirements.
Discharge & Maturation
After active fermentation, material moves to a maturation stage and becomes stable, nutrient-rich compost.
Forced Aeration System
Floor ducts push air through the material bed, feeding aerobic microbes and preventing odor-causing anaerobic zones.
Benefits of a Bio-Tunnel Composting System
Closed System Operation
Enclosed tunnels contain odor and leachate, so the plant can sit within or next to industrial premises.
Accelerated Decomposition
Controlled temperature and aeration shorten the composting cycle compared with open windrows.
Handles Diverse Feedstock
Handles municipal sludge, industrial biosolids, food waste, agricultural residue and mixed organics without major process changes.
Modular & Scalable
Each tunnel is an independent module — add tunnels to scale capacity without redesigning the system.
Continuous or Batch Mode
Staggered batch sequences across multiple tunnels give near-continuous output.
Minimal Operator Intervention
Automated turning, aeration control and monitoring cut manual labor and keep every cycle consistent.
Engineered Around Your Waste Stream
Every bio-tunnel layout is sized to your organic load, feed moisture and site. A bio-tunnel composting system can run as a stand-alone plant or alongside your existing dewatering and drying units. Thermarex brings 10+ years in industrial and municipal sludge, 350+ TPD of drying capacity installed and 15,000 sq ft of in-house manufacturing in Surat. See our case studies.
Technical Specifications
Where Bio-Tunnel Composting Fits in Your Sludge Line
Compost
Aerobic fermentation with forced aeration and automated turning.
Mature
Discharged material cures into stable compost.
Need volume reduction rather than compost? Compare our solar sludge dryer or view all solutions.
Ideal Applications
Municipal Sewage Treatment Plants
Industrial Effluent Treatment Plants
Food Processing & Agro-Industries
Slaughterhouses & Dairy Processing Units
Horticulture & Agricultural Waste Generators
Solid Waste Management Facilities
Bio-Tunnel Composting System FAQs
What is a bio-tunnel composting system?
An enclosed, insulated tunnel where sludge or organic waste is composted aerobically under controlled temperature, humidity and oxygen, with forced aeration, automated turning and biofilter odor control.
Which wastes can it process?
Municipal sludge, industrial biosolids, food waste, agricultural residue and mixed organic streams. See the industries we serve.
How is it different from a solar sludge dryer?
A bio-tunnel stabilises organic matter biologically into compost. A solar sludge dryer removes water using solar heat to cut sludge weight and volume. We help you choose the right fit.
Is the compost suitable for land application?
The process yields a stable, pathogen-reduced product intended for agricultural or land use. Final use should follow CPCB and state pollution control board norms.
Interested in Bio-Tunnel
Composting?
Get a bio-tunnel composting system engineered for your capacity, organic waste type and site. Share your waste type, daily quantity and location, and our engineers will recommend the right layout.