Culver Duck Farms, a mixed-feedstock anaerobic digestion facility in Middlebury, Indiana, was struggling to maintain stable operations.
Frequent system upsets, inconsistent feedstock performance, and limited visibility into biological conditions made it difficult to sustain production or scale output.
By implementing Nirova’s real-time monitoring and analytics platform, the facility transformed from reactive and unstable to controlled, efficient, and highly productive.
The facility faced several critical issues:
Without real-time insight, operators were forced to react after problems had already developed.
Nirova (formerly Valkyrie Analytics) was implemented alongside Eco Partners and Digester Doc to stabilize and optimize the system.
The focus was on:
With continuous visibility into system performance, operators were able to move from guesswork to controlled, data-driven operation.
Following implementation and operational alignment, the Middlebury facility experienced significant improvements across key performance metrics:
increase in kWh output
increase in biogas yield
increase in daily revenue
(based on $0.12 per kWh)
These improvements were achieved within the initial phase of deployment, alongside increased system stability and reduced operational risk.
[NOTE: Results are specific to this facility and operating conditions]
The facility moved from inconsistent output to sustained, high-performance production.
Performance improvements were driven by efficiency, not just increased volume.
Operators shifted from volume-based inputs to optimized, consistent feedstock strategies.
With real-time monitoring and early intervention:
Even during disruptions, the system avoided major failure.
Operational improvements translated directly into financial performance:
This was not a single fix—it was a shift in how the system was operated:
“Valkyrie gave us the confidence we were on the right path and also suggested the potential for another 30% or more in gas production.”
Culver Duck Farms transitioned from:
Most digesters don’t fail because of hardware.
They fail because operators lack visibility into what’s happening inside the system.
When you can see conditions in real time—and act on that insight—you don’t just fix problems.
You prevent them.
Every system is different—but the opportunity to improve performance, reduce risk, and increase output exists across biogas operations.
