In the Banaskantha district of Gujarat, a tripartite partnership between Banas Dairy, the National Dairy Development Board (NDDB), and Suzuki Motor Corporation (SRDI) has transformed cattle waste into a high-tech revenue stream. The facility at Bhukhala serves as a blueprint for a circular economy, turning daily dung collection into fuel for hundreds of vehicles.
The Production Cycle: 100 Tonnes of Dung to Biomethane
The plant processes approximately 100 tonnes of cow dung daily, sourced from around 500 dairy farmers across 35 collectives.
- Digestion: The dung is mixed with water and fermented in large tanks for approximately one month.
- Methane Capture: This process produces 1.5 to 1.8 tonnes of raw biogas daily.
- Purification: Since raw gas is only 45% methane and contains corrosive hydrogen sulphide ($H_2S$), it is purified to over 95% biomethane.
- Distribution: The fuel is sold as Bio-CNG at a dedicated dispensing station. It is priced at ₹75/kg, roughly ₹5–8 cheaper than regular natural gas in Gujarat.
Revenue Model: Beyond Just Gas
Interestingly, while the Bio-CNG is the most visible product, it is not the primary revenue driver. 80% of the plant’s revenue comes from byproducts:
- Organic Fertilizer: The “digested” dung is separated into solids and mixed with phosphates to create a high-quality organic fertilizer.
- Enriched Slurry Water: The liquid waste is sold back to farmers as nutrient-rich water for their fields.
- Farmer Payouts: Farmers receive ₹1 per kilogram for dung, which can translate to an additional annual income of approximately ₹72,000 for an average household.
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Carbon Credits and Environmental Impact
The project is a significant tool for Suzuki Motor Corporation to achieve its goal of global net-zero emissions by 2050.
- Emission Reductions: Each 100-tonne plant is estimated to reduce carbon emissions by approximately 6,750 tonnes annually.
- Methane Mitigation: By capturing methane—a greenhouse gas significantly more potent than $CO_2$—from open waste, the plant prevents it from entering the atmosphere.
- Carbon Neutral Fuel: Biogas is considered a carbon-neutral fuel source, allowing Maruti Suzuki (which holds a 70% share of India’s CNG car market) to offer a truly “green” mobility solution.
The Road Ahead
Suzuki and Banas Dairy have signed agreements to establish a total of five plants in the Banaskantha district by late 2025/2026. Furthermore, Suzuki has invested in NDDB Mrida Ltd, a joint venture aimed at scaling this “dung-to-fuel” model across other states in India, aiming to turn rural waste management into a sustainable national industry.
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