How EcoFlare works

From residue to reliable heat — step by step.

EcoFlare turns sawdust, rice husk, jute waste and other residues into certified biomass pellets, backed by logistics, lab testing and data you can trust. This page walks through how the platform works from the first conversation to steady-state deliveries.

  • Circular model that upgrades locally available residues into high-value fuel.
  • Integrated supply, production and delivery for consistent boiler performance.
  • Process designed around traceability, quality control and export-grade standards.

Structured sourcing

Residues from sawmills, rice mills and agro-processors under documented agreements.

Efficient conversion

Dryers, hammer mills and presses tuned for stable pellet quality and throughput.

Lab & QA

Routine testing of moisture, ash and calorific value, with batch-level records.

Delivery & support

Designed for reliable supply, burner tuning and technical support at customer sites.

End-to-end process flow

A clear eight-step sequence from residue piles to dependable pellet deliveries. The central timeline shows the journey; each side explains what happens at that stage.

1. Residue sourcing & intake

EcoFlare contracts residues from sawmills, rice mills, jute mills and agro-processors, prioritising legality, traceability and non-deforestation.

  • Supplier agreements with sustainability and volume criteria.
  • Cluster-based sourcing for better logistics and transparency.
  • Residues segregated by source and type on arrival.
1
Residue sourcing & intake
Drying & cleaning
2

2. Drying & cleaning

Incoming residues are screened, cleaned and dried to a stable moisture window to ensure safe storage and predictable pellet quality.

  • Removal of metals and oversized contaminants.
  • Screening to reduce fines, sand and unwanted debris.
  • Dryers tuned for energy efficiency and product stability.

3. Milling

Dried residues are milled to a consistent particle size, which is critical for both pellet formation and clean combustion at the boiler.

  • Hammer mills and screens selected for local feedstock mix.
  • Monitoring of throughput, motor load and temperature.
  • Balance between power use and particle-size quality.
3
Milling
Pelletizing
4

4. Pelletising

Conditioned biomass is pressed through dies to form dense pellets that are strong enough to handle, transport and store without excessive breakage.

  • Die and roller settings tuned for durability and low fines.
  • Moisture and temperature control during pressing.
  • Cooling and initial screening before further handling.

5. Cooling & screening

Fresh pellets are cooled to ambient temperatures and screened to remove fines, ensuring cleaner handling and more predictable combustion.

  • Coolers sized for throughput and pellet durability.
  • Screening systems to separate fines and broken pellets.
  • Housekeeping practices that keep dust under control.
5
Cooling & screening
Lab & quality assurance
6

6. Lab testing & quality assurance

Each production batch is tested before being released, so customers and auditors know what they are receiving.

  • Moisture, ash, bulk density and calorific value testing.
  • Standard procedures aligned with export-grade workflows.
  • Results stored against batch IDs for full traceability.

7. Packaging & storage

Pellets are packed (or stored in bulk) under cover, with layouts designed for safety, accessibility and minimum product loss.

  • Bulk storage and bagging options depending on customer needs.
  • Warehouses and silos sized for buffer stock and reliability.
  • Safety procedures for biomass storage and handling.
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Packaging & storage
Logistics & delivery
8

8. Logistics, delivery & boiler support

Pellets are delivered according to agreed schedules, with support available for boiler-side optimisation and operations.

  • Route planning and supply planning for cost-effective deliveries.
  • Shipment documentation and tracking for each load.
  • Support for burner tuning, efficiency and troubleshooting at site.

EcoFlare pellet snapshot

A quick view of what EcoFlare pellets are engineered to deliver. Detailed datasheets and specifications are available on request.

Thermal performance

High-energy, low-ash pellets designed for industrial boilers and thermal oil heaters.

  • Typical GCV: ≈ 4200–4800 kcal/kg (as received)
  • Moisture controlled to support stable combustion
  • Low ash to reduce cleaning frequency

Sustainability profile

Residue-based fuel that supports decarbonisation, air-quality improvement and ESG goals.

  • Residues sourced from wood, agri and jute industries
  • Supports meaningful CO₂ reduction vs. coal and furnace oil
  • Designed to align with SDG 7, 8, 12 and 13

Quality & assurance

Process and documentation built for long-term contracts and export customers.

  • Batch-level lab reports available for customers
  • ENplus-ready workflows and traceability roadmap
  • Standardised documentation for lenders and auditors

Our feedstock palette

EcoFlare’s pellets are made from residues that are abundant in Bangladesh. Images are indicative; actual sourcing is documented in technical and commercial engagements.

Sawdust

Sawdust

Rice husk

Rice husk

Wood shavings

Wood shavings

Straw

Straw

Coconut shells

Coconut shells

Corn cob

Corn cob

Peanut shell

Peanut shell

Sugarcane straw

Sugarcane straw

Customer onboarding journey

A clear sequence from first conversation to steady-state pellet deliveries. Each step is designed to reduce risk and shorten your internal approval cycle.

01

Discovery & scoping

Understand your fuel mix, boiler capacities, operating profile and ESG priorities.

  • High-level fuel and cost baseline
  • Constraints, uptime and reliability requirements
02

Tech & commercial pre-study

Frame feasible pellet-switching scenarios and outline infrastructure needs.

  • Boiler/ burner compatibility review
  • Preliminary emissions & cost view
03

Pilot & tuning

Controlled trials to confirm performance, safety and operational fit.

  • Trial fuel deliveries
  • Combustion & emissions tuning support
04

Ramp-up & long-term offtake

Move from pilot to regular supply with the right commercial and data arrangements.

  • Supply agreements and SLAs
  • Reporting for finance, ESG and auditors

Technical & quality stack

Under the hood, EcoFlare combines engineering, laboratory and digital components so that pellet-switching fits into your safety, quality and reporting frameworks.

Combustion & plant integration

Practical integration support so pellets work with existing boilers, burners and fuel-handling systems.

  • Assessment of boiler and burner compatibility
  • Recommended changes for fuel feeding and storage
  • Best-practice operating envelopes and SOPs

Lab & quality assurance

Systematic testing regime aligned with local and export-grade pellet standards.

  • Routine in-house tests plus independent labs as needed
  • Specification sheets and certificates of analysis per batch
  • Quality incident tracking and corrective actions

Data & traceability

Digital spine designed to support ESG disclosures, lender requirements and audits.

  • Batch-level records linking feedstock, production and lab results
  • Shipment-level documentation for customers and regulators
  • Roadmap for blockchain-backed event logging

Process-related questions

A few common points customers raise while evaluating a switch to EcoFlare pellets.

Timelines depend on boiler size, infrastructure changes and internal approvals. As a guide, many projects move from first scoping to initial trials within a few months, with ramp-up following once commercial terms and performance are confirmed.

Requirements vary by site. Common upgrades include fuel-feeding systems, storage/handling arrangements and burner-side tuning. EcoFlare works with your engineering teams and OEMs to define a safe, cost-efficient scope.

Reliability is built through diversified feedstock clusters, structured logistics and inventory planning. Supply agreements typically define delivery profiles, minimum volumes and remedies so both sides can plan with clarity.

Yes. The process is designed to generate documented evidence on feedstock sourcing, emissions factors and delivery volumes. Over time, the data stack is intended to plug directly into ESG reporting, lender requirements and external audits.

Don’t see your question here?

Every industrial site is different. The quickest way to test feasibility is to combine a short technical call with basic fuel and boiler data.

  • We can work from existing boiler datasheets and fuel bills.
  • Joint workshops with operations, finance and sustainability teams.
Schedule a process walkthrough

Ready to map out your pellet-switching process?

Share a few details about your boilers, fuel consumption and timelines. EcoFlare will return with a structured view of process steps, responsibilities and next actions.

  • Clear roadmap from trial to long-term offtake.
  • Summary you can share internally with decision-makers.