Sewage sludge is a universal problem in the world of waste management—a “very big red number” on municipal balance sheets that typically ends up in landfills or land-applied, introducing heavy metals, PFAS, and microplastics into the environment. But for Bioforcetech, a company with roots in the Silicon Valley and manufacturing in Northern Italy, this waste stream represents an opportunity to pioneer “impact feedstocks” and reimagine the future of the built environment.

From Northern Italy to Silicon Valley

Founded 13 years ago in Redwood City, California by a team from Northern Italy, Bioforcetech didn’t start as a biocharBiochar is a carbon-rich material created from biomass decomposition in low-oxygen conditions. It has important applications in environmental remediation, soil improvement, agriculture, carbon sequestration, energy storage, and sustainable materials, promoting efficiency and reducing waste in various contexts while addressing climate change challenges. More company. “It’s not a biochar-born company, nor should it be,” explains Garrett Benisch, who leads the company’s material development. “You always begin with a waste management problem.”

“When we first set out, our mission was to generate energy from biosolids. But very quickly we realized a fundamental engineering challenge: the material was simply too wet to process efficiently. That limitation pushed us to innovate, and ultimately led to the creation of our first major technology—the BFT BioDryer.” says Dario Presezzi, CEO of Bioforcetech.

Unlike traditional energy-intensive dryers, the BioDryer functions as a contained, high-speed composting unit. It leverages the heat generated by bacterial multiplication to raise temperatures to 160°F (71°C), evaporating water and reducing the weight of the biosolids by 75%. This process not only dries the material but also creates Class A biosolids, a biomassBiomass is a complex biological organic or non-organic solid product derived from living or recently living organism and available naturally. Various types of wastes such as animal manure, waste paper, sludge and many industrial wastes are also treated as biomass because like natural biomass these More which is essentially free of pathogens and meets strict limits for pollutants like metals.

“Drying alone opened the market for us,” Benisch notes, pointing to the 50 units currently operating and in production worldwide.

The “Sigma” Process: Precision Pyrolysis

With the moisture problem solved, Bioforcetech could pursue its ultimate goal: pyrolysisPyrolysis is a thermochemical process that converts waste biomass into bio-char, bio-oil, and pyro-gas. It offers significant advantages in waste valorization, turning low-value materials into economically valuable resources. Its versatility allows for tailored products based on operational conditions, presenting itself as a cost-effective and efficient More. They developed a proprietary system called the “Sigma” reactor, named after the sigma carbon bond.

This advanced hybrid unit is designed specifically for the complex, difficult nature of biosolids. By using syngasSyngas, or synthesis gas, is a fuel gas mixture consisting primarily of hydrogen and carbon monoxide. It is produced during gasification and can be used as a fuel source or as a feedstock for producing other chemicals and fuels.   More heat for the bulk of the process and electrical resistors for the final zone, the Sigma reactor achieves precise temperature control within one degree Celsius. This precision allows Bioforcetech to decouple temperature from residence timeResidence time refers to the duration that the biomass is heated during the pyrolysis process. The residence time can influence the properties of the biochar produced.   More, a flexibility that is crucial for processing waste into high-quality carbon.

The company faced significant headwinds in bringing this technology to the U.S., including a four-year journey to obtain air emissions permits in the Bay Area. “The fact that the end product was biochar did not matter for permitting,” Benisch recalls. Yet, navigating one of the strictest regulatory environments in the world ultimately became a competitive moat, validating their emissions controls and safety standards.

A Business Model that Flips the Script

Bioforcetech’s business model is as innovative as its engineering. They sell the equipment to municipalities, who own and operate it to reduce their disposal volumes and meet regulatory requirements. But the relationship doesn’t end there.

Bioforcetech guarantees free offtake of the resulting biochar, branding it as “OurCarbon.” They then share a portion of the profits back to the municipality. “It converts a significant disposal cost into a revenue stream,” Benisch explains. “We’re like a giant solar panel; they’re paying off the system by paying less every month”.

OurCarbon: Beyond Soil

While many biochars are destined for agriculture, Bioforcetech’s biosolid-derived char is finding a different home. The material is dense, rich in silicates, and physically durable—”more like mineralssand with a carbon backpack,” as Benisch describes it.

These characteristics make it uniquely suited for the built environment. OurCarbon is being used as a structural aggregate replacement in concrete, locking carbon into cityscapes. Beyond concrete, the company is commercializing the material for use in screen-printing inks, industrial paints, and even 3D-printed furniture.

The company is also committed to rigorous science, partnering with the USDA to develop “designer carbons.” One such project involves processing almond shells into biochar to create natural rubber composites for agricultural harvesting parts, replacing synthetic rubbers that degrade into the soil.

Lessons Learned and Takeaways for the Biochar Industry

• Solve the Customer’s Problem First. Bioforcetech succeeded not by selling “biochar,” but by solving a problem of waste volume and disposal costs for municipalities. The biochar was a value-add, not the primary pitch.
• “First is the Worst”. Being a pioneer in a regulated industry is painful. Bioforcetech spent years navigating permits and standards that weren’t written for them. However, surviving this “guillotine” period establishes credibility and a defensible market position.
• FeedstockFeedstock refers to the raw organic material used to produce biochar. This can include a wide range of materials, such as wood chips, agricultural residues, and animal manure. More Determines Destiny. Not all biochar is the same. Bioforcetech leaned into the material’s unique physical properties (density, mineral content) to find value-add applications in concrete and industrial materials.
• Partnership Over Transaction. By sharing profits with municipalities and guaranteeing offtake, Bioforcetech aligns its incentives with its customers, turning a transactional equipment sale into a long-term partnership.