The agricultural landscape in the San Joaquin Valley, United States, has entered a period of forced innovation following the final implementation of the regional agricultural burn ban on January 1, 2025. This regulatory milestone has effectively removed open-air burning as a disposal method for over 1 million tons of annual woody waste, primarily from orchard removals. In this new legal environment, the collaboration between the Sitos Group and Treehouse California Almonds has transitioned from a pioneering project into a critical commercial blueprint. By utilizing advanced thermal conversion to process almond shells, these organizations are demonstrating a viable path for the almond industry to maintain operational continuity while meeting the state’s stringent air quality and carbon goals.

The primary challenge facing Central Valley growers in 2026 is the “woody waste dilemma,” characterized by a lack of scalable disposal infrastructure and prohibitive costs. With the decline of traditional 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 power plants, orchard operators are currently forced to rely on chipping and soil incorporation, which can cost between $1,600 and $2,200 per acre. Beyond the financial burden, the region’s rigorous air quality standards make the permitting of new technologies exceptionally difficult. Any proposed solution must prove a net reduction in NOx and particulate matter emissions compared to historical burning, a barrier that has stalled many emerging bioenergy projects in the valley.

To navigate these hurdles, the Sitos Group and Treehouse California Almonds have deployed an integrated slow 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 system located directly at the source of the 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. The technical solution involves three side-by-side pyrolysis units designed to process 24,000 tons of almond shells annually in a low-oxygen environment. This “showroom” facility utilizes an Organic Rankine Cycle generator to convert waste heat into clean electricity, while the co-location strategy eliminates the significant economic and carbon costs associated with biomass transportation. This localized approach bypasses the logistical bottlenecks that have historically plagued centralized biomass facilities.

The outcomes of this initiative provide a definitive model for the circular economy in a highly regulated agricultural setting. The facility produces approximately 8,000 tons of high-value 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 annually, with the entire offtake already secured by vineyard management firms to improve soil water retention and nutrient holding capacity. By successfully navigating California’s complex air permitting process, the Sitos-Treehouse project has established a repeatable template for managing agricultural co-products without permanent reliance on public subsidies. For the almond industry, this transition converts a former waste liability into a durable marketplace for carbon sequestration.