ELECSYS is leading the electrical and instrumentation and controls design for the Energy Resilience Bank Biogas Storage Project at the Little Ferry Water Pollution Control Facility, operated by the Bergen County Utilities Authority. The $40 million program replaces five steel floating digester covers with new dual-membrane covers that provide in-situ biogas storage, allowing the plant to capture and reuse gas for cogeneration and heating instead of continuous flaring. ELECSYS redesigned the secondary unit substation, motor control centers, UPS systems, and power and lighting panels, and developed new control panels for digester covers, sludge mixing, waste-gas flares, sludge heating, and hot-water systems, fully integrated into the plant’s distributed control system and fiber network.

A new prefabricated electrical building, raised above the FEMA floodplain, houses modern electrical distribution and controls to enhance flood resilience. To keep this critical facility online, the team structured staged construction so only one digester is taken offline at a time and procured key equipment under pre-purchase contracts to manage schedule and risk.

The result is a safer, more reliable, and more sustainable biosolids process that strengthens energy independence and storm resilience for the surrounding communities.