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Waste rendering plant (Make Meat Meal from waste) 2017


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Hatchery Waste, Layer Farm Manure, Slaughter House Waste and Slaughter House Fat

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Waste rendering plant (Make Meat Meal from waste) 2017

  1. 1. Offering Clean & Green Technologies For Poultry-waste - Hatchery Waste - Layer Farm Manure - Slaughter House Waste - Slaughter House Fat management
  2. 2. Global poultry production is projected to double by the year 2030. The greater portion of this global demand for poultry products will be in the form of chicken meat Using global demand for different MEAT during the years 1997to1999asabase,itisestimatedthatby2030,demand willincreaseby45%forBovine,57%forPorkand106%for Poultrymeat. Poultry Meat production was about 111 million metric tonnes(MMT) in 2015 despite the avian influenza. Projected to reach 133/2025 MMT. Poultry meat will account for more than half of the world's additional MEAT output over the next decade. Poultry's short production cycle enables producers to respond quickly to increased profitability. South east Asia will account for nearly 36% of this increase inglobalpoultryproductionby2025. Poultry Industry perpective Providing Specialised Engineering Solution Thru Process Innovation
  3. 3. Hatchery Waste Waste from poultry Layer Manure Slaughter house waste Slaughter house - fat Hatcherywasteis a natural by-product of hatcheries.This wasteconsists of egg-shells, un- hatched eggs, and rejected embryos etc. This waste is rich in Proteins and Calcium with approx. 30% Proteins and 20% Calcium. However, Un-treated waste is a source of soil and atmosphericpollution&presentlyaliability.Presentlydisposalinvolveslabour,transportation cost and merely shifts the pollution elsewhere. It is estimated that a 10,000 eggs hatch produces about 125 KGs of waste. Proper treatment of waste will offer a useful product whichcanbeusedinpoultryfeedorfertilizer. One of the most important but neglected area in poultry Sector is waste management. Poultry hatchery results in hatchery waste, Layer farms results in Layer Manure, Dressing ( slaughter) results in non-edible waste. This waste creates environmental pollution, Soil contamination,Groundwaterpollutionetc. Henceneedforefficientwastemanagement. Layer manure from layer farms poses huge problem of disposal. This manure is mostly liquid & creates odour & fly nuisance. Manure is a challenge because it can not be applied directly as fertiliser,asithashighNitrogencontent.NitrogenformsNitratesetcandleachintoSoileffecting ground water. Due to high water content, disposal of manure also involves high labour & transportationcost.Itisestimatedthatafarmwith1,00,000layersproduces10TonsofManure/day or3,650tonnesofmanureperyear.LayermanureisrichinmanyessentialPlantNutrientslikeN,P,K. Ifprocessedproperlyitwillgiveadry,baggableOrganicfertiliserwhichcanbestored&used. Slaughter of chicken for dressed meat results in separation of non-edible portions such as head, feet, feathers, offals etc. Being biological residue, these can putrify & become rancid very quickly creating air and ground pollution & a nuisance. The pathogens can also continue to pollute elsewhere. Hence disposal becomes a challenge and urgent necessity. However this waste is a rich source of Animal protein & fat. It is estimated that slaughter of bird results in waste which could be approx. 30% of live wt. Slaughter of 10,000 birds of Ave.wt.1.6 kg each will result in waste of about 5 Tons. Effective processing / Rendering of thiswastecangiveasterilised,pathogenfreeMeatmealthatcanbeusedinfeed.. Slaughter of chicken results in separation of non-edible portions and fat. While the non- edible portions can be generally Rendered together as a mix, a fair amount of body fat is separated.Thiscouldbeabout3.5%oflivewt.Thisisgenerallydisposedofftoun-organised sectorforextractionoffat.Un-processedFatisnotconsideredhealthy,Aslaughterof10,000 birds of Ave. Live wt. 1.6 kg each will result in approx.550 kg of fat. However, Proper technology can give commercial quality oil which is high in linoleic acid and Omega-6 fatty acidcontent.Thisoilcanbeusedasflavoringagentandinpetfood. based technology Digestor Dhopeshwar offers complete Technology to make a sterilised, pathogen free, Stable & dry product from each of the above waste. This Innovative Technology adopts HTST Process (High temp.- short time process at temp. upto 140 deg C for 20minutes)tomaketheby-products completely pathogen-free. Different Capacities Model 250kg and 500kg with-out boiler Model 750kg, 1000kg, 1500kg, 2000kg, 3000kg & 3500kg with boiler Providing Specialised Engineering Solution Thru Process Innovation
  4. 4. Digester with odour control systems Providing Specialised Engineering Solution Thru Process InnovationProviding Specialised Engineering Solution Thru Process Innovation
  5. 5. 1. Itsterilisesthewasteattemp.upto140degCtogiveafullysterilized (pathogen-free)stableproductwhichcanbebaggedandsold. 2. The Technology Eliminates environment pollution as well as risk of ground water contamination. It eliminates risk of pathogen andphytotoxicreleasesintosoil. 3. Itrecyclestheorganiccontents&thenutrients(N,P,K)available in layer manure. It allows nutrients in the manure to be re- cycledbysoilforplantgrowth 4. It gives a stable, bagable, dry product in shortest time. The final productisveryusefulasOrganicfertiliser. 5. This Technology is safe to be installed & operated near thelayer farms.Thatsavestransportcost.itisamoreEffectiveandprofitable optionthananyothermethod of Digestor based technology Advantages Providing Specialised Engineering Solution Thru Process Innovation
  6. 6. A commercial hatchery produces LIVE chicks in every hatch. Apart from chicks, It also produces huge quantity of waste which is its natural bye- product. Hatcheries are expanding as the Poultry sector is expanding. So also the waste from hatcheries. This waste includes Egg Shells, unhatched eggs, rejected embryos etc. This hatchery waste poses the risk of polluting environment unless it is disposed off safely. Proper handling & processing of this waste will not only saves environment but also gives a useful bye- product. In recent years, the cost of labour, transport, disposal has increased. The pollution control regulations have made it mandatory for hatcheries to find sustainable solution for waste management. Technology that can process this waste safely is the urgent need of hour. There are different options to manage hatchery waste-Incinerate, Compost, rendering etc. Each option has certain cost. The option chosen to manage waste will determine whether the waste management will mean just additional cost or some addl. Revenue. Waste from Hatcheries Providing Specialised Engineering Solution Thru Process Innovation
  7. 7. One of the most suitable option for hatcheries is rendering through the latest Digestor based Technology. This Technology converts Hatchery waste to make hatchery (waste) meal. This technology makes Hatchery meal completely sterilized & pathogen-free while retaining its protein. The finished Hatchery meal is rich in Protein, fat and nutrients. It can be used eitherasPremiumOrganicfertilizeroranimalfeed. Technology that eliminates waste of Our Technology 1. Efficient odour control system that eliminates odour and air pollution 2.Robustbuiltmachinery,designedforsafeoperations overmanyyears 3. AdvancedTechnologybackedby5decades of engineeringexperience. Salient Features Different Models 250 kg - Direct fired 500kg - Steam heated Fuel - Wood, Coal, Diesel Input - All Hatchery Waste Out put-Product - Hatchery by Product meal (HBM) Digestor Model E 250 E 500 Suitable for 20,000 Hatch 40,000 Hatch Time taken 4 - 6 hrs Waste cap. 250 kg 500 kg Out put - Qty 100 kg 200 kg Power required 9 hp (7 kw) 12 hp (9 kw) Shed - . 10x20x10' ht 20x30x 14' ht Main Specifications : Providing Specialised Engineering Solution Thru Process InnovationProviding Specialised Engineering Solution Thru Process Innovation
  8. 8. Fresh manure is a natural organic by-product of the livestock sector. Fresh manure is an excellent source of fertiliser because it contains Nitrogen, Phosporous, Potassium & other crop nutrients. However poultry manure cannot be used in its raw form. The Layer fresh manure (LFM) contains 75- 84% water. LFM is a big nuisance world-wide as it is the breeding site for flies & source of ammonia odour pollution. Flies are the cause of major health problemsinareas&communitiessurroundingLayerfarms. Layer farm manure LFM -poses huge problem of disposal. It cannot be applied as fertiliser directly as it has high Nitrogen content and direct application would not only effect soil & ground water due to leaching of Nitrates but also nutrient imbalances & phyto- toxicity in crops. Disposal involves high labour & transportation cost. It is estimated that a farm with 1,00,000 layers produces 10 Tons of Manure /day or 3,650Tonofmanure/year. Manure management has become most important aspect of Layer farm due to stringent pollution control measure implemented by governments. Technology that can process this manure is most urgent need of the hour for sustaining operationsatLayerfarms. Waste from Layer Farms Providing Specialised Engineering Solution Thru Process Innovation
  9. 9. LayermanureisrichincropNutrientslikeN,P,K.PoultrymanurecontainshighestNitrogencontent as compared to other manures. Its polluting influence minimised and it's utility maximised by processingitintoOrganicfertiliser. One of the most suitable option for processing Layer farm manure is the Digestor based Technology which adopts HTST process This technology makes Layer manure into completely dry, baggable powder / Pellet form while retaining its nutrients. The dried product can be used as Premium grade Organic fertiliser that can be stored andused.Thisenablesre-cyclingofimportantnutrients(N,P,K). Technology that eliminates waste of Our Technology 1.Starts with fresh manure in ‘as available’ condition from farm.Nopre-dryingtoreducewaterbeforeloading. 2.Efficient Vacuum drying system which eliminates Odourandairpollution. 3.Robust built machinery, designed for safe operationsovermanyyears. Salient Features Different Models Boiler Fuel - Wood, coal, Diesel Input - Fresh Manure 75-80% Water Output - Baggable, Ready to use, Organic Fertiliser, 10 to 20% Moisture Plant model - 10 MT/Day 20 MT/day Capacity based on - 24 hr/day 24 hrs/day Waste-(25% dm) - 10 MT/day 20 MT/day Output-20% Moist- 3 MT/day 6 MT/day Infrastructure - 200 m2 & 35 hp 250 m2 & 50 hp Main Specifications : Providing Specialised Engineering Solution Thru Process InnovationProviding Specialised Engineering Solution Thru Process Innovation
  10. 10. Slaughter / Dressing of chicken for meat is an extention of Broiler farm activity. It results in separation of non-edible portions such as head, feet, feathers, offalsetcfromtheediblemeatportion.. Offalsetc:Wastebeingbiologicalresiduetendstoputrify&becomerancidcreating air and ground pollution & nuisance. The pathogens from this waste become pollutantsifun-treated.Hencedisposalbecomesanurgentnecessity It is estimated that slaughter of bird results in 70% edible meat and 30%waste.Slaughterof1,000birdsofAve.wt.1.6kgeachieTotalLive wt. 1,600 kg will result in waste of 500 kg. Ie. For 10,000 birds, wastewouldbeabout 5Tons. Body fat : Slaughter of chicken also results in separation of bodyfat(about3.5%oflivewt.)Fatisnotediblebutcanbe usedforextractionofOilwhichiscommerciallyuseful Slaughter of 10,000 birds results in approx.550 kg offat. Waste from Slaughter house of chicken Providing Specialised Engineering Solution Thru Process Innovation
  11. 11. Slaughter waste can be rich source of Animal protein & fat if processed. Effective processing ( Rendering ) of this waste can give a sterilised, pathogen free Meat meal that can be used in poultryfeedorpetfoodproducts.. Proper processing of fat can give commercial quality oil which can be used as flavouring andagentinpetfoods. Technology that eliminates waste of Our Technology 1. Starts with non-edible waste like Head, feet, feathers, intestineetc.innon-rancidcondition. 2. Efficient Hydrolising of feathers and drying of material which eliminates Odour and air pollution. 3. Robust built machinery, designed for safeoperationsovermanyyears. Salient Features Main Specifications : Different models - From 250 kg / batch to 3500 kg / batch Data for - 2,000 kgs /2 MT per batch ( ie. 6 MT / day) Boiler fuel - Wood, coal, diesel Input - All waste from slaughter - approx. 2 MT / batch Output - Steriliased Meat meal - Approx. 600 Kg / Batch Product quality - Meat meal containing 55 % Protein & 20% Fat Process time - 8 hours Infrastructure - 25 x 40 x 20 ft ht. Shed, 50 hp power etc Providing Specialised Engineering Solution Thru Process InnovationProviding Specialised Engineering Solution Thru Process Innovation
  12. 12. AboutDhopeshwar Dhopeshwar Industries started as a pioneer Chemical Engineering unit at Hyderabad in 1963. Initially we used to engineer Chemical Process Equipment and special purpose machineries (SPM) for various process industries. This expertisewasfurtherdevelopedtosupplycompleteSpecialpurposeplants&machineries(SPM's)invarioussectors. Our strength is to develop the required process based on customers need. Then engineer & build Special Purpose machineries(SPMs)basedontheprocessdeveloped..TheseplantsarethensuppliedonTurn-keybasisandinstalled, commissionedforourcustomerson-site. Dhopeshwar has successfully innovated and designed for Agri. and Poultry Processing sector. Our Essential-oil DistillationplantsandPoultryDressing&WasteRenderingplantsarewellknownfortheirqualityofengineeringand longtermperformance.Ourplants havebeencommissionedin17countriesglobally. Our recent innovation involves Digestor based technology adopting HTST process & Enzymatic reaction for waste management.ThesefindwideapplicationinPoultrysectorssuchasHatcherywaste,LayerManure,Slaughterwaste.We havedevelopedcompleteplantwithOdourControlsystemforenvironmentallysafeprocessingofPoultrywaste. StartedasChemicalEngineeringcompany GrewintoSpecialisedEngineeringcompany ProvidingSpecialisedEngineeringSolutionsthruProcessInnovation Weaimtobecome atrustedpartnerinprovidingengineeringsolutionstoourcustomers. Dhopeshwar Poultry Dressing Plant The processing plant is the hub of integrated poultry operations. Dhopeshwar manufactures high quality Plant and Machineries for Poultry Processing. The Dressing Plant range covers Conveyorised Plants with On-line processing equipment. The Dressing plants are supplied in different capacities to cater to the needs of processing companies. 1. Conveyor based automation requires less man power Output capacity is given in termsofbirdsperhour 2. Theplantcanprocessbirdsweighing1.0to3.0kgs. 3. AllthemachineriesaremadeinStainlesssteel. 4. Scientificallydesignedprocessensuresmosthygienicprocessing. 5. Conveyorbaseddesignrovidesexcellentconsistancy. 6. Adoptsadvancedengineeringforsemiautomaticprocessing Our plants are fully Integrated, Custom-built and supplied on a Turnkey basis. These are Fabricated in our Hyderabad facility, transported to client locations in India & overseas,andinstalledandcommissionedonaTURNKEYbasis. UniquefeaturesofourPoultryDressingPlant A-16, Co-operative Industrial Estate, Balanagar, Hyderabad - 500 037, India : + 91 040 2377 1579 : +91 040 2377 2450 : + 91 93910 58963 : T F M E w: Dhopeshwar Engineering Pvt ltd. Specialised Engineering solutions