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www.azti.es VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN) DAVID SAN MARTIN ([email protected]) SUSTAINIBILITY AREA- FOOD RESEARCH DIVISION
www.azti.es 9/18/2013 1
VEGETABLE BY-PRODUCTS
VALORIZATION FOR ANIMAL FEED
IN BASQUE COUNTRY (SPAIN)
DAVID SAN MARTIN ([email protected])
SUSTAINIBILITY AREA - FOOD RESEARCH DIVISION
www.azti.es 9/18/2013
INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
WORLD SITUATION
THE WORLD
POPULATION IS
GROWING UP
ENORMOUSLY
NATURAL RESOURCES
NEED
WASTE
GENERATION
1.- MANAGEMENT COSTS
FOR COMPANIES
2.- ENVIRONMENTAL
IMPACTS
FEED
PRODUCTION
3.- OPORTUNITY
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INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS
AN EXPERIENCE
TO VALORIZE VEGETABLE BY-PRODUCTS FOR ANIMAL FEED
www.cleanfeed.org
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
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INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS
CLEAN FEED PROJECT
IT IS LOCATED IN BASQUE COUNTRY
ITS MAIN AIM IS:
• “TO DESIGN, PROVE AND VALIDATE AN ACTION PLAN TO MAKE USE
OF THE VEGETABLE FOOD SURPLUS GENERATED IN THE FOOD
RETAILING BY TRANSFORMING THEM INTO ANIMAL FEED”.
THE BENEFICIARIES ARE:
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
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INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS
TASK 1: INVENTORY AND CHARACTERIZATION
• WHICH KINDS OF VEGETABLES BY-PRODUCTS ARE GENERATED;
WHERE AND WHEN
• HOW DIFFERENT BY-PRODUCTS ARE MANAGED
• WHICH ARE THE NUTRIONAL VALUE OF EACH BY-PRODUCT FOR
ANIMAL FEED
• GUARANTEE THE ABSENCE OF UNDESIRABLE SUBSTANCES IN
EACH BY-PRODUCT FOR ANIMAL FEED
“THE AIM OF THE INVENTORY AND THE CHARACTERIZATION IS TO
DETERMINATE THE FEASIBILITY OF THEIR INCLUSION IN FEED
FORMULATION”
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
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INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS
TASK 2: PILOT TRAIL_PRODUCTION OF VEGETABLE DRIED MEAL
• WHICH DRYING TECHNOLOGIES ARE TECHNICALLY SUITABLE FOR
DRYING VEGETABLE WASTES
• IN WHICH CONDITIONS: TIME, TEMPERATURE, ETC.
“THE AIM OF THE DRYING PROCESS IS TO STABILIZE VEGETABLE BY-
PRODUCTS IN TIME AND TO ALLOW THEIR INCLUSION IN THE FEED
FORMULATIONS”
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
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INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS
TASK 3: DEVELOPMENT OF AN ACTION PLAN
• STORAGE AT THE POINT OF GENERATION
• COLLECTION AT THE POINT OF GENERATION
• TRANSPORT TO THE TREATMENT PLANT
• TREATMENT AND FINAL STORAGE
“THE ACTION PLAN MUST ENSURE THE TECHNICAL, ECONOMICAL
AND ENVIRONMENTAL FEASABILITY OF THIS EXPIERENCE ”
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
www.azti.es 9/18/2013
INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS
TASK 1: INVENTORY AND CHARACTERIZATION
• KINDS OF VEGETABLES BY-PRODUCTS GENERATED
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
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INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS
TASK 1: INVENTORY AND CHARACTERIZATION
• VEGETABLE BY-PRODUCTS DISPERSION and QUANTITIES
• SEASONAL VARIABILITY OF CIDER AND WINE SECTOR
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
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INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS
TASK 1: INVENTORY AND CHARACTERIZATION
• LABORATORY ANALYSIS OF EACH BY-PRODUCT
UNDESIRABLE SUBSTANCES
MYCO-TOXINS
PESTICIDES
HEAVY METALS
MICROBIOLOGY
DIOXINS
NITRITES
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
ALL OF THEM SET THE MAXIMUM LEGAL
LIMITS
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INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS
TASK 1: INVENTORY AND CHARACTERIZATION
• LABORATORY ANALYSIS OF EACH BY-PRODUCT
NUTRITIONAL VALUE
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
NOT SO MANY DIFFERENCES IN THE NUTRITIONAL VALUE BETWEEN ALL
VEGETAL BY-PRODUCTS
IT IS NOT ADVISABLE
TO MANAGE THEM SEPARATETLY.
LOW NUTRITIONAL QUALITY LIMITS THEIR INCLUSION
IN FEED FORMULATION TO 3-6%.
MAKES NECESSARY A DRYING PROCESS
MOISTURE LEVEL < 12 %
STABILIZE THEM IN TIME
A MOISTURE LEVEL OF MORE
THAN 70%
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INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS
TASK 2: PILOT TRAIL_PRODUCTION OF VEGETABLE DRIED MEAL
• DRYING TEST SAMPLE: A MIXTURE OF ALL BY-PRODUCTS
TO INCREASE THE CRITICAL MASS TO VALORIZE
TO MAKE MORE FEASIBLE THEIR VALORIZATION.
BY-PRODUCTS % TONS
POTATO 42,16 7.500
MARKET 23,62 4.201
COFFEE 0,21 37
BREAD 32,89 2.847
HORTICULTURE 1,12 200
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
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INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS
TASK 2: PILOT TRAIL_PRODUCTION OF VEGETABLE DRIED MEAL
• STATIC OVEN
85 º C
SAMPLE
STATIC OVEN 85° C TIME(min) MOISTURE (%) ENERGY CONSUMPTION
(kWh)
Test 1 P0 0 70,1
1,4 P1 176 7,6
Test 2 P0 0 65,5
1,4 P1 480 9,5
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
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INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS
TASK 2: PILOT TRAIL_PRODUCTION OF VEGETABLE DRIED MEAL
• ROTATORY OVEN
SAMPLE
90-110º C
ROTATORY OVEN 90-110° C
TIME(min) MOISTURE (%) ENERGY CONSUMPTION (kWh)
Test 1 P0 0 70,1
1,4 P1 4 4,46
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
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INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS
TASK 2: PILOT TRAIL_PRODUCTION OF VEGETABLE DRIED MEAL
• MICROWAVE
1.000 W
SAMPLE
MICROWAVE TIME (MIN) MOISTURE (%) ENERGY CONSUMPTION (kWh)
1000 W P0 0 62,95
1,2-1,3 P1 36,25 9,95
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
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INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS
TASK 2: PILOT TRAIL_PRODUCTION OF VEGETABLE DRIED MEAL
• PULSE COMBUSTION DRYING
130-140º C SAMPLE
P.C.D. TIME (min) INSERTING SPEED (HZ) MOISTURE (%) ENERGY CONSUMPTION (kWh)
Tª: 130° C P0 0 - 74,84
1,1 P1 7 10-12 26,20
Tª: 140° C P0 0 - 74,84
1,1 P1 5 7-10 25,20
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
www.azti.es 9/18/2013
INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS
TASK 2: PILOT TRAIL_PRODUCTION OF VEGETABLE DRIED MEAL
• STATIC OVEN
• ROTATORY OVEN
• MICROWAVE
• PULSE COMBUSTION DRYING
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
ARE TECHNICALLY SUITABLE FOR DRYING VEGETABLE WASTES
NEEDS TO BE REDESIGNED TO REDUCE THE MOISTURE OF THE
FINAL PRODUCT
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INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS
TASK 3: DEVELOPMENT OF AN ACTION PLAN
1. STORAGE AT THE POINT OF GENERATION
IN CLOSED CONTAINERS
• CLEANED EVERY DAY THAT THEY ARE COLLECTED
• LOCATED:
IN A CLEAN and DRY PLACE; AWAY FROM POLLUTION
IF IT IS POSSIBLE, IN REFRIGERATION OR IN A FRESH PLACE
2. COLLECTION AT THE POINT OF GENERATION
MINIMUM FRECUENCY:
• EVERY DAY
• ONCE EVERY TWO DAYS
A FIRST QUALITY CONTROL
• BY THE DRIVER OF THE LORRY
• BASED ON FEED ANIMAL MANUFACTURES REQUIREMENTS
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
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INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS
TASK 3: DEVELOPMENT OF AN ACTION PLAN
3. TRANSPORT TO THE TREATMENT PLANT
ACORDING TO THE REGULATION 183/2005 ABOUT HYGIENIC
REQUIREMENTS FOR FEED MATERIAL
• CLEANING PROTOCOL
• TRAINING OF WORKERS INVOLVED
• DOCUMENTATION TO FILL
4. TREATMENT AND FINAL STORAGE
RECEPTION: A SECOND QUALITY CONTROL
HOMOGENIZATION: CRUSHING DIFFERENT BY-PRODUCTS
DEHYDRATION: TO GET LESS THAN 12% MOISTURE
STORAGE: IN VERTICAL SILOS IN BULK
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
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INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS
CONCLUSIONS:
• IT IS FEASIBLE TO USE THESE VEGETABLE BY-PRODUCTS AS A RAW
MATERIAL FOR ANIMAL FEED;
CONSIDERING THAT ALL UNDESIRABLE SUBSTANCES ARE BELOW MAXIMUM LEGAL
LIMITS
• THEIR INCLUSION IN FEED FORMULATIONS IS LIMITED TO 3-6%
BECAUSE OF THEIR LOW NUTRITIONAL QUALITY
• IT IS NECESSARY A DRYING PROCESS TO STABILIZE THEM IN TIME
DRYING PROCESS MUST GUARANTEE NOT IMPORTANT CHANGES IN THEIR
COMPOSITION
• THE ACTION PLAN MUST BE EFFICIENT ENOUGH TO ENSURE THE ECONOMIC,
TECHNICAL AND ENVIROMENTAL FEASIBILITY
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
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INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS
FUNDED BY:
• LIFE + Environment Policy and Governance Programme: LIFE 09 ENV/ES/000473.
• Innovation and Food Industry Management.
Environment, Territorial Planing, Agriculture and Fishing Department.
Basque Government.
• Environmental Quality Management.
Environment, Territorial Planing, Agriculture and Fishing Department.
Basque Government.
COLLABORATORS:
• ELIKA: Basque Foundation for Agro-Food Safety
• EPEA: Feed Manufacturers Association of the Basque Country
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
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