NZRG RENDERING WORKSHOP SEPT 2019PRESENTED BY STEVE DUNN
Rendering Systemswithin New Zealand
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Press Dewatering Plant – Alliance Lorneville
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Rendering in New Zealand
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Rendering in New Zealand
Rendering in NZ is an export industry
• Approx. 85% of our end products are exported to the world.
The New Zealand Renderers Group comprises of:
• 8 meat companies with rendering plants – 14 rendering premises.
• 10 independent plants – 4 rendering companies.
• 23 associated members – exporters and service providers.
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Rendering premises in New Zealand
WELLINGTON
CHRISTCHURCH
DUNEDIN
AUCKLAND
AFFCO MoerewaWallace CorporationAFFCO Rangiuru
AFFCO WairoaHawkes Bay Protein
Kakariki ProteinsAlliance Levin Taylor Prestons
Keep It Clean - WallaceWallace - SilverstreamSouth Pacific Meats Awarua
PVL ProteinsTuakau ProteinsAFFCO Horotiu
Taranaki Bio ExtractsTaranaki By-ProductsAFFCO Imlay
Value Proteins
Blue Sky Meats Alliance LornevillePrime Range Meats
ANZCO Seafield
Alliance Smithfield
Wallace Timaru
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Changes in the Industry
• For the NZ meat industry, rendering is becoming an increasingly important business.
• Cash at gate as opposed to trade risk.
• Carbon credits – NZD19/tonnecarbon credit until 2015.
% revenue for meat company
% of maintenance costs
1970’s – 1980’s
4%
4%
2019
8%
1-2%
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NZ Meat & Rendering Industry History
• 1800 – Whaling & sealing, had basic rendering facilities.
• 1879 – The second registered rendering plant, rabbits and sheep.
• 1882 – The first export of frozen mutton, from NZ to London.
• 1880s-mid 1960s – Rendering plants were high temp, Batch Dry Rendering systems.
• 1966 – First high temp continuous plant was commissioned.
• 1979 – Fist low temp continuous plant was commissioned.
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Rendering
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Rendering
What is rendering?
• Process for recovery of valuable products from meat, fish, and poultry waste.
• Processes the ‘inedible’ portions of the animal.
• Produces oils and fats (tallows) and protein meals – meatmeal, fishmeal, feathermeal & bloodmeal.
• To be done in an environmental friendly manner.
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Rendering
Rendering is a separation process
Raw MaterialWater 60%
Fat 20%Protein 20%
Water Tallow/Oil Protein Meal
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Rendering
Uses of tallow and oil
• Soap & detergents
• Pharmaceuticals
• Lubricants
• Glue & paint
• Food applications
• Explosives
• Biofuels
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Rendering
Protein meal uses
• Stock feed for animal, poultry and aquaculture industries.
• Pet food market.
• Fertiliser.
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Types of Rendering processes
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Types of Rendering processes
Two types of rendering:
High temperature
‘Dry’ rendering all the water is removed thermally or dried.
Batch and Continuous
Low temperature
‘Wet’ rendering some of the water is removed mechanically, remainder thermally.
MLTR and PDS Systems
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Types of Rendering processes – High temperature rendering
Batch Dry Rendering (BDR)
• Flexible – can process a variety of products in one cooker.
• Labour & energy intensive.
• End product quality can be variable.
• Difficult to capture odours.
• Only applicable for very small plants.
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Types of Rendering processes – High temperature rendering
BDR – Effects on the process
• Raw Material
– Species: Type
– Age & Particle Size
– Cleanliness
– Raw material blending, mixing
• Cooking temperatures & times.
• Separation & refining temperatures.
• Above requires regular monitoring & control.
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Types of Rendering processes – High temperature rendering
Continuous Dry Rendering (CDR)
• Well proven on red & poultry meat by-products.
• High energy use – all water thermally removed.
• Tallow quality inferior to low temperature.
• Maintenance costs can be high.
• Odour Control – more difficult.
• Wastewater – viscera washing.
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Types of Rendering processes – High temperature rendering
CDR – Effects onthe process
• Raw Material
– Species: Type, Size, Age, Cleanliness
– Raw material mixing
• Cooking temperatures & times.
• Blending of fines with cracklings.
• Separation & refining temperatures.
• Above requires regular monitoring & control.
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MIRINZ
MIRINZ work in Rendering
• 1974 – Oil shocks – MIRINZ undertook energy surveys, and energy efficiency surveys.
• Different rendering technologies were evaluated.
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MIRINZ – Low temperature rendering
MLTR System –objective:
• Separation of solids, tallow and stickwater at less than 100oC.
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MIRINZ – Low temperature rendering
MLTR System –process advantages
• Processes wide variety of material from various species.
• Handles unwashed material including paunch content.
• Resultant meal has a low fat content.
• Moisture content controlled.
• Ability to sterilize tallow and meal independently if required.
• Handles edible or inedible with further downstream products.
• Processes blood in same system.
• Reduced product load in stickwater.
• Reduced steam (energy) requirement.
• Small footprint in factory.
• Well suited to automation.
• Modular process, flexible capacity (3-10 tonne/hour per module).
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MIRINZ – Low temperature rendering
Benefits were immediately apparent
First plant was commissioned in 1979.
• Reduced capital cost
• Lower running costs:
– Energy
– Labour
• Increased revenues from:
– Higher prices for tallow
– Higher prices for meal
REMEMBER: These developments took place over 30 years ago.Since then continuous improves have refined the process further.
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These savings are based on:
• 60% moisture
• 20% fat
• 20% solids
Benefits of Low temperature rendering
0 100 200 300 400 500 600 700
AltaTemperatura
BaixaTemperatura
Thermal Energy Consumption
(kCal/kg RM)
0 30 60 90 120 150
AltaTemperatura
BaixaTemperatura
Process Temperature (ºC)
0 3 6 9 12 15 18
AltaTemperatura
BaixaTemperatura
% of Fat in the Meal
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MIRINZ – Low temperature rendering
MLTR System – Effects on the process
• Raw material quality etc – less critical.
• Cooking & separation temperatures & times.
• pH of liquid phase for good phase separation.
• Meal drying temperatures.
• Above requires regular monitoring & control.
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Continuous improvement
Improvement by way of the Press Dewatering System (PDS)
• Lower maintenance costs.
• Lower operating costs (especially electrical).
• Simpler to operate: no recycle streams.
• More robust.
• Plant capacity: 3-25 tonne/hr.
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Press Dewatering System – Low Temperature
INDIRECT steam
High gradeWater 6-8%Fat 9-11%
Raw Material
Precooker(Temperature 85-95oC)
Twin Screw Press Decanter
Fat
EvaporatorDryer
Meal
Sizing
Separator
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Types of Rendering processes – PDS Low temperature
Press Dewatering System (PDS)
• High quality end products.
• Low energy consumption.
• Utilises waste heat evaporator for stickwater recovery.
• Virtually zero loss system.
• Low wastewater loads.
• Durable – low maintenance requirements.
• Indirect steam heating.
• Eliminates fines.
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Types of Rendering processes – Key PDS equipment
Precooker
• Indirect steam injection.
• Used in both low temperature and low energy systems.
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Types of Rendering processes – Key PDS equipment
Twin Screw Press
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Types of Rendering processes – Key PDS equipment
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Types of Rendering processes – Key PDS equipment
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Types of Rendering processes – Key PDS equipment
Contact Drier
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Types of Rendering processes – Key PDS equipment
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Types of Rendering processes – Key PDS equipment
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Types of Rendering processes – Key PDS equipment
Waste Heat Evaporator
• Single or multiple effect.
• Finisher stage for higher concentration.
• Heat recovery – potable hot water.
• Retrofit to existing low temperature plants.
• Retrofit to dry rendering to increase capacity and reduce energy consumption.
• Integral part of low energy system.
Alliance Lorneville
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Types of Rendering processes – Key PDS equipment
Waste Heat Evaporator
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Types of Rendering processes – Key PDS equipment
Waste Heat Evaporator – the benefits
• Waste heat – use vapour from the drier as the energy source.
• Concentrates the stickwater –boiled off the water under vacuum.
• Concentrate returned to drier and recovered as meal.
• Meal yield recovered 8 – 18%.
• High strength wastewater stream eliminated.
• In some plants, processing the wastewater from blood processing.
• Potable hot water recovered from vacuum condenser at 55oC.
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Stickwater
• The challenge with low temperature rendering is how to dispose of the stickwater, and to successfully capture the additional yield.
• This has been achieved with the Waste Heat Evaporator.
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Odour Research
Biofilter
• Biofiltration is well researched by AgResearch and MIRINZ.
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Types of Rendering processes
Plant control room
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Steve DunnEmail: [email protected]: +64 9 634 5375Cell: +64 21 372 954Skype: steve.dunn110
Thankyou.