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Dr. sc. agr. M. Samer | Food Processing Waste Management | 1Cairo University

Food Processing Waste Management

In the framework of the postgraduate course “Agricultural Waste Management”

Mohamed Samer, Dr. sc. agr. Associate ProfessorBioresource EngineeringDepartment of Agricultural Engineering Faculty of Agriculture, Cairo UniversityE-Mails: [email protected]; [email protected]: http://scholar.cu.edu.eg/samer/biocv

mailto:[email protected]

mailto:[email protected]

http://scholar.cu.edu.eg/samer/biocv


INTRODUCTIONINTRODUCTION


Mailhem Ikos Environment


Cheese WheyCheese Whey


Cheese Manufacturing(10 kg milk)

Cheese Whey(9 kg)

Cheese(1 kg)

Biogas

EthanolBiodegradable

Ethanol

Organic Acids

Single Cell Protein

Plastics

ChemicalIndustry

Anti-icingAgentsHuman

FoodAnimal

Feed

Pharmaceuticals

Source: Lectures of Prof. Dr. A. Ghaly, Dalhousie University


Slaughtering WasteSlaughtering Waste


Animal Pathology Evaluation

Receiving & Holding

Stunning

Hide Opening In The Neck

Sticking Dehiding Head Removal

SLAUGHTERING PROCESS

In The NeckSticking Dehiding

Removal

Final Wash

Whole Carcass

Chilling

Variety Meats

Chilling

• Storing• Packaging• Distribution

Processing

Animal Pathology Evaluation

Evisceration

Carcass Shipping

Source: Lectures of Prof. Dr. A. Ghaly,

Dalhousie University


Wastes

SLAUGHTERING WASTES

BloodHeads

HoovesFeet

Lungs Spleen

Stomach Intestines

Tissues Trimming

FatBone

Animal feed Rendering



Rendering Waste

Handling and Pretreatment

Extraction

Tallow


GlycerolBiodiesel

ChemicalTransesterification

Tallow

Conventional Biodiesel Production Process


§ Environmental

Rendering Waste


Extraction

§ Chemicals

§ Thermal Energy

Problems Associated with Conventional Process

§ Environmental Problems

§ Loss of value added Products

GlycerolBiodiesel


Tallow



§ Protein§ Nutraceuticals§ Collagen§ Protein§ Amino Acids§ Fatty Acids§ Enzymes

Rendering Waste

Characterization


Characterization of Animal Rendering Waste

Extraction

GlycerolBiodiesel


Tallow




Proteins

Animal Feed

Enzymes

Enzyme Inhibitors

Rendering Waste

Characterization


Extraction

Fertilizer

Amino Acids

Anticoagulant

Enzymes

Extraction of high value co-products from animal rendering by biological transesterification

Extraction

§ Low Energy Requirement

§ High Quality Glycerol

GlycerolBiodiesel

BiologicalTransesterification

Tallow



Rendering Waste

Characterization


ExtractionProteases, lipases,

collagenases

Collagen

Proteins

Fish Meal

Amino acidsJadomycin



Production of value added products from glycerol fermentation

Nutraceuticals omega-3 fatty acids

carotonoids, isoflavones, luteinFish silage

Amino acids

GlycerolBiodiesel

Tallow

Fermentation

Dihydroxy-acetoneHydrogen Ethanol 1,2-propanediol

1,3-propanediolLactic acid Methanol

§ Low energy requirement

§ High quality glycerol


Jadomycin

Jadomycin


Fish WasteFish Waste


ANATOMY OF FISH



Eviscerating

Chilling

FISH PROCESSING

Chilling

Deboning

Filleting

Canning

Mar

ket




Fish waste

Solid625,000 t/y

Liquid4,760,000 m3/y

FISH PROCESSING WASTES

HeadsTailsFinsFramesSkinOffal (guts, livers, kidney)

Cleaning fishCleaning equipment

• 27% Production of gutted and headed fish• 66% Production of fillets• 80% Production of surimi (paste made by fish)




q Problems•Large Amount of Fish Waste (55% of fish)•Loss of Resource•Environmental Problems

FISH PROCESSING INDUSTRY

•Environmental Problems

qBioenergy and Value Added Products•Biodiesel•Pharmaceuticals•Nutraceuticals•Industrial Chemicals

qNew Opportunities•New Industries•Employment Opportunities


§Biodiesel§Bioethanol§Hydrogen

§ Development of economically and environmentally feasible extraction techniques

§ α-2 macroglobulin§ α -1 antiproteinase§ Heparin

OBJECTIVE

§Hydrogen§Methanol§Lactic acid§Propanediol§Dihydroxyacetone

§ Heparin § Heparin-like glycosaminoglycans§ Chymotrypsin § Pepsin§ Collagenase§ Fish oil§ Omega-3 fatty acids§ Amino acids§ Jadomycin


§ Fish oil§ Nutraceuticals§ Collagen§ Protein§ Amino Acids§ Fatty Acids§ Enzymes

Fish Processing Waste

Characterization


Characterization of Fish Processing Waste

Extraction

GlycerolBiodiesel


Fish Oil




Proteins

Fish Meal

Proteases, Lipases,

Collagen


Characterization


Extraction



Fish Silage

Amino AcidsNutraceuticals omega-3 fatty acids

carotonoids, isoflavones, lutein

Lipases, Collagenases

Extraction of high value co-products from fish processing waste and biological transesterification

Extraction

§ Low Energy Requirement

§ High Quality Glycerol

GlycerolBiodiesel


Fish Oil



Characterization


ExtractionProteases, lipases,

collagenases

Collagen

Proteins

Fish Meal

Amino acidsJadomycin



Production of value added products from glycerol fermentation

Nutraceuticals omega-3 fatty acids

carotonoids, isoflavones, luteinFish silage

Amino acids

GlycerolBiodiesel

Fish Oil

Fermentation

Dihydroxy-acetoneHydrogen Ethanol 1,2-propanediol

1,3-propanediolLactic acid Methanol

§ Low energy requirement

§ High quality glycerol


Jadomysin

Jadomycin


Organic Fertilizer Fish FeedAnimal Feed Biogas

FoodsSurimiFibrous fish meatScallopsFish powderFish nuggetsFish cakes

SnacksCreamy fish bitesSpreadsDipsCrackersFish cheesy

Pharmaceuticals

NutraceuticalsFish oil

Omega-3Amino acids

POTENTIAL USES OF FISH WASTE

BiochemicalsBile saltsGlueGelatinLeatherPearl essence

Fish cakesFish burgersFish ballsFish pattiesFish sticksFish finger Fish filling for shellsFish filling for baked bunsFish entreesFermented sausagesCanned fish meatBreaded fish stripsCanned fish in cheese sauce Canned fish in mushroom sauceCanned fish with vegetables and rice

Fish cheesyFish crunchyMini fish fingersFish popcorn

Pharmaceuticals

Chymotrypsin PepsinCollagenaseEnzyme inhibitors AnticoagulantsJadomycinInsulinNucleic Acid NucleotidesProtaminesProteolytic Enzymes




Integrated Bioindustrial Integrated Bioindustrial Systems


Resources

LINEAR MODE OF AGRO-INDUSTRIAL PRODUCTION

WasteWaste

Production ConsumptionResources Extraction

Waste



Resource Extraction

CYCLIC MODE OF PRODUCTION


Production ResidualLimitedWaste

Consumption


COCOUNUT OIL INDYSTRY


COCONUT OIL INDUSTRY

qRaw MaterialsqEnergy qWater

Oil

Coconut Oil

Free Fatty Acids

OilProduction

System

Solid Waste

Wastewater Air EmissionsWaste Energy

Coconut Meal

Spent Bleaching

EarthShells

Coconut Husk



Bleaching Earth Water Copra Bottles

Materials Energy

Oil

Processing Operation

Meal Husk ShellsWasteEnergy

Heat Exchange

Oil AnimalFeed Cushions Activated

Carbon Fertilizer

Meal Husk

Fuel

Shells

Charcoal

Biogas

Sludge

AnaerobicDigestion

Wastewater

Biodiesel

Fatty Acid

Energy



ETHANOL INDUSTRY


School

Fermentation

Waste

Ethanol

MushroomProduction

Irrigation Water

LivestockEmployment

Mushroom



INTEGRATED BIO-INDUSTRIAL SYSTEMS

AnimalProduction

Anaerobic Digestion

Fertilizer

Electricity

FeedEmployment

Animal Waste

Meat & Milk

Seeds/Grains

Sludge

Methane

Composting

CropProduction


Bioproducts EngineeringBioproducts Engineering


Bioprocess and Bioproducts Engineering includes use of engineered microbiological (bacterial and algal) systems for treating waste air and water streams, for regeneration of polluted land and groundwater, and for generating biofuels, bio-electricity and new high-value bio-products.

In addition researchers are exploring the use of forestry products in nontraditional applications, including industrial foams, flame-retardant materials, and paper surface science.

Bioprocess engineering is a conglomerate of mathematics, biology and industrial design, and consists of various spectrums of biotechnological processes.


Bioproducts engineering (also referred to as bioprocess engineering)refers to engineering of bioproducts from renewable bioresources.

This pertains to the design, development and implementation ofprocesses, technologies for the sustainable manufacture ofmaterials, chemicals and energy from renewable bioresources.materials, chemicals and energy from renewable bioresources.

Bioprocess Engineering is a specialization of Biotechnology,Chemical Engineering, and Biological and Agricultural Engineering.

It deals with the design and development of equipment andprocesses for the manufacturing of bioproducts such as food, feed,pharmaceuticals, nutraceuticals, chemicals, polymers and paperfrom biological materials (i.e. biomaterials).


Bioproducts or bio-based products are materials, chemicals andenergy derived from renewable biological resources.

Biological resources include agriculture, forestry, and biologically-derived waste, and there are many other renewable bioresourceexamples.examples.

One of the scientific terms used to denote renewable bioresourcesis lignocellulose.

Cellulose-based materials and lignocellulosic tissues arebiologically-derived natural resources containing some of the mainconstituents of the natural world.


Conventional bioproducts and emerging bioproducts are twobroad categories used to categorize bioproducts.

Examples of conventional bioproducts include building materials,pulp and paper, and forest products.

Examples of emerging bioproducts include biofuels, bioenergy,starch-based and cellulose-based ethanol or bioethanol, bio-basedadhesives, biochemicals, bioplastics, etc.

Bioproducts derived from bioresources can replace much of thefuels, chemicals, plastics etc. that are currently derived frompetroleum→ Environment? Independent on foreign sources of oil?


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