rendering systems within new zealand€¦ · nzrg rendering workshop sept 2019 presented by steve...

NZRG RENDERING WORKSHOP SEPT 2019PRESENTED BY STEVE DUNN

Rendering Systemswithin New Zealand

2© RENDERTECH LTD 2019

Press Dewatering Plant – Alliance Lorneville


Rendering in New Zealand


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.


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


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%


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.


Rendering


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.


Rendering

Rendering is a separation process

Raw MaterialWater 60%

Fat 20%Protein 20%

Water Tallow/Oil Protein Meal


Rendering

Uses of tallow and oil

• Soap & detergents

• Pharmaceuticals

• Lubricants

• Glue & paint

• Food applications

• Explosives

• Biofuels


Rendering

Protein meal uses

• Stock feed for animal, poultry and aquaculture industries.

• Pet food market.

• Fertiliser.


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


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.



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.



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.



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.



MIRINZ

MIRINZ work in Rendering

• 1974 – Oil shocks – MIRINZ undertook energy surveys, and energy efficiency surveys.

• Different rendering technologies were evaluated.


MIRINZ – Low temperature rendering

MLTR System –objective:

• Separation of solids, tallow and stickwater at less than 100oC.



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).



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.


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



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.



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.


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


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.


Types of Rendering processes – Key PDS equipment

Precooker

• Indirect steam injection.

• Used in both low temperature and low energy systems.



Twin Screw Press



Contact Drier



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



Waste Heat Evaporator



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.


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.


Odour Research

Biofilter

• Biofiltration is well researched by AgResearch and MIRINZ.



Plant control room


Steve DunnEmail: [email protected]: +64 9 634 5375Cell: +64 21 372 954Skype: steve.dunn110

Thankyou.

mailto:[email protected]

rendering systems within new zealand€¦ · nzrg rendering workshop sept 2019 presented by steve...

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