Sedicanter
The poultry rendering sector focuses on converting by-products like fat, blood, offal and feathers from the poultry waste rendering process into valuable materials such as protein meals, poultry fat and renewable fuel sources. This process reduces waste and contributes to sustainability by reusing what would otherwise be discarded. The recovered materials are widely used in industries ranging from animal feed to biodiesel production, promoting a circular economy.
We offer solutions that optimize every step of the poultry rendering process, addressing challenges like efficient separation, energy consumption and odor control. The equipment provided by our partners enhances process efficiency, reduces waste and ensures regulatory compliance while offering substantial operational cost savings.
The 3 key processes of poultry rendering
1. Blood dewatering: Blood from poultry is rich in proteins and can be dewatered to produce dried blood meal, which is commonly used in pet food, livestock feed and fertilizers. Removing water from the blood is crucial for concentrating proteins and reducing disposal costs.
2. Poultry fat extraction: Rendering allows the extraction of poultry fat, which can be repurposed for biodiesel or used as an energy source in animal feed. The process involves separating fat from other poultry by-products to ensure maximum recovery of valuable lipids. After cooking the poultry by-products in large renderers (cookers), the material is typically passed through a belt press. During this step, the solid materials (often called “cracklings”) are pressed to remove the fat, which can then be separated from the liquids using a separator.
3. Feather processing: Feathers, largely composed of keratin, undergo hydrolysis to break down the fibers and transform them into valuable ingredients for animal feed. Hydrolyzed feathers are high in protein and contribute to the sustainability of the entire chicken rendering process.
Main challenges involved in the poultry rendering process
Efficient separation: One of the main challenges in poultry rendering is ensuring efficient separation of solids and liquids. Without proper separation, yields decrease and waste increases, which impacts profitability and overall efficiency.
Odor and VOC emission control: Poultry rendering emits strong odors and volatile organic compounds (VOCs) that need to be managed to meet environmental regulations. Without proper control measures, rendering plants can face community opposition and regulatory fines.
Water and energy management: Water and energy consumption are crucial concerns. Processing poultry by-products consumes large amounts of water for cleaning and cooling, while energy is needed for heating, dewatering and extraction processes. Efficient water and energy management can significantly reduce operational costs and improve environmental compliance.
How do our solutions support efficient poultry rendering operations?
Centrifugal Decanters and Separators
We offer Flottweg decanter centrifuges and Tricanter® systems that ensure efficient separation of poultry fat and blood during the rendering process. These systems provide high-quality fat separation, blood dewatering and solid-liquid separation, significantly improving yield and product quality. They are designed for continuous operation, optimizing the flow and minimizing downtime.
- Practical use case: A leading poultry by-product processor in Romania required efficient 3-phase separation to enhance poultry fat clarification while meeting high environmental standards. We provided a FLOTTWEG TRICANTER® Z4E-4/441, featuring Simp-Drive® technology, designed for continuous separation of fat, water, and solids at up to 4 tons per hour. This solution ensured precise separation, with a fume-tight design to prevent odor emissions, meeting the company’s needs for improved product quality and environmental compliance.
Heat exchangers
Proper temperature control is vital during poultry rendering to ensure efficient fat extraction and product drying. We provide HRS heat exchangers for precise energy transfer, allowing rendering plants to maintain optimal processing temperatures without excessive energy consumption. These systems ensure higher levels of energy efficiency, reducing operational costs while improving product quality.
Water treatment systems
Water management is a critical concern in poultry rendering due to the large volumes of wastewater generated. Our water treatment solutions, filtration systems and decanter centrifuges, are tailored for wastewater treatment and dewatering, ensuring clean water is discharged or reused in compliance with environmental regulations.
- Practical use case: A poultry plant was struggling with rising water costs and wastewater compliance issues. After implementing advanced water treatment systems provided by our partners, the facility reduced water consumption by 30% and achieved full regulatory compliance, avoiding hefty fines.
Odor and emissions control
To tackle the strong odors generated by poultry rendering, our air filtration and VOC management systems effectively remove harmful emissions and reduce odors. These solutions meet stringent air quality regulations, providing a cleaner work environment and minimizing the impact on nearby communities.
- Practical use case: A poultry rendering facility dealing with community complaints due to strong odors adopted HFiltration VOC control systems. The result was a dramatic reduction in emissions, with community feedback improving significantly, allowing the plant to continue operating without disruptions in the surrounding areas.
Profitability & rendering regulations: key metrics and how long does it take to achieve ROI
What volume of by-products do I need to render to achieve profitability?
To determine the required volume for profitability, facilities should assess processing costs, market value of by-products and operational efficiency. For profitability, many rendering facilities find they need a steady supply of at least 20-30 tons of raw poultry by-products per day to cover costs and make a profit.
However, profitability also relies on the selling prices of rendered products (e.g., fat, protein meal, and feather meal) and on minimizing operational costs by maximizing energy efficiency and waste management. Our solutions are designed to maximize yield and recovery, ensuring high returns on investment even for smaller operations by optimizing each phase, from blood dewatering to fat recovery.
Are there specific by-products that are more valuable than the others?
In the rendering industry, not all by-products have equal value. For example, recovered poultry fat is valuable for both biodiesel production and animal feed, while dried blood meals have high protein content for pet and livestock feeds. With solutions that allow precise separation and processing we help you extract the highest-quality outputs from each by-product, enhancing profitability.
How to efficiently adhere to the European rendering laws and regulations & avoid fines?
Every rendering plant needs to be well aware of the EU laws for rendering, which are rigorous, with strict standards for environmental impact, health, and safety.
Under Regulation (EU) 1069/2009, rendered animal by-products are categorized to manage potential risks, especially for animal or human health, and must be processed accordingly. Furthermore, regulations like the Animal Health Law (Regulation 2016/429) and specific directives like the one focused on broiler welfare (Directive 2007/43/EC) establish health, transportation, and facility requirements for handling poultry by-products safely within the EU.
Regular audits and monitoring help ensure adherence to these standards, supporting sustainability and minimizing the risk of fines. Our water treatment, VOC management, and odor control solutions are designed to ensure compliance with EU environmental and safety standards, avoiding penalties and securing operational approval.
How long does it take to achieve Return on Investment?
The time required to achieve ROI depends on factors like production volume, equipment efficiency and process optimization. With solutions designed to enhance yield and minimize costs, plants can often see ROI within a few years. Specific timelines can be estimated by analyzing operational goals and expected savings from optimized energy use, reduced waste, and improved compliance.
How to efficiently address logistics, storage and transport concerns in the rendering process?
Ensuring efficient logistics and infrastructure for a rendering facility involves analyzing several factors, from raw material transport to the efficient distribution of end products. Our audit addresses these factors. We assess transport needs, suggesting tailored solutions based on volume and location to ensure cost-effective, scalable logistics. Infrastructure suitability is evaluated through on-site inspections to identify potential storage or facility upgrades for uninterrupted processing. For distribution, we identify streamlined methods to support energy-efficient delivery while maintaining quality. This process combines data-driven recommendations with hands-on feasibility assessments, ensuring each aspect of your infrastructure aligns with operational goals.
Optimizing the poultry rendering process is crucial for improving efficiency and profitability while minimizing waste. Our equipment components are made from high-quality, easily cleanable stainless steel, reducing the risk of bacterial growth and contamination. To ensure your facility operates at its best, we offer tailored solutions for every need.
Contact us today to schedule an audit and explore how our systems can optimize your operations.
