Dry Rendering Optimizer
Get a more protein-rich meal and higher fat yield with the Alfa Laval Dry Rendering Optimizer. Turning your existing dry rendering processing line for animal by-products into a highly efficient hybrid system or a complete, automated wet rendering system contributes to up to 40% savings in energy and operating expenditures. It can also raise the protein content in the meal by up to 5% and the yield of high-purity fat by more than 10%.
Energy-efficient rendering increases the quality and yield of protein-rich meal and high-purity fat
- Increase the protein content in meal by up to 5% while improving meal stability
- Boost fat yield by more than 10% with a higher -quality animal fat for use in biofuel production
- Cut operating and energy costs by about 40% due to automation and the reuse of waste heat
- Reduce carbon emissions through energy-efficient reuse of animal by-products, natural resources and waste heat
The Alfa Laval Dry Rendering Optimizer enhances the value of your end-product stream while boosting your sustainability credentials. Minimal investment in essential equipment results in significant cost savings. Plus, the rendering system heats animal by-products using less energy than conventional systems and reuses waste heat from drying, reducing your electricity bill.
The responsible reuse of animal agriculture resources and waste heat helps reduce carbon emissions, fossil fuel use, and utility costs – making the Dry Rendering Optimizer a wise investment.
We are always collaborating with Alfa Laval to finetune operations. We look forward to continuing our close and constructive partnership and using Alfa Laval know-how to tailor solutions to meet our requirements.”–Salvatore Papa, General Manager, Proteg SpA
Optimizing dry rendering processes for 40% in energy savings and improved protein and fat quality and yields
Fat and meat and bone meal producer Proteg SpA approached Alfa Laval to improve product quality while reducing energy costs and environmental emissions. The request? A higher protein content to raise the sales price of protein meal for pet food and higher quality fat for use in biofuel, which translates into higher yield.
Food system services
Alfa Laval Food system services help extend the performance of your food systems by maximizing the performance of your processes. This enables you to:
- Continually improve your operations to maintain competitive advantage
- Focus on uptime, optimization and availability
- Maximize return on investment throughout the life cycle of your food systems
Related products and industries
How does the Alfa Laval Dry Rendering Optimizer work?
The Alfa Laval Dry Rendering Optimizer provides two upgrading options: (1) converting a conventional dry rendering processing line into a hybrid rendering system or (2) converting a conventional dry rendering processing line into a complete wet rendering system. Upgrading requires investment in easily integrated components, including grinders, a direct steam injection heater, pumps, decanters, high speed separators, evaporators and a dryer/cooker.
Upgrading option 1: Alfa Laval Dry Rendering Optimizer Hybrid
Upgrade a conventional dry rendering processing line to a hybrid rendering system.
The Alfa Laval Dry Rendering Optimizer Hybrid delivers energy savings. It turns an existing dry rendering plant into a hybrid system with minimal investment while reducing energy consumption by about 40%. Reducing energy costs and carbon emissions requires the addition of these components:
- Raw material grinding, including heavy-duty pumps
- A direct steam injector (DSI) heater to secure fast and efficient
- A two- or three-phase decanter to dewater the cooked product, and
- A waste heat evaporator (WHE) to capture and reuse heat from the rendering cooker system
The quality and quantity of the meal and fat are similar to that produced by conventional dry rendering. However, adding an optional three-phase decanter makes it possible to extract a fraction of the fat as high-purity fat comparable in quality to wet-rendered fat.
Upgrading option 2: Alfa Laval Dry Rendering Optimizer
Upgrade a conventional dry rendering processing line to a complete low-fat, wet-rendering system.
The Alfa Laval Dry Rendering Optimizer turns an existing dry rendering processing line for animal by-products into a complete, automated Alfa Laval wet rendering system. This system optimizes energy use and enhances end-product quality and yield.
Convert a conventional dry rendering processing line into a complete wet rendering system. Besides adding the raw materials handling equipment for the hybrid system mentioned above, the Alfa Laval Dry Rendering Optimizer requires the addition of an Alfa Laval fat-stripping decanter for initial fat extraction before the two-phase decanter as well as a high speed separator skimmer to remove all light-phase material from the water phase before concentrating the water phase in the waste heat evaporator.
Removing the light-phase material from the water phase alters the drying profile and calls for careful evaluation of the existing cooker’s overall capacity. Alfa Laval can analyze drying capacity requirements and, if necessary, recommend solutions if additional capacity is needed.
A lower fat level in meat and bone meal enables manufacturers to market a product with up to 5% higher protein content than dry rendered meal or meal with similar protein levels as dry rendered meat and bone meal. Optimizing the moisture content in meal reduces thermal damage to the dried meat and bone meal protein, providing meal yields comparable to dry rendered meal.