Our technology can be deployed to service a number of different industries and can produce high quality protein meals and oils from a wide variety of sources.
Rendering Industry
Traditional rendering has been essentially the same process for decades and produces significant odor and waste water. Using the Flash Evaporation ABVRS technology eliminates odors and waste water, resulting in a highly efficient and eco-friendly rendering process that can be deployed right in city centers, as opposed to the long-distance deployments typically forced upon the rendering industry due to the noxious odors and waste associated with the antiquated rendering process.
Waste Water
The conventional rendering process creates waste water, as a result of its reliance on the slow cooking process. According to a study conducted by the engineering firm Bolton & Menk, “Rendering plants generate significant volumes of waste water. The waste water contains contaminates that are relatively low in long-term environmental risk, but cannot be released directly into rivers, streams, or lakes without proper treatment.”
In addition to environmental concerns and costs associated with waste water and waste water treatment, financial drawbacks exist as well. The very contaminants inherent in rendering waste water represent quantifiable lost product.
International Proteins's advanced ABVRS technology eliminates environmentally unfriendly waste water and associated costs.
Noxious Odors
According to the EPA, air pollutants emitted by traditional rendering facilities include volatile organic compounds (VOCs). These air pollutants have low detection thresholds and include 15 particulate emissions including ammonia, hydrogen sulfide, and quinoline, classified as a hazardous air pollutant (HAP).
A facility designed for inedible rendering operations will typically have seven primary sources of VOC emissions, including cookers, dryers, centrifuges and processing tanks.
To mitigate these volatile air pollutants and reduce their undesirable effects on nearby communities, a traditional rendering plant will be required to apply several costly emission controls, usually boiler incinerators and multi-stage wet scrubbers. Scrubbers require continuous purchase of scrubbing agents such as sodium hypochlorite or chlorine dioxide. Plants located near residential areas may also install additional costly duct work to further reduce emissions.
As our technology produces only clean steam, VOCs and the technologies required to address them are non-existent and not necessary. The absence of unwanted odors means ABVRS can operate in high-density urban areas, taking advantage of nearby protein sources.
FISH WASTE
The ABVRS technology has the ability to process the offal from processed fish into meal and oil while suspending the fat without loss or burning. In addition to handling the fat efficiently, ABVRS is much less capital-intensive when compared to conventional rendering operations. Further, ABVRS does not create foul odors, toxic emissions or waste water and requires no water treatment system to meet environmental standards. This advantage, when coupled with a small footprint, allows a fish processing plant to build an ABVRS system on-site and retain ownership of the resulting meal and oil. This allows the offal to become a profit center, rather than a costly disposal problem.
Slaughterhouse waste
Currently, the processing of bovine, ovine, equine and porcine waste is done via the conventional rendering process. The resulting Meat Bone Meal and tallow/oils sell on the international markets as an animal feed supplement.
International Protein’s ABVRS Process can produce high-protein meal and oil on a much smaller footprint, with very little odor, no toxic emissions and no waste water. Further, an ABVRS plant can be installed at a fraction of the cost of a full-scale conventional rendering plant.
poultry WASTE
The ABVRS processes poultry waste into a usable meal with value as an animal feed supplement.
Conventional processing of poultry waste is done with standard dryers, similar to those used to dry alfalfa and other farm products. These systems require longer dwell time to remove the moisture.
The ABVRS Technology will economically produce a high quality grade poultry meal. With rising energy and protein values, it has become very important to look at the all-in cost of producing a feed grade product. The Agricultural Byproduct Value Recovery System has the advantages of low capital costs and an energy-efficient short dwell time.
MANURE
The animals that provide the raw material for meat and dairy production create an enormous amount of manure. For example, one dairy cow can produce up to 120 lbs of manure each day. Traditionally, this manure has been used as a cheap form of fertilizer and spread on fields all across the nation. The regulatory agencies have begun to be concerned about the continued use of manure as a fertilizer, both from a public health perspective and as a carbon source contributing to global warming. There are a variety of technologies currently being developed to deal with manure in an environmentally sound manner, including the extraction of methane for use as a fuel and composting for safer fertilizer.
The ABVRS Technology converts manure into a burnable fuel source with a BTU value of approximately 7,500 BTU per pound. This is comparable with high-quality wood chips.
HATCHERY WASTE
Hatchery waste consists of shells from hatched chicks, dead chicks and unhatched eggs (including infertile eggs and eggs containing dead embryos). ABVRS Technology can convert the hatchery waste into hatchery meal in a highly efficient and environmentally safe manner. Because raw hatchery waste is low in fat (typically less than 10%), it does not require a backmix.
Furthermore, hatchery waste, in its raw form, does not require grinding prior to processing using ABVRS. As a finished product, hatchery meal can be used in the operator's own feed mill as an ingredient in their chicken feed or sold on the open market as an animal feed protein supplement.
WHOLE CHICKENS
According to officials from the State of Georgia, there are three main issues involved with the remediation of an avian influenza outbreak. Once the quarantine area has been established, depopulation, disposal and decontamination must take place. There are existing viable methods for both depopulation and decontamination. However, the solution for disposing of large quantities of infected, or possibly infected, birds has proven to be challenging. Methods of disposal that have been discussed include incineration, composting and land-filling. Incineration and land-filling would likely require removing the birds from the quarantine area. Composting such a large quantity of birds would pose practical and environmental issues.
There are 3 main advantages of implementing ABVRS technology in the event of an avian influenza outbreak:
ABVRS installation can be mobilized. This eliminates the need to move infected birds or infected litter from the quarantine area.
The exposure of material to high heat in the ABVRS central processing unit will kill the virus. The avian influenza virus is very fragile and susceptible to heat. Theoretical data suggests that the virus could not survive being exposed to the high-heat temperatures utilized in the ABVRS system.
Although the resulting meal created using the ABVRS technology would end up being pathogen and virus free, it is highly unlikely that it could be sold as a value added product due to perceived contamination problems. However, the resulting meal, in terms of total mass, would be approximately 40% of the original volume of the whole chickens and litter. Disposing of the pathogen and virus-free meal in a landfill would then be much safer and more feasible.
POULTRY TANKAGE
International Protein has successfully produced byproduct meal from poultry tankage containing feathers, sludge, viscera, blood, heads and feet. The meal is quickly processed through the ABVRS central processing unit with a short dwell time of approximately 90 seconds.
The finished meal, which exits the ABVRS at 160 degrees Fahrenheit, can then be pressed to release the poultry oil.