Commission of the European Communities

energy
Inedible rendering by means
of the wet pressing process
Demonstration project

Report
EUR 10652 EN

Commission of the European Communities

energy
Inedible rendering by means
of the wet pressing process
Demonstration project
KOFO Kdfodfabrikken stjyden
DK-8723 Lsning

Contract No EE/084/82

Final report

Directorate-General
Energy

1986

EUR 10652 EN

Published by the
C O M M I S S I O N OF THE EUROPEAN C O M M U N I T I E S
Directorate-General
Telecommunications, Information Industries and Innovation
Btiment Jean Monnet
LUXEMBOURG

LEGAL NOTICE
Neither the Commission of the European Communities nor any person acting on
behalf of the Commission is responsible for the use which might be made of the
following information

Cataloguing data can be found at the end of this publication

Luxembourg: Office for Official Publications of the European Communities, 1986

ISBN 92-825-6519-X

Catalogue number:
ECSC-EEC-EAEC, Brussels Luxembourg, 1986
Printed in

Luxembourg

C O N T E N T S

Page

1. Introduction

2. Objectives of the project

3. Description of the project

4. Implementation of the project

5. Commissioning and operation

6. Measurements

7. Technical and economical results

8. Conclusions and outlook

11

9. References

12

Tables

13

Figures

19

III

1. Introduction
Traditional inedible rendering of offals and waste materials f r o m slaughtering and
meat processing is based on batchwise dry rendering (sterilization and drying in a
cooker) followed by separation of meal and f a t by means of hexane e x t r a c t i o n . This
process has two major disadvantages: 1) The energy consumption is high (approx. 75
kg o i l per ton raw material) and the process does not allow f o r secondary use of the
energy in the exhaust steam f r o m the cookers - 2) Hexane e x t r a c t i o n involves risks
of explosion and the risk of undesirable residues in the e x t r a c t e d f a t and m e a l .
In order to overcome the high energy costs in rendering a new concept f o r the
process of rendering has been developed at the Danish Meat Research I n s t i t u t e in
Roskilde and tested in pilot experiments at a Danish rendering plant. The new
process was termed "wet pressing".
The process is based on the discovery t h a t i t is possible at low temperature
( 5 0 - 6 0 C , just above melting point of the animal f a t ) to separate nearly a l l f a t and
more than 60% of the water f r o m the solids of the raw materials by means of a
pressing process. This has made possible the design of a process w i t h o p t i m i z e d use
of the energy necessary f o r s t e r i l i z a t i o n and removal of w a t e r , thus reducing the
energy consumption f r o m 75 kg o i l per ton raw materials in the t r a d i t i o n a l process
to an expected figure of approx. 35 kg o i l per ton raw materials in the new process.
As a f u r t h e r advantage no organic solvents are needed f o r the new process.
The i n i t i a l work indicated t h a t the pressing of raw materials was feasible but also
t h a t a lot more work had to be done in order to t u r n the process into a f u l l scale
operation.
Thus, an experimental processing line was constructed at the rendering plant KOFO
( f o r m e r l y stjyden) and an extensive R & D work was i n i t i a t e d .
2. Objectives of the project
The project relates to the erection of a f u l l - s c a l e production line f o r converting
inedible o f f a l and the like to meat-and-bone meal and animal f a t by means of the
wet pressing system.
The production line was designed f o r handling 10 tons raw materials per hour at the
cooperative plant of KOFO in Lsning, Denmark.
The line was connected to the existing 5 t / h experimental
constructed and used in the preliminary R & D w o r k .

processing

line,

The project has been divided into two phases, a phase f o r the construction and
running in of the new processing line and a measuring phase.
The objective of the f i r s t phase of the project was to design and construct the
full-scale production line and to show feasibility of the process in f u l l - s c a l e
operation. The objective of the second phase was to obtain key figures for the
energy f l o w in the system and to obtain figures for the energy saving.

- 1 -

3. Description of the project

The basic new principle in the process is the use of a conditioning and pre-pressing
of the raw materials, a process which has never been t r i e d out on rendering
materials. The pressing procedure divides the raw materials in a solid and a liquid
phase, thus enabling the design of a whole operation aiming at minimizing the
energy consumption of rendering.
This is achieved by evaporating 80-90% of the water in the liquid phase f r o m the
press in a vacuum evaporator using waste energy f r o m the drying of the solid phase
f r o m the press. The principle of the process is shown in diagram, Figure 1 .
The wet pressing plant at KOFO is shown in diagram in Figure 2. The existing 5 t / h
plant used f o r the research and development phase is in white whereas the
equipment installed in order to extend the production line to 15 t / h (this project) is
shown in hatching. The energy f l o w system is shown in Figure 3.
O f f a l and condemned animals are prebroken (max. size 70 mm) and transported to a
weighing bin. The raw materials then pass a magnet and a metal detector which in
turn sort out magnetic m a t e r i a l and materials containing non-magnetic m e t a l . The
rejected raw materials are conveyed out of the system and f i n a l l y treated in a dry
rendering cooker. The raw materials freed of m e t a l are hashed to a size of less than
19 mm and indirectly heated w i t h hot water to 60 C in a coagulator. They pass a
strainer screw w i t h adjustable hole size and are then pressed in a t w i n screw press,
which divides the raw materials in two phases, a solid phase (press cake) containing
40-50% water and 4 - 7 % crude f a t on a dry m a t t e r basis, and a liquid phase
containing f a t , water and some solids. The liquid phase is heated to 100 C w i t h live
steam and passed through a 3-phase decanter (tricanter) which separates i t into f a t ,
stickwater and grax. The grax is returned to the coagulator, the f a t is sent f o r
refining and s t e r i l i z a t i o n and the stick water containing 8% dry m a t t e r and 0.6%
crude f a t is pumped into the 3 stage waste heat evaporator for concentration. The
concentrate containing 35% dry m a t t e r ( 8 - 9 % f a t in DM) is mixed into the
presscake, which is dried in a plate contact dryer indirectly heated by live steam.
The meal leaves the dryer at no less than 110 C at which temperature s t e r i l i z a t i o n
is accomplished. The meal has a moisture content of 5-7% and a f a t content of
7-8%. I t is transported to milling by means of a pneumatic transport system. The
dryer gasses pass a scrubber where the particulates are removed f r o m the vapours
and a small proportion of the vapours is condensed. The scrubber liquid delivers hot
water (90 C) to the coagulator via a heat exchanger.
The gasses then pass a heat exchanger where part of their energy is transferred to
the d i s t r i c t heating system. The gasses finally serve as heating medium f o r stage I in
the waste heat evaporator.
The principal equipment used in the 15 t / h wet pressing system is the f o l l o w i n g :
2 hashers:

SIMO 400/190.0, 2F 2500 - 90 kW

1 coagulator:

Atlas OC2-600 - 11 kW

1 strainer screw:

Atlas OC450 - 5 kW

2 t w i n screw presses:

A t l a s - S t o r d BS 35 F - 45 kW

3 dryers:

Atlas PCD 1854 - 110 kW

- 2 -

2 tricanters:

F l o t t w e g Z 4 2 3 / 4 4 18.5/25 kW

1 waste heat evaporator:

Atlas WHE 3084.

In order to enable measurements of energy consumption in the system the following

measuring points were established (the figures refer to Figure 3):

O
D

manual reading
automatic recording

S
04

102J

Temperature of steam f o r dryers

Temperature of condensate f r o m dryers

EU

Pressure of steam f o r dryers

OS

Temperature of gas before scrubber

Temperature of gas a f t e r scrubber

IH)
EU
EU

ED

Temperature in overflow f r o m scrubber

Temperature of gas a f t e r heat exchanger
Temperature of gas a f t e r evaporator, stage 1
Temperature of gas a f t e r condenser f o r evaporator
Temperature of gasses before f i n a l condenser
Temperature of noncondensible gasses a f t e r condenser
Temperature in condensate
Temperature in condensate f r o m evaporator
Power consumption (kWh):

Hashers e t c .
Dryer No. 3 and 4 e t c .
Screw presses e t c .
Dryer No. 5 e t c .
Cooling towers
Pneumatic transport system
Hammer mills etc.
Pump f o r noncondensibles
T o t a l of plant.

Steam consumption f o r dryers

Live steam and flash steam consumption (tricanter)
Amounts of condensate f r o m evaporator
Amounts of condensate f r o m scrubber
Amounts of condensate f r o m various sources
Efficiency of heat exchanger

Measurements and recordings were performed at 60 minutes intervals, except f o r

the recording of t o t a l power consumption, which was done every 24 hours.
3

4. Implementation of the project

As the construction of the plant was expected to be an important and d i f f i c u l t task,
a project management group was made by making the chief engineer responsible for
the technical aspects on a f u l l t i m e basis during the construction period. The
measuring and reporting aspects were the responsibility of an engineer f r o m the
Danish Meat Research Institute being f a m i l i a r w i t h the project as he had been
involved in the pilot experiments f r o m the very beginning. The economical aspects
were taken care of by the managing director of K O F O . These three people formed
the project management groupAs the project required the supply of a l o t of d i f f e r e n t equipment, and as the
process was new and consequently process guarantees could be d i f f i c u l t to obtain i t
was decided not to c a l l f o r tenders for a f u l l process line. Instead the process was
divided in several parts and f r o m a list of potential suppliers i n v i t a t i o n f o r tenders
were invited f o r each part process. This procedure was chosen for the following
reasons:
1) to obtain the highest possible expertise regarding each single part of the process
2) to obtain the best possible guarantees as to the individual parts of the process
3) to achieve competitive prices
In certain cases i t was necessary to test equipment f r o m alternative manufacturers
before deciding which equipment to buy.
The result was t h a t 21 companies made tenders f o r the most important parts of the
project, and out of these 12 were chosen to supply the equipment.
The suppliers (and sub-contractors) chosen were as follows:

4 -

Sub-contractor

Equipment

Supplier

Equipment for raw

m a t e r i a l handling

Svrtek, S t r i b ,
DK-9500 M i d d e l f a r t

1 hasher

Zias-Trading
DK-4220 Korsr

1 coagulator

stjyden,
D K - 8 7 2 3 Lsning

1 screw press

A t l a s , D K - 2 7 5 0 Ballerup

2 PCD-dryers

A t l a s , D K - 2 7 5 0 Ballerup

1 tricanter

Crnicas, London

Simotek,
DK-4200 Slagelse

F l o t t w e g Werk,
D-8313 Vilsbiburg

A t l a s , D K - 2 7 5 0 Ballerup
1 evaporating system
Pneumatic meal transport Fjordvejens Maskinfabrik,
D K - 7 8 0 0 Skive
Ventilation of process
air

Strm & Petersen,

D K - 7 1 0 0 Vejle

Steam transfer

Svrtek, Strib
DK-9500 Middelfart

Installation of dryers
and evaporator

Centrum Isolering,
DK-7100 Vejle

E l e c t r i c installations

Horsens E l e k t r o ,
D K - 8 7 0 0 Horsens
Damstahl,
D K - 8 6 6 0 Skanderborg

Stainless steel tubes

The coordination and planning of the deliveries and the responsibility f o r assembling
a lot of d i f f e r e n t equipment into a process line was taken care of by the chief
engineer.
The construction phase was concluded according to plan and no real d i f f i c u l t i e s were
encountered during construction.
5. Commissioning and operation
During commissioning a number of problems were encountered and solutions sought.
Some major problems are listed below:
Mechanical drive f o r the coagulator often broke down due to overloading. Has
been replaced by a more r i g i d construction.
Bearings in t r i c a n t e r were leaking at high temperatures. Replaced.
Transfer of grax f r o m the t r i c a n t e r into the dryer had to be abandoned due to an
occasionally rather high f a t content in the grax. Grax is now returned to the
coagulator.
-

Ventilator for dryer broke down frequently. Was placed immediately

scrubber. Moved to a position a f t e r the condenser f o r the evaporator.

- 5 -

after

C i r c u l a t i o n pump f o r the evaporator was unable to pull out viscous concentrate.

A concentrate pump was installed.

The heating of the liquid before the t r i c a n t e r and the proper separation of the three
phases in the t r i c a n t e r is one of the more t r i c k y parts of the wet pressing system. In
f a c t , the amount of energy used f o r heating was far higher than expected f r o m
t h e o r e t i c a l calculations (see below).
Development work is s t i l l going on in order to design a system which
1) minimizes the energy consumption
2) results in a good separation of the three phases in the t r i c a n t e r
3) is easily controlable
C e r t a i n other operational problems have been experienced during the long t e r m
testing of the system:
-

Temperature c o n t r o l of meal at discharge f r o m dryers has been inaccurate and

unreliable. Various electronic components have been replaced w i t h more reliable
electronic hardware.
Excess wear of plates in dryer has been discovered. The wear only takes place in
certain positions. This may mean a serious reduction in l i f e expectancy of dryers.
Solutions are being sought in collaboration w i t h the supplier.

However, i t should be stated t h a t no major problems have shown up during the

operation of the plant, thus proving the feasibility of the process on an industrial
scale.

6. Measurements
Measurements of energy consumption took place in the spring of 1984, the f i n a l
calculations being based on 20 production days, or a t o t a l of 460 production hours.
KOFO runs various productions: Production of meat-and-bone meal and animal f a t
by means of wet pressing and by means of a batch cooking system followed by
solvent e x t r a c t i o n , processing of hogs' hair into a hydrolized meal and a production
of a pulp f r o m chicken o f f a l . Energywise these productions are mixed up and cannot
be separated. Consequently the calculation of energy consumption in the wet
pressing system in parts had to be carried out in an indirect manner.
The following procedure was applied:
Evaporated water leaves the system as condensate f r o m the scrubber and f r o m
various condensers and drains (Pos. , O and R in Figure 3). The amounts have all
been measured.
F u r t h e r m o r e , some water (M t/h) leaves the system w i t h the non-condensibles. The
average temperature of these gases was 42 C (Table VI), = 100%, p~ = 8365 Pa,
R~ (gas constant) = 461.52 N m / k g and the flow (measured) = 1866 m 7 h :
M
M

x-

8365 1866
461.52(273 + 42) 1000

- 6 -

n n

.,.
t/h

The water leaving the system consists of water f r o m raw materials and f r o m added
w a t e r , i.e. live steam and flash steam injected into the press liquid before the
t r i c a n t e r . These amounts are measured (pos. M and N , Figure 3) and subtracted.
Table I shows the recordings and calculations of figures f o r evaporated
each measuring period (normally 24 hours).

water in

During measuring a t o t a l of 3302 t water has been evaporated. The dry m a t t e r yield
(meat and bone meal plus animal f a t ) in the corresponding period was 44.7%. Thus,
the amount of raw materials t r e a t e d in the wet pressing system during measuring,
X , is

x=_2g2

5jmi

or 13 t raw materials per hour ( t o t a l : 460 h) as compared to the expected 15 t / h .

L i v e steam is used as heating medium f o r the dryers and is also injected into the
press liquid before the t r i c a n t e r in order to increase the temperature of the liquid t o
approx. 100C. The amounts of steam used have been measured (pos. I, K, L and N in
Figure 3), and converted to kg o i l , using the figures f o r the KOFO boilers, i.e. 14.87
kg steam per kg fuel o i l .
The day to day and overall figures f o r steam and f u e l o i l consumption in the
measuring period are shown in Table I I .

PCD 3 used
4 5 -

in

460
460
460

638.6
933.3
1020.3

t steam
- - -

3 PCD'sused

in

460

2592.2

t steam (or 5.6 t steam/h)

corresponding to

174,324 kg fuel oil (or 380 kg oil/h)

Likewise, the fuel o i l consumption f o r the dryers can be related to evaporated water
or raw materials t r e a t e d :
52.8 kg fuel o i l per t water evaporated or
29.2 kg f u e l o i l per t raw materials.
Similar figures can be calculated f o r th t r i c a n t e r :
Steam consumption over 460 h: 328.7 t (0.7 t / h ) corresponding to
fuel o i l consumption over 460 h: 22,105 kg (48 kg/h)
A l t e r n a t i v e l y the t r i c a n t e r used
6.7 kg fuel o i l per t water evaporated or
3.7 kg fuel oil per t raw materials.
I t should be noted t h a t the t r i c a n t e r f u r t h e r m o r e used
125.1 t flash steam during the measuring period, or
350 kg flash steam per hour.

- 7-

Roughly speaking 150 kg f a t + 250

before entering the t r i c a n t e r f r o m
steam is needed for t h a t . In f a c t 54
f o r the purpose of heating the press
times the t h e o r e t i c a l amount.

kg water per ton raw materials w i l l be heated

50 to 100 C and theoretically approx. 30 kg
kg live steam plus 27 kg flash steam were used
liquid f r o m 1 t raw materials, i.e. nearly three

Energy, in the f o r m of live steam is also used f o r refining and sterilizing the f a t
f r o m the t r i c a n t e r . The f a t contains on average just over 1 % of water. This water is
evaporated during s t e r i l i z a t i o n of the f a t (heating the f a t to 125 C for several
hours). However, this procedure which is an indispensable part of the system (e.g.
required f o r veterinary reasons) has not been included in the measuring programme,
since f a t f r o m various sources are mixed up in the refinery.
The theoretical energy consumption in r e f i n i n g , however, may be calculated as
follows:
One ton of raw materials produces 150 kg
Heating 150 kg f a t f r o m 100C to 125C
approx. 2.700 k c a l , corresponding to 0.3 kg
of f a t uses 0.3 kg fuel o i l / t raw materials or

f a t plus 1.5 kg water f o r the r e f i n i n g .

and evaporating 1.5 kg water require
fuel o i l . Thus, s t e r i l i z a t i o n and refining
0.6 kg fuel o i l / t water evaporated.

Consequently, the t o t a l fuel o i l consumption for wet pressing is

60.1 kg per t of water evaporated or
33.2 kg per t of raw materials
Part of the heat in vapours f r o m dryers which cannot be utilized in the evaporator is
sold to the local d i s t r i c t heating system. These calories are also tabulated in Table
I I . A t o t a l of 310 Gcal was delivered during the measuring period, corresponding to
35 t of fuel o i l . The fuel o i l consumption during the measuring period was 196 t ,
which means t h a t nearly 20% of the input energy is recovered and u t i l i z e d for
d i s t r i c t heating purposes. Using an overall view on energy one may say that the fuel
o i l consumption in rendering at stjyden by means of wet pressing is not 60.1 kg per
t water evaporated as calculated above but 49.4 k g / t due to the u t i l i z a t i o n of waste
heat. This, however, has nothing to do w i t h the wet pressing system as such and,
indeed, a similar use of waste energy has taken place for years at KOFO in
connection w i t h their traditional rendering system.
The daily figures for fuel o i l consumption and for the evaporated amounts of water
are summarized in Table III which also includes calculated figures for kg oil per t
evaporated w a t e r .
Similarly to the recording of fuel oil consumption the consumption of electric power
has been measured. Figures for each measuring day are shown in Table IV. I t may be
noted that a d i r e c t recording of energy usage in the milling of wet pressed meal is
impossible as meals f r o m solvent e x t r a c t i o n and f r o m pressing are milled s i m u l t a neously. I t was assumed that 50% of the power consumption in milling could be
assigned to the wet pressing system.
The figures are summarized in Table V in which also the electric power consumption
for various parts of the plant is calculated in relation to tonnes evaporated water
and tonnes raw materials t r e a t e d . The overall figures are
125 kWh/t of evaporated w a t e r , or
69.1 kWh/t of raw materials t r e a t e d .
- 8 -

It should be noted that the dryers are by far the most power consuming part of the
machinery, using nearly 40 kWh/t raw materials or more than 55% of the total.
The kWh's used on each measuring day per ton water evaporated are calculated and
tabulated (Table III).
Temperatures in various parts of the system were automatically recorded by a data
logger every hour in the measuring period (pos. 0005, 0918, Figure 3). Ranges and
average figures for temperatures are shown in Table VI.
7. Technical and economical results
Energy savings in the 10 t/h wet pressing production line may be calculated by
comparing the energy consumption in the measuring period with the energy
consumption at KO FO in one year immediately preceeding the installation of wet
pressing.
The savings will be related to the expected production of 50,000 t/year although the
capacity of the production line (the combined 5 t/h R & Dplant and the project) lies
1015% below that.
Fuel oil consumption 1781 to 30682:
Raw materials 1781 to 30682:
Own production of electricity 1781 to 30682:
Fuel oil used for electricity production:

8,693 t
124,857 t
5,576,240 kWh

o%fVi gofT

568,593 kg

Average dry matter yield (1781 to 30682):

43%

Average electrical power consumption (1781 to 30682):77.8 kWh/t raw materials

or
136.5 kWh/t water evaporated
Energy savings for 50,000 t/year:
r . ,
Fuel oil
Electricity
Total saving:

(65.1 33.2) 50,000

-*
000
(77.8 - 69.1) 50,000 8.6 IO" 5
1,632 toe

The costs of the plant are as follows (less VAT):

- 9 -

, .
^595 toe

= 37 toe

Construction and erection

D.Kr.

Equipment for raw m a t e r i a l handling

^ - ^ Hasher
Coagulator and strainer screw
Screw press, dryers, evaporating system
Tricanter
Pneumatic meal transport
Ventilation of process air
Steam transfer
Insulation
Cooling towers
E l e c t r i c installations
Stainless steel tubes

349,937
253,850
840,000
OHU,UUU

11,777,612
612,856
430,386
193,952
256,606
180,357
735,579
1,007,786
116,059

T o t a l , construction and erection

16,754,980

Measurements and reports

Apparatus and installation
Data collection

72,586
37,400

Reporting

34,710

T o t a l , measurements

144,696

T o t a l costs of the project

16,899,676
The c a p i t a l costs are accordingly (based on D.Kr. 16,754,980, an estimated l i f e of
equipment of 7 years and an interest rate of 14% p.a.):
Depreciation
Interest

2,393,569
1,172,849

Total
or

D.kr.
-

3,566,418
D.kr.
71 D . k r . / t raw materials

The operating costs may be calculated as follows (based on 1984-prices, 3 men per
shift in 3 shifts and a supervisory staff of 3 persons):
Fuel oil 33.2 50,000 2,038
E l e c t r i c i t y 69.1 50,000 0.30
Labour costs 3 3 180,000 + 3 300,000
Maintenance 0.03 50,000 1,000

3,383,080
1,036,500
2,520,000
1,500,000

D.kr.
-

Total

8,439,580

D.kr.

169

D.kr.

Cost per t raw materials treated

- 10 -

The overall costs (Operating and c a p i t a l costs) are thus 240 D . K r . / t raw materials.
A calculation of the economical v i a b i l i t y of the new system compared w i t h
conventional rendering may lead to the following figures (all costs based on 1984
figures):
Savings in energy consumption (p.a.):
Heavy fuel o i l saved 1,595 2,038 =

3,250,610

kWh saved: (77.8 - 69.1) 50,000 0.30 =

130,500

D.kr.
-

Savings in the cost of materials consumed (p.a.):

Hexane saved: 450,000 2.75 =

1,237,500

D.kr.

180,000
500,000
5,298,610

D.kr.
D.kr.

Savings in other costs

Labour costs (less one man)
Maintenance costs
T o t a l annual savings =
Pay back period

5 298 610

= 3.2 years

8. Conclusions and outlook

The wet pressing process has now been successfully tested under real production
conditions and the tests have proven that d i f f e r e n t types of o f f a l can be processed
by the procedure. A number of minor modifications of the system has been made as
a result of the project.
An energy consumption of 33.2 kg oil and 69.1 kWh per unit of o f f a l handled, or 60.1
kg fuel and 125 kWh per ton water evaporated have been found. An annual saving of
1,632 toe was recorded f o r the wet pressing system compared to the conventional
system at KOFO (based on a throughput of 50,000 t o f f a l per year).
There are no real technical problems outstanding in the development of the wet
pressing process although the problem discovered about excess wear of certain
plates in the dryer ought to be solved in order to avoid a short l i f e - t i m e of the
dryers. Improvements ought to be made in the heating system f o r t r i c a n t e r fluids
and in the controlling of the f l u i d temperature.
An o p t i m i z a t i o n of the whole separation process in the t r i c a n t e r seems indicated.
A l l leads to the assumption t h a t the commercial potential is high and t h a t there are
no real obstacles to a successful industrial development of the system. In f a c t , the
wet pressing system, as marketed by Atlas Danmark, is installed in three Danish
plants w i t h a rated throughput of 50 t raw materials per hour in t o t a l . To our best
knowledge the system is also in use in one German and one Irish plant, and a 14 t / h
plant is being installed in the USA. Equipment for the wet pressing system is
delivered f r o m a number of EEC manufacturers, e.g. the evaporating system,
coagulators and dryers are produced in Denmark, the t r i c a n t e r in Germany, and in
future the presses in I t a l y , thus creating new jobs in a number of EEC countries.
- 11

Finally, i t may be mentioned that a considerable number of visitors f r o m a l l over

the world has been visiting KOFO in order to study the wet pressing system, among
others the technical c o m m i t t e e of the Union of Associations of European Meat Meal
Producers, a visit which was described in an a r t i c l e in the German magazine "Die
Fleischmehlindustrie" (1). A t annual general meetings of the above EEC-union and
of the National Renderers Association, USA the wet pressing system has been
described in d e t a i l . Papers describing the system have appeared in the "National
Provisioner" (USA) (2) and the American magazine "Render" (3).
9. References
(1)

Braun, S. (1983): Das knnte ein neuer Weg sein. Die Fleischmehlindustrie 35
(3), 6 1 .

(2)

Anon (1984): Renderers move to enhance their share of world markets. N a t .

Prov. 191 (21), 10.

(3)

Burnham (1984): Update: New European Systems. Render 13 (3), 12.

- 12 -

Table I:

Evaporated water during measuring

Measur
ing

Hours

period

V>J

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

24
24
22
20
24
24
24
24
26
24
24
24
18
25
24
24
24
19
24
18

460
Total
Averag per h
Temper ature
Density

Pos .
(Scrubber)
3
ton
m

Pos . R
(Miscellaneous)
3
ton
m

9.2

8.9

12.2

11.8

8.6
6.2

8.3
6.0

12.7

12.3

4.5
4.9
3.4
6.1

4.4
4.8
3.3
5.9

11.3
10.8

11.0
10.5

8.9
5.9
8.1

8.6
5.7
7.9

10.3
11.7
15.2
12.0

10.0
11.3
14.7
11.6

5.5
5.2

5.3
5.0

85.1
80.5
77.9
57.0
73.4
92.8
92.8
74.0
74.3
81.8
94.3
106.6
78.2
91.3
94.7
92.6
87.2
79.5
86.4
70.1

167.3
0.36

70.0
77.6
58.7
81.0
70.1
75.9
117.7
70.4
55.2
69.1
59.0
140.6
84.1
58.2
62.2
65.9
66.6
49.3
47.7
65.0

0.97

69.3
76.8
58.1
80.2
69.4
75.1
116.5
70.0
54.6
68.4
58.4
139.2
83.3
57.6
61.6
65.2
65.9
48.8
47.2
64.4
1430.0
3.11

Non

condens
ables
(ton)

0.99

Flash
steam

Live
steam

(ton)

(ton)

2.6
2.6
2.5
2.4
2.6
2.6
2.6
2.6
2.7
2.6
2.6
2.6
2.2
2.7
2.6
2.6
2.6
2.3
2.6
2.3

(6.3)
(6.3)

50.9
0.11

125.1
0.27

35

55

90

( ) Estimated (average) values

84.2
79.7
77.1
56.4
72.7
91.9
91.9
73.3
73.6
81.0
93.4
105.5
77.4
90.4
93.8
91.7
86.3
78.7
85.5
69.4
1653.9
3.60

Pos . 0
(Evaporator)
3
ton
m

0.99

4.9
4.9
4.3
6.0
5.3
4.1
6.3
7.3
9.4
7.2
7.2
7.6
5.4
8.4
8.5
6.9
4.6
4.2

18.3
18.4
16.3
16.4
18.2
18.8
18.7
14.0
16.1
17.5
18.1
17.9
13.7
16.0
(16.3)
15.7
15.4
11.8
17.5
13.6
328.7
0.71

Total
evapo
rated
(ton)
189.6
195.6
167.2
166.3
179.5
198.8
239.8
167.3
159.2
187.8
192.4
281.0
189.5
182.2
189.7
194.9
193.1
160.4
162.7
158.9

Total
evapo
rated from
raw

materials
165.0
170.9
146.0
145.0
157.0
174.0
215.8
149.2
136.8
163.0
164.9
255.9
168.6
158.6
168.0
170.8
169.2
141.7
140.6
141.1
3302.1
7.18

Table H:

Fuel oil consumption per period during measuring

Measuring
Hours
period

L ive steam
PCD 3 PCD 4 PCD 5 Tricanter Total
(pos I) (pos K) (pos L) (pos N)
(ton)
(ton)
(ton)
(ton)
(ton)

District heating
Converted to kg.
Convertfuel o i l r ; Gcal ed to kg
oil

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Total

24
24
22
20
24
24
24
24
26
24
24
24
18
25
24
24
24
19
24
18

27.5
26.2
48.9
19.9
18.4
32.6
16.7
51.7
25.1
28.6
30.8
31.0
47.0
32.0
29.8
33.5
32.3
51.0
29.2
26.4

51.9
49.2
46.2
35.6
47.1
50.3
46.0
12.7
69.1
50.2
51.4
55.3
43.4
48.2
52.1
49.8
47.9
45.3
44.4
37.2

55.5
54.3
58.3
40.6
50.3
52.4
52.9
55.7
45.3
50.5
52.7
69.2
41.6
50.9
52.7
52.5
49.9
52.1
47.2
35.7

460

638.6

933.3

1.39

2.03

Average per h

1) Conversion factor:
( )

18.3
18.4
16.3
16.4
18.2
18.8
18.7
14.0
16.1
17.5
18.1
17.9
13.7
16.0
(16.3)
15.7
15.4
11.8
17.5
13.6

153.2
148.1
169.7
112.5
134.0
154.1
134.3
134.1
155.6
146.8
153.0
173.4
145.7
147.1
150.9
151.5
145.5
160.2
138.3
112.9

10303
9960
11412
7566
9011
10363
9032
9018
10464
9872
10289
11661
9798
9892
10148
10188
9785
10773
9301
7592

20.0
18.4
15.3
7.9
14.0
18.9
11.3
15.5
13.7
17.9
22.0
10.3
9.0
22.8
23.4
19.1
19.5
15.6
10.5
5.5

2279
2097
1743
900
1595
2154
1288
1766
1561
2040
2507
1174
1026
2598
2667
2177
2222
1778
1197
627

1020.3

328.7

2920.9

196429

310.6

35396

2.22

0.71

6.35

427

0.68

76.9

1,000
14.87

2) Conversion factor:

Estimated (average) values

- 14 -

1,000
9.75x0.9

Table III:
Measuring
period

Specific power consumption (oil and electricity) during measuring

Hours

Oil
consumption
(kg)

Evaporated
from raw
materials (t)

Kg fuel oil
per t
evaporated
water
62.4
58.3
78.2
52.2
57.4
59.6
41.9
60.4
76.5
60.6
62.4
45.6
58.1
62.4
60.4
59.6
57.8
76.0
66.2
53.8

133
121
138
117
122
127
89
140
137
129
135
85
121
133
128
131
137
145
149
126

59.48

125

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

24
24
22
20
24
24
24
24
26
24
24
24
18
25
24
24
24
19
24
18

10303
9960
11412
7566
9011
10363
9032
9018
10464
9872
10289
11661
9798
9892
10148
10188
9785
10773
9301
7592

165.0
170.9
146.0
145.0
157.0
174.0
215.8
149.2
136.8
163.0
164.9
255,9
168.6
158.6
168.0
170.8
169.2
141.7
140.6
141.1

Total

460

196429

3302.1

Per t aw materieus:

32.9

- 15 -

kWh per t
evaporated
water

69.1

Table IV:

E l e c t r i c power consumption (pos. A - ) during measuring

Measur

ing

Hours

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

24
24
22
20
24
24
24
24
26
24
24
24
18
25
24
24
24
19
24
18

Total

460

period

Pos.

A
kWh

Pos.

kWh

Pos.

C
kWh

Pos.

D
kWh

Pos.

Pos.

5 0 % of
Pos. G

Pos.

838

1965
1903
2275
1933
2123
2003
2305
2485
1873
2013
2038
2128
2115
1660
1813
1685
1915
1573
1673
1560

208
206
195
179
151
207
175
210
193
190
186
168
179
196
199
197
170
181
208
154

21881
20594
20213
16796
19143
22183
19120
20791
18791
21058
22340
21834
20450
21046
21537
22432
23247
20496
20991
17686

21479

39038

3752

412629

E
kWh

F
kWh

1168
1135
1154

1158
1014
1131
1002
1092
1170
1067
1155
1071
1126

3068
3040
2952
2588
2872
3200
2904
3176
2888
2948
3168
3008
3012
3172
3112
3148
3176
3048
3100
2336

7896
7120
6824
5288
6148
8192
5724
7060
6340
7412
8068
7760
7068
7632
7628
8408
8544
7744
7576
6664

1620
1540
1280
1280
1360
1440
1320
1300
1400
1460
1540
1400
1200
1460
1440
1500
1560
1240
1340
1060

4798
4636
4402
3532
4320
4846
4272
4212
3952
4634
5048
4682
4324
4566
4674
4782
4958
4172
4402
3612

1077
1125
1353
1193
1074
1275
1293
1568
1463
1412
1522
1684
1745
1511
1576
1462

59916

145096

27740

88824

26784

994

999

1120
1089

948

1149
1028
1179
1027
1116

kWh

H
kWh

Total

kWh

Table V:

Electric power consumption in wet pressing

Total for
period
(kWh)

kW

kWh/t
kWh/t
raw
evaporated
water
materials

Hashers, evaporator, t r i c a n t e r s ,
raw materials to process e t c . (Pos. A)

59916

130

Presses, conveyors (Pos. C)

27740

60

233920

509

Cooling towers (Pos. E)

26784

58

8.1

4.5

Pneumatic meal transport (Pos. F)

21479

47

6.5

3.6

M i l l i n g ( i Pos. G)

39038

85

11.9

6.6

3752

1.1

0.6

412629

897

Dryers (Pos. B + D)

V e n t i l a t o r f o r noncondensibles (Pos. H)
Total

-17-

18

8.4

71

125

10

4.6

39

69.1

Table VI:

Temperature measurements
Pos.

Lowest - highest
recorded

Average

Temperature of steam f o r dryers

00
01
02

158-65

162

Condensate f r o m dryers

03
04
05

129-39

133

Dryer gas before scrubber

09

87-101

98

Dryer gas a f t e r scrubber

10

78-94

85

Overflow f r o m scrubber

11

65-94

88

Dryer gas a f t e r heat exchanger

12

72-93

83

Gas f r o m evaporator 1 . stage

13

54-84

67

Gas f r o m evaporator a f t e r condenser

14

20-42

32

Gas before f i n a l condenser

15

50-84

66

Noncondensibles

16

30-64

42

Condensate f r o m f i n a l condenser

17

40-75

62

Condensate f r o m evaporator condenser

18

31-46

38

All figures: Degree Centigrade

- 18 -

werefl

^o

6.

OP FM.

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OIN

CRUSHee
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ni f e r i a i

I k/

OFFL
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QlM

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EXISTI t / 6

/s,,//////////,

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M C AL

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,
Z777777777777

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MILLIN

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FIG.

20

FAT

Readings every 60 minutes (_)

Recording by datalogger

I
ro

-+-^

[^

European Communities Commission

EUR 10652 Inedible rendering by means of the w e t pressing process
Demonstration project
KOFO Kdfodfabrikken

stjyden

Luxembourg : Office for Official Publications of the European Communities

1986 III, 21 pp., 6 tab., 3 fig. 21.0 29.7 cm
Energy series
EN
ISBN 928256519X
Catalogue number :1
Price (excluding VAT) in L uxembourg
ECU 4.50
BFR 200
L
IR 3.20
UK
L

2.80

USD 4.50

The rendering of offal and waste materials from slaughtering and meat
processing is based traditionally on batchwise dry rendering followed by separa
tion of meat and fat by means of solvent extraction.
The energy consumption in such a process is high, i.e. of the order of 75 kg fuel
oil per tonne raw materials having an average water content of nearly 60 /o. A
new energysaving process has been developed based on a conditioning and
prepressing of the raw materials at temperatures of the order of 60 C. The
pressing procedure divides the materials into a solid phase with low fat content
and a fluid phase containing more than 60 /o of the total water and nearly all the
fat. The solid phase is dried in an indirectly heated drier. The fat from the fluid
phase is removed in a tricanter. 8090 % of the water in the resulting liquid
phase is removed in a threestage vacuum evaporator using waste heat from the
driers as heating medium. Pilot experiments have indicated that such a process
is feasible and that the energy consumption in the process would be of the order
of 35 kg fuel oil per tonne.
The objective of the present project was to design and construct a fullscale
production line using the wet pressing system, to demonstrate the feasibility of
the process in fullscale operation and to obtain key figures for the energy
consumption. The project was carried out at the Danish cooperative rendering
plant KOFO in L sning.
It was proven that the process with minor modifications is highly feasible
in largescale operation. The measuring of energy consumption showed the
following figures :
(i) 33.2 kg fuel oil per tonne offal or 60.1 kg per tonne water evaporated, and
(ii) 69.1 kWh per tonne offal or 125 kWh per tonne water evaporated.
An annual energy saving of 1 632 toe was recorded for the wet pressing system
compared to the conventional process formerly used at KOFO and based on a
throughput of 50 000 t offal per year.

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