I worked in the rendering industry for 11 years. It has went through a large change in the last few years since Mad Cow. Integrated renders don't stink? B.S., Was coming through Austin Minnesota on January 6, 2013, yep Hormel still runs an integrated rendering plant, last I knew a Dupps 1800 cooker with a super shaft and a waste heat evaporator and I could smell it on I-90. Same day I smelled one in Mason City Iowa and Green Bay Wisconsin too!
With Mad Cow there was a firewall put in place that prohibits the use of ruminant derived proteins in feed for ruminants. We as an industry missed the market trend, when the firewall went in place we figured the price of porcine derived meat & bone meal would spike, it didn't, it settled in in a trend that follows soy bean meal as they can be interchanged in rations almost 1 for 1.
Fats can be used as a fuel or run through another process to make Bio diesel. The company I worked for in Green Bay also had a marketing company that sold tallows and greases as boiler fuel and equipped their boilers to run on this fuel.
Processes, the article talked about cookers and running at 220 degrees, most plant's I've been in the cookers are under a vacuum and they usually cook at less than 190 degrees. The lower you can cook the less damage to the protein and the less fuel used to cook the water off. One really great day I ran poultry offal most of a shift between 160 and 165 degrees. There are continuous cookers that run under a vacuum. Batch cookers that may run under pressure or a vacuum. Some plants use evaporators were the materiel is heated in shell and tube heat exchangers, at various stages the material is run through a vacuum that pulls the water vapor out. I also worked at a plant that had a wet rendering process that heated with a shell and tube exchangers and separated fats solids and water through a series of centrifuges and used a dryer to dry the solids enough to make them safe to store without spoilage.
Feathers are run through a different process, either in a batch hydrolizers or continuous hydrolizers. If processed correctly you get 80% protein with good palatable and digestibility. One plant I worked in when we ran good feathers you would salivate because of the smell, actually it smelled like something you wanted to eat. I have worked in plants that also used batch hydrolizers to cook hide trimmings and fleshings to soften them up enough to be able to be run through a rendering process.
As well as meat scraps, dead and fallen animals and slaughter house waste renders also run waste cooking oil. Waste cooking oil is the stuff the restaurants throw out from their fryers and oils cooked off in restaurants or food processing plants. Some renderers also clean out grease traps and process the solids and greases out of them, usually the grease is of such low quality and attempt to feed it back to animals results in palatability problems (they won't eat it).
Products: Meat and Bone meal- solids recovered from the rendering process usually about 50% protein. Poultry meal- solid recovered from rendering of poultry products, typically the spec is 60%. Quality factors are the lighter the color the better and the more "powderey" it is indicates higher quality. Poultry meal is usually sold at a premium and into the companion animal feed market. In fact many of the contracts with the poultry processors are the poultry firm gets all the oil back and equivalent tonnage of meat & bone meal and the renderer collects a service fee and sells the poultry meal.
Greases and oils Tallow (fancy, extra fancy, bleachable fancy, technical, feed grade) Choice white grease (pig fat), Yellow grease (restaurant grease) and Brown Grease (from grease traps or reclaimed from other processes that heat or burn the grease and mess it up) Quality indications on greases and oils are color (the closer to clear the better) the amount of Free Fatty Acids and the hardness (melting point)
Feather meal, Bone meal and blood meal
Rendered products are used in Bio fuels, organic fertilizers as well as animal feed for companion or production animals.
In the last ten years the industry has undergone consolidation, both the firms I worked for have been swallowed up by bigger firms. One firm I worked for was in the 5th generation of family ownership spanning 120 years before it bought out it's competitor to the west and then itself selling out to a competitor headquartered in Canada. One of the business problems we were having was the cost of liability insurance. In another deal we saw the largest street renderer absorb the 2nd and 3rd largest rendering companies in the business.
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