Dry Rendering Optimizer
Get more value from every batch with a rendering upgrade that delivers clear, measurable gains. The Alfa Laval Dry Rendering Optimizer transforms your existing dry rendering line into a high-efficiency hybrid or fully automated wet rendering system, reducing energy and operating costs by up to 40 %. Increase protein levels by up to 5 % and boost high-purity fat yields by more than 10 %. It helps you reduce expenses, raise product quality, and run a more profitable, resource-efficient operation.
Increase the protein-meal quality and fat yield with an energy-efficient rendering system
- Increase the protein content in the 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
- Boost fat yield by more than 10% with a higher-quality animal fat for use in biofuel production
- Reduce carbon emissions through energy-efficient process, waste heat utilization and reuse of utilities
Maximize resource efficiency and product value with minimal investment by upgrading your legacy dry rendering system to the Alfa Laval Dry Rendering Optimizer. It recycles heat from the drying process, reducing energy costs and delivering significant savings.
Responsible resource utilization in animal agriculture goes beyond processing efficiency. By maximizing protein recovery and minimizing energy waste, the Dry Rendering Optimizer helps animal by-products processors meet environmental standards while improving profitability.
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
How does the Alfa Laval Dry Rendering Optimizer work?
Depending on your facility’s production goals and existing infrastructure, there are two distinct upgrade paths: (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.
Upgrading option 1: Alfa Laval Dry Rendering Optimizer Hybrid
Cut energy costs and boost sustainability with the Alfa Laval Dry Rendering Optimizer Hybrid. With a minimal upgrade, you can turn your existing dry rendering plant into a high-efficiency hybrid system, reducing energy use by approximately 40%.
To achieve these energy savings and lower your carbon footprint, the upgrade includes:
- Raw material grinding and heavy-duty pumps for smoother, more efficient processing
- A DSI heater for fast, reliable heating with less energy waste
- A two- or three-phase decanter to efficiently separate water, fat, and solid (solid will be sent to the existing dry rendering system)
- A waste heat evaporator that captures and reuses heat from the cooker instead of letting it go to waste
The result: the same reliable meal and fat quality as conventional dry rendering – with the option to add a three-phase decanter for premium, wet-rendered-quality fat that can generate additional revenue through higher-value products.
Upgrading option 2: Dry Rendering Optimizer as a complete wet rendering system
Transform a conventional dry rendering line into a fully integrated, low-fat wet rendering system. This advanced solution maximizes protein recovery and improves fat purity through state-of-the-art mechanical separation.
The Alfa Laval Dry Rendering Optimizer converts an existing dry rendering processing line for animal by-products into a complete, automated Alfa Laval wet rendering system. The upgrade optimizes energy efficiency while enhancing end-product quality and yield.
To convert a conventional dry rendering line into a complete wet rendering system, the upgrade requires all raw material handling components used in the hybrid system, plus:
- An Alfa Laval fat-stripping decanter for initial fat extraction before the two-phase decanter
- A separator skimmer to remove all light-phase material from the water phase before concentration in the waste heat evaporator
Removing the light-phase material from the water phase alters the drying profile, potentially requiring careful evaluation of the existing expeller's press capacity. Alfa Laval can assess drying requirements and recommend solutions to meet additional capacity needs.
Reducing fat content in meat and bone meal allows manufacturers to achieve up to 5% higher protein than conventional dry-rendered meal, or maintain similar protein levels with lower fat content. Optimizing the moisture content also minimizes thermal damage, delivering meal yields comparable to those from dry rendering while maintaining high-quality protein.
Optimizing dry rendering processes for 40 % energy savings and improved protein and fat quality and yields
Animal fat, bone meal, and processed animal protein 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 a higher yield.
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Services voor voedingsmiddelensystemen
Alfa Laval Services voor voedingsmiddelensystemen helpen de prestaties van uw systemen uit te breiden door de prestaties van uw processen te maximaliseren. Zo kunt u:
- Uw activiteiten voortdurend verbeteren om concurrentievoordeel te behouden
- Focussen op uptime, optimalisatie en beschikbaarheid
- Het rendement op uw investering maximaliseren gedurende de hele levenscyclus van uw systemen voor voedingsmiddelen
