Together with the support of his partners, LM10 has acquired MORC,
the largest rendering plant in the Philippines, in order to produce:
Feather Meal, Blood Meal, Poultry Meal and Poultry Oil.
The poultry rendering process handles the by-process of the poultry slaughter process. The poultry by-products that are not intended for human consumption are transformed into valuable proteins, minerals and oils.
APPLICATION OF THE ANIMAL BY-PRODUCTS
None of the poultry by-products are thrown away! However, to use the poultry by-products in other processes they have to be treated first. Our systems transfer the poultry by-products into Meat and bone meal, Whole meal, Feathers meal, Blood meal and fats/tallow/oils. This process is called rendering. These meals can be sold to the pet food industry, feed industry etc. and the fats to the pharmaceutical industry, chemical industry, oil industry and many other. The way of processing determines the value of the end products. This is why we claim “Rendering is not waste handling it’s nutrient management!
PROCESSING POULTRY BY-PRODUCTS
The processing of the poultry by-products starts with raw material handling, followed by heat treatment to reduce the moisture content and to kill micro-organisms. Separation of the melted oil from the solids (protein) is achieved through draining and pressing. The solid fraction is then ground into a powder, such as whole meal, poultry meat meal, feather meal, blood meal and poultry oils. The oil can be clarified through decanting or settling.
COMPACT RENDERING PLANTS
In the Philippines, the average size of a chicken is between 1.2 to 1.4 kilos, so the waste generated by local Dressing Plants is low in terms of mass. The thinking goes that when the volume of waste is relatively low, spending a lot of money installing large-scale Rendering Plants will not give a good return on investment. So in order to keep a good return on investment, the initial capitalization should be minimized.
Compact Rendering Plants suit low-waste facilities and offer the advantage of having a smaller initial investment. Like large-scale plans, our Compact Rendering Plants can take care of processing mortality, feathers, blood and any other animal waste not consumable to humans.
For more information on LM10’s Compact Rendering Plants, please watch the video.
LM10 PROJECT LOCATIONS
LARGE SCALE RENDERING PLANTS
LM10 is a fast-growing company operating locally and internationally. It has more than 120 Rendering Plants installed in Latin America, Europe, Africa and Asia, and currently has 7 Rendering Plants in the Philippines, with more still in the pipeline.
The company helps firms from project design, implementation, up to the bank loan application for the turnkey projects. Its equipment fabrications are intricately done in Argentina, Brazil, and China, and its joint ventures with established companies nationwide continue to grow LM10’s business in the Philippines.
LM10 Rendering Plants are based on four pillars that need to be constantly maximized in order to ensure the success of a rendering plant. The base of the pillars are the minimum amount of feathers and the technology that allows us to process them.
Figure 1: Four Pillars of a Successful Rendering Plant
Quality of the feather mill depends on different variables, with the most significant factors being:
- Moisture: ideally between 9-12% depending on the client’s requirements;
- Crude Proteins: LM10 can guarantee a crude protein content of between 80-90%; and
- Digestibility: with pepsin at 0.2%, LM10 can guarantee a digestibility of between 80-90%.
The price of the feather mill depends on the quality of these variables. Under the latest technology and proper plant management, the maximum quality achievable can fetch a higher selling price.
In order to achieve a high quality of the feather mill, the logistics, hydrolyzing and drying must be coordinated and operated proficiently.
Energy consumption represents between 50-60% of the total costs of a Rendering Plant, and the energy needed to run the Plant will depend on the volumes of feather processed, the process implemented, and the equipment used. If the equipment is not fabricated, installed, and used according to efficiency principles and in correlation to the plant as a whole, the profitability of the plant can be jeopardized due to the high energy cost.
Since rendering plants require feathers, and feathers come from the dressing plants, the partnership between the two is important. The Rendering Plants should never work at full capacity and instead maintain extra capacity, in order to contribute to the long service life of the equipment. If to be prosperous, Rendering Plants should be planned with a horizon of 10 years. This means that the Plants have—or can be easily adapted—to incorporate the feathers that represent the growth of the coming 10 years from its poultry partners.
Rendering Plants present a challenge when it comes to the odors coming out of the hydrolyse process of the feathers, and exposes the companies who manage them to government fines and complaints from neighbours which could lead to the suspension of rendering plant activities. LM10 guarantees that no odors will come out of its Rendering Plants, since the ability of our plants to work hinges on the mechanisms for strict odor control. After the hydrolyzing process, the steam coming out of our Batch Cookers are diverted by tubes to the equipment in charge of its treatment. We do the same for after the drying process, and with our rendering plants, the steam from the batch cookers never come into contact with air, effectively controlling the odor. LM10’s rendering plants are built on environment-friendly principles and exhaustive odor control policies.