k Iepper Rendering Presentation
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1 Handling of Broiler Processing By-Products Brian H. Kiepper, Ph.D. Poultry Science College of Agricultural & Environmental Sciences The University of Georgia Athens, Georgia, USA Processing Yield • Products produced from the slaughter of poultry fall into two basic categories: edible and inedible • In the U.S., the maximum percent yield of edible or ‘dressed’ product from the various poultry species ranges from a high of 77% for turkeys to a low of 58% for ducks • Inedible by-products from processing are generally referred to as ‘offal’ Broiler Processing Yield • Young chickens or ‘broilers’ processed in the U.S. average a 72% edible yield • In 2010 poultry processors slaughtered 41.5 x 10 9 broilers with a total live weight of 103.3 x 10 6 metric tons (MT) of Ready-to-Cook (RTC) product worldwide • Thus in 2010 along with generating 74.4 x 10 6 MT of RTC product, poultry processors also generated 28.9 x 10 6 MT of poultry by- products worldwide Poultry Processing Offal • In the United States, poultry processing plants produce offal in the form of blood, feathers, heads and viscera • However, this is not true in all parts of the world Chicken Feet or ‘Paws’ • Chicken feet or ‘paws’ are an example of how global demand has changed handling of traditional offal in the U.S. 1998 2008 Offal Isn’t Offal Everywhere Part P.Peso/Kg $US / Lb Good Liver + Heart 98 1.01 Pale Liver + Heart 68 0.70 Gizzard 78 0.80 Head 21 0.22 Good Feet 40 0.41 Trimmed Feet 31 0.32 Bumble Feet 21 0.22 Small Intestine 40 0.41 Cooked Intestine 17 0.17 Provent 43 0.44 Crops 40 0.41 Fats 30 0.31 Blood 20 0.21 Trachea 13 0.13 Good Trimmings 64 0.66 Spleen 41 0.42 Wholesale price sheet from major poultry supplier in the Philippines You created this PDF from an application that is not licensed to print to novaPDF printer (http://www.novapdf.com)
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Transcript of k Iepper Rendering Presentation
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Handling of Broiler Processing By-Products
Brian H. Kiepper, Ph.D.Poultry ScienceCollege of Agricultural & Environmental SciencesThe University of GeorgiaAthens, Georgia, USA
Processing Yield Products produced from the slaughter of poultry
fall into two basic categories: edible and inedible
In the U.S., the maximum percent yield of edible or dressed product from the various poultry species ranges from a high of 77% for turkeysto a low of 58% for ducks
Inedible by-products from processing are generally referred to as offal
Broiler Processing Yield Young chickens or broilers
processed in the U.S. average a 72% edible yield
In 2010 poultry processors slaughtered 41.5 x 109 broilers with a total live weight of 103.3 x 106 metric tons (MT) of Ready-to-Cook (RTC) product worldwide
Thus in 2010 along with generating 74.4 x 106MT of RTC product, poultry processors also generated 28.9 x 106 MT of poultry by-products worldwide
Poultry Processing Offal
In the United States, poultry processing plants produce offal in the form of blood, feathers, heads and viscera
However, this is not true in all parts of the world
Chicken Feet or Paws Chicken feet or paws are an example of how
global demand has changed handling of traditional offal in the U.S.
1998
2008
Offal Isnt Offal EverywherePart P.Peso/Kg $US / Lb
Good Liver + Heart 98 1.01Pale Liver + Heart 68 0.70Gizzard 78 0.80Head 21 0.22Good Feet 40 0.41Trimmed Feet 31 0.32Bumble Feet 21 0.22Small Intestine 40 0.41Cooked Intestine 17 0.17Provent 43 0.44Crops 40 0.41Fats 30 0.31Blood 20 0.21Trachea 13 0.13Good Trimmings 64 0.66Spleen 41 0.42
Wholesale price sheet from major
poultry supplier in
the Philippines
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Rendering Rendering is the use of pressure and heat to
cook raw offal materials to remove moisture and separate fat, protein and bone
These rendered products are then sold domestically and exported for use in the manufacturing of: Pet food and livestock feed Soaps Pharmaceuticals Lubricants Plastics Personal care products, and even crayons!
Rendering Rendered products have a greater value than
raw offal material because cooking significantly increases the stability or shelf life of the fat and protein by reducing the moisture content and killing the microbes present in the raw offal
In general, raw offal contains 50% moisture, 25% fat, and 25% protein and bone
2010 World Poultry Processing(1 000 MT) Total
Live WtTotal RTC
Total Offal
Blood Feathers Viscera
USA 23 001 16 561 6 440 920 1 610 3 910
China 16 521 11 895 4 626 661 1 156 2 809
Brazil 15 324 11 033 4 291 613 1 073 2 605
EU-27 11 889 8 560 3 329 476 832 2 021
Mexico 3 894 2 804 1 090 156 273 662
India 3 458 2 490 968 138 242 588
Russian Fed 2 222 1 600 622 89 156 378
Iran 1 979 1 425 554 79 139 336
Argentina 1 972 1 420 552 79 138 335
Japan 1 760 1 267 493 70 123 299
S. Africa 1 486 1 070 416 59 104 253
Others 15 450 11 124 4 326 618 1 082 2 627
Total 98 957 71 249 27 708 3 958 6 927 16 823100% 15% 25% 60%
Poultry Processing By-Products
Blood Following electrical stunning, U.S. broilers necks
are cut and blood is allowed to drain 1-2 minutes Average U.S. broiler live wt 2010 = 2,5 kg (5,5 lb) Blood represents ~8% of broiler live weight ~30 50% of total blood volume drains during
processing (~3% of live weight) Typical U.S. plant processing 200 000 bpd will
collect 15 000 kg (33 000 lb) of blood daily
Bleedout
Blood Tunnel
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Poultry Processing By-Products Blood
Products = Blood meal, blood flour, fresh blood U.S. plants typically render and use blood meal as a
supplemental protein source in animal feed Typically heated to 100oC for ~15 minutes to destroy
pathogens Excessive heating reduces digestibility of Crude Protein
(CP) Blood meal is hydroscopic (water loving) and needs to be
dried to
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Picker Exit
Offal Recovery Area
Primary Screening of Feathers
Feather Truck
Poultry Processing By-Products Feathers
Products = Feather meal, Hydrolyzed feather meal, Poultry feather meal, Hydrolyzed poultry feather meal, Keratin meal
U.S. plants typically render and use feather meal as a supplemental protein source in animal feed
Unprocessed feathers are high in CP, but are highly indigestible so rendering is required
Moist heat is applied at elevated temperatures to cleave cystine cross linkages in keratin CP becomes readily digestible
Feathers are cooked in a pressurized chamber at 30 to 45 psi for 30 to 60 minutes - resultant CP digestibility is >75%
Nutrient Characteristics: As % of dry matter (DM)DM CP CF Ash EE NFE Ca P
Feather meal, hydrolyzed 90,5 86,1 0,3 2,5 3,6 - - -Poultry feathers, hydrolyzed 93,0 91,4 0.4 3,8 3,9 0,5 0,42 0,51
Poultry Processing By-Products
Viscera Following defeathering, U.S. broilers are
eviscerated using a series of mechanical devices Average U.S. broiler live wt 2010 = 2,5 kg (5,5 lb) Viscera (with heads, inedible organs, etc)
represents ~10% of broiler live weight Typical U.S. plant processing 200 000 bpd will
collect 50 000 kg (110 000 lb) of viscera daily Viscera are typically water-flumed to offal
recovery areas
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Preen Gland Remover
Eviscerator
Presenter
USDA Inspector
Preparing viscera for edible organ or
giblet recovery
Giblet Recovery
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Giblet Processing
Gizzard Peeling
Giblet Chiller
Broiler Feet or Paws
Feet Peeling
Peeled Feet
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Renewed interest in foot-pad dermatitis
Deboned Frames
Vacuum Transportation Systems
Primary Screening of Viscera
Viscera Truck
Poultry Processing By-Products Viscera
Products = Poultry by-product meal, Poultry offal meal, Poultry meal
U.S. plants typically render and use viscera as a supplemental protein and energy (fat) source in feed
Combination of all poultry by-products processed together in the same proportions as they occur in the processing plant
Composition can be quite variable for plant to plant and batch to batch, depending upon what is being included.
Nutrient Characteristics: As % of dry matter (DM)DM CP CF Ash EE NFE Ca P
Poultry by-product meal 94,2 60,0 2,1 15,5 17,1 5,4 3,75 1,80Poultry offal meal 92,4 68,5 - 7,8 23,1 - - -
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Biofuels from Poultry Fat
Questions?
Dr. Brian Kiepper [email protected] www.poultry.uga.edu [email protected] 706-542-6776 706-542-6907
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