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SLAUGHTERHOUSES

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Title: SLAUGHTERHOUSES


1
SLAUGHTERHOUSES
  • Patricia García García de Pereda
  • Sonia García Redondo
  • Beatriz Gómez Fernández
  • Irene Huerta Illera

2
1. General information
  • 1.1 The slaughtering industry in the European
    Union


18
17
14
3
1.2 Trends which may influence future resources
in the slaughtering industry
Larger installations
lower consumption per unit easier to solve
environmental problems

Food safety
Microbiological contaminants BSE crisis Increase
hygiene requirements ?Higher intensity of
cleaning and sterilisation?Increased consumption
of water and energy Packaging
Animal welfare/ethics
Reduction in the use of animal by-products in
animal feed
Eating quality
Control of carcase chilling processes
Working environment
health employees?not repetitive
operation Automation ? requirement for
energy Improved lighting and ventilation
Processing
Increase due to the demand of products prepared
quickly and simply
Other considerations
Not to clean intestines if a reduction of
water usage or pollution of the waste water is
required Cooling of blood requires considerable
amount of energy but provides better products and
less pollution Capital availability?production
improvements
4
1.3 Technical characteristics of slaughterhouses
Classification those who carries out
slaugtherhouse operations only those
that also operates cutting plants to produce
specific meat cuts and portions. Most poultry
processors These are then packed as chilled or
frozen meat for sale. Concentration of the
industry into fewer larger units? downstream
activities and/or disposal or recycling of animal
by-products take place on the same premises as
slaughtering? reduce consumption and emission
levels on the integrated site as a whole Process
lines automated? Peak periods Lifetime 25-40
years
5
1.5 Key environmental issues
  • Air Water vapour from boilers
  • Refrigerant gases
  • Water high water consumption (EU MS meat
    legislation)
  • high BOD, COD and TSS concentrations?blood
    treated at WWTP or pretreatment
  • proportional to floor area used, method of
    slaughter, carcase dressing cooling and
    degree of automation
  • Energy Refrigeration plant? 45-90 electrical
    energy
  • Heat water? oil and/or natural gas
  • Odour blood storage and handling, slurry,
    occupied lairages and inedible offal storage
  • Noise animal noises during unloading and
    marshalling, vehicle movements, compressors

6
1.6 Economic overview
  • Diseases Meat consumption grows (developing
    world)? transport and risk of spread diseases
  • Hidden costs in animal disease epidemics
    price paid to farmers for these animals
  • Keep costs to a minimum contracts with larger
    companies
  • fierce competition? bankrupt
  • Costs provision and maintenance of abatement
    equipment
  • cleaning up and repairing damage to plant
    and environment
  • studies to avoid pollution
  • changing technological and operational
    techniques
  • Have increased for the treatment and
    disposal of animal by-products

7
1.7 Food and veterinary legislation influences
  • Directive set out the main hygiene requirements
    for slaughterhouses.
  • some have significant environmental
    consequences (water energy consumption)
  • Other food, veterinary and animal welfare
    legislation influences the applied processes and
    techniques.
  • ABP Regulation prevent animal by-products
    derived from animals not fit for human
    consumption, following health inspection, from
    entering the feed chain and presenting a risk to
    animal or public health.

8
2 Applied processes and techniques
  • - Vary depending on the type of animal
  • Machinery is being developed to mechanise carcase
    dressing and this tends to incorporate automatic
    carcase washing at every stage
  • Animal reception and lairage animals are
    unloaded via ramps
  • Animals arrive clean?wet hides and skins can
    deteriorate more quickly
  • Animals are held in the lairage? recover from
    the stress of the journey.
  • Slaughter Animals are moved along a walled
    passageway Animals are stunned using a
    captive bolt pistol
  • The traditional stunning method for
    pigs involves applying scissor
  • For pigs is also used CO2 baths.
  • Animals could be killed by
    electrocution
  • After stunning, animals are hung on an
    overhead rail

9
  • Bleeding starts just after stunning and is
    carried out rapidly, profusely and completely
  • Is carried out according to certain
    religious rites.
  • Consists on incising the carotid
    arteries
  • Blood is pumped to a refrigerated and
    agitated tank ? additives to prevent
    coagulation.
  • Environmental controls
  • Hide and skin removal pull the hide/skin from
    the carcase.
  • Sometimes are salted to improve preservation
  • Head and hoof removal for cattle and sheep
  • Pig scalding remove bristles, toenails and hair.
  • Pig hair and toenail removal By an automatic
    de-hairing machine which brush or scrape the
    surface of the carcase.
  • Pig singeing to remove residual hair, to provide
    a firmer skin texture and to eliminate
    micro-organisms.
  • This unit consist on gas burners firing
    intermittently

10
  • Rind treatment to polish the skin and remove
    singe hair and other debris.
  • Evisceration manual removal of the respiratory,
    pulmonary and digestive organs
  • Splitting split the carcases along the spine
    using a saw
  • Chilling Carcases are chilled to reduce
    microbiological growth
  • The refrigeration systems use a
    refrigerant to transfer heat from the carcases
    to be cooled to ambient air
  • Associated downstream activities
  • Viscera treatment use of casings for example for
    sausage casings
  • Hide and skin treatment the best option is
    salting? trimming reduces the amount of salt
    consumption as salt in waste water is difficult
    to treat

11
2.2 Waste water treatments
  • Types treatment on-site
  • discharge directly to local water course
  • Best ways of minimising
  • preventing animal material entering the waste
    water stream
  • avoiding the spillage of high strength organic
    liquids
  • The sludge produced may be used or disposed of in
    a variety of ways
  • The main uses of water and the waste water
    pretreatments are

12
2.2 Waste water treatments
  • Primary screening to remove organics debris and
    avoid blockages in the WWTP
  • DAF treatment plant use of very fine air
    bubbles to remove suspended solids
  • Secondary biological treatment which converts
    soluble and colloidal materials into biosolids
  • Aerobic digestion (activated sludge) remove
    inorganic nutrients.
  • Anaerobic digestion for water which has high
    organic load ? reduction of the concentration of
    impurities, low excess sludge production and
    biologically stable sludge.
  • sludge used to be incinerated?
    limitations on land spreading
  • storage, handling and spreading?odour
    problems
  • Removal of nitrogen and phosphorus combine the
    carbon oxidation, nitrification and
    denitrification steps in a single process ?
    reducing the volume of air needed, elimination of
    the need for intermediate clarifiers and
    return-sludge systems
  • Tertiary filtration, coagulation and
    precipitation as final cleaning step to reduce
    the BOD and suspended solids

13
EMERGING TECHNIQUESBio-refining of animal
by-products to produce soil improvers and
fertilisers
  • bio-refining treatment of Animal carcases and
    parts of carcases which sterilises pathogenic
    agents.
  • heated in a hyperbaric reactor vessel at 180 -
    200 ºC and 1000 1380 kPa for 20 40 minutes.
  • to create saturated steam, to hydrolyse and to
    inactivat pathogenic agents
  • Environmental benefits inactivate pathogens,
    including TSE prions.
  • Applicability this technique is not permitted in
    the EU.

14
Biotechnological treatment of animal by-products
inorder to increase energetic valorisation
  • Animal meal is sorted by grain size,
  • Then treated with active microorganisms ability
    to degrade animal and vegetable fat, proteins and
    starch.
  • An enzymatic reaction is activated by the
    micro-organisms. This substantially reduces the
    fat content and causes the calorific value of the
    material to increase.
  • The time needed for the process is 15 20 days.
  • The reaction conditions are between 20 - 27 ºC in
    semi-darkness.
  • Applicability At the time of writing, this
    technique is not permitted in the EU,

15
CURRENT CONSUMPTION AND EMISSION LEVELS
  • Air Reported emissions of CO2, SO2 and NOX are
    shown in the next table.
  • Water
  • All slaughterhouses must have a pressurised
    supply of potable water within the meaning of
    Directive 80/778/EEC. This requirement for
    potable water to be used limits the opportunities
    for re-use of water.
  • A non-potable water supply is authorised in
    exceptional cases for steam production, fire
    fighting and the cooling of refrigeration
    equipment,

16
CURRENT CONSUMPTION AND EMISSION LEVELS
  • Energy
  • Slaughterhouses have an energy consumption even
    when no production takes place (heating and
    operation of the refrigeration system)?range of
    36 - 154 kWh/t carcase

17
CURRENT CONSUMPTION AND EMISSION LEVELS
  • Solid waste
  • include lairage and vehicle wash solids animal
    by-products sludge, clean and contaminated
    packaging protective clothing and equipment.
  • In the UK, solid wastes are commonly sent to
    landfill, but in Denmark, they are used in biogas
    production.
  • Noise and vibration Typical noise levels found
    measured at the perimeter fence of a
    slaughterhouse or at the nearest buildings are
  • 55 - 65 dB(A) during working hours
  • 40 - 50 dB(A) in the evening
  • 35 - 45 dB(A) at night,
  • The main sources of noise and vibration are
    animal noises during unloading and marshalling to
    the slaughter-line vehicle movements
    compressors air conditioners ventilation fans
    and carcase splitting.

18
BEST AVAILABLE TECHNIQUES
  • This chapter are a reference point against which
    to judge the current performance of an existing
    installation or to judge a proposal for a new
    installation.
  • The BAT conclusions are presented in this Figure

19
(No Transcript)
20
Slaughterhouses and animal by-products
installations
  • General processes and operations
  • BAT for environmental management
  • Integration of same site activities
  • Collaboration with upstream and downstream
    activities
  • Installation and equipment cleaning
  • Treatment of waste water

21
General processes and operations
  • A system of environmental management
  • The formation(training)
  • The utilization of a program of planned
    maintenance
  • The system application of management of the
    energy, the refrigeration, the light and the
    noises
  • The management and minimization of the water
    quantities and emaciated detergents

22
BAT for environmental management
  • Definition of an environmental policy for the
    installation by top management
  • Checking performance and taking corrective
    action,
  • Review by top management.
  • Giving consideration to the development of
    cleaner technologies

23
Integration of same site activities
  • For slaughterhouses and/or animal by-products
    installations, operating on the same site,BAT is
    to do the following
  • re-use heat and/or power produced in one activity
    in other activities
  • share abatement techniques, where these are
    required,

24
Installation and equipment cleaning
  • Manage and minimise the quantities of water and
    detergents consumed
  • Select those detergents which cause minimum
    impact on the environment
  • Where the equipment is suitable, operate a
    cleaning-in-place system

25
Treatment of waste water
  • Some examples of reached BAT
  • To avoid the stagnation of the waste water
  • To apply leaked(filtered) initial of solid by
    means of sieves
  • To eliminate the fat of the residual water by
    means of a grid of fats
  • To use a plant(floor) of flotation to eliminate
    solid additional
  • To submit the effluent one to a process of
    biological treatment
  • To eliminate the produced mires

26
Additional BAT for the slaughter of large animals
  • To stop the nourishment of the animals 12 hours
    before the slaughter
  • To use a system of control of the water of drink
    according to the demand
  • To douche the porks with atomizers temporized of
    water saving
  • To re-use the cold water in the machines of
    depilated of porks
  • To empty the stomaches and the intestines in I
    dry
  • To regulate and to minimize the water used to
    displace the intestines

27
7.1. General techniques applicable in
slaughterhouses
  • This techniques consider the possible routes for
    recovery and recycling of by-products and waste
    to minimize the impact on the environment.
  • Emissions from by-products can be prevented by
    storing, handling, processing and transferring
    materials within a suitable building.
  • Storing animal by-products over prolonged periods
    at ambient temperature in the open air increases
    the risk of direct pollution ? Necessary to use
    freezers (energy, refrigerant leaks).
  • It is necessary for all staff to be committed to
    its successful operation information and
    training about the use of the techniques.

28
7.2 Slaughterhouses general techniques
applicable at installation level
  • Delivery
  • Vehicles are scraped before being cleaned to
    remove manure and to reduce the pollution burden
    in the waste water.
  • At cleaning time, it is used a high-pressure
    trigger-operated adjustable water jet in order to
    reduce water consumption.
  • Slaughter
  • Process automation to avoid and minimise carcase
    rinsing, combined with clean slaughter
    techniques, that improve products quality and
    reduce the use of energy.
  • Reduction of odours by the refrigeration of
    blood.
  • Cleaning They are based on the minimisation in
    the use of water and, therefore, on the
    minimisation of the energy necessary to pump it
  • Dry collection of floor waste.
  • Maintenance techniques in order to avoid the
    waste of energy.
  • Monitoring of compressed air use.
  • Monitoring of ventilation use cleaning of
    filters, use of backward bowed centrifugal fans.
  • Monitoring of hot water use. Reduce temperature
    in some applications.
  • Groundwater can be used to cool refrigerant gases.

29
7.2 Slaughterhouses Slaughter of large animals
  • Animal reception and lairage
  • Techniques to reduce BOD contents in wastewater
    and odours
  • Cessation of feeding of animals 12 hours prior to
    slaughter ? () hygiene.
  • Minimise animals time in the slaughterhouse to
    reduce manure production.
  • Addition of dry bedding to existing bedding, to
    soak up manure ? (-) odours.
  • Techniques to reduce the use of water
  • Demand-controlled drinking water teats instead
    of water troughs ? () cleanliness.
  • Showering of pigs, using water saving, timer
    controlled nozzles ? () less dust.
  • Dry cleaning of the lairage floor and
    periodically cleaning it with water ?
  • (-) odours, () less pollution of waste water.

30
7.2 Slaughterhouses Slaughter of large animals
  • Bleeding
  • Optimisation of bleeding and blood collection
  • The maximum quantity of blood is collected and
    contained at the bleed area. This reduces the
    requirement to manage dripping blood along the
    length of the slaughter-line.
  • Use of hollow knives and blood recovering
    orifices under the animal?
  • () more hygiene, less recovering time, more
    capacity, less pollution in wastewater.
  • (-) high consumption of energy.
  • Use of a squeegee for initial cleaning of the
    blood collection trough
  • () Reduction of water consumption, waste water
    production and waste water contamination (less
    COD and BOD). Increased potential for waste
    minimisation. Increased potential for recovery or
    recycling of blood.

31
7.2 Slaughterhouses Slaughter of large animals
  • Pig scalding
  • Insulation and covering of pig scalding tanks ?
    () Less consumption of energy and water. Less
    ventilation needs. Less production of odours
    (reduced evaporation).
  • Water level control on pig scalding tanks ? ()
    Energy and water saving, by preventing the loss
    and need for replacement of water heated to
    approximately 60 C.
  • Condensation/steam scalding of pigs (vertical
    scalding) ?
  • () Reduced water and energy consumption. The
    lungs can be used.
  • (-) The carcases will have to be washed prior to
    scalding. If there is any dirt on the skin, this
    will prevent the steam from contacting the skin.
    Expensive.

32
7.2 Slaughterhouses Slaughter of large animals
  • Pig hair and toenail removal
  • Recirculation of water within pig de-hairing
    machines ? () Reduced water consumption and
    energy use.
  • Replace irrigation pipes at the top of de-hairing
    machines, with nozzles ? () the spray to
    transport the hair away can be moved over and
    beneath the pig. Reduced water consumption.

33
7.2 Slaughterhouses Slaughter of large animals
  • Pig singeing
  • Re-use of cooling water from the singeing kiln
    and use of nozzles fitted directed to the pigs ?
    () Reduced consumption of water.
  • Heat recovery from pig singeing exhaust gases to
    preheat water ? () less energy, less odour.
  • Post singeing showering with flat jet nozzles
    instead of shower heads ? The water supply can be
    arranged so that water only flows when a carcase
    is present (less consumption of water).

34
7.2 Slaughterhouses Slaughter of large animals
  • Rind treatment
  • Replace irrigation pipes with flat jet nozzles ?
    () Less consumption of water.
  • Evisceration
  • Saw sterilisation in a cabinet with automated hot
    water nozzles ?
  • () Reduced water consumption and energy too.
  • Regulation and minimisation of water use for
    moving intestines ?
  • () Reduced water consumption and reduced water
    entrainment of high BOD material, especially
    intestine contents.
  • () The intestines can be used for sausage
    casings or pet food.

35
7.2 Slaughterhouses Slaughter of large animals
  • Chilling
  • Blast-chilling/shock-cooling tunnel ?
  • () Low shrinkage and small tunnel dimensions.
  • () Low process temperatures cause surface
    freezing, which kills all non-cold tolerant
    bacteria and improves food safety.
  • (-) The low chilling temperature, increases the
    energy consumption.
  • Water-spraying/mist-cooling as a method of
    cooling pigs ?
  • () Reduction in energy consumption for cooling
    and ventilation.
  • () Low carcase shrinkage and high process
    temperature (avoid surface freezing).
  • (-) High water consumption.
  • NOT showering carcases before they are chilled in
    a chilling tunnel ?
  • () Reduced water consumption.

36
7.2 Slaughterhouses Slaughter of large animals
  • Associated downstream activities - viscera and
    hide and skin treatments
  • Removal of chopping blades from a by-product
    washer ?
  • () Further recovery and recycling of substances.
  • () Reduction in BOD, suspended solids, and other
    pollutants in wastewater.
  • Dry emptying of stomachs ?
  • () For for use in biogas production or
    composting.
  • () Reduced water consumption and consequently a
    reduced volume and BOD loading of wastewater.
  • () The stomachs can be used as human food, e.g.
    ox tripe, or for pet food.
  • Dry collection of the contents of small
    intestines?
  • () Reduced water consumption. Reduced volume and
    BOD loading of wastewater.
  • () The intestines can be used for sausage
    casings or pet food.

37
7.2 Slaughterhouses Slaughter of large animals
  • Associated downstream activities - viscera and
    hide and skin treatments
  • Dry emptying of pig intestines, which are not
    to be used for casings?
  • () Reduced water consumption and consequently a
    reduced volume and BOD loading of wastewater. The
    water used is warm so there are also energy
    savings.
  • () The reduced water content of the condemned
    intestines also reduces the energy costs
    associated with driving off the water at the
    rendering plant.
  • () The manure can be used as fertiliser, after
    gas production in a biogas plant.
  • Use of nozzles instead of showers to flush out
    large intestines (pigs), control of water
    consumption for small and large intestine
    washing, minimise water usage during rinsing of
    tongues and hearts ? () Reduced water
    consumption.
  • Use of a mechanised fat trap for removing fat
    from water ?
  • () Preventing the fat from dissolving makes its
    collection easier.
  • () Reduction of BOD and N in waste water.
  • () The fat can be used for rendering.

38
7.2 Slaughterhouses Slaughter of large animals
  • Associated downstream activities - viscera and
    hide and skin treatments
  • Collection of the mucosa from small intestines
    (pigs)?
  • () Reduction of organic matter (BOD) in the
    waste water.
  • () Mucosa can be used by the pharmaceutical
    industry, for manufacturing heparin or it can be
    rendered or used in biogas installations.
  • Trimming of all hide/skin material not destined
    for tanning immediately after removal from the
    animal, storage of hides/skins at 10 - 15 ºC,
    drum salting of hides and skins (also with added
    boric acid), dry collection of salt residues from
    hide, skin or fur preservation, preservation of
    hides and skins by refrigeration or by cooling
    with flaked or crushed ice. ?
  • () Minimise the consumption of substances used
    in the preservation processes, of process
    chemicals, of water and reduce odour problems.
  • () Prevent the growth of some bacteria.
  • () Energy is saved.
  • (-) The contamination of water is involved.
  • (-) Salt can reduce the efficiency of the
    wastewater treatment.

39
7.2 Slaughterhouses Slaughterhouse cleaning
  • Use of detergents using enzymes
  • () Less harmful to the environment.
  • () Lower temperatures ? energy savings.
  • () Lower COD than other chemicals.
  • () Non-corrosive.
  • Pre-cleaning blood and meat juice contamination
    with cold water
  • ()Reduced energy consumption (it can be carried
    out with cold water).
  • () Reduced use of detergents and contamination
    of waste water by detergents.
  • CIP (Cleaning-in-place)
  • () Reduction in the consumption of water,
    detergents and the energy needed to heat the
    water (the consumption levels are set).
  • (-) High capital investment.
  • Use of cyclonic vacuum cleaners
  • () Reduced water contamination.
  • (-) Increased use of energy compared to simply
    hosing down, or using a squeegee.

40
7.2 Slaughterhouses Storage and handling of
slaughterhouse by-products
  • Segregated storage and handling of different
    kinds of by-products
  • By-products can be collected, handled and stored
    separately or in categories, depending on their
    further use or disposal route and on the
    potential environmental consequences of mixing
    them.
  • () Reduced odour emissions associated with the
    storage of malodorous by-products.
  • () Reduced cross contamination between different
    by-products.
  • () The refrigeration capacity required will be
    less.
  • () Segregation enables individual by-products to
    be used instead of disposed of.
  • () Reduced waste disposal costs.

41
7.2 Slaughterhouses Slaughterhouse waste water
treatment
  • Moving bed trickling filter - for the treatment
    of air, water and air/water mixtures
  • () Low energy consumption.
  • () COD levels and nitrogen compounds are reduced
    by 90 and 55 , respectively.
  • Treatment of slaughterhouse waste water at
    municipal WWTPs
  • () No need to reduce BOD levels.
  • (-) Necessary to remove fats and gross solids
    before the treatment.
  • () Waste water from slaughterhouses contains
    easily degradable organic matter with a
    favourable CN ratio complete denitrification is
    obtained easily.
  • Use of sequencing batch reactors (SBR) in
    slaughterhouse wastewater treatment
  • () The system allows equalisation, COD removal,
    nutrient removal and clarification.
  • () The energy consumption is low (no need for
    recirculation between tanks).
  • () No requirement to use chemicals ? No
    chemically contaminated sludge ? Composting.
  • (-) CO2 and nitrates emissions ? Global warming.
  • () Flexible technique. Not requiring much space
    and not requiring a clarification system.

42
7.2 Slaughterhouses Slaughterhouse waste
treatment
  • Microbiological treatment of slaughterhouse
    waste
  • () Waste water treatment producing water and
    solids which can be used instead of needing to be
    disposed of.
  • The sludge produced by the digesters is dewatered
    to give a biomass with a commercial value as a
    fertiliser.
  • Liquid is used for land spreading, or used for
    belt washing.
  • The final effluent is suitable for yard washing,
    after veterinary approval.
  • () Capable of treating high-strength wastes with
    a COD content of over 100 g/l and of adapting to
    a wide range of pollutant loads.
  • (-) Some energy use for the operation of the
    process and odour from the biomass.
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