EFFICIENT UTILIZATION OF FALLEN/DEAD LIVESTOCK WITH VALUE ADDITION IN INDIA
by-DR. RAJESH KUMAR SINGH, (LIVESTOCK & POULTRY CONSULTANT), JAMSHEDPUR, JHARKHAND,INDIA 9431309542, rajeshsinghvet@gmail.com
Animal mortality losses are a normal part of livestock and poultry production facilities.
Producers may have losses due to disease, accidents, inter-animal competition or natural disasters such as flooding or blizzard. They need to think about mortality management before a death occurs to avoid having problems after the fact.
The producer is responsible for disposing of these mortalities within 48 hours in an environmentally acceptable manner. Carcass abandonment is not considered an acceptable disposal practice.
Safe disposal of carcasses is an important issue for day-to-day, routine management of livestock and poultry mortalities to prevent disease transmission and to protect air and water quality.
Therefore, carcass disposal remains one of the major problems facing livestock and poultry producers.
Owners and operators of animal feeding operations (AFOs) have several options for disposing of mortalities, including rendering, incineration, burial and composting. Each option has a set of advantages and disadvantages that must be considered during planning for and prior to mortality disposal.
Producers must take special precautions with the disposal of diseased animals because states may have stricter and different mortality handling and disposal requirements pertaining to certain infectious diseases.
India is bestowed with vast livestock wealth and it is growing at the rate of 6% per
annum. The contribution of livestock including poultry and fish is increasing substantially in GDP of country which accounts for >40% of total agricultural sector and >12% of GDP. This contribution would have been much greater had the fallen animals been also efficiently utilized. Efficient utilization of fallen animals has direct impact on the economy and environmental pollution of the country. Non-utilization or under utilization of this not only lead to loss of potential revenues but also lead to the added and increasing cost of disposal of these products. Non-utilization of fallen animals in a proper way may create major aesthetic and catastrophic health problems. Utilization of fallen livestock helps to facilitate prevention of environmental pollution and check spread of livestock diseases, provides employment opportunity to rural poor engaged in carcass collection, flaying and by-product processing by producing better quality hides and skins and thus improves the income levels.
METHOD FOR CARCASSES DISPOSAL IN INDIA
Producers have several options for disposing of carcasses, including rendering, incineration, burial and composting. The choice of disposal options depends on location, availability of raw materials or equipment and services, affordability and limitations on properly protecting the environment.
Carcass composting is considered one of the best disposal options due to its greater affordability, better biosecurity and low inputs and investment requirements, but composting needs proper management for complete decomposition and to ensure that objectionable odors are not generated. Complete destruction of pathogens and weed seeds occurs by maintaining thermophilic conditions during the active composting period.
If done properly, composting animal carcasses is an environmentally safe disposal option to manage emergency mortalities that do not require very high temperatures for complete destruction of transmissible diseases such as BSE.
The following is a brief discussion of each disposal option. Contacting your local regulatory agency to determine what regulatory requirements may need to be met before adopting any of the following options also is helpful.
Rendering—–
Rendering is the process of converting animal carcasses to pathogen-free, useful byproducts such a feed protein. In the process of rendering, the carcasses are exposed to high temperatures (about 130 C or 265 F) using pressurized steam to ensure destruction of most pathogens. However, rendering poses biosecurity concerns due to the transportation of livestock mortalities to multiple locations en route to the rendering plant .
Incineration———-
Incineration is the thermal destruction of carcasses by auxiliary fuel such as propane, diesel or natural gas. Modern incinerators reduce carcasses to ash and generally are biosecure. Incineration requires a great deal of energy, compared with other disposal methods, and is not considered a viable economic disposal option due to cost and labor.
Incineration is a preferred method for managing small carcasses (for example, poultry and swine), but often large carcasses and/or a large number of mortalities cannot be handled due to the small incineration capacities (mostly are limited to less than 300 pounds per head) of most on-site farm incinerators.
The capital cost of incineration may be a limiting factor for some producers, but poultry and small-livestock producers may find incineration to be a convenient option to dispose of mortalities as they are generated, eliminating the need for temporary storage.
However, regular cleaning and maintenance are required to keep the incinerator functioning properly. Also, incinerators must be loaded and operated according to the manufacturer’s recommendations. Odor nuisance complaints generated due to a poorly functioning incinerator are common.
Burial———-
Burial is a common method of carcass disposal to manage mortalities, but it poses a groundwater contamination risk if the burial site is not selected and managed properly. Therefore, selection and maintenance of a burial site is very important. For example, areas with sandy or gravelly soil and a shallow groundwater table must not be used as burial sites. The disposal site should be away from any residence, drinking water well, shallow aquifers or areas that may be flooded. Often, excessive pollutants can build up in burial sites, and leaching of nitrogen and phosphorus into water bodies causes eutrophication . From a biosecurity point of view, burial is a viable option. But the challenges of disposal by burial may include identifying suitable on-farm burial sites due to the risk of groundwater contamination.
Prompt burial will prevent nuisance problems such as odors, flies and scavengers. On-farm burial might be the quickest way to dispose of nondiseased animal mortalities. The disposal trench bottom should be compacted and mortalities should be placed in 3- to 4-feet layers in the disposal trench. A layer of 6 to 12 inches of soil can be placed between layers of carcasses.
The trench should be covered with soil mounded to shed rainwater, and the mound should be inspected periodically for settling or caving. Anyone burying dead livestock needs to take personnel and equipment safety precautions during trench digging, carcass handling, placing carcasses in the trench and backfilling the trench with soil.
Burial is difficult during winter and not an option during flooding or in areas prone to flooding. Livestock owners may find that digging a long trench in the summer for animal carcass burial during winter is economically advantageous because the excavation of frozen soil may be impossible.
A dead animal may be placed at one end of the trench and covered with soil. When another carcass needs to be added, the carcass can be placed in the trench immediately and covered even if the ground is frozen. Livestock owners need to take proper precautions, such as fencing the trenched area, with this system because an open trench can be a safety hazard.
Composting———–
Composting is a naturally occurring process in which the dead animal is broken down into basic elements (organic matter) by microorganisms, bacteria and fungi. Composting has advantages over other methods of carcass disposal, including lower costs, easy-to-prepare piles and windrows created with available on-farm machinery, and lower risk of air and water pollution when done properly.
Composting has gained popularity in areas where burial and incineration are not practical or have become restricted.
Utilization of blood ————
Animal blood has a high level of protein and heme iron, and is an important edible by-
product. In Europe, animal blood has long been used to make blood sausages, blood pudding,
biscuits and bread. In Asia, it is used in blood curd, blood cake and blood pudding. It is also used
for non-food items such as fertilizer, feedstuffs and binders. Blood is used in food as an
emulsifier, a stabilizer, a clarifier, a color additive, and as a nutritional component. Most blood is
used in livestock feed in the form of blood meal. It is used as a protein supplement, a milk
substitute, a lysine supplement or a vitamin stabilizer, and is an excellent source of most of the trace minerals. Plasma is the best water and fat binder of the blood fraction. Plasma gels appear very similar to cooked egg whites. Blood plasma also has an excellent foaming capacity, and can be used to replace egg whites in the baking industry. Blood factor XIII is a transglutaminase that occurs as an enzymogen in plasma, placenta and platelets. Transglutaminase can be use to
improve the binding ability of fresh meat products at chilling temperature. In the laboratory,
many blood products are used as a nutrient for tissue culture media, as a necessary ingredient in blood agar, and as peptones for microbial use. Glycerophosphates, albumins, globulins, sphingomyelins, and catalase are also used for biological assay. Many blood components such as fibrinogen, fibrinolysin, serotonin, kalikreninsa, immunoglobulins and plasminogen are isolated for chemical or medical uses. Purified bovine albumin is used to help replenish blood or fluid
loss in animals. It is used in testing for the Rh factor in human beings, and as a stabilizer for
vaccines. It is also used in antibiotic sensitivity tests.
Utilization of hides and skins
Animal hides have been used for shelters, clothing and as containers by human beings
since prehistoric times. The hides represent a remarkable portion of the weight of the live animal, from 4% to as much as 11%. Hides and skins are generally one of the most valuable by-products from animals. Examples of finished products from the hides of cattle and pigs, and from sheep pelts, are leather shoes and bags, rawhide, athletic equipment, reformed sausage casing and cosmetic products, sausage skins, edible gelatin and glue. Gelatin is produced from hides and bones contain large quantities of collagen. Gelatin extracted from animal skins and hides can be
used for food. In countries, pork skin is immersed, boiled, dried and then fried to make a snack
food (pork rinds/pork scratching). Collagen from hides and skins also has a role as an emulsifier in meat products because it can bind large quantities of fat. This makes it a useful additive or filler for meat products. Collagen can also be extracted from cattle hides to make the collagen sausage used in the meat industry. Gelatin is added to a wide range of foods, as well as forming a
major ingredient in jellies and aspic. Its main use is the production of jellied desserts, because of its “melt in the mouth” properties, but is also added to a range of meat products, in particular to meat pies. Gelatin is also widely used as a stabilizer for ice cream and other frozen desserts.
High-bloom gelatin is added as a protective colloid to ice cream, yoghurt and cream pies. Most
of gelatin is used to make the outer covering of capsules in the pharmaceutical industry. Gelatin
can also be used as a binding and compounding agent in the manufacture of medicated tablets
and pastilles. It is used as an important ingredient in protective ointment, such as zinc gelatin for the treatment of ulcerated varicose veins. Gelatin can be made into a sterile sponge by whipping it into foam, treating it with formaldehyde and drying it. Such sponges are used in surgery, and also to implant a drug or antibiotic directly into a specific area. Because gelatin is a protein, it is
used as a plasma expander for blood in cases of very severe shock and injury. Gelatin is an
excellent emulsifier and stabilizing agent for many emulsions and foams. It is used in cosmetic
products, and in printing for silk screen printing, photogravure printing etc.
Utilization of bone
Eleven percent of pork carcasses, 15% of beef carcasses and 16% of lamb carcasses are
bone. These values are higher if they include the meat clinging to the bone. The marrow inside some of the bones can also be used as food. The marrow may be 4.0-6.0% of the carcass weight. For centuries, bones have been used to make soup and gelatine. In recent years, the meat industry has been trying to get more meat from bones, and new techniques have been used for this purpose. Meat and bone meal (MBM) was widely recommended and used in animal nutrition as a protein source in place of proteinaceous feeds because of its content of available essential
amino acids, minerals and vitamin B12. MBM and related rendered protein commodities have
potential for use in applications other than animal feed, including use as a fuel or a phosphorus fertilizer.
Utilization of glands and organs
Animal organs and glands offer a wide variety of flavors and textures, and often have a
high nutritional value. Cholesterol is also used as an emulsifier in cosmetics. The hormone
melatonin is extracted from the pineal gland. Bile consists of acids, pigments, proteins,
cholesterol etc., and can be obtained from the gall bladder. It is used for the treatment of
indigestion, constipation and bile tract disorders. It is also used to increase the secretory activity
of the liver. Bile from cattle or pigs can be purchased as a dry extract or in liquid form. Some
ingredients of bile, such as prednisone and cortisone, can be extracted separately, and used as
medicines. Gallstones are reported to have aphrodisiac properties, and can be sold at a high price.
They are usually used as ornaments to make necklaces and pendants. Liver extract is used as a raw material by the pharmaceutical industry. Liver extract can be obtained from pigs and cattle, and has been used for a long time as a source of vitamin B12, and as a nutritional supplement used to treat various types of anaemia. Heparin can be extracted from the liver, as well as the
lungs and the lining of the small intestines. It is used as an anticoagulant to prolong the clotting time of blood. It is also used to thin the blood, to prevent blood clotting during surgery and in organ transplants. Progesterone and oestrogen can be extracted from pig ovaries. It may be used
to treat reproductive problems in women. Relaxin is a hormone taken from the ovaries of
pregnant sows, and is often used during childbirth. The pancreas provides insulin, which
regulates sugar metabolism and is used in the treatment of diabetes. Glucagon extracted from the
cells of the pancreas is used to increase blood sugar, and to treat insulin overdoses or low blood sugar caused by alcoholism. Chymotrypsin and trypsin are used to improve healing after surgery or injury. The intestines of sheep and calves are used for the manufacture of catgut, to make internal surgical sutures.
Utilization of edible tallow and lard
Animal fats are an important by-product of the meat packing industry. The major edible animal fats are lard and tallow. Lard is the fat rendered from the clean tissues of healthy pigs. Tallow is hard fat rendered from the fatty tissues of cattle or sheep. Lard and edible tallow are obtained by dry or wet rendering. Traditionally, tallow and lard were used for deep frying. However, this use is declining in the fast-food industry, due to consumer health concerns. An alternative liquid tallow product has been developed for the preparation of French fries and other fast foods, since less fat is absorbed. Tallow and lard are also used for margarine and shortening. Some edible lasrds are used in sausages or emulsified products.
Fish waste/by-products utilization
Fish waste is a great source of minerals, proteins and fat. Enzymes and bioactive peptides
obtained from fish waste used for fish silage, fish feed or fish sauce production. Waste fish
viscera are subjected to auto-hydrolysis to produce peptone hydrolysates and used in
microbiological media to support growth and bacteriocin production by lactic acid bacteria.
There are several alternative uses of fish waste, like utilization of fish mince, applications of fish gelatin, fish as a source of nutraceutical ingredients, fishmeal production, the possible use of fish and protein concentrate as a food source. Production of organic acids and amino acids from fish meat by sub-critical water hydrolysis would be an efficient process for recovering useful substances from organic waste such as fish waste discovered from fish markets. Use of fish
waste for animal feed production was investigated and the considerable potential for use of fish waste for poultry feeding was established. Fish collagens are of interest to the food processing industry as they are used to produce gelatin which is extracted from the collagen.
Utilization of waste as biofuel
The availability of wet biomass as waste from industrial processes and the need to meet
the environmental standards stand for the main stimuli towards investigating all options in order
to dispose this waste. The thermal recycling of residues as secondary fuel is of increasing interest for power plant operators. Studies documented the usage of poultry litter as an alternative for
natural fuel source generation. It is noteworthy that poultry litter with water contents less than
9% can burn without extra fuel. Therefore these samples were suitable for being used as fuel for
generation of electrical power. Physicochemical treatment of meat industry waste-water is used to increase the organic matter removal efficiency, and it generates great amounts of sludge.
Due to sanitary, environmental problems and operational costs related to the discharge, land disposal and re-use of wastes, the utilization of this Biofuel (dried sludge) for steam generation has shown to be a viable alternative. This type of fuel has a high heating value, and it is a renewable energy
source. The combustion test with a Biofuel to sawdust ratio of 4:1 met the technical requirements for the characterization of this promising fuel; nevertheless, operating conditions must be well
designed to achieve NO2 and SO2 emissions below local and/or international limits. Biodiesel
fuel acquired from the oils and fats of meat and fish is a substitute for, or an additive to diesel
fuel derived from petroleum.
GOVT. SCHEMES RELATED TO CARCASS DISPOSAL OF FALLEN ANIMAL IN INDIA——
Schemes included under the National Livestock Mission
Under this component establishment of carcass utilization centres, bone crushing units, renovation / modernization of existing carcass utilization centres, training and insurance of flayers will be supported. The programme will be implemented through Panchayati Raj Institutions. There will be three models of carcass utilization centres with processing capacities of 5-6 animals per day, 7-19 animals per day and 20-25 animals per day for which subsidy ceiling of Rs.110 lakh, Rs.165.00 lakhs and Rs.220.00 lakh will be allowed, respectively, at 75% of project cost whichever is less. Priority will be given to locations identified by Air Force Headquarters. Training of flayers will be undertaken at CLRI, Chennai or other existing training centres. A cost of Rs.5000 per trainee will be allowed.
CSIR- CLRI Technology for Rural Development—————–
Collection of Fallen Carcass and its utilization—– It involves integrated utilization of all tissues of fallen carcass for value added product. Finds application in Animal feed/Leather industry/Fertilizer/Chemical Industry.
Salient features of technology/process——- It is an eco-friendly and sustainable technology developed by CLRI for total utilisation of fallen animals (cattle and buffalo). It provides economically useful products from waste. The process includes lifting of fallen animals, flaying techniques, preservation of hides and skins, rendering (cooking) of the flayed carcass, preparation of meat meal, bone meal, tallow, besides treatment of effluent waste water and utilisation for agri-horticultural purposes and conversion of rumen contents into manure.
Raw materials———– Fallen animals (cattle and buffalo)
Machinery/Equipment————– Flaying tools, wet rendering cooker, meat mincer, bone crusher, drier and pulveriser, transportable flaying and lifting device.
Minimum economic unit and total investment———– 3-4 carcasses per day Rs. 20 lakhs.(It may go upto Rs.40Lakhs when transportable device is included)
Name and address of technology generating institute/ individual———– Director CSIR-Central Leather Research Institute Adyar, Chennai – 600 020. Phone : 91-44-24910897 / 24910846 / 24437158 Fax : 91-44-24912150 E-Mail : directorclri@gmail.com, director@clri.res.in ppbd@clri.res.in, bpdclri@yahoo.com Website : www.clri.org
HATCHERY / CHICKEN / GOAT / FISH WASTE RENDERING PLANT OF DHOPESHWAR
Dhopeshwar has come up with innovation in the livestock waste management technology. By utilizing their technology the livestock & poultry farmers not only save money but can earn money by value addition of waste materials besides keeping the environment free from pollution & hazard.
Dhopeshwar supplies Rendering Plants for different types of waste. The Rendering Plant converts your waste into sterilized Meat Meal.
They supply Rendering plants for following :
Hatchery waste
Slaughter House waste
Fish waste
Goat waste.
All their Rendering plants come with advanced odour control Barometric Spray system. Their Waste Rendering Plants for finds wide application in poultry processing industries. The baro spray system sprays are used to ensure Environment-friendly operation in slaughterhouses, rendering cookers. These barometric spray for rendering plants are easy to install and carries low power consumption.
Features:
- Environment friendly operation in slaughterhouses
- Easy to install
- Carries low pressure consumption
The Rendering Plants For Poultry include a Digestor-Cooker-Homogeniser unit to cook and sterilize the waste. It is supplied with a sophisticated barometric spray system to scrub all the foul smelling gases released during the cooking of the chicken waste. Poultry waste rendering plants are indispensable in any Poultry dressing operation. They render and convert all the non-edible Poultry waste parts into a sterilized meat meal.
The digestor based technology has been put to treat 3 different kinds of waste –
- Hatchery waste – egg shells, unhatched eggs, rejected embryos, etc. This waste is converted into Hatchery meal.
2. Layer Manure – Manure collected under the cages of layer birds in commercial poultry layer farms. This waste is converted into an organic fertilizer.
3. Slaughterhouse waste – Left over, non-edible portions of the chicken such as Head, feet, intestines, feathers, etc. from chicken processing. This waste is converted into a Meat and Bone meal.
POULTRY FAT EXTRACTION PLANT
Slaughter of chicken results in separation of non-edible portions and fat.
While the non-edible portions can be generally rendered together as a mix, a fair amount of body fat is separated. This could be about 3.5% of live weight.
This is generally disposed off to the un-organized sector for Fat extraction. Un-processed Fat is not considered healthy, A slaughter of 10,000 birds of Ave. Live weight. 1.6 kg each will result in approx. 550 kg of fat. However, proper technology can give commercial quality oil which is high in linoleic acid and Omega-6 fatty acid content. This oil can be used as a flavouring agent in pet food.
POULTRY WASTE RENDERING PLANTS
Poultry Waste Rendering Plants for Sterilized Meat Meal are an indispensable part of poultry dressing operations. Poultry dressing or slaughter results in waste which is almost 30 % of live bird weight. All the waste resulting from processing is pressure cooked, sterilized & rendered into a sterilized meat meal. This is also technically known as ‘Poultry By-product Hydrolyzed Feather Meal (PBHFM).’
This meat meal made from poultry waste contains about 60-65% protein and 20-22% fat & 8-10% moisture. Hence, Rendering plants are also known as Protein Recovery Plants.
The process of Rendering is done in batches. The poultry Waste Rendering Plants are supplied in different capacities from 500 Kg. to 3500 Kg of waste per batch. These plants can process about 6000 kg of waste per day in 1 digestor. A battery of digestors can be used when the waste is in a larger quantity. Larger batch capacities can also be supplied.
Following are some of the important features of the rendering plants:
- Incorporates the latest vacuum drying operation
- Digestor-Cooker- Homogenizer has all the safety features for consistent operations
- Incorporates Barometric spray system to absorb all the foul smell. It Prevents air pollution to ensure eco-friendly operations
- Robustly built
- Provided with sophisticated monitoring system to ensure maximum convenience and safety of operation
Advantages:
- Prevents environment pollution by disposing of all biological waste.
- Offers optimum utilization of animal resources since meat meal is used for making animal feed
- More effective and profitable than any other waste-disposal method
- Converts entire poultry waste into high protein sterilized meat meal
DRY LAYER MANURE PLANT
Fresh Layer manure is a natural organic by-product of the livestock sector. Fresh manure is an excellent source of fertilizer because it contains Nitrogen, Phosphorous, Potassium & other crop nutrients. However poultry manure cannot be used in it’s raw form. The Layer fresh manure [LFM] contains 75-84% waster. LFM is a big nuisance world-wide as it is the breeding site for flies & source of ammonia odour pollution. Flies are the cause of major health problems in areas & communities surrounding Layer farms.
Nitrogen forms nitrates and other compounds which leach into the soil effecting ground water and also leads to nutrient imbalances and phyto-toxicity in crops. Due to high waster content, disposal of manure involves high labour & transportation cost. it is estimated that a farm with 1,00,000 layers produces 10 tonnes of manure / day or 3,650 tonnes of manure per year. Layer manure is rich in many essential Plant Nutrients like N,P,K. If processed properly it will give a dry, baggable organic fertilizer which can be stored and used.
Manure management in layer farms has become a critical issue due to stringent pollution control measures implemented by governments.
Salient Features of Dhopeshwar technology –
- Starts with fresh manure in ‘as available’ condition from the farm without any processing / drying required before loading the manure into our dry manure plant.
- Efficient vacuum drying system which eliminates odour and air pollution.
- Robust built machinery, designed for safe operations over many years.
They offer our ‘Dry Layer Manure Plant’ in 2 capacities, namely,
- 10 tonnes per day of Layer manure drying.
- 20 tonnes per day of Layer manure drying.
Contact Details
Dhopeshwar Engineering Private Limited
Mr. Shirish Dhopeshwar (Chief Executive Officer) Plot A 16, Co – Operative Industrial Estate, Balanagar Hyderabad – 500037, Telangana, India
Mobile:
+(91)-9391058963
+(91)-9652158908
Telephone:
+(91)-(40)-23771579
Fax:
+(91)-(40)-23772450
Email: sales@dhopeshwar.in
Conclusion
Now a days our society, in which there is great demand for appropriate nutritional
standards, is beset by rising cost and often decreasing availability of raw materials together with
much more concern about environmental pollution, leading to the consequence that there is much occupation with recovery and recycling of wastes. Beside pollution and hazard aspects, in many cases, meat waste have a potential for recycling raw materials, or for conversion into useful products of higher value as by product, or even as raw material for other industries, or for use as
food or feed after biological treatment. Particularly utilization of meat wastes is receiving
increased attention in view of the fact that these wastes represent a possible and utilizable
resource for conversion to useful products. Today, with the increased concerns over health,
technology has been developed to permit more efficient utilization of these byproducts. These
innovations also increase the value of the carcass, and increase the profits of livestock raisers.
We have not quite reached the point where “The packer uses everything but the squeal”, but we are improving all the time.
