Reference Document on Best Available Techniques in the

4,35
MB Slaughterhouses and Animal By-products Industries

469
stron

1137
ID JRC-IPTS Instituto de Prospectiva Tecnológica (IPTS)

2005
rok

EXECUTIVE SUMMARYI

PREFACE XV

SCOPE XXXIII

1 GENERAL INFORMATION. 1

1.1 The slaughtering industry in the European Union 1

1.2 The animal by-products industry in the European Union. 10

1.2.1 Fat melting . 11

1.2.2 Rendering 11

1.2.3 Fish-meal and fish-oil production 12

1.2.4 Blood processing 13

1.2.5 Gelatine manufacture . 14

1.2.6 Dedicated incineration of carcases, parts of carcases and animal meal . 14

1.2.7 Burning of tallow. 15

1.2.8 Land spreading/injection 15

1.2.9 Biogas production 15

1.2.10 Composting 16

1.3 Key environmental issues. 16

1.3.1 Slaughterhouses . 16

1.3.2 Animal by-products installations . 18

1.3.2.1 General information about key environmental issues 18

1.3.2.2 Fat melting . 18

1.3.2.3 Rendering . 19

1.3.2.4 Fish-meal and fish-oil production 19

1.3.2.5 Blood processing 20

1.3.2.6 Gelatine manufacture . 20

1.3.2.7 Glue manufacture . 20

1.3.2.8 Dedicated incineration of carcases . 21

1.3.2.9 Dedicated incineration of animal meal. 21

1.3.2.10 Burning of tallow . 22

1.3.2.11 Land spreading/injection 22

1.3.2.12 Biogas production 22

1.3.2.13 Composting 23

1.4 Economic overview 23

1.4.1 Slaughterhouses and animal by-products. 23

1.4.2 The economic cost of consumption and emissions 25

1.5 Food and veterinary legislation influences. 27

2 APPLIED PROCESSES AND TECHNIQUES 29

2.1 Slaughter . 29

2.1.1 Activities described in this chapter 29

2.1.2 Slaughter of large animals 29

2.1.2.1 Animal reception and lairage . 30

2.1.2.2 Slaughter 31

2.1.2.3 Bleeding . 32

2.1.2.4 Hide and skin removal . 33

2.1.2.5 Head and hoof removal for cattle and sheep 34

2.1.2.6 Pig scalding 34

2.1.2.7 Pig hair and toenail removal. 35

2.1.2.8 Pig singeing 35

2.1.2.9 Rind treatment 35

2.1.2.10 Evisceration 36

2.1.2.11 Splitting 36

2.1.2.12 Chilling. 37

2.1.2.13 Associated downstream activities - viscera and hide and skin treatments . 38

2.1.3 Slaughter of poultry . 41

2.1.3.1 Reception of birds.41

2.1.3.2 Stunning and bleeding 41

2.1.3.3 Scalding 42

2.1.3.4 De-feathering 42

2.1.3.5 Evisceration 43

2.1.3.6 Chilling .43

2.1.3.7 Maturation 44

2.1.4 Slaughterhouse cleaning .44

2.1.5 Storage of slaughterhouse by-products.45

2.2 Animal by-products installations 46

2.2.1 Fat melting46

2.2.2 Rendering .50

2.2.2.1 Rendering of carcases and waste 53

2.2.2.2 Rendering of feathers and pig hair56

2.2.3 Fish-meal and fish-oil production.57

2.2.4 Bone processing61

2.2.5 Blood processing - plasma and dried red cell production.61

2.2.6 Gelatine manufacture64

2.2.7 Glue manufacture .82

2.2.8 Dedicated incineration of carcases and parts of carcases and of meat and bone meal82

2.2.8.1 Dedicated incineration of carcases and parts of carcases82

2.2.8.2 Dedicated incineration of animal meal .85

2.2.8.3 Gasification of meat and bone meal87

2.2.9 Burning of tallow88

2.2.10 Landfill and land spreading/injection .88

2.2.11 Biogas production.88

2.2.12 Composting 90

2.3 Waste water treatments used at slaughterhouses and animal by-products installations93

2.3.1 Slaughterhouse waste water treatment93

2.3.1.1 Primary slaughterhouse waste water treatment.96

2.3.1.2 Secondary slaughterhouse waste water treatment.97

2.3.1.3 Tertiary slaughterhouse waste water treatment.99

2.3.2 Animal by-product installation waste water treatment .99

2.3.2.1 Rendering waste water treatment99

2.3.2.1.1 Mechanical waste water treatment100

2.3.2.1.2 Physico-chemical treatment 100

2.3.2.1.3 Biological treatment101

2.3.2.1.4 Feathers - elimination of hydrogen sulphide.101

2.3.2.2 Fish-meal and fish-oil manufacturing waste water treatment .101

2.3.2.3 Blood processing waste water treatment.101

2.3.2.4 Gelatine manufacture waste water treatment 102

3 CURRENT CONSUMPTION AND EMISSION LEVELS103

3.1 Slaughterhouses 103

3.1.1 Slaughterhouses - overall consumption and emission data at installation level .103

3.1.2 Slaughter of large animals 114

3.1.2.1 Animal reception and lairage115

3.1.2.2 Bleeding115

3.1.2.3 Hide and skin removal 116

3.1.2.4 Head and hoof removal for cattle and sheep.116

3.1.2.5 Pig scalding.116

3.1.2.6 Pig hair and toenail removal .117

3.1.2.7 Pig singeing 117

3.1.2.8 Rind treatment 117

3.1.2.9 Evisceration 117

3.1.2.10 Splitting 118

3.1.2.11 Chilling .118

3.1.2.12 Associated downstream activities - viscera and hide and skin treatments 118

3.1.3 Slaughter of poultry119

3.1.3.1 Reception of birds.119

3.1.3.2 Stunning and bleeding 119

3.1.3.3 Scalding 120

3.1.3.4 De-feathering 120

3.1.3.5 Evisceration 120

3.1.3.6 Chilling. 120

3.1.4 Slaughterhouse cleaning - equipment and installation . 121

3.1.5 Storage and handling of slaughterhouse by-products. 123

3.1.6 Slaughterhouse waste water treatment . 123

3.2 Animal by-products installations 124

3.2.1 Fat melting . 124

3.2.2 Rendering. 124

3.2.2.1 Rendering of carcases and waste 134

3.2.2.2 Rendering of feathers and pig hair . 134

3.2.3 Fish-meal and fish-oil production 136

3.2.4 Blood processing 139

3.2.5 Bone processing . 140

3.2.6 Gelatine manufacture . 141

3.2.7 Dedicated incineration of carcases, parts of carcases and meat and bone meal . 142

3.2.7.1 Dedicated incineration of carcases and parts of carcases . 142

3.2.7.2 Dedicated incineration of animal meal. 143

3.2.8 Burning of tallow. 146

3.2.9 Biogas production 147

3.2.10 Composting 148

3.2.11 Animal by-products installation waste water treatment plants. 149

3.2.12 Combined processes and techniques 149

4 TECHNIQUES TO CONSIDER IN THE DETERMINATION OF BAT 151

4.1 General techniques applicable in slaughterhouses and animal by-products installations. 151

4.1.1 Environmental management tools 153

4.1.2 Training provision 160

4.1.3 Use of a planned maintenance programme 161

4.1.4 Dedicated metering of water consumption. 162

4.1.5 Separation of process and non-process water. 163

4.1.6 Use of cooling water and water from vacuum pumps 164