Slaughterhouses and animal by-products BREF Tallinn - 27 and 28 March 2007 Rosemary Campbell rosemarycampbell@btinterne

1. Slaughterhouses and animal by-products BREFTallinn - 27 and 28 March 2007Rosemary Campbellrosemarycampbell@btinternet.com

2. Slaughterhouses and Animal By-products BREF Live animal Slaughter Food products Waste Non-food products Hides and skins

3. BREF scope (Annex 1) 6.4. (a) Slaughterhouses with a carcase production capacity greater than 50 tonnes per day 6.5. Installations for the disposal or recycling of animal carcases and animal waste with a treatment capacity exceeding 10 tonnes per day

4. BREF scope (Annex 1) 6.4. (a) Slaughterhouses with a carcase production capacity greater than 50 tonnes per day

5. Key environmental issues • energy • cooling of carcases • refrigeration of by-products • drying of by-products • odour • inherent • due to decomposition • water consumption/contamination • infectivity • cleaning and disinfection • destruction of TSE risk ---------------------------------------------------- • (now avian influenza)

6. Other driving forces at slaughterhouses and animal by-products installations • Regulation (EC) No 1774/2002 • prescribes routes for the use and disposal of by-products • food and veterinary legislation • animal welfare • hygiene • customer preferences/market forces • regional eating habits of consumers • downstream industry requirements

7. Information submitted • 362 references • BREF - 435 pages • balance between too general or too detailed • BREF outline and guide - structure • late • included at the insistence of TWG members ------------------------------------------------------------ • Estonia

8. BREF structure EXECUTIVE SUMMARY PREFACE SCOPE Chapter 1 GENERAL INFORMATION Chapter 2 APPLIED PROCESSES AND TECHNIQUES Chapter 3 CURRENT CONSUMPTION AND EMISSION LEVELS Chapter 4 TECHNIQUES TO CONSIDER IN THE DETERMINATION OF BAT Chapter 5 BEST AVAILABLE TECHNIQUES Chapter 6 EMERGING TECHNIQUES Chapter 7 CONCLUDING REMARKS Chapter 8 REFERENCES Chapter 9 GLOSSARY Chapter 10 ANNEXES

9. Chapter 5 BEST AVAILABLE TECHNIQUES

10. Slaughterhouses and animalby-products installations General processes and operations • environmental management system • training • maintenance • meter water • drains with screens +/or traps • dry clean, pressure clean, hoses fitted with hand operated triggers

11. Slaughterhouses and animalby-products installations General processes and operations • energy management system • formal approach identifying areas for successful reduction of energy consumption and consequent financial benefit - • identify unit operations with high consumption • show the importance of management commitment for success • necessary to understand the issues and the potential benefits, including financial • shows the success of personally attributed service, e.g. the use of hot water

12. Slaughterhouses and animalby-products installations General processes and operations • energy management system • e.g. in a an example operation, reduce the use of hot water leads to benefits • reduced water consumption • reduced energy use to heat water • reduced contamination of water • reduced volume of waste water from the installation requiring treatment (using energy and possibly chemicals and potentially causing odour)

13. Slaughterhouses and animalby-products installations General processes and operations • store animal by-products for short periods and possibly refrigerate them • reduced odour • during storage • during processing • during waste water treatment • reduced waste • reduced energy consumption • upstream and downstream collaboration

14. Slaughterhouses and animalby-products installations Integration of same site activities, e.g. • slaughterhouse and rendering plant • reduced energy consumption, e.g. use heat from rendering to heat water for the slaughterhouse, render animal by-products before they become malodorous • slaughterhouse and animal carcase incinerator • reduced energy consumption, e.g. use heat from incineration to heat water for the slaughterhouse, incinerate animal by-products before they become malodorous • rendering plant and animal meal incinerator • burn malodorous gases from rendering (raw materials, process odours and non condensable gases)

15. Slaughterhouses and animalby-products installations BAT is to seek collaboration with upstream and downstream partners, to create a chain of environmental responsibility, to minimise pollution and to protect the environment as a whole

16. Slaughterhouses and animalby-products installations Collaboration with upstream and downstream activities, e.g. • cessation of feeding large animals 12 hours prior to slaughter • use of fresh raw materials in animal by-products installations • where it is not possible to treat animal by-products before their decomposition starts to cause odour problems and/or quality problems, refrigerate them as quickly as possible and for as short a time as possible

17. Slaughterhouses and animalby-products installations Collaboration with upstream and downstream activities, e.g. • use of low total volatile nitrogen feedstock in fish-meal and fish-oil processing • trimming of all hide/skin material not destined for tanning , immediately after removal from the animal • avoid salting hides (alternatives – depend on time lapse before processing)

18. Slaughterhouses and animalby-products installations Cleaning the installation and equipment • water – amount, temperature, contamination • consequences for waste water treatment • detergents – amount and harmfulness • technology – CIP • operation – control of responsible, trained individuals

19. Slaughterhouses and animalby-products installations Waste water treatment – not concluded whether BAT is on-site or off-site, but some treatments are prior to the WWTP • prevent stagnation • screen out solids • remove fat

20. Additional BAT for slaughterhouses • dry scrape vehicles • avoid carcase washing • collect by-products dry • optimise bleeding and the collection of blood • double drain from the bleed hall • immediately trim off all hide/skin not destined for tanning • optimise use of trimmings • minimise use of substances used in hide processing • reduce waste in the leather industry • reduce odour from putrescible trimmings

21. Additional BAT for large animal slaughterhouses • stop feeding 12 hours prior to slaughter • demand-controlled drinking water • dry clean lairage floor • steam scald pigs • in existing slaughterhouses, where not econ viable to change to steam scalding insulate and cover pig scalding tanks • re-use cooling water from pig singeing kilns • don’t shower pigs before chilling • empty stomach and small intestines dry

22. Additional BAT for poultry slaughterhouses E.g. • remove carcase washing equipment from the line, except after de-feathering and evisceration • steam scald poultry • in existing slaughterhouses, where not econ viable to change to steam scalding insulate poultry scalding tanks and use the water to carry feathers

23. Additional BAT for animal by-products installations E.g. • use sealed storage, handling and charging facilities for animal by-products • reduce odour • reduce vermin and biological risk • applicable in, e.g. fat melting, rendering, fish-meal and fish-oil processing, blood processing, bone processing, gelatine manufacture, incineration and biogas production,

24. Additional BAT for rendering E.g. • reduce the sizes of carcases and parts of animal carcases before rendering • reduced energy consumption to process completely • remove water from blood, by steam coagulation, prior to rendering • burn the non-condensable gases in an existing boiler and to pass the low intensity/high volume odours through a biofilter or burn the whole vapour gases in a thermal oxidiser and to pass the low intensity/high volume odours through a biofilter

25. Additional BAT for fish-meal and fish-oil processing E.g. • use fresh, (low total volatile nitrogen) feedstock • incinerate malodorous air, with heat recovery

26. Additional BAT for incineration E.g. • enclose buildings used for delivery storage, handling and processing of animal by-products • seal the storage, handling and charging of animal by-products to incinerators • duct air from the installation and the pre-combustion equipment to combustion chambers • alarm and interlock combustion temperatures to charging mechanisms • operate continuous incineration

27. BAT – blood collection(water consumption and contamination) Optimisation of blood collection • extension of blood collection times • collection over a blood collection trough until the amount of blood dripping from the carcase is “insignificant” • design troughs to facilitate wet suction and/or scraping of blood or coagulated blood lumps to the blood tank prior to cleaningwith water

28. BAT – blood storage(energy, odour and infectivity) • use or dispose of blood before its decomposition starts to cause odour problems and/or quality problems otherwise • refrigerate it as quickly as possible and for as short a time as possible • cross-media effects – energy consumption • economic issues – investment and running costs

29. BAT – blood – treatment (downstream considerations) • fresh blood • can be used, so less waste for disposal • odour problems during storage, processing and waste water treatment can be avoided • waste water treatment is easier

30. Recommendations for future work • collect data per tonne of carcase produced and per tonne of animal by-product treated • measure consumption and emission levels at unit operation level (including all the associated information) • collect detailed information about cleaning techniques • supplement the incomplete information about many techniques

31. Suggested topics for future R & D projects • reduction of the energy consumption associated with chilling and refrigerated storage • optimisation of the energy use associated with drying animal by-products and identifying opportunities for heat recovery • use of non-potable water at slaughterhouses