IES83714Y1 - A process for producing purified tallow - Google Patents
A process for producing purified tallowInfo
- Publication number
- IES83714Y1 IES83714Y1 IE2004/0214A IE20040214A IES83714Y1 IE S83714 Y1 IES83714 Y1 IE S83714Y1 IE 2004/0214 A IE2004/0214 A IE 2004/0214A IE 20040214 A IE20040214 A IE 20040214A IE S83714 Y1 IES83714 Y1 IE S83714Y1
- Authority
- IE
- Ireland
- Prior art keywords
- tallow
- temperature
- drum
- bath
- filtered
- Prior art date
Links
- 239000003760 tallow Substances 0.000 title claims abstract description 84
- 238000000034 method Methods 0.000 title claims abstract description 28
- 238000001914 filtration Methods 0.000 claims abstract description 20
- 238000010438 heat treatment Methods 0.000 claims abstract description 6
- 238000004659 sterilization and disinfection Methods 0.000 claims description 9
- 238000003860 storage Methods 0.000 claims description 9
- 238000009877 rendering Methods 0.000 claims description 6
- 239000003925 fat Substances 0.000 description 12
- 235000019197 fats Nutrition 0.000 description 11
- 239000012535 impurity Substances 0.000 description 6
- 239000000047 product Substances 0.000 description 6
- 238000001816 cooling Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 210000001519 tissues Anatomy 0.000 description 4
- 239000007787 solid Substances 0.000 description 3
- 210000000988 Bone and Bones Anatomy 0.000 description 2
- 235000019735 Meat-and-bone meal Nutrition 0.000 description 2
- 238000011109 contamination Methods 0.000 description 2
- 238000010411 cooking Methods 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- 235000019737 Animal fat Nutrition 0.000 description 1
- 210000004369 Blood Anatomy 0.000 description 1
- 210000000003 Hoof Anatomy 0.000 description 1
- 210000000936 Intestines Anatomy 0.000 description 1
- 210000001847 Jaw Anatomy 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 210000002784 Stomach Anatomy 0.000 description 1
- 229920002522 Wood fibre Polymers 0.000 description 1
- 230000001580 bacterial Effects 0.000 description 1
- 235000015278 beef Nutrition 0.000 description 1
- 239000008280 blood Substances 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 239000001913 cellulose Substances 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 235000014113 dietary fatty acids Nutrition 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 239000000194 fatty acid Substances 0.000 description 1
- 150000004665 fatty acids Chemical class 0.000 description 1
- 238000005187 foaming Methods 0.000 description 1
- 150000002632 lipids Chemical class 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 235000013372 meat Nutrition 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 210000000056 organs Anatomy 0.000 description 1
- 230000001590 oxidative Effects 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 102000004169 proteins and genes Human genes 0.000 description 1
- 108090000623 proteins and genes Proteins 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000004062 sedimentation Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Abstract
ABSTRACT A process for producing purified tallow comprises the steps of adjusting the temperature of rough tallow to a temperature of from (75°) to (80°C), delivering the temperature adjusted tallow into a tallow bath, and rotating a filtration drum through the tallow in the bath, the drum having a filtration media on the outer surface thereof and having an interior for receiving filtered tallow. The tallow is drawn through the filtration media by applying a vacuum to the drum interior. The filtered tallow received in the drum interior is separated form entrained air. The process involves heating the filtered tallow to a temperature of approximately (137°C) and applying a pressure of about (3) bar abs to the heated tallow for a period of about (20) minutes to produce sterilised purified tallow.
Description
A process for producing purified tallow
Introduction
The invention relates to a process for producing purified tallow.
Rendering processes are used to treat waste by-products from meat slaughterhouses
and cutting plants. The materials which are rendered include non—saleable tissues
such as internal organs; hooves; feet and jaws; blood; intestines and stomachs;
skeletal bones; and extraneous materials.
Such materials tend to have a high level of bacterial contamination due to their origin
and non-refrigerated means of storage and distribution in air. The latter also
contributes to deterioration in tissue quality due to an increase in their fat content of
free fatty acids and oxidative rancidity. This means that rendering plant tallow is of
lower grade than other fats.
There is therefore a need for a process for producing purified tallow which will not
only reduce waste disposal but also provide a product which is fit for re-use in other
products such as animal feed.
tat v nt'
According to the invention there is provided a process for producing purified tallow
comprising the steps of:
adjusting the temperature of rough tallow to a temperature of from 75° to
°C;
delivering the temperature adjusted tallow into a tallow bath:
rotating a filtration drum through the tallow in the bath, the drum having a
filtration media on the outer surface thereof and having an interior for
receiving filtered tallow;
drawing the tallow through the filtration media by applying a vacuum to the
drum interior;
separating the filtered tallow received in the drum interior from entrained air;
heating the filtered tallow to a temperature of approximately 137°C;
applying a pressure of about 3 bar abs to the heated tallow for a period of
about 20 minutes; and
delivering the sterilised purified tallow to a storage tank.
In one embodiment the process comprises the steps of:-
delivering rough tallow at a temperature of about 110°C from a rendering
process into a reception tank;
adjusting the temperature of the tallow in the reception tank to a temperature
of from 75°C to 80°C
In another embodiment the process comprises the steps of:-
delivering the temperature adjusted tallow into a buffer tank; and
circulating tallow from the buffer tank to the tallow bath to maintain a
substantially consistent level of tallow in the bath.
Preferably the filtration drum is rotated through the tallow bath at a speed of from 2
to 3 revolutions per minute.
The vacuum maintained in the interior of the filtration drum is approximately
mbar.
In one embodiment the step of removing deposits from the filtration medium as the
drum is rotated. The deposits may be removed periodically. Alternatively, the
deposits may be removed continuously as the drum is rotated.
In one embodiment the filtered tallow is separated by leading the filtered tallow and
entrained air through a cyclone separator under a vacuum.
In a preferred embodiment the separated tallow is delivered into a pre—sterilisation
storage tank and the separated tallow is pre—heated in the pre—sterilisation storage
tank to a temperature of from 70°C to 120°C prior to delivery into a sterilisation
vessel.
Brief Deseriptien Qf the Drawings
The invention will be more clearly understood from the following description given
by way of example only, in which:—
Fig. 1 is a schematic diagram illustrating the process of the invention; and
Fig. 2 is a cross sectional view of a portion of a filtration drum used in the
process of the invention.
Detailed Description
The rendering process involves mixing and feeding raw materials through a metal
detector and bone crusher. The materials are transported to the main render cooker
which comprises a horizontal steam jacketed vessel with a large steam heated screw
type central impeller which imports heat to the mixture. Cooking involves heating
the tissue so as to boil off most of the water content at 100°C to 110°C under slightly
less than atmospheric pressures. The cooking also melts the fat tissue and converts it
to beef tallow which is pure lipids.
Cooked product (solids and fat) continuously leaves the cooker and passes through a
perforated conveyor. Fat goes one way, solids (called meat and bone meal) go the
other. The meat and bone meal pass through presses to squeeze out more fat. All fat
then passes through a centrifuge to remove solid protein particles. The fat still
contains suspended levels of impurities.
In general, the process of the invention involves initially cooling rough tallow as
represented by block 1, filtration of the rough tallow as represented by block 2 and,
sterilisation of filtered tallow as represented by block 3.
Two tallow cooling tanks 5, 6 receive hot tallow 7 at about 110° from a rendering
process. These tanks 5, 6 are used to cool the product to 75°C to 80°C using ambient
cooling over a 24 hour cycle. The tanks 5, 6 are kept under a negative pressure to
ensure odour containment which is sent to an on-site bio—filter. A steam coil 8. 9 is
present in the tanks to re—heat the product should overcooling occur. An auger type
pump 10 fitted with steam injectors (to clear lines after each pump) and trace heated
insulated pip—work feeds product from the cooling tanks 5, 6 to a filtration buffer
tank 12.
Tallow at 75°C to 80°C is filtered using a rotary vacuum drum filtration system. The
system consists of a slowly rotating variable speed drum 20 which dips into a bath 25
of infeed tallow which is under constant circulation to/from the buffer tank 12 via an
auger pump 26 thus keeping a constant level in the bath 25 and preventing
sedimentation of impurities in the bath 25. The inner shell 28 of the drum 20 is
maintained at a vacuum of 300 mbar using a 1,400 m3/hr centrifugal pump 27.
Referring in particular to Fig. 2, at start up, a nylon fabric mesh 30 (300 micron dia
pores) is applied to the drum 20 while under vacuum. On top of this a 90mm layer
of filtration media 31 (Filtron 120) is applied. This media 31 consists of an organic,
cellulose based, free—flowing wood fibre powder with particle size 100 to 120
microns. A layer of rough tallow 35 prior to filtration is shown schematically on the
outside of the filtration media 31 in Fig. 2.
In use, the drum 20 is slowly rotated at a speed of typically 2 to 3 revolutions per
minute through the bath 25 of rough tallow. The rotation of the drum 20 dips the
media 31 and mesh 30 into the bath 25 of tallow. The vacuum applied inside the
drum causes the tallow to be strained through the media 31 and mesh 30 into the
inner drum shell and thus, filters the fat. Impurities build up on the outside layer of
the media 32. This contaminated layer is scraped off the drums 20 as it rotates out of
the bath 25 and towards a scraper station 36 which consists of an adjustable knife.
The contaminated layer removed per revolution is normally in the range of 120 to
250 microns. The machine operator controls the degree of filtration by observing the
build up of contamination present on the filter medium after the scraper 36 and. if
required, adjusts the scraper depth and drum rotation to ensure that build up is
minimised. Normally, a 90mm layer of media lasts approximately 24 hours of
production.
Purified tallow and entrained air is transported along a line 40 via the vacuum pump
27 to a separator cyclone 41 which separates the tallow from the air and protects the
vacuum pump 27 from tallow carryover. The slightly contaminated air rejoins a
main air supply which is periodically circulated to an on-site bio—filter for cleaning.
The purified tallow is delivered by a pump 46 to two 35 tonne pre—sterilisation
storage tanks 48. These tanks 48 are used to store and pre—heat the fat from 70°C to
°C using steam coils 50 prior to sterilisation.
The system can process up to 3.5 tonnes/hr of tallow and reduces insoluble
impurities from 0.2 — 0.4% to 0.01 — 0.01%. It reduces polythene content from
ppm to 30ppm.
A pump 51 is used to deliver the filtered tallow from which air has been separated
into a pressure vessel. The tallow is introduced into a 14 tonne pressure vessel and
subjected to the following sequence. The steriliser top vent 54 is opened and tallow
is pumped into the vessel. As tallow is being introduced, a steam coil is activated to
commence heating to 137°C. When the tallow has reached a high set point, pumping
is stopped. When a tallow temperature of 137°C is reached, the top vent 54 is closed
and dry compressed air is introduced through an inlet 59 into the top of the vessel
headspace to pressurise the tallow to 3.1 bar abs (2.1 barg). When the headspace
pressure reaches 3.1 bar abs, a timer is activated and these pressure—temperature
conditions are maintained for 21 minutes. After 21 minutes, steam heating supply to
the coil is shut off and the vessel is de-pressurised by releasing the tallow from a
base outlet of the tank at a defined rate which is actuated by a stepper motor and
valve 62. Full de—pressurisation can take less than 2 minutes with this method
without causing fat foaming. When headspace pressure reaches 0.5 barg. the out-
feed pump 65 is activated to remove the fat from the steriliser to a pre—set low level
and send it to 35 tonne final storage tanks 66.
The operation of the entire steriliser sequence is controlled by dedicated PLC 70
which feeds relevant process parameters to an on—site SCADA based monitoring and
control system 71.
The system typically processes 13 tonnes per batch and a typical cycle time is 40
minutes.
The system enables render animal fat to be filtered and sterilised so that the fat
contains less than 0.15% insoluble impurities by weight. The tallow produced by the
process of the invention can be sold as animal feed which represents a considerable
economic premium over other market outlets such as oleo—chemical or fuel
applications. The process also removes a large proportion of polythene based
impurities which is of particular importance to downstream oleo—chemical and fuel
markets. The process is robust, efficient and relatively simple to operate and
maintain.
The invention is not limited to the embodiments hereinbefore described which may
be varied in detail.
Claims (1)
- A process for producing purified tallow comprising the steps of: adjusting the temperature of rough tallow to a temperature of from 75° to 80°C; delivering the temperature adjusted tallow into a tallow bath; rotating a filtration drum through the tallow in the bath, the drum having a filtration media on the outer surface thereof and having an interior for receiving filtered tallow; drawing the tallow through the filtration media by applying a vacuum to the drum interior; separating the filtered tallow received in the drum interior from entrained air; heating the filtered tallow to a temperature of approximately 137°C; applying a pressure of about 3 bar abs to the heated tallow for a period of about 20 minutes; and delivering the sterilised purified tallow to a storage tank. A process as claimed in claim 1 comprising the steps of:— delivering rough tallow at a temperature of about 110°C from a rendering process into a reception tank; adjusting the temperature of the tallow in the reception tank to a temperature of from 75°C to 80°C A process as claimed in claim 1 or 2 comprising the steps of:- delivering the temperature adjusted tallow into a buffer tank; and circulating tallow from the buffer tank to the tallow bath to maintain a substantially consistent level of tallow in the bath. A process as claimed in any preceding claim wherein the separated tallow is delivered into a pre—sterilisation storage tank and the separated tallow is pre- heated in the pre—sterilisation storage tank to a temperature of from 70°C to 120°C prior to delivery into a sterilisation vessel. Purified tallow when produced by a process as claimed in any preceding claim.
Publications (2)
Publication Number | Publication Date |
---|---|
IE20040214U1 IE20040214U1 (en) | 2004-12-15 |
IES83714Y1 true IES83714Y1 (en) | 2004-12-15 |
Family
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