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Animal (except Poultry) Slaughtering - 311611
Meat Processed from Carcasses - 311612
Rendering & Meat Byproduct Processing - 311613
Poultry Processing - 311615
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CHP Market Saturation / Geographic Location / Industry Drivers / Thermal Opportunities / Process Description / Associations / Events / Industry Leaders & Case Studies
• Over $54 billion in revenue is generated from the sale of unprocessed meat (U.S. Census Bureau)
Data not available
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• Energy Intensive Industry – this subsector is responsible for 5% of total energy consumption in the food processing industry (ACEEE)
• Food Safety – large amounts of hot water and steam used for sanitation
• Reliable Power – eliminates power outages that allow frozen meat to thaw and spoil
Reciprocating engines, with a power size range of 30kW–8MW, generate engine jacket heat from 180-200°F, and exhaust heat at around 1200 °F. Industrial turbines, with a power range from 1-20+ MW, generates heat from 900-1100°F. This heat can be recovered and used to heat or cool products in a variety of food processing steps such as:
• Hair is often removed from hides using scalding water or steam
• Hot water and steam are used for decontamination during evisceration – knives must be cleaned in water at a temperature of at least 82 degrees F; surfaces are cleaned with steam that can reach 180 degrees F (University of Aberdeen)
• Carcasses must be thoroughly chilled to temperatures between 41-50 degrees F – refrigeration accounts for 47% of the plants total energy use (Tri-State Generation)
Animals are first stunned, and then exsanguinated. They are many different ways to do this, varying with the type of animal being slaughtered. The plasma from waste blood may be recovered for use in animal feed products. Carcasses are then eviscerated, and the hide is removed and retained to make leather products. The carcass is then cooled before further processing and butchering to prevent the growth of microbes. If done properly, meat can have a shelf life of up to three weeks. Animal wastes are disposed of by rendering to produce lard, tallow, soap, and grease. If the plant is an integrated plant, it will cut and continue to process the meat. Otherwise, the carcasses are shipped to processing plants in sterile, refrigerated trucks (University of Aberdeen).
American Meat Institute
Facility Sanitary Design Workshop - September 29, 2004
2004 AMI Innovation Showcase - September 30-October 2, 2004
Listeria Intervention & Control Workshop - November 3-4, 2004
2005 Animal Care and Handling Conference - February 9-10, 2005
Annual Meat Conference - March 6-8, 2005
Smithfield Packing Company
Rockdale Beef, Australia - http://www.energysmart.com.au/wes/images/pdf/Rockdale_combined.pdf
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CHP Market Saturation / Geographic Location / Industry Drivers / Thermal Opportunities / Process Description / Associations / Events / Industry Leaders & Case Studies
• Over $24 billion in revenue is generated from processed and preserved meat and meat by-products, as well as packed meats from purchased carcasses. (U.S. Census Bureau)
Data not available
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• Food Safety – large amounts of hot water and steam used for sanitation
• Reliable Power – eliminates power outages that allow frozen meat to thaw and spoil
• Large amounts of refrigeration required to store carcasses before processing, and finished meat products before sale. Temperatures as low as –4° F (-20° C) are necessary to retain freshness. (UNFAO)
• When making sausages, the meat must be cured in an environment with strict humidity and temperature controls.
• When canning meat, steam at temperatures as high as 284° F (140° C) is used to sterilize the meat and cans (UNFAO)
• Retorts use pressurized steam to decontaminate canned goods
• Upon removal from the retort, the pressurized cans must be immediately cooled to 104° F (40° C) to prevent overcooking (UNFAO)
Frozen carcasses arrive at the processing plant via large refrigerated trucks. Poor quality meat is used for highly-processed products, such as sausages and ground meat. Higher quality meat is cut into steaks and roasts. Meat is sold in a variety of cuts, and may be sold wholesale for further in-store processing or packaged for individual sale.
Meat may be salted, cured, spiced or smoked as a part of the preparation process. Salting both adds flavor to and dehydrates the meat, allowing it to be preserved more readily. Curing adds nitrate-based compounds to the meat, affecting flavor, inhibiting microbial growth, and allowing the meat to retain its bright red color even after cooking. Spicing meat affects only taste and color, and generally has not effect on microbial growth or meat preservation. Smoking meat gives it a distinctive flavor and helps to preserve it through dehydration. Generally low-smoke sawdust fires are used when meat is being smoked.
Low quality meat is processed even further into many different types of products. Three common processed meat products are ground hamburger meat, sausages and salami, and canned meat. Ground hamburger meat is made by first mincing the meat through a 5 mm plate. The meat is mixed with other ingredients that may include soy, salt, seasonings, or onions. The ingredients are well-blended, and the meat is formed into patties and frozen. For sausage and salami production, frozen meat is allowed to thaw, and then is finely chopped and ground. Many ingredients, that may include salt, curing substances, sugar, or spices, are mixed together. The casings (usually animal intestines) are filled with this mixture and tied off. Sausage is hung in a curing room and allowed to ferment for 3-5 days. Finally, sausages are dried in a temperature and humidity controlled environment, packaged and sealed. Canned meat and the cans themselves must both be sterilized before the cans are sealed and passed through a retort. The retort heats and pressurizes the meat inside the can, cooking it and creating a vacuum that inhibits microbe growth. (UNFAO)
American Meat Institute
North American Meat Processors Association
Facility Sanitary Design Workshop - September 29, 2004
2004 AMI Innovation Showcase - September 30-October 2, 2004
NAMP's 62nd Annual Convention - October 14-17, 2004
Listeria Intervention & Control Workshop - November 3-4, 2004
Annual Meat Conference - March 6-8, 2005
C&F Packing – Sausage Factory http://www.poweronsite.org/AppGuide/CaseStudies/CS_CFPacking.htm
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CHP Market Saturation / Geographic Location / Industry Drivers / Thermal Opportunities / Process Description / Associations / Events / Industry Leaders & Case Studies
• This industry generates nearly $2.6 billion from the sale of products obtained by the rendering of animal wastes (fat, bones, meat scraps) (U.S. Census Bureau)
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• Energy intensive process that leads to high electricity costs
• Drastic increase in process efficiency
• Large amounts of contaminated waste steam obtained from the rendering process
• Large amounts of heat and steam needed to cook the animal wastes
Animal wastes are passed through a grinder before being poured into a cylindrical cooker that is surrounded by a steam jacket. The animal wastes are approximately 50% water. This water is removed during the cooking process in the form of a contaminated steam. This steam may contain compounds such as ammonia, ketones, and fat aerosols. This system requires a lot of energy, but can be made more efficient by using the contaminated steam in a waste heat recovery system. Cooking can last anywhere from 20 minutes to a few hours. The remaining slurry is pumped to a fat press to make meal, lard, tallow, grease, etc. (Tri-State Generation)
American Meat Institute
North American Meat Processors Association
Facility Sanitary Design Workshop - September 29, 2004
2004 AMI Innovation Showcase - September 30-October 2, 2004
NAMP's 62nd Annual Convention - October 14-17, 2004
Listeria Intervention & Control Workshop - November 3-4, 2004
Annual Meat Conference - March 6-8, 2005
Smithfield Packing Company
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CHP Market Saturation / Geographic Location / Industry Drivers / Thermal Opportunities / Process Description / Associations / Events / Industry Leaders & Case Studies
• Nearly $32 billion in revenue is generated from the sale of poultry meat products (U.S. Census Bureau)
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• Food Safety – lots of hot water and steam required for proper sanitation
• Energy Intensive Industry
• Power Reliability – loss of power can lead to lost revenue due to spoiled products
• Chickens are scalded to loosen feathers using water no warmer than 136º F (58º C) (University of Aberdeen)
• Knives and surfaces must be cleaned and sterilized using hot water or steam after the exsanguination and evisceration processes
• Large amounts of refrigeration are required to keep the carcasses from spoiling
Chickens are rounded up in crates, and may or may not be stunned before exsanguination. The chickens are scalded to loosen the feathers, which are removed by a rotating drum with rubber fingers as the chickens pass by on a conveyor belt below. Remaining feathers must be hand plucked. The chickens are then eviscerated, which can be done in a number of ways. In some cases in large processing plants, the process has been automated. The carcasses are then cooled in freezers before further processing and commercial sale. (University of Aberdeen)
American Meat Institute
U.S. Poultry & Egg Association
Facility Sanitary Design Workshop - September 29, 2004
2004 AMI Innovation Showcase - September 30-October 2, 2004
Listeria Intervention & Control Workshop - November 3-4, 2004
International Poultry Exposition - January 26-28, 2005
Annual Meat Conference - March 6-8, 2005
Allen Family Chicken Processors
Perdue
Tyson Chicken
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