Essential Rendering Safe, High Quality Products

Transcription

1 Essential Rendering Safe, High Quality Products David L. Meeker, Ph.D., MBA Senior Vice President, Scientific Services National Renderers Association

2 Additional information in a book available from the National Renderers Association Free download: nationalrenderers.org under Publications This presentation is for educational purposes only.

3 Additional information on NRA Website:

4 The Rendering Industry (U.S. and Canada) 273 facilities in the U.S. and 29 in Canada $3.5 billion annual revenue 26.3 MMT (59 billion lb) raw material each year 72.3 million kg raw material each day

5 What is Rendering? Rendering is Cooking and Drying. Rendering is Recycling. Rendering is Essential to Public Health.

6 Rendering is Essential To protect the environment To protect human health To protect animal health It is sustainable and contributes to sustainability

7 Rendering Plants

8 Rendering Plant

9 Rendering Plant Up Close

10 Rendering Plant Up Close

11 Rendering Plant Up Close

12 U.S. Animal Agriculture Annual Production 35 million cattle (49% of live wt. not used for human food) 100 million hogs (44% not used for human food) 8 billion chickens (37% not used for human food) 280 million turkeys (36% not used for human food)

13 Our Green Impact Rendering Annually Recycles (million lb) : Rendering protects the environment: If not recycled, the large amounts of carbon, nitrogen, and phosphorus present in inedible animal by-products may contribute to global warming, soil loading and water contamination. U.S. rendering facilities utilize world-class processing equipment, treatment processes and control equipment to minimize the impact on the local environments air and water.

14 Rendering s Carbon Footprint Recycling fat and protein significantly reduces the amount of greenhouse gases, such as CO 2, released into the environment. According to the US-EPA, the CO 2 renderers recycle each year is equivalent to the following actions taken to reduce greenhouse gases:

15 The modern rendering industry invests heavily in odor control and air pollution equipment.

16 The modern rendering industry invests heavily in odor control and air pollution equipment.

17 The modern rendering industry invests heavily in modern equipment to control water pollution.

18 Renderers Employ Water Treatment

19 The industry converts more than 26.3 MMT (59 billion pounds) of animal by-products into usable commodities annually. Highly valued protein supplements for livestock, poultry, pets Tallow for the manufacture of fatty acids and as a source of energy in feed rations.

20 Rendering is Recycling Today s industry produces approximately 9 MMT (20 billion pounds) annually of finished rendered products, continues to grow, and is integrated into the dynamic and productive agricultural system.

21 Raw Materials Offal Bones and fat Blood Animals dead on arrival, in transit or on farms Restaurant grease Feathers Recalled meat

22 Turning This:

23 Into This:

24 Rendering is Cooking and Drying Continuous flow or batch Steam cookers 115º to 145º C. for 40 to 90 minutes (245º to 290º F.) Inactivation of bacteria, viruses, protozoa, and parasitic organisms.

25 Rendering Protects Human & Animal Health US Industry safely and responsibly sanitizes and recycles more than 54 billion pounds of inedible materials generated each year by the animal production and meat industries. Rendering offers a sanitary and eco-friendly way to dispose of the massive amount of meat and food by-products produced every year. Such materials spoil easily and make an excellent media for pathogens to grow and multiply. Temperatures (> 245 F) used during processing are more than adequate to kill conventional disease-causing organisms, such as bacteria and viruses.

26 Rendering Code of Practice (Why) Educate about the safety of animal proteins and rendered fats Establish process controls based on HACCP Principles Audits to verify the controls are in place Participation is voluntary The marketplace expects participation

27 Rendering Code of Practice (Basis) A Hazard Analysis and Critical Control Point (HACCP) - based Program Types of hazards to consider: Physical glass, metal, wood etc? Biological bacteria, viruses, etc. Chemical pesticides, PCBs, toxic substances

28 Rendering Code of Practice (How) Basic elements of sanitation and hygiene Good manufacturing practices (GMPs) Process Controls

29

30 Process Controls in Rendering It is critical that sufficient temperatures are attained, so cooking would be a CCP in any rendering HACCP plan (Biological hazards). Cooking temperatures should be closely monitored, controlled, and recorded. Process Control #1

31 Decomposing Tissues Are Laden with Conventional Pathogens A A University of Illinois, different rendering facilities sampled during winter and summer. Percentages indicate number of samples found to have pathogens present.

32 Biological Safety Hazards Adequate heat kills conventional pathogens BSE agent is a potential hazard, but is addressed through compliance with FDA regulations Select indicator organism for validation Salmonella may not be a good choice due to lack of specificity and potential for recontamination Control recontamination with GMPs/SSOPs Assess the extent of heat treatment needed for each product

33 Potential Biological Hazards - Bacteria D-value: The time required at a given temperature to kill 90% (1 log) of the organisms Z-value: The increase in temperature required to reduce the D-value by 1 log.

34 Predicted Bacteria Death Rate

35 Factors Affecting Destruction of Biological Hazards Particle size and consistency Raw material composition Fat increases heat resistance Bone causes inconsistent heat transfer Salt (heat resistance increased by salinity) Water content of RM Effective kill enhanced with moisture More moisture increases retention time in cooker Initial pathogen load increases need for more severe processing conditions

36 Plant Operator Screen

37 Recordkeeping Cooker Temperature Trending and Statistical Analysis

38 Rendering Destroys Bacteria of Food Safety Concern U. Of Illinois, rendering facilities sampled summer and winter. Percentage of samples having pathogens present.

39 Procedures for Recalled Food Recalled food is considered adulterated by FDA Rendering process certainly kills common pathogens FDA Compliance Office is to be notified before recalled food is rendered in to animal feed ingredients Renderer must certify that process is adequate to kill pathogens

40 Representation National Renderers Association (NRA) NRA was organized in 1933 to represent renderers interests to Congress, regulatory and other government agencies, promote greater use of rendered products, and foster the opening and expansion of trade between North American exporters and foreign buyers. Tom Cook, President

41 Biosecurity Animal Protein Producers Industry (APPI) APPI was organized in 1984 to develop a voluntary Salmonella education and monitoring program. APPI s role has since been expanded to address virtually all food security issues. David L. Meeker, Ph.D, MBA

42 Research Fats and Proteins Research Foundation (FPRF) FPRF was organized in 1962 to direct and manage research to increase usage of, and to develop new uses for rendered animal products to add value to all animal production. Dr. Sergio Nates, President