Essential RenderingSafe, High Quality Products

David L. Meeker, Ph.D., MBASenior Vice President, Scientific Services

National Renderers Association

Additional information in a book available from the

National Renderers Association

Free download:nationalrenderers.orgunder “Publications”

This presentation is for educational purposes only.

Additional information on NRA Website:http://nationalrenderers.org/

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

Rendering is Cooking and Drying. Rendering is Recycling. Rendering is Essential to Public Health.

What is Rendering?

• To protect the environment• To protect human health• To protect animal health• It is sustainable and contributes to

sustainability

Rendering is Essential

Rendering Plants

Rendering Plant

Rendering Plant—Up Close

Rendering Plant—Up Close

Rendering Plant—Up Close

• 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)

U.S. Animal Agriculture Annual Production

Our Green Impact

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.

Rendering Annually Recycles (million lb) :

Rendering’s Carbon Footprint

• Recycling fat and protein significantly reduces the amount of greenhouse gases, such as CO2, released into the environment.

• According to the US-EPA, the CO2 renderers recycle each year is equivalent to the following actions taken to reduce greenhouse gases:

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

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

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

Renderers Employ Water Treatment

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.

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.

Rendering is Recycling

Raw Materials

• Offal• Bones and fat• Blood• Animals dead on

arrival, in transit or on farms

• Restaurant grease• Feathers• Recalled meat

Turning This:

Into This:

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.

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.

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

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

• Good manufacturing practices (GMPs) • Process Controls

Rendering Code of Practice (How)Basic elements of sanitation and hygiene

Process Controls in RenderingIt 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

Decomposing Tissues Are Laden with Conventional Pathogens A

A University of Illinois, 2001. 17 different rendering facilities sampled during winter and summer. Percentages indicate number of samples found to have pathogens present.

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

Potential Biological Hazards - Bacteria

D-value: The time required at a given temperature to kill 90% (1 log) of the organismsZ-value: The increase in temperature required to reduce the D-value by 1 log.

Predicted Bacteria Death Rate

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

Plant Operator Screen

RecordkeepingCooker TemperatureTrending and Statistical Analysis

Rendering Destroys Bacteria of Food Safety Concern

U. Of Illinois, 2001. 17 rendering facilities sampled summer and winter. Percentage of samples having pathogens present.

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

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.

Representation

www.renderers.org Tom Cook, President

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.

Biosecurity

www.animalprotein.org David L. Meeker, Ph.D, MBA

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.

Fats and Proteins Research Foundation (FPRF)

Research

www.fprf.org Dr. Sergio Nates, President