The End of the Rendering Plant Eben van Tonder 10 September 2021
I have been working with traditional equipment and novel technology such as DCD Technology for the last few years. I realised that I was able to replace the rendering plant completely with higher yield products and much-improved functionality for raw materials. I have been looking at applications for my replacement products of the traditional rendering plant since 2016. The applications are many. It makes meat-on-meat injection for bacon injection possible without the hassles associated with current systems.
See my article: Meat-on-Meat Bacon and Ham: Injection for Profit and Taste
I house the work on the 5th quarter and alternative ways to approach fine emulsion sausages at, Nose-to-Tail and Root-to-Tip, but it is much wider than that. The rendering plant has traditionally been the wastebasket of the abattoirs but this is about to change. My approach to the 5th quarter requires no heating and when we processed the full 5th Quarter, we end up with a POSITIVE yield. Using DCD Technology one can process:
- Blood (for animal feed and fertaliser)
- Hair (for animal feed and fertaliser, increasing digestibility to levels far above what is normal for keratin)
- Hide (extract collagen for human consumption and the rest for animal feed)
- Hooves (for animal feed)
- Intestines including the stomach matter (approved intestines for human consumption; rest for animal feed)
- Tendons (the collagen for human consumption)
- The bones (the collagen for human consumption)
My alternative approach is set to replace rendering plants and make a range of raw materials available to local meat processing including collagen and other functional ingredients which has in recent years been traded through the spice industry. This technology has been packaged in equipment that is easy to maintain and install anywhere in the world. Its use will eliminate abattoir waste completely. It will wrestle back meat technology from the hands of the spice industry to the meat industry who should be the rightful custodian of meat processing technology.
One of the novel forms of technology I use is DCD Technology.
My Own Articles on the DCD Technology:
Current Ongoing and Future Projects
– Lab Work
At the moment I am working my way through the full 5th quarter and doing the lab work required to give us the full scientific understanding of the power behind DCD Technology.
– Factory waste
We are starting trails next week whereby we will eliminate all factory meat waste by re-thinking our approach to waste and producing high-quality pet food for a local meat processor.
– Back to nature
We are able to process potatoes and other tubers and grains, rich in starch. The equipment owners will be able to produce their own starch, dietary fibres and sugars. By understanding the composition of potato, to use one example, formulations can be re-worked where potatoes are used that has been DCD’ed to replace highly concentrated and processed starch, fibres and sugars customarily added to the meat block for sausages, etc.
– Vegetable Sausages
Over the last 75 years or so a very unfortunate trend emerged in meat processing whereby meat hybrids emerged which is a combination of serials, grains and meat. We continue to call these products meat but in reality, it is not pure meat. While it is a fact that we consume far too much meat and too little fruits and vegetables, we are often limited in our choices for little-processed fruits and vegetables that can be taken to work or school and that will fill us enough to do our work. The accompanying trend for imitation meat is even more worrying.
New technology makes it possible to produce vegetable and grain-based sausages without the inclusion of any meat so that the producer can offer the consumer the option of pure meat products and fruits and vegetables that are produced with no additives or e-number ingredients but packaged in convenient ways like sausages or nuggets. It allows for people to completely move away from imitation meat products which are packed with highly processed functional ingredients. Consumers have options to reduce their meat intake with the peace of mind that the meat they eat and the vegetables they consume are minimally processed and yet, safe to consume and conveniently packaged for the modern family with all our unique demands.
We are busy with all these developments! Re-looking at existing technology and incorporating new technology such as DCD Technology into the processes enable us to accomplish what has never been done before!
Application Page Featuring Technology to Process the 5th Quortar
A Page Dedicated to Industrial Products and Consumer Products produced from 5th Quorter: Endless Possibilities: Combining Fruit, Veg and 5th Quarter Products or 5th Quarter Products on their Own.
Below is a list of my own feedback videos. Some of the products have been made using DCD Technology at a fraction of raw material cost compared to if one would procure it through the spice trade or other channels.
80% Beef Collagen, 20% Beef Fat.
Processing pig hooves (Keratin) into highly nutritious animal feed.
Here we made a fat replacer with 60% collagen which we obtained from beef tendons and skin and beef kidney fat. We added about 20% water. 2.5kg fat makes 15kg final product.
Processing pigs hair using novel technology ensures high digestibility. The relationship between digestibility and comminution has been firmly established in recent literature.
Case Study 1: Pork Rinds
Pork Rinds, Functionals and Water blended together.
Look at the product consistency. One could inject it!
After setting for 12 hours in the fridge, the rinds form a stable and sterile gel which can be added to a bowl cutter or emulsifier for inclusion in a fine emulsion sausage recipe.
Pork rinds gel after setting for 12 hours in the fridge.
Pork rinds gel after setting for 12 hours in the fridge.
Case Study 2: Creating collagen rich “smoothies” for the health industry or high quality pet food.
Animal parts rich in collagen before processing.
The collagen-rich gel after processing.
Case Study 3: Pork Trim 80/20
80/20 pork trim DCD’ed.
DCD’ed 80/20 Cured Pork Trim. The consistency is such that it can be injected, even under low pressure. Temperature is kept sufficiently low not to denature the proteins.
Case Study 4: Fat Replacer After Setting Overnight
Collagen, processed and chilled overnight to set.
After chilling overnight to set, the mix is minced.
After chilling it overnight, a paste is formed, stable enough for mincing and inclusion as a possible fat replacer.
End-uder Feedback of Final Product
Final products and comments by clients who tasted the final products are featured in this section.
The commentary is in Afrikaans but you can tell the Dei owner is very happy!
Gel strength after heating of sausage.
It has been high time meat professionals re-look how the 5th quarter is processed. Functional ingredients that are subjected to high processing will become something of the past and this new look at how we do things will make food more affordable and substantially contribute to making food less processed. The British Agency for Food Safety talks about food that must be consumed in the way that it would be done if nothing is refined, extracted and concentrated. All this becomes available if we change the
Rendering plants as the wastebasket for the abattoir is something of the past, to be replaced by this new technology. Instead of a wastebasket, what is about to replace it is a completely new concept which materially contributes to the future of our lives on earth!
(c) Eben van Tonder
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