Hatchery Waste, Layer Farm Manure, Slaughter House Waste and Slaughter House Fat

1. www.dhopeshwar.in
Offering Clean &
Green Technologies
For Poultry-waste
- Hatchery Waste
- Layer Farm Manure
- Slaughter House Waste
- Slaughter House Fat
management

2. Global poultry production is projected to double by the
year 2030. The greater portion of this global demand for
poultry products will be in the form of chicken meat
Using global demand for different MEAT during the years
1997to1999asabase,itisestimatedthatby2030,demand
willincreaseby45%forBovine,57%forPorkand106%for
Poultrymeat.
Poultry Meat production was about 111 million metric
tonnes(MMT) in 2015 despite the avian influenza. Projected
to reach 133/2025 MMT. Poultry meat will account for
more than half of the world's additional MEAT output over
the next decade. Poultry's short production cycle enables
producers to respond quickly to increased profitability.
South east Asia will account for nearly 36% of this increase
inglobalpoultryproductionby2025.
Poultry Industry perpective
Providing Specialised Engineering Solution Thru Process Innovation

3. Hatchery Waste
Waste from poultry
Layer Manure
Slaughter house waste
Slaughter house - fat
Hatcherywasteis a natural by-product of hatcheries.This wasteconsists of egg-shells, un-
hatched eggs, and rejected embryos etc. This waste is rich in Proteins and Calcium with
approx. 30% Proteins and 20% Calcium. However, Un-treated waste is a source of soil and
atmosphericpollution&presentlyaliability.Presentlydisposalinvolveslabour,transportation
cost and merely shifts the pollution elsewhere. It is estimated that a 10,000 eggs hatch
produces about 125 KGs of waste. Proper treatment of waste will offer a useful product
whichcanbeusedinpoultryfeedorfertilizer.
One of the most important but neglected area in poultry Sector is waste management.
Poultry hatchery results in hatchery waste, Layer farms results in Layer Manure, Dressing
( slaughter) results in non-edible waste. This waste creates environmental pollution, Soil
contamination,Groundwaterpollutionetc. Henceneedforefficientwastemanagement.
Layer manure from layer farms poses huge problem of disposal. This manure is mostly liquid &
creates odour & fly nuisance. Manure is a challenge because it can not be applied directly as
fertiliser,asithashighNitrogencontent.NitrogenformsNitratesetcandleachintoSoileffecting
ground water. Due to high water content, disposal of manure also involves high labour &
transportationcost.Itisestimatedthatafarmwith1,00,000layersproduces10TonsofManure/day
or3,650tonnesofmanureperyear.LayermanureisrichinmanyessentialPlantNutrientslikeN,P,K.
Ifprocessedproperlyitwillgiveadry,baggableOrganicfertiliserwhichcanbestored&used.
Slaughter of chicken for dressed meat results in separation of non-edible portions such as
head, feet, feathers, offals etc. Being biological residue, these can putrify & become rancid
very quickly creating air and ground pollution & a nuisance. The pathogens can also
continue to pollute elsewhere. Hence disposal becomes a challenge and urgent necessity.
However this waste is a rich source of Animal protein & fat. It is estimated that slaughter of
bird results in waste which could be approx. 30% of live wt. Slaughter of 10,000 birds of
Ave.wt.1.6 kg each will result in waste of about 5 Tons. Effective processing / Rendering of
thiswastecangiveasterilised,pathogenfreeMeatmealthatcanbeusedinfeed..
Slaughter of chicken results in separation of non-edible portions and fat. While the non-
edible portions can be generally Rendered together as a mix, a fair amount of body fat is
separated.Thiscouldbeabout3.5%oflivewt.Thisisgenerallydisposedofftoun-organised
sectorforextractionoffat.Un-processedFatisnotconsideredhealthy,Aslaughterof10,000
birds of Ave. Live wt. 1.6 kg each will result in approx.550 kg of fat. However, Proper
technology can give commercial quality oil which is high in linoleic acid and Omega-6 fatty
acidcontent.Thisoilcanbeusedasflavoringagentandinpetfood.
based technology
Digestor
Dhopeshwar offers complete Technology to make a sterilised, pathogen free,
Stable & dry product from each of the above waste. This Innovative Technology
adopts HTST Process (High temp.- short time process at temp. upto 140 deg C for
20minutes)tomaketheby-products completely pathogen-free.
Different Capacities
Model 250kg and 500kg with-out boiler
Model 750kg, 1000kg, 1500kg, 2000kg, 3000kg & 3500kg with boiler
Providing Specialised Engineering Solution Thru Process Innovation

4. Digester with
odour control systems
Providing Specialised Engineering Solution Thru Process InnovationProviding Specialised Engineering Solution Thru Process Innovation

5. 1. Itsterilisesthewasteattemp.upto140degCtogiveafullysterilized
(pathogen-free)stableproductwhichcanbebaggedandsold.
2. The Technology Eliminates environment pollution as well as
risk of ground water contamination. It eliminates risk of pathogen
andphytotoxicreleasesintosoil.
3. Itrecyclestheorganiccontents&thenutrients(N,P,K)available
in layer manure. It allows nutrients in the manure to be re-
cycledbysoilforplantgrowth
4. It gives a stable, bagable, dry product in shortest time. The final
productisveryusefulasOrganicfertiliser.
5. This Technology is safe to be installed & operated near thelayer
farms.Thatsavestransportcost.itisamoreEffectiveandprofitable
optionthananyothermethod
of Digestor based technology
Advantages
Providing Specialised Engineering Solution Thru Process Innovation

6. A commercial hatchery produces LIVE chicks in every hatch. Apart from
chicks, It also produces huge quantity of waste which is its natural bye-
product. Hatcheries are expanding as the Poultry sector is expanding. So
also the waste from hatcheries. This waste includes Egg Shells, unhatched
eggs, rejected embryos etc. This hatchery waste poses the risk of polluting
environment unless it is disposed off safely. Proper handling & processing of
this waste will not only saves environment but also gives a useful bye-
product.
In recent years, the cost of labour, transport, disposal has
increased. The pollution control regulations have made it
mandatory for hatcheries to find sustainable solution for
waste management. Technology that can process this
waste safely is the urgent need of hour.
There are different options to manage hatchery
waste-Incinerate, Compost, rendering etc. Each
option has certain cost. The option chosen to
manage waste will determine whether the
waste management will mean just
additional cost or some addl. Revenue.
Waste from Hatcheries
Providing Specialised Engineering Solution Thru Process Innovation

7. One of the most suitable option for hatcheries is rendering through the latest Digestor based
Technology. This Technology converts Hatchery waste to make hatchery (waste) meal. This
technology makes Hatchery meal completely sterilized & pathogen-free while retaining its
protein. The finished Hatchery meal is rich in Protein, fat and nutrients. It can be used
eitherasPremiumOrganicfertilizeroranimalfeed.
Technology
that eliminates waste
of Our Technology
1. Efficient odour control system that eliminates odour
and air pollution
2.Robustbuiltmachinery,designedforsafeoperations
overmanyyears
3. AdvancedTechnologybackedby5decades
of engineeringexperience.
Salient Features
Different Models
250 kg - Direct fired
500kg - Steam heated
Fuel - Wood, Coal, Diesel
Input - All Hatchery Waste
Out put-Product - Hatchery by Product meal (HBM)
Digestor Model E 250 E 500
Suitable for 20,000 Hatch 40,000 Hatch
Time taken 4 - 6 hrs
Waste cap. 250 kg 500 kg
Out put - Qty 100 kg 200 kg
Power required 9 hp (7 kw) 12 hp (9 kw)
Shed - . 10x20x10' ht 20x30x 14' ht
Main Specifications :
Providing Specialised Engineering Solution Thru Process InnovationProviding Specialised Engineering Solution Thru Process Innovation

8. Fresh manure is a natural organic by-product of the livestock sector. Fresh
manure is an excellent source of fertiliser because it contains Nitrogen,
Phosporous, Potassium & other crop nutrients. However poultry manure
cannot be used in its raw form. The Layer fresh manure (LFM) contains 75-
84% water. LFM is a big nuisance world-wide as it is the breeding site for flies
& source of ammonia odour pollution. Flies are the cause of major health
problemsinareas&communitiessurroundingLayerfarms.
Layer farm manure LFM -poses huge problem of disposal. It cannot be
applied as fertiliser directly as it has high Nitrogen content and direct
application would not only effect soil & ground water due to
leaching of Nitrates but also nutrient imbalances & phyto-
toxicity in crops. Disposal involves high labour &
transportation cost. It is estimated that a farm with
1,00,000 layers produces 10 Tons of Manure /day or
3,650Tonofmanure/year.
Manure management has become most
important aspect of Layer farm due to
stringent pollution control measure
implemented by governments.
Technology that can process this
manure is most urgent need of
the hour for sustaining
operationsatLayerfarms.
Waste from Layer Farms
Providing Specialised Engineering Solution Thru Process Innovation

9. LayermanureisrichincropNutrientslikeN,P,K.PoultrymanurecontainshighestNitrogencontent
as compared to other manures. Its polluting influence minimised and it's utility maximised by
processingitintoOrganicfertiliser.
One of the most suitable option for processing Layer farm manure is the Digestor based
Technology which adopts HTST process This technology makes Layer manure into
completely dry, baggable powder / Pellet form while retaining its nutrients. The
dried product can be used as Premium grade Organic fertiliser that can be stored
andused.Thisenablesre-cyclingofimportantnutrients(N,P,K).
Technology
that eliminates waste
of Our Technology
1.Starts with fresh manure in ‘as available’ condition from
farm.Nopre-dryingtoreducewaterbeforeloading.
2.Efficient Vacuum drying system which eliminates
Odourandairpollution.
3.Robust built machinery, designed for safe
operationsovermanyyears.
Salient Features
Different Models
Boiler Fuel - Wood, coal, Diesel
Input - Fresh Manure 75-80% Water
Output - Baggable, Ready to use, Organic
Fertiliser, 10 to 20% Moisture
Plant model - 10 MT/Day 20 MT/day
Capacity based on - 24 hr/day 24 hrs/day
Waste-(25% dm) - 10 MT/day 20 MT/day
Output-20% Moist- 3 MT/day 6 MT/day
Infrastructure - 200 m2 & 35 hp 250 m2 & 50 hp
Main Specifications :
Providing Specialised Engineering Solution Thru Process InnovationProviding Specialised Engineering Solution Thru Process Innovation

10. Slaughter / Dressing of chicken for meat is an extention of Broiler farm activity.
It results in separation of non-edible portions such as head, feet, feathers,
offalsetcfromtheediblemeatportion..
Offalsetc:Wastebeingbiologicalresiduetendstoputrify&becomerancidcreating
air and ground pollution & nuisance. The pathogens from this waste become
pollutantsifun-treated.Hencedisposalbecomesanurgentnecessity
It is estimated that slaughter of bird results in 70% edible meat and
30%waste.Slaughterof1,000birdsofAve.wt.1.6kgeachieTotalLive
wt. 1,600 kg will result in waste of 500 kg. Ie. For 10,000 birds,
wastewouldbeabout 5Tons.
Body fat : Slaughter of chicken also results in separation of
bodyfat(about3.5%oflivewt.)Fatisnotediblebutcanbe
usedforextractionofOilwhichiscommerciallyuseful
Slaughter of 10,000 birds results in approx.550 kg
offat.
Waste from
Slaughter house of chicken
Providing Specialised Engineering Solution Thru Process Innovation

11. Slaughter waste can be rich source of Animal protein & fat if processed. Effective processing (
Rendering ) of this waste can give a sterilised, pathogen free Meat meal that can be used in
poultryfeedorpetfoodproducts..
Proper processing of fat can give commercial quality oil which can be used as flavouring
andagentinpetfoods.
Technology
that eliminates waste
of Our Technology
1. Starts with non-edible waste like Head, feet, feathers,
intestineetc.innon-rancidcondition.
2. Efficient Hydrolising of feathers and drying of
material which eliminates Odour and air
pollution.
3. Robust built machinery, designed for
safeoperationsovermanyyears.
Salient Features
Main Specifications :
Different models - From 250 kg / batch to 3500 kg / batch
Data for - 2,000 kgs /2 MT per batch ( ie. 6 MT / day)
Boiler fuel - Wood, coal, diesel
Input - All waste from slaughter - approx. 2 MT / batch
Output - Steriliased Meat meal - Approx. 600 Kg / Batch
Product quality - Meat meal containing 55 % Protein & 20% Fat
Process time - 8 hours
Infrastructure - 25 x 40 x 20 ft ht. Shed, 50 hp power etc
Providing Specialised Engineering Solution Thru Process InnovationProviding Specialised Engineering Solution Thru Process Innovation

12. AboutDhopeshwar
Dhopeshwar Industries started as a pioneer Chemical Engineering unit at Hyderabad in 1963. Initially we used to
engineer Chemical Process Equipment and special purpose machineries (SPM) for various process industries. This
expertisewasfurtherdevelopedtosupplycompleteSpecialpurposeplants&machineries(SPM's)invarioussectors.
Our strength is to develop the required process based on customers need. Then engineer & build Special Purpose
machineries(SPMs)basedontheprocessdeveloped..TheseplantsarethensuppliedonTurn-keybasisandinstalled,
commissionedforourcustomerson-site.
Dhopeshwar has successfully innovated and designed for Agri. and Poultry Processing sector. Our Essential-oil
DistillationplantsandPoultryDressing&WasteRenderingplantsarewellknownfortheirqualityofengineeringand
longtermperformance.Ourplants havebeencommissionedin17countriesglobally.
Our recent innovation involves Digestor based technology adopting HTST process & Enzymatic reaction for waste
management.ThesefindwideapplicationinPoultrysectorssuchasHatcherywaste,LayerManure,Slaughterwaste.We
havedevelopedcompleteplantwithOdourControlsystemforenvironmentallysafeprocessingofPoultrywaste.
StartedasChemicalEngineeringcompany
GrewintoSpecialisedEngineeringcompany
ProvidingSpecialisedEngineeringSolutionsthruProcessInnovation
Weaimtobecome atrustedpartnerinprovidingengineeringsolutionstoourcustomers.
Dhopeshwar Poultry Dressing Plant
The processing plant is the hub of integrated poultry operations. Dhopeshwar
manufactures high quality Plant and Machineries for Poultry Processing. The Dressing
Plant range covers Conveyorised Plants with On-line processing equipment. The
Dressing plants are supplied in different capacities to cater to the needs of processing
companies.
1. Conveyor based automation requires less man power Output capacity is given in
termsofbirdsperhour
2. Theplantcanprocessbirdsweighing1.0to3.0kgs.
3. AllthemachineriesaremadeinStainlesssteel.
4. Scientificallydesignedprocessensuresmosthygienicprocessing.
5. Conveyorbaseddesignrovidesexcellentconsistancy.
6. Adoptsadvancedengineeringforsemiautomaticprocessing
Our plants are fully Integrated, Custom-built and supplied on a Turnkey basis. These
are Fabricated in our Hyderabad facility, transported to client locations in India &
overseas,andinstalledandcommissionedonaTURNKEYbasis.
UniquefeaturesofourPoultryDressingPlant
A-16, Co-operative Industrial Estate, Balanagar, Hyderabad - 500 037, India
: + 91 040 2377 1579 : +91 040 2377 2450 : + 91 93910 58963
: sales@dhopeshwar.in www.dhopeshwar.in
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Dhopeshwar Engineering Pvt ltd.
Specialised Engineering solutions