Meat and bone meal: production technology from waste, composition and application. How to start the production of bone and meat and bone meal Sanctions and their consequences

Used equipment for the production of meat and bone meal:

ML-A16 (-01)
ML-A16M (-01)
ML-A16M2 (-01)
Ya8-FOB-MA05P (-01)
Ya8-FOB-MA06P (-01)
Ya8-FOB-MA22P (-01)

Where to buy equipment for meat and bone meal and what benefits can it bring to the manufacturer? The process of processing farm animals is inextricably linked with the issue of the need for disposal or recycling of waste. A similar problem is facing meat processing plants, sausage shops, processing plants. Despite the improving technologies that make it possible to obtain mechanically deboned meat, make a protein stabilizer from the skins of pigs, and include low-value by-products in the composition of manufactured goods, a certain part of the processed products remains. Most manufacturers prefer to implement them if there is such an opportunity. On the other hand, their most beneficial use will be further processing, since these types of raw materials are high-quality ingredients for the production of feed flour.

Distinctive features of the proposed equipment

One of the traditional processing methods is to obtain meat and bone meal and fat through processing in vacuum boilers, but it has serious drawbacks, high energy consumption and foul-smelling gases during operation, due to which enterprises refuse to use them.

We draw your attention to the advantages of the technology used on our lines.

High biological and nutritional value of the finished product ( technical fat and feed flour).
Feed flour and fat fully comply with GOST.
During the processing of raw materials on our lines, there are COMPLETELY NO SMELLING GASES, therefore, equipment for gas purification is not required.
The equipment DOES NOT REQUIRE REGISTRATION IN THE BOILER SUPERVISION AUTHORITIES.
From service personnel high qualification and special skills are not required.
Waste-free and environmentally friendly process.
High maintainability and ease of post-warranty maintenance of the line.

Meat and bone meal is one of the most important biologically active products used for feeding animals, birds, fish and plants.

The product is in demand due to its nutritional value, natural origin and ease of use.

Flour is a powder from gray to brown, dry, crumbly, with a rather pleasant aroma.

What is this product obtained from? The scope of flour is practically unlimited: from fuel and fertilizers to the synthesis of individual components of the product. The main direction of use is as the main ingredient in combined feeds for all types of animals, birds and fish.

The total annual volume of animal waste in our country, according to Rosstat, is close to 5 million tons. At the same time, the shortage of food protein is more than 1 million tons, feed protein - 770 thousand tons.

Large-scale problems in the field of processing, to which the resources and efforts of processors will be directed in the near future:

Irrational use of resources: cremation, burial and production of low-quality meat and bone meal from meat waste.
Huge technological losses in the processing of raw materials at meat processing plants: from 0.5 kg or more per 1 kg of meat.
Shortage of fodder animal protein in agriculture.
Utilization of the case in the event of epidemics of swine fever, rabies of cows, etc.

Problem solving lies in building up, modernizing and opening new production capacity for the production of meat and bone meal from the waste of the meat processing industry.

Manufacturing technology and composition

The raw material for the production of meat and bone meal is the waste from the slaughter and death of farm animals and poultry, unsuitable for the production of food products for humans.

Technologies for the production of meat and bone meal are aimed at maximum preservation in the composition of proteins, because the higher the protein content, the higher the value and cost of the product.

The recycling process is usually consists of three main steps, each of which has its own section of equipment:

Reception and shredding: waste meat production or cases are collected in the receiving bunker. Next, they go to crushing plants where the raw material is crushed to the required fraction. Then, through conveyors or pumps, the crushed mass is fed into the brewing tanks.
Heat treatment: in the digester, the raw materials are boiled and sterilized. During the cooking process, saturated vapors are formed, which are utilized in special equipment.
Separation of flour and fat. The main condition for the quality of flour is its release from fat. The process is carried out by pressing. Then the flour is cooled, crushed, sieved and tared. Fat after pressing moves in the equipment for cleaning.

Manufacturing equipment

The most common production lines used in Russia and abroad are:

domestic lines K7-FKE and V2-FZhL;
Alfa-Laval's Swedish Centrimille equipment;
Dutch StorkDuk lines.

The cost of technological lines full cycle quite high, and the price of imported equipment from Europe exceeds Russian counterparts by several times.

Asian producers offer more affordable prices, but still, complex lines are too expensive for domestic small and medium-sized flour producers.

Therefore, often in our factories independently complete the lines different performance from compatible machines and fixtures of Russian and foreign production

Industry Leading Manufacturers

Clear criteria for selecting the best enterprises for the production of meat and bone meal have not been developed.

At the same level in terms of product demand, there can be specialized factories, where raw materials are brought hundreds of kilometers away, and relatively small meat processing plants for processing their own raw materials.

The former have large volumes, the latter have a high protein content in the product and an ideal organization. production process. But both types of enterprises are in demand.

There are also a number of other indicators. All manufacturers produce flour in accordance with GOST 17536-82 “Fodder flour of animal origin. Specifications".

Based on this, it is reasonable to list the most significant plants on a territorial basis, designating enterprises by districts.

Central Federal District:

Ventsanutilzavod Orlovsky (Oryol region).
Company "Protein" (Moscow region).

Privolzhsky Federal District:

Dubovo-Umetsky ventsanutilzavod (Samara region).
Soviet Veterinary Sanitary Plant (Republic of Mari El).
"Saria Bioindustries Volga" (Republic of Tatarstan).

Northwestern Federal District:

Abiogroup company (Vologda region).

Siberian Federal District:

Veterinary sanitary plant Kormilovsky (Omsk region).
Company "Rialsib" (Novosibirsk region).

Southern Federal District:

Premix Company.
Kuban Ecological Company (both from the Krasnodar Territory).

The concentration of strong industries across regions is uneven, but reflects the general technical level and the availability of a raw material base. The most modernized, working with large volumes of raw materials and producing meat and bone meal with a high protein content, are located in the Central and Volga Federal Districts.

Russian market: expectations and forecasts

The market for the consumption of meat and bone meal in Russia, as well as throughout the world, depends on the amount of meat consumed.

The higher the purchasing power of the population, the more a person consumes meat.

To increase the number of livestock, a fodder base is needed. The modern meat industry is unthinkable without the use of meat and bone meal in animal feed.

Our domestic producers are not yet able to meet the demand for feed flour. Until recently, there has been an increase in production in the industry, but its pace is low, so part of the flour was purchased abroad.

Animal husbandry in Russia has been steadily growing since 2013, and accordingly, the need for feed as a source of protein, amino acids and other ingredients is also increasing.

Also, the production of meat and bone meal must increase with the growth of livestock - this is a direct interdependence.

In recent years, Russians eating more pork and poultry is more cheap product than beef. Accordingly, the flour of domestic producers is most often made from pork and poultry waste.

Russian-made products are represented on the domestic market in the amount of 69.4% of its volume, mainly chicken and meat flour. Imports are 30.6% with a predominance of flour from cattle.

In the meat and bone meal market, a stable growth in demand of 2-3% is predicted due to sustainable development animal husbandry.

Sanctions and their consequences

In a number of industries Russian manufacturers asking for an extension of the food embargo.

The share of domestic meat products in the domestic market was 90.4%.

The growth has occurred in recent years of sanctions. As a result food security threshold for meat and meat products, indicated in the doctrine by an indicator of 85%, was exceeded by 5.4%.

Therefore, the head of the executive committee of the National Meat Association, S. Yushin, believes that Russia is quite capable of independently producing the required amount of meat and bone meal. Russia has enough raw materials, and therefore we do not need tens of thousands of tons of flour from the European Union.

SoyaNews analysts gave interesting figures for the production of meat and bone meal in Russia:

in July 2019, a record flour production indicator was reached - 43.6%;
the figure for July 2019 is 1.31 times higher than in July 2018;
the growth in volumes for 7 months of 2019 compared to the same period in 2018 amounted to 18.9%.

SoyaNews data does not always coincide with Rosstat data, but the reliability is beyond doubt.

We need different factories

Important argument in favor of creating new industries can be given by considering the consequences of the ongoing epidemics of African swine fever.

In July 2017, ASF infection spread to 13 districts of the Omsk region. Then there was an acute problem of eliminating the source of infection - that is, burning pigs. Tens of thousands of heads were burned - and it was very difficult to implement.

Bonfires were created from tires and logs, the length of the fires was up to 40 meters and at least 3 meters in height.

A lot of work has been done and huge costs have been incurred. Only the Russkom-Agro company took the pigs to the Kormilovsky ventilation and sanitation plant, where deep heat treatment was carried out.

The plant received a good product - high-quality meat and bone meal and a fee for the disposal of infected livestock.

At temperatures above 70 degrees, the virus dies, so the flour turned out to be safe.

The conclusion about the need for processing enterprises is not discussed. Such productions are needed on any scale.

The best option is when mini-factories for the processing of animal waste are located in each rural settlement. In this matter many organizational difficulties, but with the participation and interest of the state, it can be completely solved.

Domestic product or import?

The Ministry of Agriculture of the Russian Federation is constantly discussing the possibility of limiting the supply of meat and bone meal from Europe, primarily from countries that have supported sanctions against Russia.

Restrictions are possible, they will primarily affect manufacturers of pet food - cats and dogs.

Companies Pedigree, Purina, Whiskas and a number of others famous brands purchase more than 50% of meat and bone meal imported from Europe.

As for quality, this is a special topic for our:

Meat holdings consider flour just as a product of the disposal of waste they do not need. Therefore, they do not deal with sorting of raw materials, quality is secondary for them.
Small quality-oriented companies are few and weak financially.
In the Russian Federation, there are no clear standards and definitions of the quality of meat and bone meal, and each manufacturer selects the composition of raw materials at his own discretion or based on his ideas about quality.
Domestic equipment is designed primarily for bone processing, and the meat residue on the bone is considered the basis of high-quality flour.
Foreign flour producers are guided by well-established quality standards, which are absent in Russia.
Despite serious difficulties, a breakthrough in the quality of Russian flour is planned. Already working innovative technologies production, product standards are being developed, domestic equipment is being improved.

Flour in pet food is no more than 8%, but without it, a complete food will not work, because it contains proteins.

Optimistic scenario: reorientation of companies that use imported flour to supplies from Belarus or from Asia and Latin America.

By the way, the share of Belarus is about 30% of all flour imports. Most of the imports are flour made in China.

Conclusion

The importance of the industry is undeniable. The issues of returning secondary resources to circulation are especially relevant today, against the backdrop of the waste reform and new environmental standards. There is reason to believe that Russia will successfully solve the problems with the processing of meat waste and the production of an important product - meat and bone meal.

In contact with

Meat and bone meal is a feed additive that is produced in the process of drying and grinding waste, which has valuable feed properties. Experts have established the fact that protein in the form of a powder is absorbed by animals and livestock more efficiently than protein from plant-based feed.

Feed meat and bone meal, used as an additive to other feeds poor in protein and vegetable fats, helps to accelerate the growth of animals, increase their total and muscle mass, and improve their overall health. In addition, flour obtained by crushing bones is used to enrich the soil of gardens, vegetable gardens and fields.

Typification of the production of meat and bone meal by grade

Bone and meat and bone meal during processing has the form of a homogeneous, specific smelling dry powder of a gray-white hue. If a appearance the resulting product is always the same, then its moisture content and protein composition in the content may vary.

Therefore, the volumes of manufactured meat and bone meal are divided by grade:

first grade;
second grade;
third grade.

It is no secret that bone meal is superior in quality to third grade flour and its price is higher.

Technological process for the production of meat and bone meal.

The raw materials are:

waste from meat processing plants;
dead cattle unsuitable for food production;
veterinary confiscations.

Since the required percentage of components depends on the raw materials used, they must be subjected to strict control.

Features of equipment for the production of meat and bone meal

There are various bone meal machines on the market today, such as:

bone grinder;
hammer crusher;
gate for loading;
screw conveyor;
a pump that pumps water and fat;
centrifuge for filtration;
a pump that pumps out water and fat.

Note that these units are widely used as equipment for the production of meat and bone meal.

Equipment for obtaining meat and bone meal:

conveyor;
receiving conveyor;
gate for loading and unloading;
blocks for drying;
conveyor rack;
bone meal bin.

Bone Meal Equipment on the Market

Bone meal is made from animal bones, meat and bone meal is made from bones from veterinary confiscated goods, carcasses and carcass fragments of dead cattle that cannot be eaten, as well as from waste from meat-producing and meat-processing industries unsuitable for food. Raw materials for the production of bone meal must be checked for quality and safety by veterinary authorities and veterinary supervision.

Such flour contains fiber, minerals, proteins, is a source of protein and is used as an additive in the production of animal feed for Agriculture, feed for dogs, cats and other domestic animals, as well as poultry and livestock.

In addition, bone and meat and bone meal, as a valuable source of phosphorus, is used in the production of fertilizers for outdoor and tub plants. Another way to use animal bone meal is to use it as an environmentally friendly fuel in industrial plants.

The main consumers of these products are agricultural enterprises, farms, producers of compound feed and feed for pets, livestock, poultry, agricultural enterprises and individuals, fertilizer manufacturers, as well as zoos, nature reserves and large industrial enterprises using alternative fuels.

The main equipment for the production of bone meal

For enterprises operating in this field, for equipping production, they are offered as separate units for use in certain areas technological process and complete production lines.

The minimum complete set of the production line consists of the following units:

grinder of bone and meat and bone raw materials;

a container into which the crushed raw materials are received;

crushed raw material conveyor;

installations for cooking raw materials;

chopper of boiled raw materials;

a centrifuge in which filtration, settling of the boiled mixture and its separation into minced meat and bone and fat is carried out;

water pump;

drying complex for complete removal of moisture from raw materials;

conveyor for transferring raw materials further along the line;

crusher for the final grinding of flour;

receiver of finished products;

apparatus for filling and packing finished products.

This is an approximate list of sections, depending on the technological process approved at the enterprise, the equipment of the production line may vary. In addition to these devices and units, the enterprise must organize the storage of raw materials and finished products - for this it is necessary to have premises equipped with refrigeration equipment.

Offers on the market of equipment for the production of bone meal

In our country, equipment for the production of bone meal is widely represented by the products of Russian enterprises - it is characterized by high performance, reliability, has a competitive cost and is subject to warranty service and repair.

Russian companies producing such equipment offer both complex mini-lines that can be used at small processing enterprises, as well as separate high-performance units for equipping production lines. large factories for the production of meat and bone meal.

Equipment for the production of meat and bone meal at the exhibition

Today, there are both separate meat and bone meal equipment and complete complexes on the market of manufacturers, since the manufacturing process is continuous. After that, the flour is loaded into boxes or bags, where it is stored for about a year.

Activities such as Agroprodmash, are very important and necessary for the national economy, because in recent years they have been actively attracting new investors, which allows not only to bring to the proper level not only business, but also the country's economy itself.

Since the fifties of the last century, an international exposition has been held in the pavilions of the Expocentre Fairgrounds Agroprodmash, which aims to maximize the development of its industry. A separate subject of consideration of this exhibition forum is equipment for the production of meat and bone meal.

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Each farming interested in purchasing quality feed for their animals. And since this industry is still poorly developed in our country, various additives have to be purchased abroad, and they cost a lot. For example, bone meal, the most valuable component in compound feed, can be quite problematic to get. It turns out that there is a demand for this product, but there are very few offers. And if you buy equipment for the production of bone meal, you can own business in this area, which will be in demand among consumers not only in the local market, but also in the regional one.

Meat and bone meal is a product obtained by processing animal bones. It is actively used as a protein-rich additive in feed for pets (dogs and cats), livestock. Also, many farmers who grow fruits and vegetables for sale use bone meal to enrich the soil.

Our business valuation:

Starting investments - from 700,000 rubles.

Market saturation is low.

The complexity of starting a business is 6/10.

The business idea is to launch a small bone meal plant that would sell finished products in small and large wholesale. And with a competent approach to planning activities, you can establish a profitable business, since the resulting products have an attractive price for consumers, while being characterized by excellent nutritional values.

Classification of bone meal by grade

Bone meal obtained during the processing of raw materials is a homogeneous dry powder of a grayish tint with a specific smell. And if the appearance of the product is always almost the same, then its moisture content and protein content can vary.

Therefore, the entire volume of flour produced is divided into varieties:

1 grade.
2 grade.
3 grade.

Bone meal of the 1st grade is much better in quality than the goods of the 3rd grade, and, accordingly, its price is higher.

The sale of bone meal will be much more profitable if potential clients a full range of products will be offered.

The process of obtaining bone and meat and bone meal

An important advantage of this direction is affordable and cheap raw materials. And as processed components can be:

And since the composition of bone meal will directly depend on the raw materials used, it must undergo strict incoming control. Each component, in order to obtain quality certificates for products, is checked by sanitary and veterinary supervisory services.

In order to avoid interruptions in the supply of raw materials during the work process, it is better to establish cooperation with several suppliers at once.

The technology for the production of bone and meat and bone meal is relatively simple and is as follows:

Crushing and grinding of raw materials.
Cooking crushed raw materials.
Grinding boiled raw materials.
Settling the mixture and separating it into minced meat and fat emulsion.
Complete removal of moisture from minced meat.
Secondary grinding of flour.
Packing and packaging of the finished product

The water-fat emulsion obtained in the process can be used in the technological chain again, or it can be sold as a final product to the same consumers. It turns out that it is quite possible to make production practically waste-free.

The technology for obtaining the finished product is also simplified by the fact that the main operations here are carried out by special equipment for the preparation of bone meal - manual labor is reduced to a minimum.

Technical equipment of the workshop

And since the quality of the resulting product, as a whole, depends on technical equipment workshop, which means that special attention should be paid to this moment when developing a business plan. On the market today there are bone meal lines that are very different in terms of power and functionality - there are separate machines, and there are entire factories. And what equipment to choose will depend on some factors - planned sales volumes and available investments.

Production Line

Almost all bone meal lines include the following machine names:

Bunkers for storage of raw materials and finished products.
Crusher.
Chopper.
Centrifuge with filter.
Drying complex.
Packing machine.

In order to get a larger volume of finished flour at the output, it is better to immediately buy automatic line which will allow a continuous production process.

The price of equipment for bone meal is quite high, but the final figure will depend on the power and degree of automation of the machines. For example, a line with a capacity of up to 1000 kg of finished product for an 8-hour shift will cost ≈1,500,000-1,900,000 rubles. More powerful equipment (5000 kg/day) is much more expensive - up to 6,500,000 rubles. It is necessary to spend money on cold rooms necessary for the storage of raw materials.

To accommodate a complex line, a fairly spacious workshop with an area of 50-100 m 2 will be required. When working out a business plan, do not forget about office and warehouse space. This is not the food industry, so supervisory authorities too strict requirements for the organization and preparation of premises will not be presented. But since it is necessary to work with a dusty product, good ventilation must be provided in the workshop. In warehouses, in order not to expose the finished product to quick spoilage, certain temperature and humidity indicators must be observed.

Profitability of the launched enterprise

Business in the production of bone and meat and bone meal, due to the demand for products, promises to be highly profitable. But the enterprise will only then reach the break-even point when distribution channels are established.

The use of bone meal is extensive, so it is worth trying to establish cooperation with the following potential buyers:

Farms.
Animal feed factories.
Animal kennels and private veterinary clinics.

Constantly high incomes will only bring wholesale clients, but do not forget about the private consumer, who may need bone meal to fertilize the garden and as a feed additive for poultry and animals. Given this, it will not be superfluous to organize the sale of products directly from the factory to everyone.

Investments in the business will be considerable - at least 2,500,000 rubles. The cost items include: the purchase of equipment and raw materials, the provision of a raw material base and the preparation of the premises. Capital investment can be reduced to 2,000,000 rubles if you buy equipment for bone meal from China. All funds will pay off, as practice shows, no later than in 2 years. But this is on condition that the plant will work in full power, and the finished product will immediately be sold to the buyer. For profit calculations, you can take the average wholesale price for bone meal at 15,000-18,000 rubles / t.