The ABVRS Process

Alpha Environment uses newly patented, revolutionary technology that allows agricultural waste to be more efficiently converted into marketable meals, oils and other value-added products in an environmentally preferential and cost effective manner.

By deploying the ABVRS Process, Alpha Environment is empowering partners with the ability to efficiently process raw materials into high-quality protein meals and oils in a clean, waterless, odor-free and eco-friendly manner.

The process for the Agricultural Byproduct Value Recovery System is comprised of essentially three main steps: grinding, mixing and processing.

Grinding and mixing are two preparatory steps that take place prior to the raw material entering the ABVRS system for processing. In some situations, depending upon the raw material, grinding and/or mixing may not be required.

Grinding is usually required for most sources of raw material, including sources e.g. whole fishes, as well as cattle and poultry offal.

Raw material sources that do not necessarily require grinding include materials such as hatchery waste, manure and shrimp waste.

Fat and Moisture Mixing Guidelines

Generally, mixing is required when there is a substantial amount of fat or moisture in the raw material. ABVRS utilizes a
proprietary method of mixing the raw material with an appropriate back mix.

Few seconds of exposure to our flash dry system, followed by pressing to separate the fats from the protein: ABVRS delivers the 2 finished products within just few a minute from the beginning of the whole process.

Higher quality protein meals and fats due to the controlled temperature exposure of the raw material that maintains better the nutritional properties of the by-products.

Back mix usually consisting of finished meal derived from a source similar to that of the original raw material and an AAFCO (Association of American Feed Control Officials) approved reagent.

The back mix makeup is determined by the raw material source, and its moisture and fat content. The purpose of the back mix is to provide a consistent feedstock.

And a more important purpose of black mix is to suspend the fat content (preventing the fat from liquifying) in the raw material as the ABVRS process removes the desired amount of moisture using high heat. The Agricultural Byproduct Value Recovery System can process a wide variety of agricultural byproduct materials with varying moisture and fat contents.

Traditional rendering has been essentially the same process for decades and produces significant odor and waste water.

Using the Flash Evaporation ABVRS technology eliminates odors and waste water, resulting in a highly efficient and eco-friendly rendering process that can be deployed right in city centers, as opposed to the long-distance deployments typically forced upon the rendering industry due to the noxious odors and waste associated with the antiquated rendering process.

Waste Water

Noxious Odors

The conventional rendering process creates waste water, as a result of its reliance on the slow cooking process.

According to a study conducted by the engineering firm Bolton & Menk, “Rendering plants generate significant volumes of waste water. The waste water contains contaminates that are relatively low in long-term environmental risk, but cannot be released directly into rivers, streams, or lakes without proper treatment.”
In addition to environmental concerns and costs associated with waste water and waste water treatment, financial drawbacks exist as well. The very contaminants inherent in rendering waste water represent quantifiable lost product.
Our advanced ABVRS technology eliminates environmentally unfriendly waste water and associated costs.

According to the EPA, air pollutants emitted by traditional rendering facilities include volatile organic compounds (VOCs). These air pollutants have low detection thresholds and include 15 particulate emissions including ammonia, hydrogen sulfide, and quinoline, classified as a hazardous air pollutant (HAP).

A facility designed for inedible rendering operations will typically have seven primary sources of VOC emissions, including cookers, dryers, centrifuges and processing tanks. To mitigate these volatile air pollutants and reduce their undesirable effects on nearby communities, a traditional rendering plant will be required to apply several costly emission controls, usually boiler incinerators and multi-stage wet scrubbers. Scrubbers require continuous purchase of scrubbing agents such as sodium hypochlorite or chlorine dioxide. Plants located near residential areas may also install additional costly duct work to further reduce emissions. As our technology produces only clean steam, VOCs and the technologies required to address them are non-existent and not necessary. The absence of unwanted odors means ABVRS can operate in high-density urban areas, taking advantage of nearby protein sources.

Strategic Moisture Control

Feedstock Processing

Efficient Moisture Evaporation

While the typical makeup of offal based raw material contains 50-75% moisture, compositions containing well below, and above, that range can be handled by the ABVRS technology.

Additionally, while the fat content of offal-based raw material is typically between 10-25%, ABVRS can easily process material with significantly higher, and lower, fat compositions as well.

Once the raw material is properly ground and mixed, the resulting feedstock is ready to be processed.

The feedstock is loaded into the ABVRS feed hopper where a variable-speed auger is used to move the material through a system of mixing paddles for further blending and controlled flow rate.

The material is fed into the ABVRS central processing unit where the inlet temperature ranges from 600 - 840 degrees F (315 - 448 degrees C).

At this point, up to 95% of the moisture is flash evaporated and exits through a ventilation stack as water vapor.

Skillful Flow Rate Control

The careful consideration of each step reveals our commitment to quality.

As a result of the moisture content being removed, the specific gravity of the material has been lowered.

This allows the meal, now subjected to a temperature of approximately 240 degrees F (115 degrees C), to be moved upward through piping by means of forced air, then downward through a cyclone and deposited as the finished product into a collection bin.

The temperature of the finished product exits from the cyclone at approximately 130-160 degrees F (54 – 71 degrees C). The total elapsed time from when the material is introduced to the ABVRS system, until it is processed into the final collection bin is typically between 40 – 60 seconds.

Finished product moisture content is generally around 10%. However, depending on the application of the finished product, higher or lower moisture content can be attained. For example, if the application for the finished meal requires that it then be pelletized, the ABVRS process can be simply adjusted to provide the typically required 15% moisture content.

ABVRS offers both direct and indirect heat alternatives

The technology employed by the ABVRS differs from traditional rendering methods.

Contacts

Location

Phone

Email

Follow us

The ABVRS Process

Resource-Efficient Processing TechniqueCreative features from ABVRS process

Essential Grinding in Raw Material Preparation

Fat and Moisture Mixing Guidelines

Flash Dry to finished products

High Heat Treatment for Moisture Removal in ABVRSRole of Moisture and Fat Content in Back Mix Design

Rendering Industry

Environmental Concerns Surrounding Rendering Waste Water

AdaptabilityEfficient Processing of Variable Moisture Offal Materials

Gravity ReductionMaterial Transformation: Lowering Specific Gravity through Moisture Removal

The Precise Product Exit at 130-160°FFrom Raw Material to Finished Product

ABVRS offers both direct and indirect heat alternatives

We are always ready to help you and answer your questions.

UNITED ARAB EMIRATES

P.O. Box