VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
DAVID SAN MARTIN (dsanmartin@azti.es) SUSTAINIBILITY AREA - FOOD RESEARCH DIVISION
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9/18/2013
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VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS WORLD SITUATION
THE WORLD POPULATION IS GROWING UP ENORMOUSLY
NATURAL RESOURCES NEED
FEED PRODUCTION
WASTE GENERATION
1.- MANAGEMENT COSTS FOR COMPANIES 2.- ENVIRONMENTAL IMPACTS
3.- OPORTUNITY www.azti.es
9/18/2013
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS AN EXPERIENCE TO VALORIZE VEGETABLE BY-PRODUCTS FOR ANIMAL FEED
www.cleanfeed.org
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9/18/2013
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS CLEAN FEED PROJECT IT IS LOCATED IN BASQUE COUNTRY ITS MAIN AIM IS: • “TO DESIGN, PROVE AND VALIDATE AN ACTION PLAN TO MAKE USE OF THE VEGETABLE FOOD SURPLUS GENERATED IN THE FOOD RETAILING BY TRANSFORMING THEM INTO ANIMAL FEED”. THE BENEFICIARIES ARE:
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9/18/2013
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS TASK 1: INVENTORY AND CHARACTERIZATION • • • •
WHICH KINDS OF VEGETABLES BY-PRODUCTS ARE GENERATED; WHERE AND WHEN HOW DIFFERENT BY-PRODUCTS ARE MANAGED WHICH ARE THE NUTRIONAL VALUE OF EACH BY-PRODUCT FOR ANIMAL FEED GUARANTEE THE ABSENCE OF UNDESIRABLE SUBSTANCES IN EACH BY-PRODUCT FOR ANIMAL FEED
“THE AIM OF THE INVENTORY AND THE CHARACTERIZATION IS TO DETERMINATE THE FEASIBILITY OF THEIR INCLUSION IN FEED FORMULATION”
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9/18/2013
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS TASK 2: PILOT TRAIL_PRODUCTION OF VEGETABLE DRIED MEAL •
WHICH DRYING TECHNOLOGIES ARE TECHNICALLY SUITABLE FOR DRYING VEGETABLE WASTES
•
IN WHICH CONDITIONS: TIME, TEMPERATURE, ETC.
“THE AIM OF THE DRYING PROCESS IS TO STABILIZE VEGETABLE BYPRODUCTS IN TIME AND TO ALLOW THEIR INCLUSION IN THE FEED FORMULATIONS”
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9/18/2013
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS TASK 3: DEVELOPMENT OF AN ACTION PLAN • • • •
STORAGE AT THE POINT OF GENERATION COLLECTION AT THE POINT OF GENERATION TRANSPORT TO THE TREATMENT PLANT TREATMENT AND FINAL STORAGE
“THE ACTION PLAN MUST ENSURE THE TECHNICAL, ECONOMICAL AND ENVIRONMENTAL FEASABILITY OF THIS EXPIERENCE ”
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9/18/2013
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS TASK 1: INVENTORY AND CHARACTERIZATION •
KINDS OF VEGETABLES BY-PRODUCTS GENERATED
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9/18/2013
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS TASK 1: INVENTORY AND CHARACTERIZATION •
VEGETABLE BY-PRODUCTS DISPERSION and QUANTITIES
• SEASONAL VARIABILITY OF CIDER AND WINE SECTOR
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9/18/2013
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS TASK 1: INVENTORY AND CHARACTERIZATION •
LABORATORY ANALYSIS OF EACH BY-PRODUCT UNDESIRABLE SUBSTANCES MYCO-TOXINS PESTICIDES HEAVY METALS MICROBIOLOGY
ALL OF THEM SET THE MAXIMUM LEGAL LIMITS
DIOXINS
NITRITES
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9/18/2013
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS TASK 1: INVENTORY AND CHARACTERIZATION •
LABORATORY ANALYSIS OF EACH BY-PRODUCT NUTRITIONAL VALUE
A MOISTURE LEVEL OF MORE THAN 70%
MAKES NECESSARY A DRYING PROCESS
LOW NUTRITIONAL QUALITY
MOISTURE LEVEL < 12 % STABILIZE THEM IN TIME LIMITS THEIR INCLUSION IN FEED FORMULATION
TO 3-6%.
NOT SO MANY DIFFERENCES IN THE NUTRITIONAL VALUE BETWEEN ALL VEGETAL BY-PRODUCTS www.azti.es
IT IS NOT ADVISABLE TO MANAGE THEM SEPARATETLY. 9/18/2013
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS TASK 2: PILOT TRAIL_PRODUCTION OF VEGETABLE DRIED MEAL •
DRYING TEST SAMPLE: A MIXTURE OF ALL BY-PRODUCTS TO INCREASE THE CRITICAL MASS TO VALORIZE TO MAKE MORE FEASIBLE THEIR VALORIZATION. BY-PRODUCTS
%
TONS
POTATO
42,16
7.500
MARKET
23,62
4.201
COFFEE
0,21
37
BREAD
32,89
2.847
HORTICULTURE
1,12
200
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9/18/2013
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS TASK 2: PILOT TRAIL_PRODUCTION OF VEGETABLE DRIED MEAL •
STATIC OVEN
SAMPLE 85 º C
STATIC OVEN 85° C Test 1 Test 2
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P0 P1 P0 P1
TIME(min)
MOISTURE (%)
0 176 0 480
70,1 7,6 65,5 9,5
ENERGY CONSUMPTION (kWh) 1,4 1,4
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VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS TASK 2: PILOT TRAIL_PRODUCTION OF VEGETABLE DRIED MEAL •
ROTATORY OVEN
SAMPLE 90-110º C
ROTATORY OVEN 90-110° C Test 1
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P0 P1
TIME(min) 0 4
MOISTURE (%) ENERGY CONSUMPTION (kWh) 70,1 4,46
1,4
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VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS TASK 2: PILOT TRAIL_PRODUCTION OF VEGETABLE DRIED MEAL •
MICROWAVE
1.000 W SAMPLE
MICROWAVE 1000 W
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P0 P1
TIME (MIN)
MOISTURE (%)
ENERGY CONSUMPTION (kWh)
0 36,25
62,95 9,95
1,2-1,3
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VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS TASK 2: PILOT TRAIL_PRODUCTION OF VEGETABLE DRIED MEAL •
PULSE COMBUSTION DRYING 130-140º C
SAMPLE
P.C.D. Tª: 130° C Tª: 140° C
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P0 P1 P0 P1
TIME (min)
INSERTING SPEED (HZ)
0 7 0 5
10-12 7-10
MOISTURE (%) ENERGY CONSUMPTION (kWh) 74,84 26,20 74,84 25,20
1,1 1,1
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VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS TASK 2: PILOT TRAIL_PRODUCTION OF VEGETABLE DRIED MEAL • • •
•
STATIC OVEN ROTATORY OVEN MICROWAVE
PULSE COMBUSTION DRYING
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ARE TECHNICALLY SUITABLE FOR DRYING VEGETABLE WASTES
NEEDS TO BE REDESIGNED TO REDUCE THE MOISTURE OF THE FINAL PRODUCT
9/18/2013
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS TASK 3: DEVELOPMENT OF AN ACTION PLAN 1. STORAGE AT THE POINT OF GENERATION IN CLOSED CONTAINERS • CLEANED EVERY DAY THAT THEY ARE COLLECTED • LOCATED: IN A CLEAN and DRY PLACE; AWAY FROM POLLUTION IF IT IS POSSIBLE, IN REFRIGERATION OR IN A FRESH PLACE 2. COLLECTION AT THE POINT OF GENERATION MINIMUM FRECUENCY: • EVERY DAY • ONCE EVERY TWO DAYS A FIRST QUALITY CONTROL • BY THE DRIVER OF THE LORRY • BASED ON FEED ANIMAL MANUFACTURES REQUIREMENTS www.azti.es
9/18/2013
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS TASK 3: DEVELOPMENT OF AN ACTION PLAN 3. TRANSPORT TO THE TREATMENT PLANT ACORDING TO THE REGULATION 183/2005 REQUIREMENTS FOR FEED MATERIAL • CLEANING PROTOCOL • TRAINING OF WORKERS INVOLVED • DOCUMENTATION TO FILL
ABOUT
HYGIENIC
4. TREATMENT AND FINAL STORAGE RECEPTION: A SECOND QUALITY CONTROL HOMOGENIZATION: CRUSHING DIFFERENT BY-PRODUCTS DEHYDRATION: TO GET LESS THAN 12% MOISTURE STORAGE: IN VERTICAL SILOS IN BULK
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9/18/2013
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS CONCLUSIONS: • IT IS FEASIBLE TO USE THESE VEGETABLE BY-PRODUCTS AS A RAW MATERIAL FOR ANIMAL FEED; CONSIDERING THAT ALL UNDESIRABLE SUBSTANCES ARE BELOW MAXIMUM LEGAL LIMITS
• THEIR INCLUSION IN FEED FORMULATIONS IS LIMITED TO 3-6% BECAUSE OF THEIR LOW NUTRITIONAL QUALITY
• IT IS NECESSARY A DRYING PROCESS TO STABILIZE THEM IN TIME DRYING PROCESS MUST GUARANTEE NOT IMPORTANT CHANGES IN THEIR COMPOSITION
• THE ACTION PLAN MUST BE EFFICIENT ENOUGH TO ENSURE THE ECONOMIC, TECHNICAL AND ENVIROMENTAL FEASIBILITY
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9/18/2013
VEGETABLE BY-PRODUCTS VALORIZATION FOR ANIMAL FEED IN BASQUE COUNTRY (SPAIN)
INTRODUCTION METHODOLOGY RESULTS & DISCUSSION CONCLUSIONS ACKNOWLEDGEMENTS
FUNDED BY: •
LIFE + Environment Policy and Governance Programme: LIFE 09 ENV/ES/000473.
•
Innovation and Food Industry Management. Environment, Territorial Planing, Agriculture and Fishing Department. Basque Government.
•
Environmental Quality Management. Environment, Territorial Planing, Agriculture and Fishing Department. Basque Government.
COLLABORATORS: •
ELIKA: Basque Foundation for Agro-Food Safety
•
EPEA: Feed Manufacturers Association of the Basque Country
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9/18/2013
THANK YOU FOR YOUR ATTENTION dsanmartin@azti.es
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