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Dr. sc. agr. M. Samer | Food Processing Waste Management | 1Cairo University
Food Processing Waste Management
In the framework of the postgraduate course “Agricultural Waste Management”
Mohamed Samer, Dr. sc. agr. Associate ProfessorBioresource EngineeringDepartment of Agricultural Engineering Faculty of Agriculture, Cairo UniversityE-Mails: [email protected]; [email protected]: http://scholar.cu.edu.eg/samer/biocv
Dr. sc. agr. M. Samer | Food Processing Waste Management | 2Cairo University
INTRODUCTIONINTRODUCTION
Dr. sc. agr. M. Samer | Food Processing Waste Management | 3Cairo University
Dr. sc. agr. M. Samer | Food Processing Waste Management | 4Cairo University
Dr. sc. agr. M. Samer | Food Processing Waste Management | 5Cairo University
Mailhem Ikos Environment
Dr. sc. agr. M. Samer | Food Processing Waste Management | 6Cairo University
Cheese WheyCheese Whey
Dr. sc. agr. M. Samer | Food Processing Waste Management | 7Cairo University
Cheese Manufacturing(10 kg milk)
Cheese Whey(9 kg)
Cheese(1 kg)
Biogas
EthanolBiodegradable
Ethanol
Organic Acids
Single Cell Protein
Plastics
ChemicalIndustry
Anti-icingAgentsHuman
FoodAnimal
Feed
Pharmaceuticals
Source: Lectures of Prof. Dr. A. Ghaly, Dalhousie University
Dr. sc. agr. M. Samer | Food Processing Waste Management | 8Cairo University
Slaughtering WasteSlaughtering Waste
Dr. sc. agr. M. Samer | Food Processing Waste Management | 9Cairo University
Animal Pathology Evaluation
Receiving & Holding
Stunning
Hide Opening In The Neck
Sticking Dehiding Head Removal
SLAUGHTERING PROCESS
In The NeckSticking Dehiding
Removal
Final Wash
Whole Carcass
Chilling
Variety Meats
Chilling
• Storing• Packaging• Distribution
Processing
Animal Pathology Evaluation
Evisceration
Carcass Shipping
Source: Lectures of Prof. Dr. A. Ghaly,
Dalhousie University
Dr. sc. agr. M. Samer | Food Processing Waste Management | 10Cairo University
Wastes
SLAUGHTERING WASTES
BloodHeads
HoovesFeet
Lungs Spleen
Stomach Intestines
Tissues Trimming
FatBone
Animal feed Rendering
Source: Lectures of Prof. Dr. A. Ghaly, Dalhousie University
Dr. sc. agr. M. Samer | Food Processing Waste Management | 11Cairo University
Rendering Waste
Handling and Pretreatment
Extraction
Tallow
Source: Lectures of Prof. Dr. A. Ghaly, Dalhousie University
GlycerolBiodiesel
ChemicalTransesterification
Tallow
Conventional Biodiesel Production Process
Dr. sc. agr. M. Samer | Food Processing Waste Management | 12Cairo University
§ Environmental
Rendering Waste
Handling and Pretreatment
Extraction
§ Chemicals
§ Thermal Energy
Problems Associated with Conventional Process
§ Environmental Problems
§ Loss of value added Products
GlycerolBiodiesel
ChemicalTransesterification
Tallow
Source: Lectures of Prof. Dr. A. Ghaly, Dalhousie University
Dr. sc. agr. M. Samer | Food Processing Waste Management | 13Cairo University
§ Protein§ Nutraceuticals§ Collagen§ Protein§ Amino Acids§ Fatty Acids§ Enzymes
Rendering Waste
Characterization
Handling and Pretreatment
Characterization of Animal Rendering Waste
Extraction
GlycerolBiodiesel
ChemicalTransesterification
Tallow
Source: Lectures of Prof. Dr. A. Ghaly,
Dalhousie University
Dr. sc. agr. M. Samer | Food Processing Waste Management | 14Cairo University
Proteins
Animal Feed
Enzymes
Enzyme Inhibitors
Rendering Waste
Characterization
Handling and Pretreatment
Extraction
Fertilizer
Amino Acids
Anticoagulant
Enzymes
Extraction of high value co-products from animal rendering by biological transesterification
Extraction
§ Low Energy Requirement
§ High Quality Glycerol
GlycerolBiodiesel
BiologicalTransesterification
Tallow
Source: Lectures of Prof. Dr. A. Ghaly, Dalhousie University
Dr. sc. agr. M. Samer | Food Processing Waste Management | 15Cairo University
Rendering Waste
Characterization
Handling and Pretreatment
ExtractionProteases, lipases,
collagenases
Collagen
Proteins
Fish Meal
Amino acidsJadomycin
Source: Lectures of Prof. Dr. A. Ghaly,
Dalhousie University
Production of value added products from glycerol fermentation
Nutraceuticals omega-3 fatty acids
carotonoids, isoflavones, luteinFish silage
Amino acids
GlycerolBiodiesel
Tallow
Fermentation
Dihydroxy-acetoneHydrogen Ethanol 1,2-propanediol
1,3-propanediolLactic acid Methanol
§ Low energy requirement
§ High quality glycerol
BiologicalTransesterification
Jadomycin
Jadomycin
Dr. sc. agr. M. Samer | Food Processing Waste Management | 16Cairo University
Fish WasteFish Waste
Dr. sc. agr. M. Samer | Food Processing Waste Management | 17Cairo University
ANATOMY OF FISH
Source: Lectures of Prof. Dr. A. Ghaly, Dalhousie University
Dr. sc. agr. M. Samer | Food Processing Waste Management | 18Cairo University
Eviscerating
Chilling
FISH PROCESSING
Chilling
Deboning
Filleting
Canning
Mar
ket
Source: Lectures of Prof. Dr. A. Ghaly,
Dalhousie University
Dr. sc. agr. M. Samer | Food Processing Waste Management | 19Cairo University
Fish waste
Solid625,000 t/y
Liquid4,760,000 m3/y
FISH PROCESSING WASTES
HeadsTailsFinsFramesSkinOffal (guts, livers, kidney)
Cleaning fishCleaning equipment
• 27% Production of gutted and headed fish• 66% Production of fillets• 80% Production of surimi (paste made by fish)
Source: Lectures of Prof. Dr. A. Ghaly,
Dalhousie University
Dr. sc. agr. M. Samer | Food Processing Waste Management | 20Cairo University
q Problems•Large Amount of Fish Waste (55% of fish)•Loss of Resource•Environmental Problems
FISH PROCESSING INDUSTRY
•Environmental Problems
qBioenergy and Value Added Products•Biodiesel•Pharmaceuticals•Nutraceuticals•Industrial Chemicals
qNew Opportunities•New Industries•Employment Opportunities
Dr. sc. agr. M. Samer | Food Processing Waste Management | 21Cairo University
§Biodiesel§Bioethanol§Hydrogen
§ Development of economically and environmentally feasible extraction techniques
§ α-2 macroglobulin§ α -1 antiproteinase§ Heparin
OBJECTIVE
§Hydrogen§Methanol§Lactic acid§Propanediol§Dihydroxyacetone
§ Heparin § Heparin-like glycosaminoglycans§ Chymotrypsin § Pepsin§ Collagenase§ Fish oil§ Omega-3 fatty acids§ Amino acids§ Jadomycin
Dr. sc. agr. M. Samer | Food Processing Waste Management | 22Cairo University
§ Fish oil§ Nutraceuticals§ Collagen§ Protein§ Amino Acids§ Fatty Acids§ Enzymes
Fish Processing Waste
Characterization
Handling and Pretreatment
Characterization of Fish Processing Waste
Extraction
GlycerolBiodiesel
ChemicalTransesterification
Fish Oil
Source: Lectures of Prof. Dr. A. Ghaly,
Dalhousie University
Dr. sc. agr. M. Samer | Food Processing Waste Management | 23Cairo University
Proteins
Fish Meal
Proteases, Lipases,
Collagen
Fish Processing Waste
Characterization
Handling and Pretreatment
Extraction
Source: Lectures of Prof. Dr. A. Ghaly,
Dalhousie University
Fish Silage
Amino AcidsNutraceuticals omega-3 fatty acids
carotonoids, isoflavones, lutein
Lipases, Collagenases
Extraction of high value co-products from fish processing waste and biological transesterification
Extraction
§ Low Energy Requirement
§ High Quality Glycerol
GlycerolBiodiesel
BiologicalTransesterification
Fish Oil
Dr. sc. agr. M. Samer | Food Processing Waste Management | 24Cairo University
Fish Processing Waste
Characterization
Handling and Pretreatment
ExtractionProteases, lipases,
collagenases
Collagen
Proteins
Fish Meal
Amino acidsJadomycin
Source: Lectures of Prof. Dr. A. Ghaly,
Dalhousie University
Production of value added products from glycerol fermentation
Nutraceuticals omega-3 fatty acids
carotonoids, isoflavones, luteinFish silage
Amino acids
GlycerolBiodiesel
Fish Oil
Fermentation
Dihydroxy-acetoneHydrogen Ethanol 1,2-propanediol
1,3-propanediolLactic acid Methanol
§ Low energy requirement
§ High quality glycerol
BiologicalTransesterification
Jadomysin
Jadomycin
Dr. sc. agr. M. Samer | Food Processing Waste Management | 25Cairo University
Organic Fertilizer Fish FeedAnimal Feed Biogas
FoodsSurimiFibrous fish meatScallopsFish powderFish nuggetsFish cakes
SnacksCreamy fish bitesSpreadsDipsCrackersFish cheesy
Pharmaceuticals
NutraceuticalsFish oil
Omega-3Amino acids
POTENTIAL USES OF FISH WASTE
BiochemicalsBile saltsGlueGelatinLeatherPearl essence
Fish cakesFish burgersFish ballsFish pattiesFish sticksFish finger Fish filling for shellsFish filling for baked bunsFish entreesFermented sausagesCanned fish meatBreaded fish stripsCanned fish in cheese sauce Canned fish in mushroom sauceCanned fish with vegetables and rice
Fish cheesyFish crunchyMini fish fingersFish popcorn
Pharmaceuticals
Chymotrypsin PepsinCollagenaseEnzyme inhibitors AnticoagulantsJadomycinInsulinNucleic Acid NucleotidesProtaminesProteolytic Enzymes
Source: Lectures of Prof. Dr. A. Ghaly,
Dalhousie University
Dr. sc. agr. M. Samer | Food Processing Waste Management | 26Cairo University
Integrated Bioindustrial Integrated Bioindustrial Systems
Dr. sc. agr. M. Samer | Food Processing Waste Management | 27Cairo University
Resources
LINEAR MODE OF AGRO-INDUSTRIAL PRODUCTION
WasteWaste
Production ConsumptionResources Extraction
Waste
Source: Lectures of Prof. Dr. A. Ghaly, Dalhousie University
Dr. sc. agr. M. Samer | Food Processing Waste Management | 28Cairo University
Resource Extraction
CYCLIC MODE OF PRODUCTION
Source: Lectures of Prof. Dr. A. Ghaly, Dalhousie University
Production ResidualLimitedWaste
Consumption
Dr. sc. agr. M. Samer | Food Processing Waste Management | 29Cairo University
COCOUNUT OIL INDYSTRY
Dr. sc. agr. M. Samer | Food Processing Waste Management | 30Cairo University
COCONUT OIL INDUSTRY
qRaw MaterialsqEnergy qWater
Oil
Coconut Oil
Free Fatty Acids
OilProduction
System
Solid Waste
Wastewater Air EmissionsWaste Energy
Coconut Meal
Spent Bleaching
EarthShells
Coconut Husk
Source: Lectures of Prof. Dr. A. Ghaly, Dalhousie University
Dr. sc. agr. M. Samer | Food Processing Waste Management | 31Cairo University
Bleaching Earth Water Copra Bottles
Materials Energy
Oil
Processing Operation
Meal Husk ShellsWasteEnergy
Heat Exchange
Oil AnimalFeed Cushions Activated
Carbon Fertilizer
Meal Husk
Fuel
Shells
Charcoal
Biogas
Sludge
AnaerobicDigestion
Wastewater
Biodiesel
Fatty Acid
Energy
Source: Lectures of Prof. Dr. A. Ghaly, Dalhousie University
Dr. sc. agr. M. Samer | Food Processing Waste Management | 32Cairo University
ETHANOL INDUSTRY
Dr. sc. agr. M. Samer | Food Processing Waste Management | 33Cairo University
School
Fermentation
Waste
Ethanol
MushroomProduction
Irrigation Water
LivestockEmployment
Mushroom
Source: Lectures of Prof. Dr. A. Ghaly,
Dalhousie University
INTEGRATED BIO-INDUSTRIAL SYSTEMS
AnimalProduction
Anaerobic Digestion
Fertilizer
Electricity
FeedEmployment
Animal Waste
Meat & Milk
Seeds/Grains
Sludge
Methane
Composting
CropProduction
Dr. sc. agr. M. Samer | Food Processing Waste Management | 34Cairo University
Bioproducts EngineeringBioproducts Engineering
Dr. sc. agr. M. Samer | Food Processing Waste Management | 35Cairo University
Bioprocess and Bioproducts Engineering includes use of engineered microbiological (bacterial and algal) systems for treating waste air and water streams, for regeneration of polluted land and groundwater, and for generating biofuels, bio-electricity and new high-value bio-products.
In addition researchers are exploring the use of forestry products in nontraditional applications, including industrial foams, flame-retardant materials, and paper surface science.
Bioprocess engineering is a conglomerate of mathematics, biology and industrial design, and consists of various spectrums of biotechnological processes.
Dr. sc. agr. M. Samer | Food Processing Waste Management | 36Cairo University
Bioproducts engineering (also referred to as bioprocess engineering)refers to engineering of bioproducts from renewable bioresources.
This pertains to the design, development and implementation ofprocesses, technologies for the sustainable manufacture ofmaterials, chemicals and energy from renewable bioresources.materials, chemicals and energy from renewable bioresources.
Bioprocess Engineering is a specialization of Biotechnology,Chemical Engineering, and Biological and Agricultural Engineering.
It deals with the design and development of equipment andprocesses for the manufacturing of bioproducts such as food, feed,pharmaceuticals, nutraceuticals, chemicals, polymers and paperfrom biological materials (i.e. biomaterials).
Dr. sc. agr. M. Samer | Food Processing Waste Management | 37Cairo University
Bioproducts or bio-based products are materials, chemicals andenergy derived from renewable biological resources.
Biological resources include agriculture, forestry, and biologically-derived waste, and there are many other renewable bioresourceexamples.examples.
One of the scientific terms used to denote renewable bioresourcesis lignocellulose.
Cellulose-based materials and lignocellulosic tissues arebiologically-derived natural resources containing some of the mainconstituents of the natural world.
Dr. sc. agr. M. Samer | Food Processing Waste Management | 38Cairo University
Conventional bioproducts and emerging bioproducts are twobroad categories used to categorize bioproducts.
Examples of conventional bioproducts include building materials,pulp and paper, and forest products.
Examples of emerging bioproducts include biofuels, bioenergy,starch-based and cellulose-based ethanol or bioethanol, bio-basedadhesives, biochemicals, bioplastics, etc.
Bioproducts derived from bioresources can replace much of thefuels, chemicals, plastics etc. that are currently derived frompetroleum→ Environment? Independent on foreign sources of oil?
Dr. sc. agr. M. Samer | Food Processing Waste Management | 39Cairo University
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Dr. sc. agr. M. Samer | Food Processing Waste Management | 40Cairo University
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