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Introduction to WRT's Multi-Processors

Introduction

Overview Of WRT's MAAHP™ Multi-Processor Systems

Tissue is loaded into the processor

1. Load Tissue

Tissue is loaded into the processor

The chemical catalyst is added

2. Add Catalyst

The chemical catalyst is added

Water is added to the processor

3. Add Water

Water is added to the processor

Lids are put in place and the area is cleaned

4. Close Lids & Clean

Lids are put in place and the area is cleaned

The Processor is switched on, hydrolysis commences

5. Start The Process

The Processor is switched on, hydrolysis commences

Hydrolysis takes 12 - 24 hours. No human input is required

6. Hydrolysis

Hydrolysis takes 12 - 24 hours. No human input is required

After hydrolysis HPL is discharged from the processor

7. Discharge Processor

After hydrolysis HPL is discharged from the processor

HPL is discharged into a heat tolerant tank

8. HPL Discharge

HPL is discharged into a heat tolerant tank

HPL is a fertilizer

9. HPL is a fertilizer

Greenhouse Trial has proven the beneficial properties of HPL

Soap formed during the process can be processed further

10. Soapstock Treatment

Soap formed during the process can be processed further

Fats are recovered using WRT's proprietary process

11. Recover Fats

Fats are recovered using WRT's proprietary process

Recovered Fats Are Sold To Reduce Process Costs

12. Recover Costs

Recovered Fats Are Sold To Reduce Process Costs

Introduction

Waste Resolution Technologies (Pty) Ltd. is an innovative and dynamic South African company that specializes in the development of eco-friendly and energy effecient waste avoidance, treatment, recycling and recovery solutions. Founded in 2008, Waste Resolution Technologies is today widely recognized as the industry leader in applied alkaline hydrolysis solutions for the abattoir and meat processing industries. Waste Resolution Technologies offers a number of innovative products and processes specifically tailored around the unique requirements of the South African abattoir, meat processing and animal by-product processing industries.

Tissue Processing Equipment

WRT's proprietary MAAHP Tissue Processor Technology provides a proven eco-friendly and sustainable condemned meat management alternative to small and medium sized abattoirs in South Africa.

Multi-Processor Technology

WRT's proprietary MAAHP Multi-Processor Technology provides extended capabilities to tissue processors to allow for the recovery of fats which provide a cost recovery mechanism to reduce operating costs.

About Us

Waste Resolution Technologies (Pty) Ltd. is an innovative and dynamic South African company that specializes in the development of eco-friendly and energy effecient waste avoidance, treatment, recycling and recovery solutions. Founded in 2008, Waste Resolution Technologies is today widely recognized as the industry leader in applied alkaline hydrolysis solutions for the abattoir and meat processing industries. Waste Resolution Technologies offers a number of innovative products and processes specifically tailored around the unique requirements of the South African abattoir, meat processing and animal by-product processing industries.

The People Behind Waste Resolution Technologies

The people behind Waste Resolution Technologies Mark Tecklenburg Cyril Ramaphosa Piet Kruger

Company Registration Details

Waste Resolution Technologies (Pty) Ltd.
Company Registration Number : 2006/030325/07

Postal Address

P.O. Box 3090
Nelspruit, 1200
Mpumalanga, South Africa

Physical Address

2 Wolfaard Street, Nelspruit.

Products

This section is currently under construction.

Frequently Asked Questions

Below is a list of answers to frequently asked questions that we've encountered over the years. Click on any of the topics for more detail. If there is anything not covered in this section that you would like to know more about, please do not hesitate to contact us.

Tissue Processors

WRT's proprietary MAAHP Tissue Processor Technology provides a proven eco-friendly and sustainable condemned meat management alternative to small and medium sized abattoirs in South Africa.

Introduction to MAAHP Tissue Processors

WRT's MAAHP Tissue Processor uses heat, water and a base catalyst to rapidly dissolve tissue into a Hydrolyzed Protein (HP) Liquid which is stable and pathogen free. During the hydrolysis process, the protein coats of viruses are destroyed and the peptide bonds of protein based infectious organisms are broken down thereby achieving a high level of bio-security.

Advantages of the MAAHP Tissue Processor:

  • Allows on-site treatment of all animal tissue.
  • The complete system has a small footprint and a robust design.
  • Very low odour process compared to traditional rendering processes.
  • Proven technology and equipment result in bio-secure and pathogen-free, value-added products, which are stable and do not require refrigeration
  • The resulting HP liquid and acidified tallow both have commercial value and an element of cost recovery is possible depending on the operator's circumstances.

Multi Processors

WRT's proprietary MAAHP Multi-Processor Technology provides extended capabilities to tissue processors to allow for the recovery of fats which provide a cost recovery mechanism to lower operating costs.

Multi-Processors are tissue processors built with higher specification materials and can handle a wider range of pH conditions i.e. pH 0 - pH 14 as opposed to a standard tissue processor configuration that operates within a range of pH 7 - pH 14. Tissue is processed using an alkaline stage (pH 7 - pH14) but the process of recovering the fat requires an additional acidic stage at higher temperatures than those used during the hydrolysis phase. The combination of pH and temperature necessitates the use of higher specification materials and additional controllers.

Which Products Are Suitable For Processing In A MAAHP Tissue Processor...?

Digestable Materials

WRT's MAAPH tissue processor is specifically designed to deal with animal tissue to avoid waste and to provide true denaturing. Common types of animal tissue that can be effectively treated using a WRT MAAHP tissue processor would include:
  • Meat, Blood & Tendons
  • Intestines & Organs
  • Fat and Fatty Tissue
  • Feathers, Hooves, Hair & Horns
  • Hides and Skins
  • Membranes/Butcher Waste

Indigestible Material

The MAAHP Tissue Processor is a very effective means of dealing with animal tissue that contains protein, but is not designed to digest any material derived from plants or other inorganic substances such as plastics, synthetic polymers and metals. Indigestible materials still benefit from the thermo-chemical treatment in terms of providing pathogen control, and there is no need to separate these materials if they are present in the animal tissue that is being treated. All indigestible materials can safely be removed and disposed of, once the tissue processing cycle has been completed.

A note about animal carcasses

The MAAHP Tissue processor range is not designed to be carcass disposal unit, but carcasses of smaller animals (birds, dogs, cats, lambs, piglets etc) can be processed effectively. Larger carcasses will have to be cut into smaller pieces prior to loading the processor.

What Is Hydrolysis

Hydrolysis - The Basics

Per definition, hydrolysis is a chemical process in which a water molecule is added to a substance resulting in the split of that substance into two parts. One fragment of the target molecule (or parent molecule) gains a hydrogen ion (H+) from the split water molecule. The other portion of the target molecule collects the hydroxyl group (OH-) of the split water molecule.

The problem with any unaided hydrolysis process is that either very little happens, or whatever happens takes a very long time to happen, hence the need to speed up the chemical reaction using a catalyst in the form of a strong acid or alkali

Alkaline Hydrolysis

In terms of protein hydrolysis, a strong base is utilized to catalyse the hydrolysis process and this is refered to as alkaline hydrolysis. In this instance a water molecule is inserted between the bonds that hold the protein strand together.

By inserting a water molecule in this manner, the long protein strands are sliced into shorter fragments which in turn can be further hydrolyzed in the same manner thus dissolving the protein back into its original building blocks - amino acids, short peptides, sugars, soaps, salts etc.

Biosecurity and Pathogen Control

Alkaline Hydrolysis and the vectors of Pathogen Destruction

Alkaline hydrolysis has a distinct advantage when compared to other pathogen reduction methods that only rely on heat. Not only does the process provide the traditional heat vs time exposure but the alkali itself has a detrimental effect on the protein that forms part of any micro-organism present in the feedstock that is being processed

The first major advantage is the fact that the feedstock itself is hydrolyzed and as such this effectively removes any "shielding" that the pathogen may have from tightly packed tissue that otherwise may prevent heat transfer and potentially result in pathogen survival (this is one of the insurmountable problems with traditional composting processes). Secondly, the same mechanism that hydrolyzed the feedstock also hydrolyzes any protein present in or around the pathogenic micro-organism or bacterial spores, which results in a loss of structure and leads to cell lysis and death.

Important note about prions

MAAHP tissue processors have been designed to deal with material and the associated pathogens encountered during the normal day-to-day operation of an abattoir, and have not been field tested using prion infected material.

Despite compelling scientific evidence to suggest that low pressure alkaline hydrolysis is effective in prion destruction, we currently do not recommend MAAHP systems for material that is suspected to be infected by prions

The OIE, USDA and EU recommend that high pressure alkaline hydrolysis system be used to treat material suspected to contain prions. Should you require more information on acquiring a high pressure alkaline hydrolysis system, please contact us for assistance.

Although earlier work with hot alkali and prions involved hyperbaric vessels, my own later work with the thermostable 301V strain of BSE agent showed that boiling for one minute in alkali at atmospheric pressure completely inactivated this high-titre agent. Dr. David M. Taylor, PhD MBE

Hydrolyzate

When tissue is hydrolysed the end result is a liquid which is called the hydrolyzate. The hydrolyzate itself can be split into two very distinct categories namely HPL and Soapstock.

Hydrolyzed Protein Liquid - HPL

HPL is an acronym WRT uses when refering specifically to the hydrolysed protein liquid fraction of the hydrolyzate. HPL is characterized by a dark brown colour. HPL contains micro and macro nutrients that are beneficial to plants and compost processes.

WRT commissioned Dr. Arrie Van Vuuren and his team of leading soil scientists at Greenhouse Trials and Research Centre in 2012 to conduct two seperate studies in order to establish the suitability and effectiveness of HPL as a soil ameliorant and also to test HPL's contribution when used as a liquid fertilizer base enriched with a chemical fertilizer. The studies concluded that HPL is beneficial to soil and that when used as a fertilizer base, the HPL enriched fertilizer outperformed the purely chemical fertilizer by a significant margin.

Soapstock

The second fraction of the hydroyzate is what we refer to as soapstock. Soapstock contains most of the oils and fats that once formed part of the tissue that was hydrolysed. Soapstock is creamy white to yellow in colour and floats on top of the HPL when the hydrolyzate is left to stand for a little while. Soapstock is not suitable for soil application and is seperated from the fertilizer portion (HPL) for that reason. Soapstock does however contain valuable fats and oils and these can be recovered as a commercially valuable product using WRT's prorietary multi-processor technology or can be utilized directly in biogas processes without seperating the soapstock and HPL


Downloads Available

download pdf

Hydrolyzed Protein Analysis Bovine Material

An extensive chemical and amino acid analysis of bovine derived HPL. Click the PDf link on the left to download the analysis (0.14mb PDF Format).

download pdf

HPL Analysis Chicken Abattoir I

A comprehensive chemical, microbial and heavy metal analysis of avian derived HPL. Click the PDf link on the left to download the analysis (0.05mb PDF Format).

download pdf

HPL Analysis Chicken Abattoir II

A comparative analysis of the same avian derived HPL sample expressed per dry weight. Click the PDf link on the left to download the analysis (0.04mb PDF Format).

Downloads Available

download pdf

Stabilized Blood Fertilizer Analysis

The first fertilizer laboratory results from our stabilized blood protocol is in. Click the PDf link on the left to download the analysis (0.5mb PDF Format).

download pdf

RMAA Feedback 2014

Speaker Notes of our feedback session at the 2014 RMAA annual congress available for download. Click the PDf link on the left to download the presentation (1.4mb PDF Format).

download pdf

MAAHP Tissue Processor Overview 2013

MAAHP Tissue Processor Overview as presented at the 2013 RMAA annual congress available for download. Click the PDf link on the left to download the presentation (2mb PDF Format).