ESSENTIAL RENDERING All About The Animal By-Products Industry Edited by David L. Meeker PREFACE The first book written about the rendering industry was produced by the National Renderers Association in 1978 and was titled The Invisible Industry. In 1996, a second book entitled The Original Recyclers was published to tell everyone in government, academia, and the public what renderers are—environmentally aware producers of safe products—the original recyclers. That book was to move us into the twenty-first century, but with the pace of change, we find ourselves already in need of a new book on the rendering industry. So much has happened in the past decade that it has become necessary to publish this book, Essential Rendering. This book documents the technologies, manufacturing procedures, capabilities, research, and infrastructure that make the industry so important to the United States and Canada. Two cases of indigenous bovine spongiform encephalopathy discovered in the United States and eight in Canada, as well as high pathogenic avian influenza around the world, challenge renderers today. Thus, society needs to know how renderers handle, in a biosecure manner, over 59 billion pounds of the by-products from animal food production every year in the United States and Canada. Government, which promulgates rules to answer today’s diverse challenges, academia, which influences users of rendered products, and the public, which uses the products of the industry’s operations, all need to know about rendering in today’s world. They need to know how rendering prevents both animal and human diseases and what the ramifications are of not having rendering. Society should not take renderers’ services for granted or forget that they operate in a free enterprise system. David J. Kaluzny II, Chairman, National Renderers Association ABOUT THE COVER This painting is on display in the NRA office in Alexandria, Virginia. The artist, Edward Juarez, worked at the Omar Rendering Company in San Diego, CA his entire working career. He started working at age 12, picking up cattle hides. Mr. Juarez painted this scene in 1980, one of ten paintings he did in the plant where he worked. The renderer/artist said this scene was of workers loading the batch cooker with feathers at the end of the day. The previous batch was blood from packing houses made into blood meal. Edward Juarez said, “We worked as hard as we could—we worked our butts off—but we took pride in our work and it was fun for us. We would work all day and then go to the bar.” He said he also had three brothers that worked in packing houses skinning cattle and they were “top butchers” because of their skill in producing flawless hides. Mr. Juarez lives in San Diego, CA and still paints. This image appears with his permission. RENDERING ASSOCIATION WEB SITES For updates and current industry information, visit the following sites: www.renderers.org www.animalprotein.org www.fprf.org i ACKNOWLEDGEMENTS Thanks to the officers and committees of NRA, APPI, and FPRF for providing the resources to make this book possible and to each of the authors for their academic contributions. Thanks especially to Tina Caparella, Nancy K. Cook, Tom Cook, Glenda Dixon, C. Ross Hamilton, David J. Kaluzny II, David Kirstein, Kevin Kuhni, and Sergio Nates for detailed reviewing this work at many stages. This book contains information from highly regarded sources and industry experts. Sources are indicated wherever possible, reprinted material is quoted with permission, and hundreds of references are listed. Great care has been taken to publish accurate data and reliable information, but the authors and the publisher do not assume responsibility for the validity of all materials or the consequences of use. Written permission from NRA is necessary before this book or any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, microfilming, and recording, or by any information storage or retrieval system. National Renderers Association 801 N. Fairfax Street Suite 205 Alexandria, Virginia 22314 This book was produced under the auspices of: The National Renderers Association (NRA), David J. Kaluzny II, Chairman The Fats and Proteins Research Foundation (FPRF), C. Ross Hamilton, Chairman The Animal Protein Producers Industry (APPI), Carl Wintzer, Chairman With direction from the NRA Communications Committee: Kevin Kuhni (Chairman); John Kuhni Son, Inc. Larry Angotti (Vice Chairman); Darling International, Inc. Rita Schneider; HRR Enterprises, Inc. Doug Anderson; Smithfield Foods, Inc. Ridley Bestwick; West Coast Reduction, Ltd. Stan Gudenkauf; American Proteins, Inc. Robert Desnoyers; Lomex, Inc. John Griffin; Griffin Industries, Inc. Tim Guzek; Anamax Corporation David Kaluzny II; Kaluzny Bros., Inc. Tom Cook; NRA President Neville Chandler; NRA Regional Director, London Tina Caparella; Editor, Render Copyright 2006 by the National Renderers Association ISBN: 0-9654660-3-5 Printed in September of 2006 by Kirby Lithographic Company, Inc. Arlington, Virginia ii TABLE OF CONTENTS An Overview of the Rendering Industry ………………………………….………..............1 David L. Meeker, NRA, and C. Ross Hamilton, Darling International, Inc. A History of North American Rendering……………………………………………….…17 Fred D. Bisplinghoff Rendering Operations……………………………….……………………………...............31 Doug Anderson, Smithfield Foods The Rendering Industry’s Role in Feed and Food Safety………………………….…….53 Don A. Franco, Center for Bio-security, Food Safety and Public Health The Rendering Industry’s Biosecurity Contribution to Public and Animal Health....... 71 Richard E. Breitmeyer, CA State Veterinarian; C. Ross Hamilton, Darling International, Inc.; and David Kirstein, Darling International, Inc. Edible Rendering--Rendered Products for Human Use………………….………………95 Herbert W. Ockerman and Lopa Basu, The Ohio State University Rendered Products in Ruminant Nutrition……………………………….……..............111 Thomas C. Jenkins, Clemson University Rendered Products in Poultry Nutrition……………………………….…………….….125 Jeffre D. Firman, University of Missouri Rendered Products in Swine Nutrition……………………………….……………….....141 Gary L. Cromwell, University of Kentucky Rendered Products in Pet Food………………………………...…………………...……159 Greg Aldrich, Pet Food and Ingredient Technology, Inc. Rendered Products in Fish Aquaculture Feeds……………………..…………….…….179 Dominique Bureau, University of Guelph Rendered Products in Shrimp Aquaculture Feeds……………………………….……..195 Yu Yu, NRA The Global Market for Rendered Products……………………………….………….….213 Kent Swisher, NRA Industrial and Energy Uses of Animal By-Products, Past and Future………...………229 Stewart McGlashan, Meat and Livestock Australia, Ltd. Environmental Issues in the Rendering Industry…………………………………….…245 Gregory L. Sindt, Bolton & Menk, Inc. Research in the Rendering Industry……………………………….………………..…....259 Gary G. Pearl, FPRF (retired) Future Research for the Rendering Industry……………………………….…………...273 Sergio F. Nates, FPRF What Would a World Without Rendering Look Like? …………………………...…....277 Stephen Woodgate, European Fat Processors and Renderers Association Historic Images……………………………………29, 30, 52, 70, 94, 140, 158, 178, 212, 244 Index…………………………...…........................................................................................295 iii THE AUTHORS Greg Aldrich is president of Pet Food and Ingredient Technology, Inc. Dr. Aldrich is a consulting nutritionist specializing in foods and nutrition for companion animals. His work encompasses new product development, nutritional advice and support, and technical communications for pet food companies and ingredient suppliers. He writes a monthly column for Petfood Industry magazine on ingredient issues and is a frequent speaker at industry and scientific forums. He received his B.S. in agriculture from Kansas State University, his M.S. in animal science from the University of Missouri, and his Ph.D. in nutrition from the University of Illinois. Dr. Aldrich has held several management and technical positions with Co-op Feeds, the Iams Company, Kemin Industries, Inc., and Menu Foods, Ltd. He and his wife Susan manage their consulting firm from Topeka, Kansas. Douglas P. Anderson is a fourth generation renderer. He joined Smithfield Foods, Inc., in April 2002 and is vice president, Rendering for Smithfield Foods, Inc., and president/COO of Smithfield BioEnergy, LLC. As vice president of rendering for the multi-national food company, he is responsible for inedible by-products recycling at all company locations worldwide. He has recently been named president/COO of Smithfield Bioenergy, LLC, the bio-energy subsidiary of Smithfield Foods, Inc. He is currently president of the World Renderers Association, the immediate past chairman of the National Renderers Association, and immediate past chairman of the North American Rendering TSE Coalition. His lifelong career in the industry includes previous experience as president of American Proteins, Inc., Cumming, Georgia; chief operations officer of Darling International, Inc., Irving, Texas; President of Stord, Inc. (Stord Bartz Americas), Greensboro, North Carolina; general manager of Milwaukee Tallow Co., Hide Service Corporation, Carrie Shortening Corporation, Justro Feeds, and West Wis. Pet Food; and vice president of Indianhead Rendering, Inc., Barron, Wisconsin. He is a graduate of the University of Wisconsin-Madison. Lopa Basu is pursuing a Ph.D. in animal science (international foods) at Ohio State University under