Welcome to the Food Recycle Pilot Facility

Food Recycle has manufactured a pilot facility that showcases the process and machinery at a commercial scale.

About the Facility

The Pilot Facility has been manufactured to both showcase the process at a commercial scale and also to produce actual poultry feed produced by the process for research with the University of New England to further optimise the process.

The facility can process up to ten tonnes a day and has been manufactured in Australia in five shipping containers; each container representing one of the steps in the Food Recycle Process. This facility is completely self sustained with generators and can be transported anywhere in the world for demonstration.

Five Step Process

StepOne

PROCESS: HEAT TREATMENT

This is the heat treatment step comprising of a direct steam injected screw conveyor. Killing the microbes is achieved via a combination of time and temperature. Steam is used in this case as microbes are more easily deactivated in wet conditions.

Steptwo

PROCESS: maceration and dewatering

This is the maceration and dewatering step. Reducing particle size aids in increasing surface area for more efficient dehydration. It also aids heat penetration to the core of the particle.

Stepthree

PROCESS: Heat Treatment

This is the dehydration step. The pilot facility utilises a direct heat rotary drum drier. Dehydration is important in that it ensures that the crumb generated is shelf stable by removing water activity.

Stepfour

PROCESS: accumulation and blending

The dehydrated crumb is passed through a hammer mill and then stored as a shelf stable fine powder. When the material is ready for blending, the correct proportions of powder waste can be collected according to the feed recipe.

Stepfive

PROCESS: pelletizing

The blended mix is then fed into the pelletiser to produce the final product after an additional drying step for shelf stability.

Five Step Process

StepOne

PROCESS: HEAT TREATMENT

This is the heat treatment step comprising of a direct steam injected screw conveyor. Killing the microbes is achieved via a combination of time and temperature. Steam is used in this case as microbes are more easily deactivated in wet conditions.

Steptwo

PROCESS: maceration and dewatering

This is the maceration and dewatering step. Reducing particle size aids in increasing surface area for more efficient dehydration. It also aids heat penetration to the core of the particle.

Stepthree

PROCESS: Heat Treatment

This is the dehydration step. The pilot facility utilises a direct heat rotary drum drier. Dehydration is important in that it ensures that the crumb generated is shelf stable by removing water activity.

Stepfour

PROCESS: accumulation and blending

The dehydrated crumb is passed through a hammer mill and then stored as a shelf stable fine powder. When the material is ready for blending, the correct proportions of powder waste can be collected according to the feed recipe.

Stepfive

PROCESS: pelletizing

The blended mix is then fed into the pelletiser to produce the final product after an additional drying step for shelf stability.

Food Recycle Pilot Facility Overview

Below is a video showcasing both the pilot facility launch (at the University of New England in Armidale), combined with the expertise of the team that has worked together to bring the technology to market.

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