Background: Wastewater is a singificant issue in food processing plants and city wastewater treatment plants. Oily dissolved air flotation (DAF) skimming, lagoon sludge, decanter solids, biosolids, and biomass are produced from wasterwater treatment. The oily sludge materials are major issue in these plants, which cause environmental problem.
New Processes: We have developed the patented processes (2002 and 2014) to process oily sludge materials or decanter solids into the non-oily dry encapsulated products with high fat level, which add more value and form non-oily and free-flowing dry products.
#1) One process is to encapsulate above oily sludge with the feed-grade ingredients and use a dryer to produce the non-oily dry product with free-flowing property (a dryer is not needed when moisture level is already low). Its typical analysis data are: protein 40-30%, fat 15-30%, carbohydrate 3-30% (depending on their raw materials) and moisture 6%.
#2) Another process is to use a feed-grade protein ingredient to encapsulate above oily sludge and use a dryer to produce the non-oily dry product with free-flowing property. Its analysis data are: fat 30%, protein 55% and moisture 6%.
Manufacture: Both products have high fat levels. The above encapsulated products have been manufactured in our production facilities. One of them has been commercialized for more than eight years. Our product samples are available. Also our production facilities are available for visit.
When a plant has above oily sludge or grease at 12 tons/day in solid basis, then the dry encapsulated product can add more than $2,000,000/year.
Our patented processes convert above oily sludge into the free-flowing and non-oily fat products in dry form and add more value.
The products are used as dry fat and protein ingredients for general animal feeds. For aquaculture feeds, the products have low gravity and float in water. Also the products have bypass function for dairy animals.
#1: Non-oily dry DAF
#2: Non-oily dry DAF (fat and protein product)
#3. Decanter Solids from oily and black color to non-oily and light color after the process