Melt Tanks
Pros & Cons. Why You Shouldn’t Use them in Meat Rendering
Melt tanks have pros and cons, but are very old meat rendering technology that has well and truly been surpassed.
Meat rendering is a process that transforms the parts remaining after butchering into byproducts like tallow, pellets, and more. While there are various rendering methods, using melt tanks is not recommended for several reasons. Here’s why you should reconsider using melt tanks in your meat rendering process:
1. Quality Control – Degrades Product
Melt tanks often operate at high temperatures, which can lead to the degradation of the fat and proteins. The meat can be in there for hours. When fat is exposed to excessive heat, it can develop off-flavours and lose its nutritional value. The high temperatures can also cause the fat to brown, resulting in a less desirable product. This can impact the profitability and reputation of your business.
2. Inconsistent Results
Melt tanks can produce inconsistent results due to uneven heating (it’s not first in, first out), and challenges with temperature control. This inconsistency can lead to partially rendered fat, which affects the quality and usability of the tallow. Proper rendering requires a controlled, low, and slow heating process to ensure even melting and purification of the fat.
3. Increased Risk of Contamination & Bacteria
Using melt tanks can increase the risk of contamination. The high temperatures and large volumes of fat processed in melt tanks can make it difficult to maintain cleanliness and hygiene. Bacteria and pathogens can thrive. Contaminants can easily be introduced, compromising the safety and quality of the rendered tallow. If salmonella hit, it remains in the tank until it is fully emptied, cleaned and sanitized.
4. Energy Inefficiency
Melt tanks are bad for the environment. They are often energy-intensive, requiring significant amounts of electricity or fuel to maintain the high temperatures needed for rendering. This not only increases operational costs but also has a larger environmental impact compared to more energy-efficient methods. There is considerable heat loss in melt tanks due to the large surface area exposed to the environment.
5. Inefficiency & High Cost
Melt tanks are not the most efficient method for meat rendering. They require significant energy to maintain high temperatures, more maintenance, and a large initial capital outlay. They need a lot of space and large equipment.
6. Maintenance (sticking & burn on)
Melt tanks are very challenging to clean and maintain, especially if the material being melted is prone to sticking or burning.
7. Loss of Valuable By-products
During the rendering process, valuable by-products such as cracklings (crispy bits of meat and fat) can be produced. Melt tanks, however, can destroy these by-products due to the high temperatures, resulting in a loss of potential additional revenue streams.
8. Safety Concerns
Handling large volumes of hot fat in melt tanks poses significant safety risks. The potential for burns and other injuries is higher compared to smaller-scale, controlled rendering methods. Additionally, the high temperatures can lead to the release of harmful fumes, which can be detrimental to respiratory health. Ensuring worker safety is paramount, and melt tanks can complicate this effort.
Better Modern Alternatives to Melt Tanks
There are modern alternatives to melt tanks that offer improved efficiency, safety, and environmental benefits. Technologies such as direct steam injection and its low-temperature rendering provide safer and more sustainable options. These methods not only reduce energy consumption but also produce higher quality end products.
Advantages of Direct Steam Injection
- Energy Efficiency: Direct steam injection is highly efficient as it transfers 100% of the steam’s energy to the liquid, reducing energy consumption by up to 25%.
- Speed: Steam is the fastest way to cook, and continuous cookers especially, are much, much faster than melt-tanks. It is one step heating in just 15 seconds, which enormously reduces pathogen risk.
- Gentler, more precise process: Steam can melt fat quickly without cooking the meat. The temperature is precise and consistent, which is crucial in meat rendering. You can set and forget.
- Improved Product Quality: Rapid heating preserves nutrients, colour and flavours. There’s less burning and more consistency.
- Rapid Heating: This method provides rapid and uniform heating, which is beneficial for processes requiring precise temperature control.
- Lower Maintenance: Direct steam injection systems generally have fewer components and are easier to maintain compared to melt tanks and their burn-on.
- Space Saving: These systems require less space, making them ideal for facilities with limited room. Most RotaTherms are 1m x 1m, and the infrastructure around it doesn’t take nearly as much space as a melt-tank.
- Cost-Effective: Lower energy requirements and reduced maintenance costs make direct steam injection a more cost-effective solution.
In both Rendering and Defatting, the RotaTherm® is the gold standard in processing.
Conclusion
While melt tanks have been a staple in the meat rendering industry, their drawbacks cannot be ignored. Health and safety risks, environmental impact, inefficiency, and the potential for lower quality products make them a less desirable option. By exploring modern alternatives, you can improve the efficiency, safety, and sustainability of your meat rendering process. DSI is clearly superior to melt tanks.