FIELD OF THE INVENTION The present invention relates to animal rendering processes. More particularly, the present invention relates to systems and methods for compact and energetically efficient waste disposal and animal rendering.

BACKGROUND OF THE INVENTION

Animal farming usually consists of keeping a large number of animals in a confined space, e.g. for the purpose of breeding, rearing as well as other agricultural productions. In poultry farming for instance, industrial poultry houses are used as housings for the poultry. During a typical broiler production season, about 5% of all the poultry die of various causes (e.g. from the initial total number of heads in a poultry coop) and it is therefore required to dispose of the carcasses of the dead poultry. Due to veterinarian regulations, the carcasses of the dead poultry must be disposed of as quickly as possible, inside the perimeter of the coops in order to prevent diseases spreading from the carcasses to other areas. Thus, all carcasses must be disposed of inside the physical perimeter of the farm.

Typical solutions to such disposal of carcasses include costly procedures of either dumping the carcasses in the ground inside a dedicated site within the farm, or alternatively freezing or burning the carcasses. In any case, the result of these processes increases the pollution to the environment such that other solutions are sought for.

Some commercially available solutions employ animal rendering in order to dispose of the carcasses. Rendering is a process that generally converts animal tissue into "value-added" materials. Typically, rendering simultaneously dries the waste material and separates fat tissue from the bone and protein to yield a fat commodity (such as grease) and/or a protein meal (usually feathers or bone meal). These solutions are typically cumbersome and take up a large area since different containers and devices are employed in the processing of the carcasses.

For example, US 6,055,917 describes an animal carcass incineration process employing several chambers with a large hopper with a spring loaded trap door at the top, a series of stationary and rotating blades in the center and a second set of spring loaded doors below. A large pipe is provided with an opening beneath the bottom of the hopper and includes a hydraulically driven auger for forcing the shredded carcasses upward along the pipe. Heavy smoke and ash from burning then enters a secondary incineration area with burning via natural gas, wherein throughout the incineration process the material passes through multiple areas.

Some continuous cookers have also been used for rendering, with a grinding of the carcasses to create pulp like material later filtered in a "percolator" such that after removal of all liquids (e.g. into a decanter) the remaining material is compressed and cooked. The cooked material then passes for further drying to finally result with "meat flour" typically having 25% humidity.

There is therefore a need for an on-site compact solution that may provide improved efficiency of rendering while saving energy, costs, and space.

SUMMARY OF THE INVENTION

According to a first aspect of the present invention, a compact waste disposal apparatus for treating organic material is provided, said apparatus comprising:

a tank coupled with at least one heating plate, and configured to accommodate the organic material; and

a controller configured to allow operation of the at least one heating plate, wherein the operation of the at least one heating plate corresponds to the amount of the organic material inside the tank.

In some embodiments, the organic material is transformed into flour inside the tank. In some embodiments, the tank further comprises a top opening configured to allow loading of the organic material into the tank.

In some embodiments, the tank further comprises a vent configured to allow removal of excess gasses from the tank.

In some embodiments, the tank further comprises a rotatable shaft configured to allow stirring of material inside the tank, and wherein the controller is configured to allow rotation of the shaft.

In some embodiments, the shaft further comprising at least one rod configured to rotate along with the rotation of the shaft.

In some embodiments, the waste disposal apparatus further comprises a flour extraction system configured to allow extraction of the flour from the tank.

In some embodiments, the tank further comprises an inlet configured to allow passing ambient air into the tank. In some embodiments, the tank further comprises a bottom opening configured to allow removal of the flour from the tank.

In some embodiments, the waste disposal apparatus further comprises a weight measuring device, wherein the weight measuring device is controlled by the controller.

In some embodiments, the waste disposal apparatus further comprises a temperature sensor, wherein the temperature sensor is controlled by the controller. In some embodiments, the waste disposal apparatus further comprises a humidity sensor, wherein the humidity sensor is controlled by the controller. In some embodiments, the organic material is selected from waste disposal selected from a group of waste such as animal carcasses, industrial organic waste, commercial organic waste. In some embodiments, said flour can be used as anyone of fertilizer substrate enrichment, composts, animal food, kindling or a combination thereof.

According to a second aspect of the present invention, a method for treating organic material is provided, said method comprising:

providing a tank coupled with at least one heating plate;

inserting the organic material into the tank;

weighing the organic material;

checking if weighed organic material corresponds to a predetermined amount; operating the at least one heating plate at a first predetermined temperature, wherein the first predetermined temperature corresponds to the amount of organic material inside the tank; and

boiling the organic material inside the tank.

In some embodiments, the method further comprises:

operating the at least one heating plate at a second predetermined temperature once the predetermined amount is measured, wherein the second predetermined temperature corresponds to the amount of organic material inside the tank; and

cooking and drying the organic material inside the tank,

wherein the organic material is transformed into flour inside the tank after the cooking and drying.

In some embodiments, the method further comprises:

cooling the flour inside the tank; and

extracting the flour from the tank.

In some embodiments, the method further comprises stirring of the flour.

In some embodiments, the method further comprises checking the temperature of the material inside the tank. In some embodiments, the method further comprises checking the humidity of the material inside the tank. In some embodiments, the method further comprises passing ambient air into the tank.

In some embodiments, the method further comprises removing excess gasses from the tank.

In some embodiments, the method further comprises conveying the flour to at least one storage reservoir.

In some embodiments, the organic material is selected from waste disposal selected from a group of waste such as animal carcasses, industrial organic waste, commercial organic waste.

In some embodiments, the method further comprises using said flour as anyone of fertilizer substrate enrichment, composts, animal food, kindling or a combination thereof.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described below. In case of conflict, the specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting. BRIEF DESCRIPTION OF THE DRAWINGS

The invention is herein described, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice.

In the drawings:

- Fig. 1 schematically illustrates a perspective frontal view of a compact waste disposal apparatus, according to an exemplary embodiment.

- Fig. 2 schematically illustrates a back side view of the compact waste disposal apparatus, according to an exemplary embodiment.

- Fig. 3A schematically illustrates a perspective frontal view of the compact waste disposal apparatus, according to an exemplary embodiment.

- Fig. 3B schematically illustrates a partially cross-sectional view of the compact waste disposal apparatus shown in Fig. 3A, according to an exemplary embodiment.

- Fig. 4 schematically illustrates a partially cross-sectional perspective bottom view of the compact waste disposal apparatus, according to an exemplary embodiment.

- Fig. 5A schematically illustrates a right side view of the compact waste disposal apparatus, according to an exemplary embodiment.

- Fig. 5B schematically illustrates a left side view of the compact waste disposal apparatus, according to an exemplary embodiment.

- Fig. 6A schematically illustrates a top view of the compact waste disposal apparatus, according to an exemplary embodiment.

- Fig. 6B schematically illustrates a bottom view of the compact waste disposal apparatus, according to an exemplary embodiment.

- Fig. 7 shows a block diagram for the automatic rendering process, according to an exemplary embodiment.

- Fig. 8 schematically illustrates electrical components embedded in the vicinity of the tank of the compact waste disposal apparatus, according to an exemplary embodiment.

- Fig. 9 schematically illustrates a waste disposal system using the compact waste disposal apparatus, according to an exemplary embodiment. DETAILED DESCRIPTION OF THE INVENTION

Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.

For clarity, non-essential elements were omitted from some of the drawings.

Referring now to Figs. 1-2, these figures show the external side of a compact waste disposal apparatus. Fig. 1 schematically illustrates a perspective frontal view of a compact waste disposal apparatus 10. The compact waste disposal apparatus 10 operates in a fully automatic manner once loaded with organic material for processing (for instance at least one animal carcass), further described hereinafter.

It is appreciated that the loading of the material into the compact waste disposal apparatus 10 may be carried out manually through a top opening which is covered by a cover 14, whereby the rendering operation within the waste disposal apparatus 10 carries out automatically. In some embodiments, the organic waste material for processing may be manually loaded into the waste disposal apparatus 10 by initially moving a handle 13 in order to lift the cover 14 and thereby insert a portion of organic waste material (e.g. at least one animal carcass) into the top opening. Optionally, the cover 14 may be further connected to a counterweight 15 configured to keep the cover 14 firmly open, and also allow easy opening with movement of the handle 13. Once the compact waste disposal apparatus 10 is loaded with the organic waste material, the operator may initiate the automatic processing, e.g. by pressing a button.

The waste disposal apparatus 10 comprises a tank 12 with the automatic rendering operation taking place therein such that at the end of the process, the result is dry (meat) flour. The rendering process may be conducted with a motor 16 (connected to an external power source) manipulating components on the inner side of the tank 12. Optionally, the resulting flour may be extracted through a delivery pipe 17. For stabilization, the tank 12 may be positioned onto a frame 11. In addition to the top opening of the tank 12, a vent 19 may be provided at the top of the tank 12 in order to allow removal of excess gasses from the tank 12. Such gasses may result from the rendering process and may be required to be removed in order to allow optimal processing as well as to prevent dangerous increase in pressure inside the tank 12.

Fig. 2 schematically illustrates a back side view of the compact waste disposal apparatus 10. The tank 12 comprises a plurality of heating plates 22 that are configured to radiate heat into the inner side of the waste disposal apparatus 10. In some embodiments, the heating plates 22 are positioned on the bottom portion of the tank 12, while the top portion (including the vent 19) is not heated.

Each heating plate 22 may be coupled to at least one connector 23 capable of connecting to an external power source in order to heat the heating plates 22. For example, each connector 23 may be connected to an electric power supply and thus electrically generate heat throughout the respective heating plate 22. Optionally, the connector 23 may be coupled to additional components, such as sensors.

In some embodiments, the frame 11 may be stabilized with at least one adjustable stabilizing segment 21 that may change the positioning of the frame 11 according to a predetermined choice by the operator, and are also capable of leveling the frame 11. Preferably, the at least one stabilizing segment 21 is further configured to allow weighing of the content of the tank 12.

The motor 16 may be connected to the tank 12 through a first bearing housing 28, with a corresponding second bearing housing 29 on the opposite side of the tank 12. A rotatable shaft (further described in Fig. 3B) passes between the first bearing housing 28 and the second bearing housing 29, wherein the rotation of this shaft may be controlled by the motor 16. The rotatable shaft may be used for moving the material inside the tank 12. Optionally, a stabilizing arm 26 is connected to the tank 12 and also to the motor 16 in order to provide stable positioning of the motor 16 during its operation.

It should be noted that once the organic waste material is processed (as the meat flour") it may be removed from the tank 12 into a flour extraction system 27. From the flour extraction system 27, the meat flour may be removed through the delivery pipe 17 (for instance as shown in Fig. 1). Optionally, the flour extraction system 27 may be have electrical components and operate separately from the motor 16.

Referring now to Figs. 3A-3B, these figures show the internal side of the compact waste disposal apparatus. Fig. 3A schematically illustrates a perspective frontal view of the compact waste disposal apparatus 10, and Fig. 3B schematically illustrates a partially cross-sectional view of the same. It should be noted that the flour extraction system 27 may be coupled to a flour container 37, such that flour extracted by the flour extraction system 27 passes to the container 37 and then removed through the delivery pipe 17.

The inner side of the tank 12 comprises a rotatable stirring shaft 30 that passes between the first bearing housing 28 and the second bearing housing 29, wherein the rotation of this shaft may be controlled by the motor 16. The shaft 30 comprises at least one rod 32 configured to rotate along with the rotation of the shaft 30. Once organic waste material is inserted into the inner space of the tank 12, the rotation of the at least one rod 32 may create a stirring motion and thereby induce the rendering of the material inside the tank 12. It is appreciated that the at least one rod 32 does not grind the material inside the tank 12, and only moves it along the tank 12, such that the rendering process may be completed without grinding. Optionally, the shaft 30 is only operated once the material results in the meat flour, such that the stirring by the shaft 30 cools the flour. Preferably, the shaft 30 is operated continuously throughout the entire rendering process.

Referring now to Fig. 4, this figure schematically illustrates a partially cross- sectional perspective bottom view of the compact waste disposal apparatus 10, whereby the frame is removed. In addition to the top opening, the tank 12 further has a bottom opening 44 through which the processed material may pass into the flour extraction system 27.

In some embodiments, the compact waste disposal apparatus 10 may comprise additional elements configured to blow ambient air into the tank 12 in order to cool the flour after cooking. For instance, the tank 12 may comprise an additional air inlet (not shown in the drawings). Once the flour is sufficiently cooled, it may be extracted through the bottom opening 44. Referring now to Figs. 5A-6B, these figures show the compact waste disposal apparatus from different views. Fig. 5 A schematically illustrates a right side view of the compact waste disposal apparatus 10, and Fig. 5B schematically illustrates a left side view of the compact waste disposal apparatus 10. Fig. 6A schematically illustrates a top view of the compact waste disposal apparatus 10, and Fig. 6B schematically illustrates a bottom view of the compact waste disposal apparatus 10. It is appreciated that the waste disposal apparatus 10 has a compact structure such that all procedures of the rendering process may take place in small space, including the extraction of the flour. Referring now to Fig. 7, this figure shows a block diagram for the automatic rendering process, wherein the direction of arrows indicated the direction of information flow. Initially organic waste material is collected (e.g. carcasses of dead poultry from a rearing house), and all collected material is inserted into the top opening of the compact waste disposal apparatus. Once the organic waste material is inserted into the tank 12 and the cover 14 is closed (for instance as shown in Fig. 3A), the operator may initiate the automatic rendering process. Optionally, the compact waste disposal apparatus may be used once a sufficient amount of organic waste material is collected inside the tank, since a certain amount is required for optimal rendering.

Then the waste disposal apparatus may weigh 71 the mass of the organic waste material inside of the compact waste disposal apparatus. Optionally, the weighing 71 is carried out automatically using a built in measurement device embedded into the bottom portion of the tank or alternatively embedded into the frame 11. Such a measurement device may be coupled to a controller (not shown) that may check 72 if the weighed material is in a sufficient predetermined amount. For example, in a chicken house it may take two rearing periods to achieve a full amount for rendering. For example, in the process of rearing broilers for meat it usually takes about

42-45 days to complete a single cycle. Dead poultry are typically collected from the floor of the housing every day, whereby at the beginning of the cycle the mass of organic material collected from the floor is relatively small so it might take 4-5 days to complete a full load in the tank. At the end of the cycle, a full load may be collected every day.

In case that the measured amount is not sufficient 76, the compact waste disposal apparatus may perform initial boiling 74 of the material inside the tank, with the heating plates operating in a first predetermined temperature. It should be noted that such boiling 74 may be carried out without the addition of water, whereby the fluids of the waste material are boiled. After initial boiling 74, the operation of the waste disposal apparatus may be stopped while maintaining a predetermined temperature inside the tank (preferably maintaining 70°C). It is appreciated that by maintaining a high temperature inside the tank, for instance measured with a built-in temperature sensor, a bacterial culture may be prevented.

Once the tank is reopened (for example the opening of the cover may be detected) and additional organic waste material is inserted into the tank, the controller may again check 72 if the weighed material is in a sufficient predetermined amount. In such a way the abovementioned boiling 74 process may repeat itself until the sufficient amount is measured. It should be noted that during all operations of the compact waste disposal apparatus, the stirring shaft may be engaged to stir the material inside the tank. Once the measured amount is sufficient 78, the compact waste disposal apparatus may perform full cooking and drying 73 (using the heating plates) of the accumulated material inside the tank, as it may take several cycles to achieve the predetermined amount. It should be noted that the cooking and drying 73 may be carried out with the heating plates operating in a second predetermined temperature. After the material is fully dried, it becomes the meat flour. It is appreciates that such cooking process 73 does not require any grinding or other treatment of the material and the rendering is achieved in a fully automatic manner as to result in the meat flour.

In some embodiments, the tank may comprise a built-in humidity sensor (for instance embedded into the vent) to continuously measure the humidity of the material inside the tank during the cooking 73. Once this humidity sensor detects that the flour reaches a predetermined value of humidity (preferably 10%), the heating plates may automatically stop heating and the flour is then cooled 75.

In some embodiments, the cooling of the flour 75 may be carried out by blowing ambient air into the tank and stirring the flour (with the stirring shaft) until the meat flour is cooled to a predetermined temperature (preferably 25°C).

Once the temperature inside the tank reaches a predetermined value (preferably 25°C), the bottom opening 44 (for instance as shown in Fig. 4) of the tank may be opened such that the flour extraction system may commence extracting the flour a flour storage facility (further described hereinafter) via the delivery pipe.

In some embodiments, the controller may identify that the weight of the material has reached a minimal value (indicating an empty tank) and then the operation of the compact waste disposal apparatus may be stopped, until additional organic waste material is inserted 79 into the tank for a new cooking cycle. It should be noted that nearing the end of a breeding or rearing period it may be required to conduct a full cooking cycle on a daily basis just for waste material of that day.

It is appreciated that the compact waste disposal apparatus may operate in an energetically efficient way, since all steps of the rendering process require minimal usage of power (and also no addition of water). Optionally, the compact waste disposal apparatus may use renewable energy (such as solar or wind power) in order to power the components of the tank, thereby creating a completely self-sufficient and portable unit that does not require to be connected to an external power source. It should be noted that in contrast to commercially available solutions, the entire boiling and cooking process takes place in the same tank without the need of moving the material between different compartments. Additionally, there is no requirement for water as the boiling occurs with the fluids from the organic waste material.

Referring now to Fig. 8, this figure schematically illustrates electrical components embedded in the vicinity of the tank of the compact waste disposal apparatus 10, wherein the direction of arrows indicated the direction of information flow. A central computerized controller 80 may control the operation of the different components inside the tank. Initially, the weight measuring device 81 measures the amount of material inside the tank. Based on the measured weight, the controller 80 may operate the heating plates to boil or cook the material inside the tank. The temperature sensor 82 may continuously measure the temperature inside the tank with corresponding operation of the controller 80 (and heating plates 22) until a desired temperature is achieved. Finally, after cooking and achieving the meat flour the tank is cooled. A humidity sensor 87 may continuously measure the humidity inside the tank and thereby the controller 80 may employ the flour extraction system 27 once the predetermined humidity value is achieved.

Referring now to Fig. 9, this figure schematically illustrates a waste disposal system 90 using the compact waste disposal apparatus 10. During the cooking process, various gasses may accumulate inside the tank. These gasses may pass, for instance through the vent 19 (as shown in Fig. 1), to a vapor dilution system 91. The vapor dilution system 91 is configured to dilute the gasses from the compact waste disposal apparatus 10 with a predetermined ratio (preferably 1/100) in order to prevent any odor hazard in the vicinity of the waste disposal apparatus 10. Typically, about 65% of the organic waste material is boiled as fluids to become gasses that need to be diluted. Optionally, the entire waste disposal system 90 may be positioned in a small compound (for example in a chicken house compound) such that there is no harm to the environment.

After the meat flour is extracted from the waste disposal apparatus 10, the flour may be conveyed to at least one reservoir 94, that are configured to maintain a low humidity for storage of the meat flour (for example storing up to 4 tons of flour). Typically, about 35% of the organic waste material (for instance including feathers for chickens) is finally rendered to the meat flour. Optionally, at the end of each breeding period the sterilized flour may be removed from the at least one reservoir 94 and transported to processing plants.

It is appreciated that the resulting flour may have high percentage of nitrogen and low salinity, thereby making the flour particularly effective for fertilizer substrate enrichment, and/or mixture with composts. Alternatively, the resulting flour may be utilized as animal food due to high nutritious values and also low bacterial presence. Optionally, the resulting flour may also be used as kindling.

It should be noted that while the abovementioned embodiments mostly described waste disposal of animal carcasses, the same systems and methods may be similarly applied for any organic material waste. For instance, disposal of industrial organic waste and/or disposal of commercial organic waste (e.g. waste from hotels and/or restaurants).

It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub combination. Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.