BACKGROUND TO THE INVENTION

The present invention relates to an animal processing apparatus.

Dead animals are a fact of life for commercial farmers. Poultry farms in particular process hundreds of thousands of animals every year, and as with any animal farm, there are many mortalities. Each of these corpses must be handled carefully and disposed of safely as bio-security is an important issue. Conventionally, dead animal bodies have been either buried to decompose over time, or burned. Burial, even at depth, has the potential to contaminate the surrounding soil, and more seriously could pollute water sources nearby. The contaminants may be bacteria, pathogens, or possibly antibiotics, other medicines or chemical treatments used for the animals during life. Further, the decomposition of the carcasses can produce large quantities of both carbon dioxide and methane.

For this, and for general health concerns, legislation is increasingly being introduced around the world to generally prohibit burial of animal bodies. The main alternative, is to incinerate the bodies, which removes the potential to pollute the ground or water, but can contribute carbon dioxide and other greenhouse gasses to the atmosphere, which is undesirable. It would be highly desirable therefore to find another better and safer way to deal with the dead animal bodies resultant from commercial food production.

A dead animal is a store of useful nutrients, but these nutrients are not readily accessible for use. If the body could be buried in a garden, the nutrients that would be released through the breakdown of the tissues could be used to grow plants or trees; with the regulations to prevent burial, and the potential contaminant risk, this is not possible. Decomposing bodies break down to potentially release carbon dioxide, and worse, methane into the air, and phosphorus, nitrogen, potassium, magnesium and micronutrients to the surrounding ground. It would be useful to be able to capture and use these nutrients, without the risk of also releasing contaminants into the ground or water, or release of greenhouse gases.

The inventors, have developed through careful research and extended development, a new way to dispose of animal bodies, that can recapture the valuable nutrient content, for use as a fertilizer for example, without the risk of contamination, and preventing the undesirable release of carbon dioxide and methane.

The following describes a non-limiting example of the invention being used with reference to processing dead poultry bodies, a particularly useful application of the invention. Other animals may be processed using the invention, with the invention being adapted for the specific animal. For example, more breaking up of bones may be needed for larger animals and breaking of the bones for cattle than is necessary for smaller animals such as chickens. The size of the vessel and the volumes of processing fluids may be varied to suit any suitable volume of dead animals to be processed. It is not intended to limit the scope of the invention to chicken or poultry processing, other than as defined in the claims. Use for processing of cattle is another very useful application of the invention. Further the following describes a non-limiting example of the product produced being a fertilizer product. It is envisaged that other products could be produced instead. It is not intended to limit the scope of the invention to producing fertilizer, other than as defined in the claims.

For clarity, any prior art referred to herein, does not constitute an admission that the prior art forms part of the common general knowledge, in Australia or elsewhere.

It is an object of the present invention to provide an animal processing apparatus that at least ameliorates one or more of the aforementioned problems of the prior art. It is a further and separate object of the present invention to provide a product from an animal processing apparatus that that at least ameliorates one or more of the aforementioned problems of the prior art. It is a yet further and separate object of the present invention to provide a method of use of an animal processing apparatus that that at least ameliorates one or more of the aforementioned problems of the prior art.

SUMMARY OF THE INVENTION

Accordingly, the present invention provides an animal processing apparatus to produce a useful product, the animal processing apparatus including: an operating tank into which animals can be directed for processing; a dissolving solution, which can be caused to act on the animals in the operating tank and to break down the tissues to release nutrients; and a resultant product, wherein the animals are processed to break down the tissues and produce the product.

Accordingly, the present invention provides, in a further variant, an animal processing apparatus to produce a useful product for use as fertiliser, the animal processing apparatus including: an operating tank into which animals can be directed for processing; a turbulence means, associated with the operating tank, able to cause movement or turbulence within the tank during processing to accelerate the animal processing; a dissolving solution including a blend of sodium hydroxide and potassium hydroxide blended at substantially 12.5 percent, of pH substantially 14.0, which can be caused to act on the animals in the operating tank, moved by the turbulence means, and with the addition of heat to bring the temperature between 45 and 55 degrees Centigrade, used to break down the tissues to release nutrients; and a resultant fertilizer product, wherein the animals are processed to break down the tissues and produce the resultant fertilizer product which makes use of the nutrients derived from the dead bodies.

Accordingly, the present invention provides, in a further variant, an animal processing apparatus to produce a useful product for use as fertiliser, the animal processing apparatus including: an operating tank into which animals can be directed for processing; a turbulence means, associated with the operating tank, able to cause movement or turbulence within the tank during processing to accelerate the animal processing; a dissolving solution including a blend of sodium hydroxide and potassium hydroxide blended at substantially 12.5 percent, of pH substantially 14.0, which can be caused to act on the animals in the operating tank, moved by the turbulence means, and with the addition of heat to bring the temperature between 45 and 55 degrees Centigrade, used to break down the tissues to release nutrients; and a resultant fertilizer product, wherein the animals are processed to break down the tissues and produce the resultant fertilizer product which makes use of the nutrients derived from the dead bodies.

Preferably, the animal processing apparatus is sized to be suitable for use direct, at the site of the animal production. The apparatus is scalable and in this way the number of animals to be processed can be scaled up and down by adjustments to the volume of the operating tank, and corresponding volumes of dissolving solution. The end product can be produced therefore in small, medium or larger batches as would be readily understood. It is a useful application of the invention that the apparatus can be supplied in components and assembled and installed directly near the location of the dead animals. T ransportation to a larger “factory” style apparatus could also be possible in other forms of the invention. Kit or small scale versions may also be provided for a farm or smaller scale operation with the less frequent need to make use of the animal processing. It is of particular use for an animal producer to be able to both process the dead animals and to take the benefit of the nutrient product at the same location. In some forms of the invention the nutrient product may be supplied elsewhere for further processing. The nutrient product could be used direct, being bio safe and stable, whereas the dead bodies cannot be introduced to the land due to the risk of contaminants, biohazards and release of the greenhouse gasses as they decompose, one of the many clear advantages to the invention.

The fertilizer product may be of use in agriculture. The fertilizer produce may be mixed with other nutrients or other matter to make different fertilizer products. The product may be supplied to a factory for further processing. There may be multiple sources of the product which are then further processed at the factory for on sale of the fertilizer product. The product may be produced in liquid form. The liquid may be further processed to dry solids. The end product may be dry or liquid and processed further to a product in a form useful to the end consumer. Most preferably, the liquid is directed to a tank after processing, and the product may then be used in any suitable manner. The product, the result of the processing may take any suitable form. The product may be provided in any suitable state, solid or liquid. Preferably, the product is biologically stable and safe to handle. Preferably, the product may be used directly as fertilizer. In other forms of the invention the product may be further processed into a useful fertilizer product. The product may be the nutrient result of the processing in any form or format. The nutrient result product may be further processed in any suitable way to produce a useful product. The nutrient product may be used in any suitable way, not limited to fertilizer. Preferably, the nutrient product is a beneficial product that makes use of the nutrient as fertilizer.

Preferably, the animals to be processed are dead animal bodies. The animal bodies may be any suitable animal bodies. The animals may be chickens or other poultry corpses. The animal bodies may be chosen from the following group: birds; cattle; chickens; pigs; sheep; or any animal where it is useful to process the body. The animals may be any suitable animals where the invention may be useful for processing. Preferably, the processing is to substantially separate bones from the flesh, cartilage, ligament, fat, etcetera of the animals to enable the nutrient in these tissues to be captured. Preferably, all the nutrient of the animal bodies is processed to a liquid nutrient, excepting the bones. It is envisaged that other processing of the bones may be made. Potentially, nutrient from the bones may also be captured in other forms of the invention.

The animal bodies may be produced from usual food or other animal production. The animal bodies may be the result of a pandemic, for example like H1 N5 or swine flu. It is one of the many benefits of the invention that the resultant product is safe and benign, after processing, and can then make use of the nutrient, which otherwise would be wasted and a biohazard if buried. The animal bodies could be the result of any suitable process. Or the animal bodies may be individual animal bodies, and it is desired to process them to a useful product.

The animal processing may take any suitable form. The animal processing may include a number of steps to process an animal body into a useful product. Preferably, animal bodies are processed through the apparatus to produce a nutrient liquid. The liquid may then be used as fertilizer, or processed into fertilizer. Any suitable steps and processes may be included to transform the animal bodies through to the useful product.

The nutrient product produced from processing the animals may take any suitable form. The nutrient product may be used directly after processing, may be stored or may be further processed. Preferably, a useful liquid fertilizer product is the end result of the animal processing, in a form that is biosafe and stable. Preferably, a significant proportion of the nutrient of the dead animal body is capture in the water resultant of the process. There may be steps of concentration of the resultant product.

Preferably, an operating tank is included. Preferably, it is in the operating tank that the animal bodies are processed. Preferably, the operating tank is used as a hydrolysis bath to break down the bodies. Preferably, the operating tank is a stainless steel tank. The stainless steel may be 5 millimetres thick steel. The tank may be made of any material able to receive the dissolving solution safely. Preferably, the operating tank is a 600 litre tank. Preferably, the 600 litre tank is suitable to process 200 chicken bodies, in a 12 hour processing time. Preferably, 150 kilograms of birds can be processed in a 2 hour time period. Preferably, the invention is scalable up or down to suit particular application with use of bigger or smaller tanks and corresponding volumes of dissolving solution. Any suitable alternative size tank may be used instead. Preferably, the operating tank includes a coating to protect it from the dissolving solution. Preferably, the coating is an alkali impervious coating. The operating tank may take any suitable form or shape as would be understood. Preferably, the operating tank is in fluid communication with other parts of the apparatus through use of controlled valves. The apparatus is very useful to process animals and the size of the tank and other parts of the apparatus may be adapted to suit the numbers of animals to be processed. The process required use of strong alkali solution and so a strong metal tank is preferred, with a suitable protective coating.

The direction of the animals into the operating tank may take any suitable form. It could be as simple as putting the animals in the top but in more sophisticated forms of the invention the animal bodies will be assisted into the tank. The animals may enter the tank, be put in the tank, dropped in or placed in as suits the particular application. In a preferred form animals are directed into the tank from elsewhere when it is desired to process the animal bodies. Preferably, there is an opening or inlet to the operating tank suitable to receive the animal bodies. A flap or chute may be included. The chute may direct the animals within the operating tank. The flap may cover the opening other than when the animals are being caused to enter the tank. The chute may include a spring loaded flap so that animals can enter and the flap then close again. In other forms of the invention an optional conveyor system may be used to direct the animals into the chute and or flap. A control unit may be included to provide the controls to each of the parts of the apparatus. In some forms the apparatus is fully automated and so once turned on the process will occurs controlled by the control unit. Preferably, the operating tank may be covered and may include a lid. The lid may be a soft lid or a covered lid. The lid may be automated to open on operation of the conveyor, or be controlled by a control unit. There may be an opening of any suitable size to allow the bodies to be directed into the operator tank. The operating tank may be configured as a substantially sealed tank. The tank has an entrance for the bodies and controlled inlets and outlets. Preferably, a water inlet is included. Preferably, an outlet for fluids is included. The fluid outlet may include a strainer or mesh arrangement. The resultant liquid nutrient may pass through several stages of filtering of some kind. Preferably, the resultant liquid nutrient is directed to a holding tank.

The animals may be directed into the chute in any suitable way. The animals may be put into the chute, such as from a tractor bucket, or use of shovels or bucket. In another form an opening allows the bodies to enter from a conveyor. The conveyor may take any suitable form. Preferably, operation of the apparatus includes operation of the conveyor to direct animal bodies into the operating tank. The bodies may be placed directly onto the conveyor or the animal bodies may instead be moved from another machine.

The directing can take any suitable form. The directing may be to move from A to B. The directing may be chosen from the group: tipping, pushing, moving or emptying, for example, the animal bodies into the operating tank. The animal bodies may conveniently be put into the top of the operating tank, or can be caused to enter any suitable part of the operating tank. It is also envisaged that there may be multiple tanks, in which case the animal bodies may be caused to enter any suitable tank, before ultimately entering the operating tank with the dissolving solution.

Preferably, the dissolving solution creates an alkali hydrolysis bath to break down the animal bodies. Preferably, the dissolving solution is mixed before use. Preferably, the dissolving solution will be supplied for use premixed to the end user. Alternatively, a mixing of the dissolving solution can occur before use. Preferably, the dissolving solution is an alkali solution of substantially 12 to 14 percent. The alkali may be sodium hydroxide. The alkali may be potassium hydroxide. Most preferably, the dissolving solution includes a blend of sodium hydroxide and potassium hydroxide. Preferably, the dissolving solution includes a blend of sodium hydroxide and potassium hydroxide. Preferably, the blend is substantially a 12. 5 percent solution. Other dissolving solutions may be used instead, in a range of solutions.

Preferably, the processing can be undertaken in 12 hours. The time of processing may be varied. The temperature of processing is ideally ambient temperature as a low cost form of the invention. The processing time may be accelerated by increasing the temperature. Any suitable heating may be included. Heating elements and controls may be included to provide controlled heating to a the dissolving solution to accelerate the process. For example, heating between 45 and 55 Centigrade may be suitable to accelerate the process. Any suitable heating may be used instead. Preferably, temperature sensors and controls to the heating elements are used for monitoring and control of the heating.

Preferably, agitation is used to assist the breakdown of the bodies. Any suitable form of agitation may be used. Preferably, an agitator is included in the operating tank. Preferably, turbulence means are included in the operating tank and operates through the whole process, to move the dissolving solution and contents of the operating tank. Any parts of the apparatus may include a movement or turbulence means to assist movement of the solution in the tank. Preferably, any part of the apparatus may include one or more agitator. Preferably, the agitator includes a blade to move the bodies in the dissolving solution. The blade or blades may stir the water during use to assist mixing, and the movement helps to break down the tissues from the bones. The agitator may take any suitable form. A motor or other suitable power means may be included to power the agitator. Preferably, the control of the agitator is through a control unit. Preferably, the agitator or turbulence means runs throughout the process. Preferably, the speed of the agitation can be controlled. The agitator may run to a program from commencements of the processing.

Preferably, a drain tank is included. Preferably, the drain tank received the processed liquid including the nutrient. The bones or other solids may be removed. Any suitable filter, mesh or separate means may be included to remove solid materials from the processing liquid. Other further tanks may be included such as used for separation of larger parts of the body, not yet broken down. The further tank may be a bone tank. One or more mesh or filter may be included at any suitable part of the apparatus to remove particulates or larger items from the liquid. Preferably, a filter is included and liquid from the operating tank is drained through the filter and larger parts (bones) captured by the filters are separated for further processing. The further processing may take any suitable form. The further processing may be any suitable processing to act on bones. The bones may be acted upon by a strong acid to break down the bones. Where acid, such as hydrochloric acid is used to act on the bones, this part of the processing is isolated from the rest of the operation. Any suitable isolation of parts of the processing may be used for separate processing.

Where the isolated processing is not substantially neutral, dosing is used to return the pH to close to neutral, suitable for use in the product. Where the processing contents is too acid, strong alkaline solutions are introduced. The alkaline solutions may be sodium hydroxide or potassium hydroxide. Any suitable alkali may be used. Where the processing contents is too alkaline, strong acid solutions are introduced. The acid solutions may be any suitable acid. Preferably, one or more dosing tanks are included. Most preferably an acid and an alkali dosing tank is enclosed, each in fluid communication with other parts of the apparatus suitable to provide dosing in acid or alkali to change the pH of the liquid. Preferably, valves are included with the fluid communication to the tanks from the dosing tanks and these are controlled by the control unit. The controls can include manual elements but with use of sensors the control unit is able to automatically dose the tanks as required to provide suitable pH conditions at each stage, as required. Each dosing tanks may contain useful solutions for processing. There may be an acid dosing tank. There may be an alkaline dosing tank. Preferably, control valves are included to enable controlled dosing of alkali or acid to adjust the solution. Monitoring may be achieved through use of sensors.

Preferably, one or more valves are included to control the flow of material from and between tanks. For example, each tank will have at least one inlet and one valve associated therewith. More than one inlet valve may be included. An outlet valve may be included. More than one outlet valve may be included. The processing fluid may be directed through the system in this way, ultimately to a holding tank. For dosing one or more valve may be controlled to apply the contents to a processing or isolating tank. Preferably, the valves are automatically controlled by the control unit, to open and close to control the flow of materials. Solenoid valves or any suitable actuated controls may be used to open and close the valves to allow the flow of the liquid between tanks. Preferably, a control unit is included to control the processing. The control unit may take a usual form with a screen control to open and close each valve as required. The controls may include on, off, conveyor (if this option is included), open and close openings. Valves may control the flow of dissolving solution into the operating tank. The valve controls may control entry of dissolving solution to the operating tank. The additives may be introduced separately to the water so that water only is introduced at this step. Preferably, the control unit may be mounted close to or on the apparatus. Or the control unit may be remote to the apparatus. Any stage of the flow of the processing liquid, from the introduction of the dead animals to the resultant end product may be controlled through use of the control unit. Some manual safety controls and other controls for manual control of the flow in the case of loss of power, for example, may be included as well.

Acid or alkaline dosing may be controlled through opening valves to allow the dosing from the tanks. Manual introduction of the materials to increase or decrease the pH may be used instead, in an inferior form of the invention.

Preferably, one or more sensors are included. Any suitable sensors may be included. Preferably, a plurality of sensors are included. Preferably, a pH sensor is included. Preferably, a pH sensor is included in the operating tank. Preferably, a pH sensor is included in a drain tank.

Preferably, temperature sensors are included. The operating tank may include a temperature sensor. Preferably, a drain tank includes a temperature sensor. Where heat elements are included these temperature sensors may be linked to the controls from the control unit, so that a suitable temperature can be achieved. The controls may be set to heat the water to any suitable temperature. Use of the ambient water temperature, particularly in hot countries, may be sufficient in any case. The temperature may be 45 to 55 degrees centigrade to accelerate the alkali hydrolysis process. The heating is optional. Heating elements may be included. Heating elements may be included in the operating tank. A drain tank may include a heating element. Heating may be controlled from the control unit or through a separate control.

The useful product may take any suitable form. Preferably, the product is a nutrient rich solution. Preferably, sensors are used in communication with the control unit to adjust the characteristics of the resultant product. While a substantially neutral product is useful, it could be possible to produce an acid or alkaline product in alternate form. Preferably, the nutrient rich solution is useful as a liquid fertilizer. It is anticipated that the liquid product can be concentrated and the liquid removed so leave a resultant solid or dry product for use where this may be useful. Liquid products can be readily stored or transported through use of tanks and may also be preferred. Preferably, the product is a liquid fertilizer, ready for use. Preferably, the liquid fertilizer is separated from other parts of the process in a state suitable for use. Further processing may be included, such as refinement of the product to be fertilizer product. The product may be raw product that requires further refinement to a fertilizer product. For example, the fertilizer may be concentrated. The liquid fertilizer may be processed into a dry product, for ready transport. The end fertilizer product may take any suitable form. Other additives may be added to the fertilizer product before use or sale.

Preferably, the system is an alkali hydrolysis system to covert dead bodies to a fertilizer product ready for use.

Accordingly, the present invention provides in a variant, an animal processing apparatus to produce liquid fertilizer for use as fertiliser, the animal processing apparatus including: an operating tank into which animal can be directed for processing; a dissolving solution, which can be caused to create an alkali hydrolysis bath to act on the animals in the operating tank and to break down the tissues to release nutrients; and a resultant product, wherein the animals are processed to break down the tissues and produce the product, which is suitable for use as a liquid fertiliser.

Most preferably, the animals in this variant are poultry. Any suitable animals may be used instead.

Accordingly, the present invention provides a method of using an animal processing apparatus, the apparatus includes an operating tank with turbulence means, a dissolving solution and resultant product, the method including the following steps: a. add the dissolving solution to the operating tank; b. start the turbulence means to move the dissolving solution within the operating tank; c. introduce the animals into the operating tank; d. process the animals for time until the animal has been broken down; e. separating any bones or other larger parts; and f. to producing a nutrient rich resultant product.

The steps may be performed in any suitable order. Preferably, there is a further step of making up the dissolving solution before introducing the animals. Preferably, heat may be included to accelerate the alkali hydrolysis. Preferably, use of ambient temperature water and air is sufficient for the process, being most cost effective. Preferably, the turbulence means is running before the animal bodies are introduced. The turbulence means may be replaced with any suitable agitation. The turbulence means includes blades to move the contents of the operating tank. The heating step may be omitted in inferior forms of the invention. Most preferably, the animal bodies are processed before introduction. The processing of the animal bodies may include any of the following: chopping; cutting; mashing; mincing; shredding; or any combination thereof. The resultant product may be pumped to a tank, or elsewhere for storage or further processing. The resultant nutrient product may be suitable for direct use. Or a further step may be included of further processing of the product, to produce the useful fertilizer product. Further processing may include any suitable processing to make the fertilizer product useful. The fertilizer product may be provided as liquid fertilizer, pellet or solid fertilizer. Any suitable pump and tank system may be included.

Preferably, sensors are included. Preferably, sensors are included with monitoring and controls to assist correct operation of the apparatus. The sensors may be used to detect pH, and or temperature. Preferably, the sensors may be used to correct the pH and or temperature of the resulting solution to substantially neutral. Shredders or other additional mechanisms may be included to assist to break down the animals before processing.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described in connection with a non-limiting preferred embodiments with reference to the accompanying drawings, in which: Figure 1 is a schematic view of an animal processing apparatus according to a first preferred embodiment of the invention, with the animal bodies omitted for ease of illustration;

Figure 2 is a schematic view of an animal processing apparatus according to a second preferred embodiment of the invention, including the chemical storage , and storage tank, and the chickens are omitted for ease of illustration;

Figure 3 is a schematic left side view of the animal processing apparatus of Figure 2, with the chemical storage and storage tank omitted;

Figure 4 is a plan view of the animal processing apparatus of Figure 3;

Figure 5 is a front view of the animal processing apparatus of Figures 3 or 4; and

Figure 6 is a rear view of the animal processing apparatus of Figures 3 to 5.

DETAILED DESCRIPTION OF THE DRAWINGS INCLUDING A BEST MODE

Referring to Figure 1 , a first preferred embodiment on the invention will be described, where animal processing apparatus 1 , has operation tank 10 with chute 14 and spring loaded chute flap 16 for introducing the animals to the processing. The animals themselves, typically chicken corpses, are not shown for ease of illustration. The apparatus can process any kind of animal, and the apparatus can be adapted larger or smaller to accommodate the size of material to be processed.

The corpses will be introduced to the apparatus by being put into chute 14 through the spring loaded flap 16, from a tractor bucket. In other forms of the invention a conveyor may be used instead. Liquid 18 is the dissolving liquid and the level is indicated on the drawings into which agitator unit 20 extends. Agitator unit 20 includes motor 22 and blade 24 which directly contacts the dissolving liquid with the chicken bodies.

Operating tank 10 can take any suitable form but is shown as a large 600 litre capacity stainless steel tank. Tank 10 is made of a 5 millimetre thickness of plate steel, coated internally with an alkali impervious coating. Operating tank 10 has ample room to receive the chicken bodies and the processing liquid together with room for moving around sufficiently, without being overly full. Operating tank 10 has inlet 26, connected to a water supply from fresh water inlet 28 controlled by water supply valve 29. Other components of this system as can be seen in Figure 1 include 3-way valve 30, stop valve 32 to a storage tank (not shown) and stop valve 34 to operating tank 10. System pump 37 is included to provide the pump action towards the storage tank and other parts of the system as required. Mesh strainer 42 and operating tank drain 44 strains out the bones and larger parts between operating tank 10 and drain tank 48. These bones can be removed, or removed for other processing as suitable.

Other parts of the system include level switch labelled “L” for the level of the liquid in the operating tank 10. Also sensors labelled “P” for pH sensors and “T” for temperature sensors. Not all of these sensors are labelled and the particular position and number can be varied as appropriate. Each of the level switch and sensors for pH, and temperature provide information to the monitoring and control system as described further below. Each of external heaters 56 and 57, is positioned each in operating tank 10 and drain tank 48 to heat the internal liquid if required. Once the processing has finished drain tank drain valve 58 can be opened to enable the nutrient product to be pumped to the storage tank (not shown). Other features include alkali dosing tank 64 and acid dosing tank 66.

Operating tank drain 44 leads to drain tank 48. Sensors are included throughout the apparatus, some of which are labelled “L” for a level sensor, “P” for pH sensor “T” for temperature sensors, others may be included as would be understood.

External heaters 56 and 57 are included as optional heaters to heat operating tank 10, and drain tank 48. Drain tank valve 58, alkali dose tank 64, control valve 66 for the alkali dose tank, and likewise acid dose tank 68, with control valve 70 are shown. Activated charcoal vents 72 are included in the apparatus and one is labelled 72, the central vent is not labelled but provides the same vent for the drain tank.

Control unit 74 is included to turn on and off the various valves that control the shut off or release of the liquid flow in the system, to control the input and movement of water from any one part of the apparatus to any one other part as required. It is intended that the system will be an automated system once the process is commenced so that the operator can turn on the apparatus and it will run until the liquid fertilizer product is produced. Use of sensors and automatic solenoid valves enables movement of the nutrient rich liquid to the holding tank for use as liquid fertilizer once the process is complete, the pH neutralised and the solution cooled. It is important that after the animal body has been broken down that the resultant product is cooled and neutralised to be suitable for use as a fertilizer. A manual form of the apparatus could be used instead, with the operator opening the valves to move the water in and liquid through the system as each stage completes, again using the sensors.

Therefore, in use animals are put through flap 16 in chute 14 with or into the dissolving solution of a strong alkali solution a blend of sodium hydroxide and potassium hydroxide blended at substantially 12.5 percent, of pH substantially 14.0. It is intended that the alkali will be provided in a premixed solution for ready use. Control unit 74 can be operated to start the process, agitator blades 24 causing movement powered by motor 22, to churn the dead bodies in operating tank 10, accelerating the process. Where heat is used heating element 56 can be controlled to heat the water to the predetermined range of 45 to 55 Centigrade. Feedback from sensors P and T provide information on pH and temperature and monitoring so these factor can be adjusted as required, preferably automatically by the control unit.

As the strong alkali solution and movement act on the bodies the tissues are broken down until the nutrient is separated from the bones. Use of dosing tanks 64 and 68 can be used to increase or decrease the alkali and acid in the tanks. Water can be introduced to dilute the solution and for washing. Drainage through mesh strainer 42 captures the bones and any large pieces, before draining through operating tank drain 44 to drain tank 48. Drain tank 48 also has pH sensor P and T temperature sensor, and heating element 57 and each of these can measure and report the conditions in the tank. Once the end product has been adjusted it can be stored as a biostable and neutral product, suitable for use as a fertilizer. The concentration of the liquid product can be increased by increasing the heat through use of heat element 57, before storage in the storage tank.

Chute 14 is designed to readily receive the dead corpses, and flap 16, closes after the corpses to prevent debris, or odour to leave operation tank 10 during use. A hard lid could be used instead, with an opening and closing mechanism. In other forms of the invention the chute, flap and a conveyor could be used for automated. It is most preferred to have a fully automated system whereby the operator can start the process with the chickens introduced to the conveyor and no further controls are required and liquid fertilizer is produced at the other end ready and safe to use.

Drain 44 lies below operating tank 10 with a 203.2 millimetres (8 inch) valve to allow or prevent the flow of water from operating tank 10 to drain tank 48. After the initial process, the tissues and bones can be separated, with most of the nutrient passing into the water. The nutrient rich water can flow through passing straight through from operating tank 10, through drain 44 and through mesh strainer 42, valve 44 101.6 millimetre valve (4 inch). Bones and any large bits of body for some reason not broken down will captured by the mesh 42 and prevented from passing into what will be the liquid fertilizer. The utilisation of the mesh and strainer will differ from animal to animal and will be varied to suit the particular application.

Drain tank 48 is carefully monitored from the control in order that the nature of the end product can be controlled. Drain tank valve 58, is positioned below drain tank 48 to pump 37, back to 3 way-valve 30, to take to a holding tank (not shown). The holding tank will hold will be a standard tank, useful to be readily filled, stored or transported.

The animal processing takes place in the operating tank 10, with a working volume of 600 litres water, and agitator 20 to create strong turbulence in the mixture. Heater 56 assists the chemicals in dissolving the flesh, ligament, feathers, beak, fat, organs of the animals, bone is not dissolved during this process. On completion of a cycle of 150 kilograms of birds over a 2 hour span the remaining content of the tank is larger bones and the liquid protein which are the remains of the animals, the bones are completely clean of flesh and ligament.

Depending on the number of animals being processed the tank has an operating water level of a size compatible with the animal load, approximately 2.5 litres water per 1.8 kilogram bird and an alkali charge of around 1 litre to 70 kilogram per animal. During operation the birds are mechanically broken down in the first 20 minutes from contact with the agitator. After further 15 minutes the feathers are gone and flesh is dissolving, 15 mins later muscle is noticeably reduced. At 1 hour mark most muscle is gone, ligament and cartilage as well as fatty tissue and feet are dissolving. It is most advantageous in the subject invention that a novel combination of a strong alkali solution, turbulence in the tank, with optional heat to reduce the bodies to tissues in solution, separated from the bones.

In colder zones, an external heating tank can also be used to preheat the water for the process, once the water is drained into operating tank 10 the heating tank is refilled and reheated to approximately 50 Centigrade. At the end of each cycle experience has shown some removal of bone residue in the tank bottom is beneficial. The Alkali solution in the prototype is capable of processing 2 cycles of 150 kilograms of chickens before the solution is saturated and needs to be changed out. At the completion of 2 cycles the pH in the nutrient is around 11 to 12. The solution is then pumped to a holding tank with a submersible macerater pump via valve at the bottom of the tank, the valve is to be shut when the tank is empty. It is not critical to fully empty the last residue from the tank as it will not have detrimental effect on the following cycles. If there is still a large quantity remaining it has to be cleared from the tank.

The process may be summarised:

1 . Cycle 1 Start;

2. Load water into tank to the level marker within the tank;

3. Load chemical at quantity required, Ensure correct Ph in mixture;

4. Start agitator;

5. Load birds from the sized hopper for the size of the machine;

6. Start heater on set temp required;

7. Ensure machine runs with no undue noises or vibrations; and

8. Check progress after 20 minutes and if good recheck in 2 hours.

The operating tank is made of 5mm plate steel, coated internally with an alkali impervious coating of 2 pack paint. The larger capacity operation tank 10 are designed for loads of up to 150 birds 3.5 kilogram chickens per cycle, the cycles will still take around 2 to 3 hours processing time. On the larger systems a macerater/shredder will reduce the whole animals to much smaller size and smash the bones prior to being put into the water/chemical mix. The process can be used for any animal however the tank size, agitation system, heating, chemical quantity will vary dramatically.

There is a relationship of bird weight, water capacity, chemical charge, liquid turbulence and temperature that remains fairly constant. The smaller the animal particle size can be made by prior mechanical shredding, the better the system works and the quicker the time taken to achieve the liquification of the animal. The animals are fed into the operating tank via a chute/hopper at the front end of the tank operating tank 10. The size of the hopper is worked out to provide the operator a clear indication of when the volume of animals is correct for that particular tank size. The inlet chute into the operating tank 10 will be a stainless steel 2mm spring loaded non-return flap to allow animal carcasses into the operation tank 10 and prevent odour and liquid escaping the tank The chute is sized to hold the volume of bird carcasses for that machine, allow them to enter one at a time through an opening by gravity, past the non- returnable flap into the macerater/shredder and dropping into the solution in the tank. An arrangement will be fitted to prevent access to the unit and injury to the operator during loading the animals are to be fed into the hopper/chute by a tractor bucket or similar. Initially a full mechanical system will be utilised for all operations.

The dissolving solution is a hydrolysis bath of either Sodium Hydroxide NAOH, Potassium Hydroxide H2SO4 blended at between 12.0% to 14% or a combination of the two, at 12.5% solution, PH target 14.0 and temperature between 45 and 55 Centigrade.

The alkali will be supplied to the farms in a 1000 litres storage tank (IBC) fully premixed and fed into the tank via a measured container or automatic dosing unit to the qty required so the operator never comes in contact with the chemical.

Prior to loading the animals the temperature and pH will be at the correct operating parameters listed above. However, during trials there were occasions where the temperature was well below to optimum and still performed well.

Agitation is used to assist the breakdown of the bodies and prevent boundary layering during the process. The agitation initially causes mechanical quartering of the birds in the first 20 minutes and then assists in continual erosion of the flesh by the chemical. The agitator will run once the carcasses are loaded and continue to the end of each cycle, then turned off. The agitator is designed to run continually during the cycle.

Approximately 5 to 15 kilograms of bones will settle in the operating tank 10 during the 2 cycles. Bones residue will be removed with a supplied rake and any remaining will be macerated by the suction pump as the liquid is pumped to the holding tank. The tank chemical supply may be gravity feed or eventually feed with peristaltic pump and pH and temperature is monitored on the operating tank 10 during each cycle. Heaters will be controlled automatically and agitation will run during the entire 2 cycles. The nutrient rich solution will be pumped into IBCs or large holding tanks and sent away for further treatment as a liquid fertilizer. At this point the liquid is pathologically benign and so beneficially safe for further use. Most preferably, the product is a liquid fertilizer, ready for use. Preferably, the liquid fertilizer is separated from other parts of the process in a state suitable for use. Further processing may be included. For example, the fertilizer may be concentrated. The liquid fertilizer may be processed into a dry product, for ready transport. The end fertilizer product may take any suitable form. Other additives may be added to the fertilizer product before use or sale. Preferably, the system is a hydrolysis system to covert bodies to water and fertilizer ready for use.

The corpses will be introduced to the apparatus by being put into chute 3, until all the birds are in the tank. Operating tank 10, is basically a rectangular steel tank which is fully insulated externally to hold in heat. It is coated internally with 2 pack paint to prevent corrosion. The tank total volume is a given size for a given weight of birds. As shown the total volume was 1400 litre capacity and working volume of 600 litres of water. There is a level marker visible through the inspection door to indicate the correct water level in the tank. To this was added roughly 150 litres of birds and approximately 15 litres of chemical.

The apparatus comes from primarily the chemical and agitation assisted by the optional heat. On completion of 2 cycles trial have shown pH around 11 and is what the liquid will remain in the storage tank, till its treatment elsewhere. This is to prevent bacteria growing in the mix. Agitator unit 20, is a 3 phase motor driving through a reduction gearbox to a 4 blade propellor to provide strong turbulence to the mix at 180 RPM. The shaft is supported by a plastic bush withing the tank and a roller bearing beneath the reduction gearbox.

Chute or hopper 14 is used to feed animals into the unit via a shredder (not shown). Chute 14 is sized to the unit to indicate simply to the farmer the correct amount of birds for a cycle. Animals at the level of the top of the hopper, correct, under the top, too little, above the top of the hopper, overloaded. The hopper is designed to be able to accept at least 1 tonne of birds, it is supported by 4 sturdy legs and may have hydraulic jacking to lift one end to assist in feeding the birds into the shredder which mounts directly below the hopper on the top of the operating tank 10. A shredder is included to mechanically reduce the full bird to smaller parts with tearing action of the shredder, further all bones will be broken allowing full chemical penetration of the bone thus dissolving any protein within the bone. The shredder will only run while the birds are being loaded into the operating tank 10. Optional heating tank may be included for colder zones of the country where we found the operation tank 10 heater was struggling to get the water to temperature. The idea is the tank will supply a full charge of water to the operating tank for two cycles. It is immediately refilled via a float valve and heater is turned on to get the temperature up for the next run in 5 hours. There may be a small circulating pump in this tank. The tank will be fully externally insulated.

Chemical IBC, can be used for chemical storage of the premixed solution. Similar storage can be used for the resultant product. If a chemical tank is used it would hold 1000 litre of chemical, and can be fed to the operating tank 10 via a sized gravity tank or a pre-set dosing unit. Operating Tank Heater 56, is an A 3 phase heater to hold the liquid at or near the required temp of between 45 and 55 Centigrade, it is thermostatically controlled and supplied from the control box on the operating tank 10 top.

System pump, 37 is a submersible macerater centrifugal pump to remove liquid from the tank after the second cycle. It has a macerater (not shown) to pulverise any small bone it is likely to pick up during the process of clearing the tank. Storage tank, not shown, is used to store the liquid pumped from the operating tank and hold it till a tanker pumps it and takes it to deliver to the fertiliser batching plant at another location. A bund is included to prevent leakage and may surround the whole apparatus, as a safety measure.

Chemical inlet valved, are included fitted to allow chemical from the chemical storage via the delivery system into the operating tank 10, open for transfer and shut when operating is operating. Water inlet valve 28, fitted to the top of the operation tank 10 to allow water in, this water can be from the heater tank or from cold water supply in hotter climates (open to fill, shut to run operating tank 10).

Storage tank isolating valve 32 is used to allow liquid protein from the operating tank at the cycle end and isolate the storage tank when the transfer is finished. The valve may also be where the protein is pumped to the tanker. System pump 37 to allow suction pump to suck from the operation tank 10 at the finish of the cycles (open to operate and shut on completion).

An inspection door is included, a hinged door at the top of the operation tank 10 to allow inspection of the inside of the operating tank, sized so it is impossible for the operator to accidental falling into the unit. Vents are fitted to allow pressure fluctuations within the tank.

Control Box 74 has electrical switching for all the above items with an emergency stop function, supplies of both 415 3 phase and 240 AC single phase providing power. The apparatus as illustrated is set up to process dead poultry, but could be used for any suitable dead animals. The apparatus would need to be adapted in size and volumes to accommodate larger animals but the apparatus may be used for any animal, but specifically poultry. The apparatus will work as well for small as large animals as the materials to be worked on to release the nutrient to liquid are the same, however, some adaptation may be required if processing a single large animal, perhaps a dead cow, when compared to processing several hundred mice corpses. The apparatus and method are versatile and may be adapted accordingly.

The illustrated apparatus 1 , is suitable to process 150 dead chickens in 600 litres of water in a 1 -2 hour period, and this may be repeated, or run continuously or repeatedly as required. When scaled up, a larger tank, or a plurality of tanks, are used with greater volumes of water and additives to process the greater volume of dead bodies and dissolving solution. The time taken to process the bodies in the hydrolysis bath should be around the same to process the animals to the useful product as described. The speed of the process may be altered as needed by increasing or decreasing the temperature. Using higher temperatures would be the most cost effective and use less resources for the process, desirable for chicken producers. A longer time period could be used for larger animals if needed or a greater level of additives, temperature and agitation combined if the process was needed to be sped up. For processing larger animals may require pre maceration of the body.

The apparatus can break down the tissues and bones to a soup like liquid. Drain tank 48 is carefully monitored from the control in order that the nature of the end product can be controlled. Sensors are included, pH sensor P, temperature sensor T, and external heaters 56. Suction valve 58, a 101 .6 millimetre valve (4 inch) suction valve is positioned below drain tank 48 to suction fluid through system pump 38, back to 3 way-valve, to take to a holding tank not shown. The holding tank will receive the water from the drain tank which is clean water with corrected pH after the bodies have been processed. In order that the pH is corrected back to neutral and any potential pathogens addressed pipes 60 and 62 from dose tank 64, via valve 66. It should be noted that dose tank 68 is used for inputting hydrochloric acid to act on the bones in the bone tank 40, via pipe 70. It is through adding materials to correct the pH and treat the water that the resultant water is suitable to be used again from the holding tank to further process new bodies. Again all controls are operated through use of the usual control unit controls, at a central control.

Referring to Figures 2 to 6, a second preferred embodiment on the invention will be described, similar to the first, and with a similar method of use. As shown in Figures 2 to 6, animal processing apparatus 101 , has operation tank 110 where all the animal processing will take place. Operation tank 1 10 has agitator unit 114 within for creating the agitation to assist the “digestion” of the animal bodies in the chemical liquid. Animals are put into operation tank 1 10, via hopper 1 16 which leads into shredder 1 18 in order that the pieces are broken up ready for digestion. The particular needs of the animals to be processed can be varied through use of different levels of shredding of flesh or breaking up of bones, as would be understood. Heater 120 and chemical IBC tank 122, and suction pump isolating valve 124 are included, with suction pump 126 and storage tank 128. Bund 129 is included to capture any excess. Door latch 130 allows access.

Valves are include, including water inlet valve 132 and storage tank isolating valve 134. Tank vent 137 is included, as well as base supports 142 and hopper supports 144. The whole operation can be controlled manually or through remote controls to control box 148. Water filling of operating tank 110 is via water inlet 150. Storage tank isolation valve 152 is included, as well as pH test and sample point/sensors. Loading door 156 is included as well as door power shut off switch 158.

To start the process 150 kilograms of whole birds are put into hopper 1 16, either by dropping direct or through use of a conveyor to drop the animals in. Where the animals are larger an individual animal can be placed or lifted into the tank one at a time. As illustrated the chicken bodies are put in hopper 116, and pass to shredder 118 a shredding unit to break down the bones and physically break the birds into smaller pieces. It is important to the bones are smashed or broken open to allow the chemical access to the internals of the bones which ensures any bacteria or viruses are destroyed by the alkaline liquid. With larger animals however, mechanical smashing of the bones can be used before putting the animals into tank 1 10 or through a stronger crushing mechanism on the way to operating tank 110. System details

The operating tank, item 110, is made of 6mm plate steel, coated internally with an alkali impervious coating of 2 pack epoxy paint. The tank is 2.2M in length, .94M wide and .94 M high, it has a total volume of WOOL. The working volume in the tank is 650 L at start up before animals are introduced. On completion of the first cycle the liquid volume increases to approx 800L and after the second cycle is approx 1100 L. The tank total volume is sized to allow expansion of the liquid during the heating of the water and to be able to accommodate the foam produced as the fats and oils saponify.

To fill the tank with water, a 1" ball valve, is fitted to the top of the tank at the rear, the filling operation is manually done. The correct level is displayed by a titled plate welded to the inside of the tank. This is a manual operation.

The chemical is loaded from the storage 1000L IBC through a clear plastic hose into a measured capacity tank 122, and when full the supply is shut and the discharge to the OT opened. This is done to prevent the user coming in contact with the caustic chemical. This is also a fully manual operation.

Heating, 120, the water can be done prior to operation, or after if the ambient temperature is in the mid 20s. The element is an immersion type for use in acidic or alkali liquids, of around 4kW. The heater is on for the duration of the both cycles and automatically keeps the temperature at the required setting.

The Agitator, 114, is a 2kw 3 phase motor driving through a reduction gearbox to give an output speed of 180 RPM to the four bladed 500mm diameter propeller which sits approximately 300 mm off the tank bottom, vertically .

The agitator provides continual turbulence in the liquid so that the chemical has total access to the protein. It also acts as a hammer mill in effect as the blades continually hit any parts of the bird in the early parts of the process, smashing bone and tearing flesh till after about 45 minutes only there is nothing of size that would indicate it had been a chicken.

The hopper, 116, is sized to an approximate volume of the load of birds the tank can handle and is made to support this weight. The hopper is shaped and angled to allow the birds to slowly, automatically slide down into the shredder via gravity, then uot through the loadinf door, item 9. The hopper is made of 2mm steel sheet coated in epoxy paint.

The hopper has a safety grid with a shut down switch to prevent injury to an operator who opens the grid during shredding, if the safety grid is opened the shredder stops .

The shredder 118 is fitted to reduce the size of the animal to help reduce the process time, the smaller the animal parts the quicker the process time.

During the shredding there is a flow of water to asist in the animal's bodies and feathers falling into the OT, this is a small bore pipe spraying water into the hopper from the top edge of the hopper downward into the bird mass.

There is an inspection door 156, fitted at the front on top of the tank on the left side to allow access into the tank for maintenance. The door has an electrical cut out switch if the door is opened to prevent the Agitator from running.

A Ph sensor 154 is fitted on the left wall of the tank and a small valve is fitted to sampling of the liquid.

An activated carbon filter is fitted to a vent mounted at the rear , on the tank top on centreline to absorb any process odours.

A control box 148, is mounted on the top of the tank with all the switches contactors, fuses and indicators for the operation of electrical items on the tank .

Once two cycles have been carried out the liquid in the OT is pumped with the suction pump 126 through the isolating valve 124 to the storage tank 156 through valve item 152.

This digestor is capable of dissolving 25000kg of chickens with 1000L of chemical, a very cost effective method of treatment compared to the current requirements.

The machine can do a 3 hour run with a twenty minute break to load and macerate the second load of animals then do the next run of 300Kg ad infinitum.

The machine can run almost continually, with minimum amount of maintenance. . The unit is designed to be used undercover so the elements cant damage the insulation or electrics.

The loading hopper/shredder has a sealed loading door alongside to keep the tank sealed during the cycles.

Safety cut outs and other design features are fitted to prevent operators, coming in contact with the chemical, or any rotating components or cutting/macerating items.

The dissolving solution is a hydrolysis bath of one or a combination of any of the 32 known Hydroxides, at 12.5% solution, PH target 14.0 to 12.5 and temperature between 45 and 70C. The Alkali will be supplied to the farms in a 1000L IBC fully premixed and fed into the tank via a measured container or automatic dosing unit to the quantity required so the operator never needs to come in contact with the chemical.

The process time will be approximately 3 to 3.5 hours depending on ambient air and water temperature which will effect the water heating time. The PH at the start will be 14.0 and at the finish close to 11 .5. The time to refill the OT with water will be dependant on the farm's water supply. The chemical filling time is two minutes. Loading the birds into the OT will be around 30 Mins total. Agitation is on for the whole process including loading the second cycle of birds.

Approx 5 to 10Kg of soft shattered bones will settle in the OT during the 2 cycles .

Bones residue can be removed with a supplied rake and any remaining will be macerated by the suction pump as the liquid is pumped to the holding tank.

The system may have any level of automation, including but not limited too, Chemical filling, Water filling, loading of animals including maceration, Closing of filling shute, starting and stopping of heating, running and stopping of agitator, check of Ph, Level sensing, Stopping process on completion, Opening suction valve and pumping liquid protein to storage tank, Refilling in preparation for next process. It is most likely that later versions of the system will be an automated.

The tank chemical supply may be gravity feed or eventually feed with peristaltic pump automatically at the start of the first of the two cycles. Heating will be controlled automatically with a temperature sensor directing a controller within the heating system to keep the OT within the correct range.

The nutrient rich solution will be pumped into a large holding tank and sent away for further treatment to turn it into a liquid fertilizer. At this point the liquid is biologically benign and will remain that way till neutralised prior to treatment.

The liquid protein at the end of the cycle 2, is left at Ph 1 1 .0 to 11 .5 to prevent purification and stowed in the storage tank at this Ph. Our experience has shown the liquified protein will keep for a long time without purification if kept at a high Ph. Sensors and controllers are fitted to ensure correct operation of the unit.

Equipment Details

Operating tank 1 ) is basically a 2M long rectangular tank with a widh of 2.5M and a height of 1.2M.

Its total capacity is 1900 L with a normal liquid volume of 600 L which equated to an internal level of .5M

The Agitator Propellor 1 14 will be at a depth of 300mm above the tank floor, where it will continually provide destructive contact to the birds remains ensuring the flesh is initially torn from the body as well as defeathering the carcass.

As the process continues the liquifying protein is washed from the bones and the more strongly attached proteins ligaments etc, are also liquified.

The Operating tank, 110 is of 6mm plate steel with 2 part epoxy paint coating internally and and insulated externally with foil covered foam of rubber.

The tank is designed to process 300kg of birds in two operations evey 3 to 3.5 hours.

The water capacity is 650L or fresh water of reasonable quality, filled from the farm via valve item 124.

The chemical dose for each run is 12L which is manually admitted to the tank though valve, 122 at the rear of the machine.

The operator should never come in contact with the chemical if the machine is used as instructed. The tank when fully loaded with animal, water and chemical has ample room within so overflow should not occur.

As the liquid heats up its volume increases and during the process soap is produced causing foaming in the liquid which further increases the liquid level.

The control unit, 148 is where the heater is controlled, the Agitator 1 14 is turned on and off, the Shredder, 118 is started and stopped, and the Suction pump 126 is controlled. Three phase power will be supplied from the farm to the control box 148.

The shredder, 1 18 is a series of rotating blades designed to cut the animal flesh and smash the bones to reduce the size of the animal particles which allows the chemical mix to dissolve the protein in the fastest possible time. The importance of smashing the bone is to ensure the chemical can access the inside of the bone to kill any biology within the bone, including bacteria or viruses.

The Hopper 1 16 is sized to contain the correct quantity of dead birds so as not to saturate the liquid in the tank during the process. There is a reasonable margin of water reserve regarding this.

The apparatus as illustrated is set up to process dead poultry, but could be used for any suitable dead animals, including all ruminants, fish, dead plague swarming insects, mice plagues, even veterinary killed animals. The apparatus would need to be adapted in size and volumes to accommodate larger animals but the apparatus may be used for any animal.

The apparatus will work as well for small as large animals as the materials to be worked on to release the nutrient to liquid are the same, however, any animal larger than a chicken or with a strong bone density will require maceration to smash bone and reduce particle size for the fastest process time to be achieved

The illustrated apparatus is suitable to process 300Kg dead chickens in a 1900 litre tank with an operational liquid volume of 650L, in a 3 hour period, and this may be repeated continuously as required.

When scaled up, a larger tank, can be used with greater volumes of water and additives to process the greater volume of dead bodies and dissolving solution. Process Time

The speed of the process is not designed be altered. The concept is the animal is to be reduced in size physically by smashing the flesh and bone on entry to the operating tank. The only variables would be to reduce the heat or to make the animal particles larger, both of which are inefficient use of the system.

Chemical strength

The standard strength and quantity of the chemical charge is designed to liquify the protein in the tank in the fastest time.

The Ph will drop off to around Ph1 1 toward the end of the cycle but its remaining reserve of work available is still good.

The other component involved with this is never allowing the saturation point of the water to be reached as this would stop the process. If this occurred, and we have tested it, more chemical alone is useless, more water would allow more liquifying but at the cost of process interruption, more heating, lost time and possible over filling of the tank.

So there is a balance here with the chemical Ph, chemical reserve at the end, and the importance of all protein being liquified before saturation point is reached.

By design there is ample alkali reserve and water capacity to absorb the nutrient as the birds are liquified.

Such is the turbulence in the tank there is never really anything floating on the top of the liquid. The propellor action keeps everything within the liquid in continual and relentless, non laminar mass of disturbed liquid so no dead zones can ever form ensuring rapid liquifying of the animal protein.

The temperature can be increased to a maximum temperature of 45C, to accelerate hydrolysis and break down of the birds. Higher temperatures can be used depending on the hydroxide solution being used.

To accelerate the process further, the corpses in liquid are agitated to facilitate the break down and separation of the body tissues and bones. Agitator unit 1 14 includes a 3 phase motor, drive shaft, support bearings and blades The agitator will have a 4 blade propeller with an operating diameter of 500mm, at 180 RPM the agitation prevents heavier soft tissues settling at the bottom of the tank breaking down the carcasses by contact and preventing dead flow zone within the tank and boundary layering on the carcasses.

Activated Carbon filter/ vents 16 is fitted to the OT to relieve any internal pressure within the tank during operation.

The activated carbon will absorb odours form the process during operation

Explanations

Process,

Where 150kg of shredded chickens is placed in the OT with 600L of heated water at 45C, with 12L of chemical with the agitator running providing the necessary turbulence in the tank to liquify all but the bones of the animal in a time of 1 .5 hrs.

At the end of the 2 cycles, the combined water, chemical and liquid protein of approx 1200L remains with a bone residue of approx 10Kgs

Macerater/ Shredder

Device to smash the bones and shred the flesh at entry into the OT, either word explains the same process.

In this way the clever new streamline apparatus can be used to quickly break down the animals and to enable the nutrient to be released.

The automated processed enables processing of the bodies completely, breaking down soft tissue, feathers, claws, and bone, into a nutrient rich liquid fertilizer. Incineration of the birds would destroy the bodies and any pathogens, but would also waste potentially useful nutrients, the carbon dioxide and aerosol emissions have led to this practice being unfavourable as opposed to a nutrient which as liquid fertilizer can be used instead in the garden, or be sold. The new inventive system is designed to use only a low energy input, recycle water and produce only minimal additional waste and so is also economic to run as well as environmentally friendly. The subject invention is likely to be very well received by the animal producers and the community at large as a much better solution to the problem, meeting the regulations and producing a useful product for use or sale. The automated processed enables processing of the bodies completely, breaking down soft tissue, feathers, claws, into clean water and a nutrient rich liquid fertilizer. Incineration of the birds would destroy the bodies and any pathogens, but would also waste potentially useful nutrients, which as liquid fertilizer can be used instead in the garden, or be sold. The new inventive system is designed to use only a low energy input, recycle water and produce only minimal additional waste and so is also economic to run as well as environmentally friendly. The subject invention is likely to be very well received by the animal producers and the community at large as a much better solution to the problem, meeting the regulations and producing a useful product for use or sale. INDUSTRIAL APPLICABILITY

The apparatus can be manufactured industrially and supplied to users, direct or through intermediaries.

It will be apparent to a person skilled in the art that changes may be made to the embodiments disclosed herein without departing from the spirit and scope of the invention in its various aspects.

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