The first question that determines the steam boiler in the chicken slaughterhouse is: is there rendering (feather, blood and visceral meal) in the facility? The same 9,000 birds/hour slaughterhouse requires a steam boiler of 3 t/h without rendering and 8 t/h with dry rendering; the boiler pressure also increases from 6 bar to 10 bar. In the slaughtering facility alone, the peak load is determined by the first filling of the boiling boiler and the cleaning window at the end of the shift rather than production; the hot water tank reduces the cleaning peak to one third. The Çiftel Kazan wizard calculates these loads separately.
Which machine draws how much steam?
| Machine | Typical capacity | Vapor / heat | Pressure |
|---|---|---|---|
| Scalding kettle, direct steam | 9,000 birds/hour, 53 °C, 3.5 min, 1 L/bird supplement | operating 815 kg/h (567 kW) · first filling 1,086 kg/h | 2 bar g (4 bar g with heat exchanger) |
| Scalding the foot (trotter) | 9,000 birds/hour, 60 °C | 188 kg/h | 3 bar g |
| Blade sterilizer, 82 °C | per piece | timed 4.7 kg/h (2.8 kW) · continuous flow 17.6 kg/h (10.6 kW) | 2 bar g |
| Case / module washing | 500 cases/hour, 6 kg cases | 157 kg/h (93 kW) | 3 bar g |
| Cleaning hot water | 86.4 m³/day, 60 °C | no tank 1,890 kg/h · 630 kg/h with 60 m³ tank | 3 bar g |
| Rendering plant, dry, batch cooker | 3.64 t/h raw material depending on 9,000 birds/hour | average 3,279 kg/h · peak 3,771 kg/h | 8 bar g |
| Rendering continuous cooker | 5t/h raw material | 4,040 kg/h | 8 bar g |
| Batch cooker (kuker) | 6 t batch, 3 h cycle | average 2,006 kg/h · peak 2,607 kg/h | 7 bar g |
| Pressure sterilization, 133 °C / 3 bar | 5 t/h | 469 kg/h | 8 bar g |
| Feather meal hydrolyzer + dryer | 2 t/h wet fluff | 2.156 kg/h | 8 bar g |
| Blood coagulant + blood flour dryer | 1 t/h blood, decanter 60% | 635 kg/h | 8 bar g |
| Sticky water evaporator | 2,000 kg/h water, 3 effects | 733 kg/h | 4 bar g |
Example: 9,000 birds/hour slaughterhouse, is there rendering?
The “Medium slaughterhouse” template in the wizard: 16 hours a day of slaughter at 2.3 kg bw, with 60 m³ of cleaning water. The same plant was calculated once by cutting alone and once by processing its own by-products with dry rendering (batch cookers, 20 hours per day).
| Pen | No rendering | With dry rendering |
|---|---|---|
| Boiling boiler (operation) | 815 kg/h | 815 kg/h |
| Scalding feet and rocks | 239 kg/h | 239 kg/h |
| 20 blade sterilizers + case washing | 251 kg/h | 251 kg/h |
| Room heating (100 kW) | 169 kg/h | 169 kg/h |
| Cleaning water (60 m³ tank) | 630 kg/h | 630 kg/h |
| Rendering (feathers, blood, viscera) | — | 3.771 kg/h |
| Simultaneous need | 2.103 kg/h | 5.874 kg/h |
- No rendering: 2,103 kg/h + line losses 105 + deaerator 286 + growth margin 249 = 2,743 kg/h → 3 t/h, working pressure ≥ 4.5 bar g (6 bar class); 1,767 kW ≈ 1,519,000 kcal/h; natural gas ≈ 200 Sm³/h.
- With dry rendering: 5,874 kg/h + line losses 294 + deaerator 646 + growth margin 681 = 7,495 kg/h → 8 t/h, working pressure ≥ 9.5 bar g (10 bar class); 4,889 kW ≈ 4,204,000 kcal/h; natural gas ≈ 554 Sm³/h.
- If the growth share is taken as zero, the recommendations are 2.5 t/h and 7 t/h. Condensate return is taken as 60% for indirect heating.
- Sector supply (slaughter alone): 141 kg steam/t carcass; in the range of 110–320 kg/t derived from EU BAT values.
- Without the cleaning water tank, the 4-hour cleaning window alone would draw ≈ 1.89 t/h.
- Other templates: 3,000 birds/hour, 8 hours per day, no rendering → 0.8 t/h; 2 × 12,000 birds/hour and full rendering → with continuous cooker 22 t/h (20 t/h with zero growth margin).
Boiler type and pressure in the slaughterhouse
The cutting line works with 2–4 bar g; therefore, in the plant that cuts alone, the boiler can operate at 4.5 bar g and 6 bar class is sufficient. In the field, a boiler with 8–10 bar g is often selected; thus, rendering can be added in the future. Rendering cookers, feather hydrolyzers (135–175 °C) and dryers require 7–8 bar g; in the rendering facility, the boiler is selected in the 10 bar class. Since the cutting cannot be stopped, a two-boiler (N+1) layout is recommended.
Package type and hybrid type steam boilers of Çiftel Kazan up to 6 t/h, header type water tube steam boiler are suitable for rendering facilities above 6 t/h; Economizer is added at 2 t/h and above. Cleaning and domestic hot water can be met with a steam heat exchanger with storage or a separate hot water boiler; small slaughterhouses can also work with a hot water boiler alone.
How to do the calculation?
Since the first filling of the boiling boiler is done before the shift, the operating load is included in the account. If cleaning water is stored, the heating is spread over 12 hours and the load is reduced to one third. Rendering requires 0.9 t of steam per ton of raw material in the ≈ dry system and 0.55–0.7 t in the wet system with evaporator. 5% line loss, deaeration steam and 10% growth margin are added to the collection.
Use the wizard at the top of the page to calculate with your own list of machines; Boiler Capacity Calculator for all industries.
The results of the wizard are predictions to give a preliminary idea; boiler selection should be finalized by on-site exploration and engineering calculation. Contact us for free pre-engineering support.