Using everything: How by-product processing reduces food waste

Fillets, cutlets, chicken legs – these are the parts that often come to mind first when we think of meat. But that's only half the story. Around 50 per cent of an animal consists of components beyond the primary cuts – yet they too are full of potential.

In some cultures, these so-called by- or co-products have always been utilized – whether as ingredients, remedies or raw materials. In many parts of the world, however, they have long been overlooked and even treated as waste. Today, modern technology is enabling their comeback: by-products rich in proteins, fats, minerals and bioactive substances are being refined into high-quality ingredients for animal feed, cosmetics, biofuels and even the pharmaceutical industry.

From waste to valuable ingredients: technology makes the difference

The responsible utilization of such by-products – both edible and non-edible components – requires high-performance process technology: systems that ensure safety, purity and resource efficiency while separating molecular structures and making them usable. 

GEA supplies the technology that enables this transformation in a safe and resource-saving way. As a result, the seemingly insignificant becomes a valuable contribution to the circular bioeconomy.

A market that was previously hidden

For a long time, the processing of animal by-products was a barely visible part of the food industry. But that is changing. These fat and protein-rich resources – categorized as either edible or inedible by-products –are increasingly coming into focus. Not least because they can make a significant contribution to conserving natural resources.

Dr. Martin Alm, Technical Director of the European Fat Processors and Renderers Association (EFPRA) sums it up: “The best use of resources is when virtually nothing is left over.” With modern technology, this goal can be achieved – and a new level of industrial circular economy realized.

Chemistry, structure and function – what by-products are up to

The raw materials used in recycling are biochemically highly complex: They contain a rich variety of functional proteins, fats, minerals and collagen-rich substances that can be put to specific use. For example, in gelatine, animal feed, fertilizers, biofuels and pharmaceutical applications. 

This requires differentiated process chains: the first stage often involves thermal pre-treatment (rendering), followed by separation using separators and decanter centrifuges, evaporation and drying. While low-molecular components are used in feed production or fertilizer manufacturing, high-molecular structures such as collagen enable completely different applications – from cosmetic products to medical tissue replacement.

Animal fat as a sustainable aviation fuel

The market for sustainable aviation fuels (SAF) is developing rapidly. Animal fats are coming into focus as a source of raw materials – not only in Europe, but also in the U.S., where animal fats have recently even been imported to meet the growing demand for biofuels.

The challenge lies in processing: fats must be refined so that the end result meets strict aviation fuel requirements, especially for purity and catalyst compatibility. This highlights the importance of precise separation technology and intelligent process line expertise – an area in which GEA has many years of experience.

Collagen: from waste material to high-value ingredient

The fact that collagen – the structural protein found in skin, connective tissue and bones – is now a sought-after raw material for cosmetics, pharmaceuticals and even medical products clearly illustrates this change. As a component of anti-ageing products, dietary supplements and capsule materials, collagen is no longer a niche product. Here, too, process quality determines how efficiently and to what standard extraction can be carried out. 

A good example comes from Thai Union Group PLC, one of the world's leading producers of seafood. For several years, Thai Union has processed by-products in-house, including skin, heads and bones. In addition to fish oil, they have recently added hydrolysate and collagen to their product portfolio. GEA designed and installed both processes, supplying decanters, separators and membrane filtration systems for collagen extraction, along with the appropriate equipment for evaporation and spray drying. The plant went into operation in mid-2024 and has since enabled Thai Union to process its raw materials completely and successfully, thereby maximizing added value.

Technology as an enabler of a resource-efficient industry

The requirements for process design and engineering are high: microbiological safety, product purity, energy efficiency and traceability play a central role. At the same time, expectations for flexibility, digitalization and sustainability are rising.

For GEA, this means plants must be designed for both standard processes in mass production and highly specialized applications. Technical expertise from other industries – such as dairy, pharmaceutical and environmental technology – is increasingly being incorporated into the development of modular and scalable systems.

A look into the future: by-product utilization as a key technology

Whether SAF, pet food or bio-based chemicals – the utilization of animal by-products will play an even greater role in the sustainable supply of raw materials in the future. Already today, it makes a significant contribution to preventing food waste, conserving natural resources and creating new value chains.

What was considered a waste disposal task years ago is now an industry with its own innovation engine with growing demands on technology, hygiene and efficiency – driven by the pursuit of greater sustainability. With well-designed process lines, intelligent automation and a global service network, GEA is enabling "the other 50 percent" to become another pillar of the circular bioeconomy.