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Driving sustainability and efficiencies in product quality thanks to a new Haarslev rendering unit

BZF selects Euromac to improve and simplify its production process for its meat products

The challenge​

In 2017, BZF faced a critical challenge: growing demand for its pork products outpaced the capabilities of its outdated production facilities. Limited capacity and aging infrastructure hindered operational efficiency, while the company also needed to meet EU regulatory standards in preparation for international exports. In order to address, these challenges, modernization and increased slaughter capacity were essential—not only to scale production but also to integrate legacy systems and equip the workforce with new operational standards in a developing market.
At the same time, BZF had to optimize resource management by balancing water consumption and energy efficiency across its processing units. Regulatory compliance added further complexity, requiring sustainable waste conversion into valuable byproducts while adhering to environmental standards especially as BZF was looking to export in other European markets. Most importantly, to ensure long-term viability, BZF needed to implement cost controls across multiple processing units and develop new revenue streams that could transform once unused resources into valuable byproducts

Profile

Balkan Zoo Farm (BZF), Albania

Balkan Zoo Farm (BZF) Sh.p.k is one of the largest pork meat processing facilities and distributors in Albania. Established in 2014 at Tirana (ALB), BZF offers a wide range of pork and lamb meat by-products.

The Solution

Pioneering Integrated Meat Processing in Southeastern Europe

In 2017, Euromac undertook a groundbreaking project for BZF in Albania, establishing one of the country’s first fully integrated meat processing facilities with state-of-the-art rendering capabilities. This comprehensive installation showcases Euromac’s expertise in delivering end-to-end solutions that combine production efficiency with environmental sustainability.

Advanced Slaughterhouse Development

The cornerstone of this ambitious project was the design and installation of a high-capacity pig slaughtering line engineered to process 120 pigs per hour—representing a significant advancement for Albania’s meat industry infrastructure.

Euromac’s meticulous approach included:

  • Custom-designed slaughter floor layout optimized for animal welfare and operational efficiency
  • Automated stunning and bleeding systems adhering to European humane slaughter standards
  • Advanced scalding and dehairing equipment calibrated for regional pig varieties
  • Precision cutting stations with ergonomic design for worker comfort and product quality
  • Comprehensive refrigeration systems featuring rapid chilling capabilities to maintain meat freshness
  • Integrated quality control checkpoints enabling real-time monitoring throughout the process

This sophisticated slaughtering line was designed not only to maximize throughput but also to ensure consistent product quality while meeting rigorous European hygiene standards—a critical factor in positioning BZF for potential export markets.

Revolutionary Rendering Implementation

To address the significant challenge of animal by-product management, Euromac engineered a complete rendering solution capable of processing all slaughterhouse waste streams. This pioneering system—the first of its kind in Albania—transformed what would have been disposal challenges into valuable commercial products. The solution included:
  • Haarslev 5000kg batch cooker featuring advanced thermal controls for optimal product quality
  • Specialized blood processing equipment designed to preserve protein functionality
  • High-efficiency Haarslev fat pressing screws with precise pressure control systems
  • Custom-engineered Haarslev screw conveyors designed for the facility’s specific layout
  • Industrial evaporators recovering water while concentrating valuable nutrients
  • Purpose-built receiving and storage bins with integrated inventory management capabilities
  • Comprehensive odor abatement systems ensuring community acceptance
The rendering system handles both blood and meat waste streams, processing these materials into high-value ingredients for the pet food industry and agricultural feed pellets. This approach has transformed BZF’s waste management from a cost center into a revenue-generating operation while simultaneously reducing environmental impact.
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Innovation

Euromac enhanced the rendering solution with advanced digitalization capabilities, creating a comprehensive digital twin of the complete rendering installation that enables BZK to operate with unprecedented efficiency and oversight. This digital twin technology allows the customer to remotely manage all aspects of the rendering operations, providing real-time monitoring and control capabilities from any location. The system is equipped with integrated thermal sensors throughout the installation that continuously monitor temperature conditions and automatically generate alerts when parameters deviate from optimal ranges. This digital infrastructure not only ensures consistent processing quality and equipment protection but also enables predictive maintenance scheduling and operational optimization, significantly reducing downtime and enhancing the overall reliability of the rendering process while providing the customer with complete visibility and control over their critical waste management operations.

Environmental Consciousness – Sustainable by Design

Understanding that sustainable meat processing extends beyond the facility walls, Euromac implemented an advanced water treatment system featuring:

  • 1000m³ daily treatment capacity designed to handle peak production volumes
  • Multi-stage filtration process removing solids and biological contaminants
  • Advanced nutrient removal technology preventing waterway eutrophication
  • Water recycling capabilities significantly reducing freshwater consumption
  • Real-time monitoring systems ensuring continuous regulatory compliance
  • Modular design allowing for future capacity expansion

This comprehensive water management approach ensures that BZF’s operations maintain minimal environmental impact while maximizing resource efficiency—a model recognized by the Albanian Ministry of Agriculture as setting new standards for the country’s developing meat sector.

Value-Added Processing Integration

Completing the facility’s transformation, Euromac supplied and installed specialized meat processing equipment enabling BZF to manufacture diverse consumer products:
  • Automated sausage production lines with multiple filling capabilities
  • Climate-controlled curing chambers for traditional Albanian specialties
  • Precision slicing technology for consistent pork loin products
  • Integrated packaging systems extending product shelf life
  • Quality testing equipment ensuring food safety standards
This downstream processing capability allows BZF to capture additional value from primary products, diversifying their revenue streams and strengthening their market position.