Valorization of poultry waste into calcium salt of fatty acids (bypass fat): Characterization and techno-economic assessment

Global poultry production generates millions of tons of chicken fat and eggshell waste annually, posing significant solid waste management challenges. To address the environmental burden and underutilization of poultry processing waste, this study integrated waste valorization approach to convert chicken fat and eggshell waste into value-added calcium salts of fatty acids (CSFA), which serve as a rumen-protected fat supplement used in ruminant nutrition used in ruminant nutrition, through thermal saponification. Notably, a 97.94% product recovery yield was achieved, with the augmented sample exhibiting a balanced profile of 82.61% fat, 8.14% calcium, and 11.48% ash, and the observed color characteristics resulting from the natural contribution of chicken fat-derived components. The successful formation and structural characteristics of CSFA were confirmed through comprehensive physicochemical characterization. Techno-economic analysis projected a net present value of $24.17 million, an ROI of 49.06%, a payback period of 1.72 years, and a unit production cost of $0.92/kg. Overall, the process provides a potential value-addition pathway for poultry-processing by-products.