Abattoirs have a large number of energy intensive processes. Beside energy supply, disposal costs of animal
by-products (ABP) are the main relevant cost drivers. In this study, successful implementation of a
new waste and energy management system based on anaerobic digestion is described. Several limitations
and technical challenges regarding the anaerobic digestion of the protein rich waste material had to be
overcome. The most significant problems were process imbalances such as foaming and floatation as well
as high accumulation of volatile fatty acids and low biogas yields caused by lack of essential microelements,
high ammonia concentrations and fluctuation in operation temperature. Ultimately, 85% of the
waste accumulated during the slaughter process is converted into 2700MWh thermal and 3200MWh
electrical energy in a biogas combined heat and power (CHP) plant. The thermal energy is optimally integrated
into the production process by means of a stratified heat buffer. The energy generated by the biogas
CHP-plant can cover a significant share of the energy requirement of the abattoir corresponding to
50% of heat and 60% of electric demand, respectively. In terms of annual cost for energy supply and waste