Peculiarities of Abattoir and Meat Industry

Major peculiarities of Slaughter houses and Abattoir and Meat Processing industries

1. ABATTOIR AND MEAT INDUSTRY GOODU MASTAN VALI ID NO: 16FT1D7821

2. ABATTOIR A Slaughterhouse or Abattoir is a facility where animals are killed for consumption as food products. Approximately 45-50% of the animal can be turned into edible products. About 15% is waste, and the remaining 40-45% of the animal is turned into by products. Slaughterhouses which process meat unfit for human consumption are sometimes referred to as Knacker’s yards or Knackeries. Some religions stipulate certain conditions for the slaughter of animals so that practices within slaughterhouses vary. Traditionally called Butcheries.

3. TYPES OF ABATTOIR Modern abattoir Semi-modern -Facilities for slaughter and bleeding on the floor but subsequently entire dressing, washing, halving and quartering takes place on the rails in hoist position Traditional abattoir Infrastructure depends upon the- Maximum daily kill A regular full time operation Disposal & treatment of waste Byproducts utilization

4. Selection of site Outskirt of the town or city Elevated ground for easy draining Adequate availability of potable water Concrete road facilities for transportation Uninterrupted electric supply Space for future expansion Social and religious acceptance Free from pollution, odor, chemical plants etc Availability of skilled manpower Availability of meat animals Soil quality- to support good foundations and pillars of the buildings Separate entity i.e. reasonable distance from other buildings Separation of clean and dirty area

5. SIZE Depends on the number of animals of each species to be slaughtered everyday Range of operation (slaughter/ dressing/ deboning/ packaging) Availability of fund Byproduct processing

6. Area requirement Small Abattoir < 100 LU/ day 30,000 LU/year 1-2 acre Medium Abattoir 100- 200 LU/day 50,000LU/year 2-4 acre Large Abattoir > 200 LU/day > ,1oo,ooo LU/year 4-6 acre

7. ABATTOIR Ante Mortem (CCP-1) Discarding/Emergency Slaughter Bleeding (Liquid Waste) By Products CCP-2 Suspected / Rejected Weighing CCP-4 CCP-5 CCP-6

8. PECULIARITIES Hygiene & Sanitation Lairage Drainage Light Rendering Plant ETP

9. PROCESS HYGIENE Facilities must be available for the isolation and removal of any animals showing signs of illness. Pressurized water is preferred to wash animals prior to slaughter Slaughtering should be done on tables or on hanging rail to reduce contamination The slaughtering knife should be cleaned and sterilized between each carcass at 82°C. The head should be removed and after skinning washed separately from the carcass Prevent contamination of the carcass with dirty hooks, knives and protective clothes. Do not puncture the viscera (alimentary tract), uterus, urinary bladder and gall bladder during separation cuts Regularly wash hands/aprons and sterilize knives, especially after any time contamination occurs Carcasses should be washed after spliting using cold potable water and if possible decontaminated by use of chlorinated water containing (50-100ppm)

10. PERSONNEL HYGIENE Appropriate protective clothing should be worn and replaced each day or when heavily soiled. They should be of light color, preferably white and be clean and tidy. Hands and arms should be washed and knives and equipments regularly sterilized using hot water. Chewing, eating, drinking, smoking etc., not allowed. No jewelry is allowed. Workers must wash their bodies regularly and have the nails trimmed as much as possible. Nail polish and dyes on nails and hands should be discouraged. Beards should be shaven or covered by a turban. They should not move from dirty to clean areas, but vice versa. Workers should not use heavy perfumes, lipstick, false eyebrows and eye shadows. Washing facilities should be provided where workers can wash before leaving and a canteen where they could take refreshment and rest during breaks. Workers must go for medical check-up after every 6 months

11. SANITATION Proper cleaning and sanitation of the slaughter floor, walls and equipment should occur daily and frequently during the day. Sanitary Standard operation procedures (SSOPs) for cleaning and sanitation of all parts of the plant should be in-place and well-implemented. Water points, hoses, sterilizers, hand sanitizers, and cleaning equipment should be provided in sufficient numbers . Sanitization mainly done by using Hot water, Steam, NaOCl , etc.,

12. LAIRAGE Place where animals are rested before slaughter Knowledge of animal behavior fundamental All stock – handled gently & quietly Animal- prefer walking up slopes rather than down steep gradient Rails (cylindrical or tubular)- easy to inspect Floors- solid, non-slippery Drainage- not in centre Avoid sharp corners & projections Curved passageway, narrow to prevent turning No strident voice & noise, dark objects etc

13. DRAINAGE Separate for water and blood Separate provision for water & water containing manure Blood drainage- trap screen- 4 mm Each floor drain- deep trap Direction- opposite from edible product flow

14. LIGHT Adequate natural light & provision of artificial light. Artificial light- should not disturb color/ shadow Window- north facing to get solar light Intensity Inspection point- 550 lux (50 ft candle) Work rooms- 220 lux (20 ft) Chilling room- 110 lux (10 ft) Measured at height of 0.9 M from the floor except inspection point- 1.5 M

15. RENDERING PLANT Deals with extraction of fat from carcass parts, condemned carcass /diseased one by applying high temperature processing. The whole section of rendering plant may be divided into edible fat section and inedible fat section

16. ETP

17. EQUIPMENT Stunning Pen & boxes Hide or Skin Pullers Head & Leg Cutters Splitting Saw Carcass Washing Equipment

18. STUNNING PEN

19. STUNNING EQUIPMENT

20. REMOVAL OF HIDE OR SKIN hot galvanized steel pillar and stainless steel skin removal roller Hydraulic type cattle skin removal Sheep hide punching arm Skinner Sheep hide puller & roller arm Dehider

21. HEAD & LEG REMOVAL

22. SPLITTING SAW

23. CARCASS WASHING

24. FACTORS AFFECTING PLANT LAYOUT The factors affecting plant layout can be grouped into 8 categories: Materials Machinery Labor Material Handling Waiting Time Auxiliary Services The building Future Changes

25. LAYOUT FOR ABATTOIR

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