ABATTOIR AND MEAT

INDUSTRYGOODU MASTAN VALIID NO: 16FT1D7821

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.

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

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

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

Area requirementSmall 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

ABATTOIRAnimal receiving

Lairage

Animal Washing

Slaughtering (Halal)

Hanging

Skinning, Head & Hide Removal

Evisceration

Washing

Post Mortem Inspection

Sanitization

Chilling (24-72 hrs) CCP-3

Deboning

Processing (Primal Cuts)

Inspection (Quality)

Packing

Freezing

Cartooning & Wrapping

Metal Detector

Cold Storage

Ante Mortem (CCP-1) Discarding/Emergency Slaughter

Bleeding (Liquid Waste)

By Products

CCP-2 Suspected / Rejected

Weighing

CCP-4

CCP-5

CCP-6

PECULIARITIES

1. Hygiene & Sanitation

2. Lairage

3. Drainage

4. Light

5. Rendering Plant

6. ETP

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)

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

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.,

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

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

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

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

ETP

EQUIPMENT

• Stunning Pen & boxes

• Hide or Skin Pullers

• Head & Leg Cutters

• Splitting Saw

• Carcass Washing Equipment

STUNNING PEN

STUNNING EQUIPMENT

REMOVAL OF HIDE OR SKIN

hot galvanized steel pillar and stainless steel skin removal roller

Hydraulic type cattle skin removal

Sheep hide punching armSkinner Sheep hide puller & roller arm

Dehider

HEAD & LEG REMOVAL

SPLITTING SAW

CARCASS WASHING

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

LAYOUT FOR ABATTOIR

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