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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