Date post: | 27-Jun-2015 |
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Infrastructural Requirement of modern slaughterhouse
Dr Pavan KumarAssistant Meat Technologist
Deptt of LPT, GADVASU, Ludhiana
Abattoir
Slaughter house – technically referred as Abattoir.
Traditionally called- butcheries, giving negative feeling due to foul smell, unhygienically disposal of wastes.
SH- place where animals meant for human consumptions are sacrificed.
Public acceptance - concern
Types of abattoir
Modern abattoirSemi-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
Considerations Policy decisions-
Site, size, trade practices and range of byproducts
Engineering aspects-layout plan
Cost consideration 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 cityElevated ground for easy drainingAdequate and potable waterConcrete road facilities for transportationUninterrupted electric supplySpace for future expansionAway from airportSocial and religious acceptance Free from pollution, odour, chemical plants etc
Contd--
Availability of skilled manpowerAvailability of meat animalsSoil quality- to support good foundations and
pillars of the buildingsSeparate entity i.e. reasonable distance from
other buildingsSeparation 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
Civil Infrastructure
LairageAM examinationHumane slaughterFlaying, dressing and washing of the carcassesHanging carcasses and edible offalsByproducts handlingInspection of meat and disposal of
condemned carcasses or part thereofStaff welfare
DesignPig abattoir- separate due to specialized slaughter
and dressing procedure If joint slaughter house- slaughter at different times
with different slaughter line by 5 metre space or 3 metre high wall.
Also separate Slaughter for horse and pigSeparate route for stock and meat vehicleDirection- toward East or West, window facing the
NorthClear cut separation of clean and unclean section
Design contd-
• Forward flow of operations• Direction of wind• Provision for compressed air• Adequate ventilation must to prevent excessive heat and
steam condensationFloors-– Single floor- minimizes the handling cost– Building- 2 floors preferred Ground floor- unclean operation Top floor- clean operation GRADIENT- 2cm/metre (1:50)
Building Ceiling- 3 M height or more in evisceration & cleaning
sectionFlat & smooth ceilingMaterials- easy cleaned, concrete, ceramics, tilesAvoid square angles/joints where material can accumulateFloor- non-slipperyDoorways- 1.5 M, double acting doors, rust resistantWindow- insects/ rodents barriersRoad- turning circle- 14Mx15M & separate route for stock
& meat vehicle Approach road- 6M
Water requirements
Pipes carrying cool water- painted red
Main pipeline pressure- 20 psiHot water for cleaning- 82⁰C10,000 litre/ tonne of dressed
carcass weight (1:10)Storage- 1 day consumption
ContdPig = 454 Litres/dayBovine = 272Sheep =45
+25% extra at 15 psi
As per FAO bulletin 1978Buffalo/cattle- 1000 litSheep/goat- 100 litPig- 450 lit
DrainageGradient- 1:50 for floorsRate- 1 drain/36-40 sq m of floor
areaSeparate for water and bloodSeparate provision for water & water
containing manureBlood drainage- 1:25 gradient, valley
size- 60 cm wide, trap screen- 4 mmEach floor drain- deep seal S shape
trapDirection- opposite from edible
product flow
Light• Adequate natural light & provision
of artificial light.• Artificial light- should not disturb
colour/ 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
Stock
Western IndiaCattle/ buffalo- 3 days 2 daysSheep/ goat/pig- 2 days 1 days
Essential components
1. Lairage / livestock holding pens
2. Slaughter hall Stunning section Bleeding section Skinning section Dressing section Evisceration section Postmortem section
3. Isolation block/ emergency slaughter unit
4. Chill rooms5. Detained/condemned
meat rooms
6. Hide and skin store7. Gut and tripe room8. Offal room9. Meat cutting room10. Vet office & laboratory11. Despatch room12. Cloak room13. Manure bay14. Effluent plant
1. LairagePlace where animals are rested
before slaughterKnowledge of animal behavior
fundamental All stock – handled gently &
quietlyAnimal- prefer walking up slopes
rather than down steep gradientRails (cylindrical or tubular)- easy
to inspect Floors- solid, non-slipperyDrainage- not in centre
Lairage contd
Avoid sharp corners & projections
Curved passageway, narrow to prevent turning
No strindent voice & noise, dark objects etc
Maintain social group i.e. avoid social stress
Floor gradient- 1:50Off-loading- 1.2 M height
Facilities at lairage
Ante-mortem roomRace Adequate number of well
lighted pensFeeding (withhold 12 hrs
prior to slaughter) and watering (ad-lib)
Isolation penCompetent lairage staffVet office
Pen size
Cattle (loose)- 2.3- 2.8 sq m (preferred one)
Cattle (tied)- more space (3.2 sq m)
Pig (bacon, small porker)- 0.6 sq m
Heavy pigs, calves & sheep- 0.7 sq m
Cattle lairage• Water- in long water
troughs• More sensitive to high
frequency sounds• Water spraying in warmer
climate• 7.6x6 M for 20-25 cattles• Curved race- efficient as
animal entering race cannot see the objetcs/ animals
Sheep lairage
Rails & walls both Rails- less than 15 cm apart to prevent to put head on
lower rails of pens Height- 0.9 M Water- in troughs Judas /decoy sheep- to facilitate the movement of
sheep through a lairage, utilize the innate tendency of sheep to follow one another by training/ accustom one particular sheep to pass through lairage leading others
• Cattle & sheep- combined in same building• Pig & sheep- may be• Cattle & pig- no as cattle do not like pig company
Pig lairage• Rest more against a solid wall• Rails- less than 15 cm apart to prevent to put
head on lower rails of pens• Pen- long & narrow to rest against, avoid
fighting• Electric goads- regulated (lowest effective
voltage < 50 volt) Comrade pigs- move only as a loose group,
preferring to move along beside than behind each other
• Maximum number in a group- 15• A fine spray of water
• Reduce fighting• Reduce contaminations• Cooling effect• Not in cold waether
Ante-mortem Examination
• Place- in lairage• Time- 12-24 hrs before slaughter by qualified
veterinarians• Resting of animals- atleast for 24 hrs• No feed for atleast 12 hrs before slaughter• Ad-lib water
2. Slaughterhouse/hallFrom lairage animals are transferred to
slaughterhallBetter if an uper kill floor is used and site is on a
slopeAnimal – directly walk to SH or ramp (1:6) can be
provided with battens & catwalk
Drive/ Race
First animals reach to holding pen and from here through drive/races driven to stunning pen.
Distance between slaughterhall to lairage – 10 m
Height- upto waist Stopgate- to prevent backward movement Emergency gate Usually a curved path with single file
accommodation and stop gate. Animals - continuously being guided by a
lairage personnel to stunning pen
Stunning penArea where animals are made
are unconscious before killing It’s design depends on type of
stunning procedure to be followed
3 m in width to the opposing wall/ bleeding trough
Fitted with upright bars 5 cm in diameter & 1.2 M height, spaced 40 cm intervals for safety purpose
Steady frame for ejection
Stunning box of sheep/goat
Stunning/ Knocking box for pig
Stunning pen for cattle
Stunning equipments
Booth/Batch-slaughter
• In the booth system, abattoirs or slaughter spaces are divided into many spots (“booths”), which allow for the simultaneous slaughtering of a certain number of animals (“batch”).
• The animals in a batch are each taken to a defined floor area, slaughtered and dressed in that spot
• The simultaneous slaughtering often creates congested conditions and hygienic problems. carcasses.
• Identification of animal carcass easier
Line slaughterLine slaughter- hoisting up the carcass at
an early stage, preferably beginning with the bleeding. All subsequent slaughtering and dressing procedures are carried out with the carcass suspended on and moving along an overhead rail (or line).
• Line slaughter is suitable for bovines, small ruminants and pigs
• Not suitable for small scale
Bleeding In area with enough space Blood has got nutritional as well as
commercial importance and it cannot be allowed in waste as in traditional slaughter system
Bleeding trough- at least 1.5 M wide (Cattle) 1.1-1.2 M(S+G)
Two point of reception- at actual point of sticking and bleeding thereafter
Stainless hollow knife- for hygienic collection of blood
For small meat plant- individual container for holding blood
Pig scalding, dehairing & singeing
Pig scalding at 61-64⁰C for 6 min
Dehairer (if 240 pig/ 2-3 days Singeing
Carcass dressing
In this area a number of operations are carried out such as
i. removal of hide and skin, ii. head removal, iii. evisceration, iv. splitting, v. trimming vi. final wash
Removal of hide & 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
Foot and neck shearFeet cutting saw
Head- through occipital jointLeg- forelegs- knuclebone
Hindleg- tendon
Evisceration Offal carrier
Carcass washing
Carcass is washed by high pressure spraying (19kg/cm2) with available chlorine- 50-100ppm
Slaughter of cattle
Sheep SH Sheep- driven to a passageway adjoining to SH,
carried by hand into SH & placed on crates (cradles, cratches, crutches) preparatory to stunning & dressing
Components-i. Pen sheep & stunii. Shackle & hoistiii. Stickiv. De-elevate to crutch conveyorv. Conveyor dressing (feet removal, commence fleece
removal, saw brisket)vi. Elevate to overhead railvii. Clear tail & commence backingviii. Back & chute fleeceix. Removal of headx. Eviscerate abdomenxi. Wash
Height of Rails
Height Buffalo/cattle
Sheep/ goat
pig
Bleeding rail 16 ft (4.8 M) 10.5 ft (3.15 M)
9 ft (2.7 M)
Dressing rail 11 ft (3.3 M) 10 ft (3 M) 7.5 ft (2.25 M)
Cooler rail 11 ft (3.3. M 9 ft (2.7 M) 6.5 ft (1.95 M)
Hide & skin storeAlong with other by
products hide and skin need to be stored before dispatch
Their safe storage and primary processing needs a separate section.
Gut & Tripe room
Here the initial separation and emptying of stomachs and intestine is carried out.
Red offal room Many of visceral organs have
commercial as well as food value. Liver, lungs, heart, kidney etc are the
organs, which should be trimmed and then placed in a chill or freezing room depending on ultimate system of disposal
The temperature of offal room particularly those to be used, as food should not exceed 30c
Width of visceral inspection table- 1.5 M
Table height- 2.7 M from conveyor rail
Chill Room
Dressed meat and edible offals – immediate dispatched for sale
orChilled soon after the PM
Chilling temperature- during storage & transport
Carcass- < 7⁰CPoultry - <4 ⁰Coffals- <3 ⁰CMRM- < 2 ⁰C
Chill-room contd-• Small rectangular chill rooms
• Increased chilling• Less effect of frequent opening
& closing
• Free movement of cold air around hang carcass
Cutting room- 10 – 12 ⁰CRail Spacing
Beef carcases- 0.9 MPigs- 0.7 MLamb 0.5 MWith minimum space between
carcass- 0.3 to 0.4M
Rendering plantdeals 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
Equipment wash
Adjacent to work a equipment wash section must be designed to avoid buggies, bins and washing of equipment at improper places
The one-way system of passing in equipment wash section ensures dirty equipments entry from one side and exit of only clean from other side
Available chlorine- 200-250ppm
Manure bay
A large amount of dung from lariage house, emptying of rumen and intestine need a separate section to deal with this huge mass to avoid problem of flies etc.
Veterinary office and laboratory
This section should have essential facilities and equipments to carry out inspection work
Facilities for microbiological and quality control
Effluent treatment plant
Vehicle washing
Facilities for personnel
It includes- lockers toilets, urinals, Washbasins- 1 for 15 employees, near to workplace,
Available chlorine- 20 ppm, pedal operated Boot washing changing areas, first aid room, laundry, parking areas, canteens, security arrangements etc
Storage