Major peculiarities of Slaughter houses and Abattoir and Meat Processing industries

1. ABATTOIR AND MEAT
INDUSTRY
GOODUMASTANVALI
IDNO:16FT1D7821

3. 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.

4. 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

5. 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

6. 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

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

9. ABATTOIR
Animal 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

10. PECULIARITIES
1. Hygiene & Sanitation
2. Lairage
3. Drainage
4. Light
5. Rendering Plant
6. ETP

11. PROCESSHYGIENE
 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)

12. 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

13. 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.,

14. 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

15. 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

16. 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

17. 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

18. ETP

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

20. STUNNING PEN

21. STUNNING EQUIPMENT

22. REMOVALOF 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

23. HEAD & LEG REMOVAL

24. SPLITTING SAW

25. CARCASS WASHING

26. 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

27. LAYOUT FOR ABATTOIR