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Slaughterhouse Feasibility
Report
COURSE TITLE: PROJECT MANAGEMENT
SUBMITTED BY:
MuhaMMad Zeeshan aZaM (123220)
MuhaMMad asad bin asif (112345)
ali Musyab naqvi (112301)
SUBMITTED TO: Mrs sadaf latif Name, Job title
Company name
Date
someone@example.com
TABLE OF CONTENTS
Muhammad Zeeshan Azam (123220).........................................................................................................................2
Muhammad Asad bin Asif (112345)...........................................................................................................................2
Ali Musyab Naqvi (112301).........................................................................................................................................2
..........................................................................................................................................2
TABLE OF CONTENTS.................................................................................................2
EXECUTIVE SUMMARY.............................................................................................2
BACKGROUND..............................................................................................................3
PROJECT PARAMETERS............................................................................................3
CRITERIA...................................................................................................................................................................3
REGULATORY ISSUES................................................................................................3
Food Safety and Labeling...........................................................................................................................................3
Water Supply...............................................................................................................................................................4
Environmental Considerations...................................................................................................................................4
BUSINESS FEASIBILITY.............................................................................................5
MISSION.....................................................................................................................................................................5
BUSINESS DESCRIPTION.......................................................................................................................................5
PRODUCTS AND SERVICES...................................................................................................................................6
MARKET.........................................................................................................................6
EXISTING FACILITIES AND COMPETITION........................................................7
General Environment:................................................................................................................................................7
The quality of meat .....................................................................................................................................................8
BUSINESS COMPETITION..........................................................................................9
OPERATIONAL CHALLENGES...............................................................................10
POTENTIAL OPTIONS...............................................................................................10
BRIEF PROFILE OF SECTOR...................................................................................10
BUILD A NEW FACILITY...........................................................................................11
DEVELOP COMMERCIAL CONSTRUCTION FACILITY..................................11
OPERATING COSTS MEASUREMENTS................................................................12
Executive Summary
In this project report, we have support to establish the slaughterhouse in the Pakistani
region. The report contains almost every sort of data which might be able to inculcate
the importance of running the sector of livestock. The slaughterhouse would be of
international standards and would be able to fulfill the regional laws based on the
Livestock and Slaughter sector of the country. The sector contributes to: GDP, Income
capita, Employment and in overall growth of the country. The business of
slaughterhouse is very important if it is based upon scaling, keeping an eye on every
step, and also by keeping in view the events in which meat is needed by nation. The
meat can be exported to other countries as well. The business development which we
have tried is based in Punjab region of Pakistan.
BACKGROUND
The slaughterhouses in Pakistan are much of the critical cases. They are either having
dirty places to store the meat, or they also have poor premises for their operational
activities. The thing which we wanted to implement through our project of
“slaughterhouse” is to have different operations, activities and many sort of processes
which are to be carried-on under the hygienic environment where no doubt of
cleanliness is to be noticed by any of the institutions.
A large number of small slaughterhouses are scattered all over the country, some are
licensed and others are not. A majority of licensed places lack modern amenities which
are built and controlled by the municipal committees providing anti-mortem and post-
mortem facilities under qualified veterinary officer.
The unlicensed slaughterhouses are spread in the villages without any proper plan. They
do not provide any facilities and are devoid of a qualified veterinary officer.
The slaughtering of livestock in cities like Karachi, Hyderabad, Lahore, Rawalpindi and
Peshawar is done in the municipal slaughterhouses, and at times in the streets and at
shops. Butchers prefer to slaughter animals at their convenience.
PROJECT PARAMETERS
CRITERIA
As a cooperative, farmers would theoretically have three relationships with the business
– as users, as owners and in its governance and oversight. Key information about each
of these constituencies and the identified criteria are detailed in the table below
REGULATORY ISSUES
Food Safety and Labeling
The Pakistan Standards, Punjab Food Authority and the Punjab Animals Slaughter
Control Act, 1963 as well as State laws govern the slaughtering and processing of meat
and poultry for human consumption. Pakistan’s food safety and inspection services are
responsible for ensuring that meat and poultry are safe, not adulterated and properly
marked, labeled, and packaged. These federal acts define the process for pre- and post-
mortem inspection as well as specific marking, labelling and packaging requirements.
Generally, federal inspectors oversee facilities that slaughter and process meat and
poultry. Food safety authorities have cooperative agreements with all provinces in
Pakistan, including Punjab, that allow state inspectors to enforce requirements “at least
equal to” those imposed under the federal acts for state-inspected facilities. Regardless
of how a facility chooses to operate, federal and Punjab food law require it to be
licensed if it is engaged “in the business of buying, selling, preparing, processing,
packing, storing, transporting or otherwise handling meat, meat food products or
poultry products…”
Exemption from federal inspection requirements (i.e. an inspector does not need to be
present when animals are slaughtered or processed) are provided for “custom”
slaughtering for “personal, household, guest and employee use.” Federal law dictates
that these custom facilities be licensed and examined by state inspectors on a periodic
basis. Meat packed as “custom” must be marked “not for sale.” Operators of
commercial slaughtering facilities often do custom work after hours since inspectors
require overtime pay for days longer than eight-hour shifts. Since the timing and
packaging requirements of custom slaughtering and processing are more flexible and
less-labor intensive, many slaughtering facilities charge less for custom processing than
commercial processing. Meat customers who purchase live animals prior to slaughter
effectively take advantage of this exemption.
In addition, the federal regulations provide exemptions for small-scale poultry
producers. Producers slaughtering no more than 1,000 birds annually are exempt
from the federal act as long as:
1. All of the poultry was raised, slaughtered and sold on the
producer’s own farm;
2. The poultry producer is not in the business of buying or
selling poultry products other than those produced
from their own birds
Water Supply
In order for commercial slaughtering and processing facilities to provide meat or
poultry that is clean and fit for human consumption, they must have access to drinkable
hot and cold water including “conveniently located” sanitary facilities (i.e. toilet and
washing facilities) for the inspector. Commercial facilities require permits as a “non-
public” water system. In Punjab, the sanitary facilities requirement has been understood
to mean that these facilities need to be accessed on-site. Inspectors in other states have
allowed the use of farmhouse facilities for the inspector assigned to mobile slaughtering
facilities.
Environmental Considerations
Slaughtering and processing facilities need to meet Global environmental regulations.
Expansion of an existing facility or building a new facility usually will require permits
related to the appropriate disposal of wastewater and solid waste. The project may also
be subject to local community regulations and (although the facility may qualify for an
agricultural exemption if it is located on a farm and engaged in an “on-farm activity.”)
Solid waste regulations seek to prevent or mitigate the disposal of materials that emit
noxious odors and/or compromise the waters of the State. With a slaughtering facility,
solid waste regulators are concerned about the proper disposal of rendered material and
other residuals including hides, bones, feathers, blood, and animal fat. Much of this
material may be composted on-site if the property has sufficient available land,
appropriate soils and good setbacks from waterways and neighbors. When looking at the
land availability,
Operators disposing larger amounts of slaughtering waste need to file for
certification of the facility and comply with the Solid Waste Management Rules.
The disposal of wastewater presents some additional considerations. If the wastewater
was to drain into a municipal sewage treatment plant, it is highly probable that the
treatment plant would need to request an amendment to its operating permit. Said
amendment would detail the conditions or management approach required to
accommodate the high nutrient value in blood waste. An alternative approach would be
to compost as much blood as possible by designing appropriate drains and collection
systems.
If an on-site system were to be used, an indirect discharge permit would be required
unless the waste is less than 6500 gallons per day or the wastewater is afforded an
agriculture exemption. This agricultural exemption is allowed for wastes generated solely
from products or processing of materials produced on the same property.
BUSINESS FEASIBILITY
MISSION
After reviewing the criteria, we have identified our mission as follows:
The goal of this cooperative is to enhance the economic viability
and sustainability of member farms by ensuring access to
affordable, reliable and high-quality slaughtering and
processing services.
BUSINESS DESCRIPTION
The proposed corporation will be operated as a member cooperative. This means that
it is designed to act on behalf of and be controlled by the livestock producers who use
its services. The actual corporate organization may be a cooperative or a limited
liability company.
The company will contract as a single entity on behalf of all of its
customer/members for slaughtering with one or more existing slaughterhouses and
either own, co-own or be actively involved in creating a new commercial
fabrication facility that meets the criteria outlined by the steering committee.
PRODUCTS AND SERVICES
The Steering Committee identified the following potential products and/or
services of the cooperative, in priority order:
1. Slaughterhouse services – i.e. slaughtering, processing
and wrapping
2. Marketing Venue/Brand for lower quality cuts of meat -
this will require quality standards
3.
MARKET
The size of the market for any slaughtering facility is generally dictated by the
distance farmers are willing to have their animals travel prior to slaughtering. This is
impacted by the ease, duration and cost of transport as well as how the stress from
travel affects the quality of the meat. Most farmers in the group preferred a distance
of an hour or less although many already travel further in order to obtain the
professional quality services they are seeking from their processing facility. If the
transportation issues can be resolved, the market for a quality processing and
fabrication facility might be substantially larger.
Sales include animals sold for slaughter and consumption as well as those sold
between farmers. Sales data for hogs, ruminants and poultry is likely to correlate
relatively well with the number of animals slaughtered. Simple correlations are not
as easy with cattle and calves, which take longer to reach maturity and are
compounded by the number of dairy cattle sent to slaughter.
EXISTING FACILITIES AND COMPETITION
General Environment:
The slaughtering of livestock in cities like Karachi, Hyderabad, Lahore, Rawalpindi and
Peshawar is done in the municipal slaughterhouses, and at times in the streets and at
shops. Butchers prefer to slaughter animals at their convenience.
According to the West Pakistan Slaughter Control Act 1963, the slaughtering of small
and large ruminants should be strictly by undertaken in the recognized places with ante-
and-post-mortem veterinary inspection. Presently, for small and large ruminants, it is
done in the recognized areas, municipal and cantonment and private slaughterhouses,
and in the backyards. Municipal corporations operate majority of such places with few
operating in the private sector.
In general, the existing facilities are insufficient for the requirements. The problem is
severe in Karachi, Lahore and Faisalabad. Due to the shortage of facilities, the number
of animals slaughtered outside is much higher than those within the boundaries.
Therefore, official statistics greatly understate the number of animals slaughtered.
The houses can be referred to as mere slabs with no arrangement of hygiene and
sanitation. These premises facilitate butchers and traders (not licensed) for the slaughter
of livestock at a fee of Rs10 for small and Rs20 for large animal. There are no storage
and quality control measures available. Meat rots, especially in the summer season. The
problem is intensified when meat is sold through butchers to consumers. If all meat is
not sold in daytime, there arises the problem of freezing.
Slaughterhouses are situated in thickly populated localities and the present facilities are
not reasonable due to congestion on roads. There is no space to examine the animals and
the water, drainage and electric facilities too, are limited. The slaughterhouses have no
roof but only walls and floor with no arrangements to dispose of the waste material. The
place is not properly cleaned, washed, and disinfected.
The slaughtered meat is transported to retailers’ through horse-driven carts, auto
rickshaws, or pickups. While in the case of small ruminants, butchers take the meat on
foot to the shops located nearby.
Livestock slaughtering is an important part of meat marketing. Butchers buy animals for
slaughtering. They convert them to edible and non-edible and other useful products in
merchandising channels through which they move on to consumers.
As for the quality, only ante- and post-mortem examination is carried out by the
inspectors and the carcass fit for human consumption are stamped as passed. While in
rural areas there exists no such system. At retail level, the food committee
representatives rarely visit the butcher shop for quality inspection.
In urban areas, the inspector does not have the authority to condemn the whole carcass;
only disease portions are rejected. It was also observed that all slaughter, carcass
dressing and product handling are done in the same space. In addition to this, the
facilities of drainage system, waste disposal and handling of by-products are inadequate
and sometimes non-existent, resulting in the contamination of the carcass.
The quality of meat
The quality of meat, particularly of cattle and buffaloes, is generally low but varies
widely from locality to locality. The poor quality of beef is because of very old or young
animals. Special breed for beef as evolved in other countries does not exist in Pakistan.
As a result, the average dressed carcass weight of cattle in countries rearing meat
animals is over 500kg, whereas in Pakistan it is about 300kg. Similarly, the average
dresses carcass weight of goat and sheep in Pakistan is about 15.9 g and 12.3kg,
respectively.
The livestock producers keep most of the stock on their own preferences. They never
think of consumers whose choice reflects on the price of the stock. Fair prices can be
assured by standardization and gradation. Cooperative associations play a positive role
for the livestock sector development. Such associations can accelerate the
standardization and gradation, improve the distributive process and maximize the
producer’s income.
According to the Pakistan Slaughterhouse Act of 1983, the killing of animals outside the
boundary of slaughterhouses is prohibited. Recognized slaughterhouses usually provide
separate buildings for slaughtering large and small animals. A majority are now located
in thickly populated areas. The slaughtering, carcass dressing and by-product handling
are done in the same space.
Business Competition
In Pakistan, there is a much sort of Viral Competition among slaughterhouses and every
slaughter has to follow the rules and regulations but unfortunately many of them do not
meet to follow the rules and laws issued by the Punjab Food Authority and other federal
laws and authorities.
Pakmeat Halal Sourcing Pakistan
Herbancepura Lahore
Sadiq & Saddique Enterprises Pakistan
Gpo Haji Camp Road Rawalpindi
Umh Industries Pvt, Ltd. Pakistan
Gujrānwāla Daska Road Sialkot Punjab
Malik Textile Industries (Pvt) Ltd Pakistan
L-30 Block-22 Industrial Estate Federal "B" Area Karachi
Smmexport Industries Ltd Pakistan
Green Wood St Sialkot Punjab
Azlan International Pakistan
625/a Hawks Bay Road Karachi Agriculture
Welthing Surgical Company Pakistan
Sialkot Punjab
Anaco Sports Pakistan
Sialkot Cantt Pakistan
RS International Trading Co
Lahore 3-a Board of Revnue Sociaty Johar Town Lahore Punjab
Syntronics Limited Pakistan
Mandviwala Chambers Talpur Road Karachi Sindh
Operational Challenges
All of the slaughterhouses visited by the steering committee experience seasonal
variations in the demand for their services. The busiest months are generally from mid-
August through January with significant slowdowns in May and June. Having
sufficiently skilled staff in the busy months and keeping full-time staff occupied through
the slower months can prove challenging for these facilities. As a result, slaughterhouses
welcome arrangements that better spread the demand for services over the year. The
operation of the kill floor is highly dependent on the skill and speed of the people
staffing and managing the process. In most cases, the owner of the facility is actively
managing this process. Finding qualified staff remains a challenge for these operations.
Most of the facilities only slaughter animals one or two days each week. In other words,
the factor that limits increased activity and sales is often the hanging and processing
capacity NOT the availability of slaughtering facilities. Although many of the State’s
slaughterhouses offer a meat counter, few have focused on aggressive marketing or
selling their product into niche markets. If this were to change, it could create significant
competition for farmers who are direct selling into these markets.
POTENTIAL OPTIONS
The group realized that purchase of an existing slaughterhouse was one of a
number of options that could be considered in order to achieve their goals. Other
options included building a new state of the art facility, building and operating a
mobile facility, building and operating a commercial processing facility,
contracting as a group for services.
BRIEF PROFILE OF SECTOR
There is a huge shortage of slaughter animals for meat supply. The animal growth cycle
needs a certain period to fill the gap made by slaughtered animals but rapid increase in
daily use, change in consumption patterns, use of more meat in food table and economic
up lift has increased the demand by many folds resulting in slaughtering of premature
animals, poor carcass quality and quantity wise and increase in price. If this practice
continued, there would be a huge gap between supply and demand, forcing the import
of meat at large scale. At present small ruminant i.e. sheep and goats are mainly coming
from the range/rain fed areas such as southern Punjab. Southern Punjab has a cultural
and economic tradition of sheep and goat breeding. The tradition can be converted into
profitable business activity capable of creating sustainable employment opportunities.
Poultry industry can get better organized if their produce is purchased by the processing
industry from their door steps.
Build a new facility
The construction of a new slaughtering and processing facility would require at least
$600,000 (Rs600 million) in capital costs. This cost is based upon estimates included in
a recent feasibility study conducted for the Hudson Valley and corroborated by John
Wing of Over the Hill, LLC. In addition, the operation would need to secure all
environmental and zoning permits and deal with all of the challenges faced by any start-
up including the need to identify and secure its market and engage qualified
management and staff. We question whether the potential market in the region north of
Route 2 is large enough, especially in light of the existing facilities in the region, to
support the construction of a new slaughter and processing facility. We would also note
that the permitting process could become fairly onerous if neighbors were opposed to
the idea.
Develop commercial construction facility
Some of the biggest concerns facing potential members are the need for firm
slaughtering dates and the desire to obtain finished product with the professional and
consistent cutting, packaging and presentation that is required in specialty and niche
markets. This is particularly challenging during the busy fall and winter months when a
facility might bump a lamb producer in favor of a custom customer with four or five
head of beef. The consensus opinion is that Punjab region needs additional ISO9001-
licensed fabrication capacity. Such a facility would only be able to assure certification if
the slaughtering occurred under federal inspection. Challenges include chilled transport
of carcasses, finding slaughterhouses willing to provide slaughtering without
processing, finding butchers willing to staff such an operation and making certain than
the final pricing is competitive. Ideally, the facility would be managed by someone with
experience in food service and meat processing. This experience could potentially help
farmers maximize the value of their animals by optimizing the cutting, developing
value-added products such as sausages, marinated meats and products that were pre-
seasoned and ready for cooking.
Operating costs measurements
Operating costs would depend on staffing needs and the source of financing. A sample
operating budget is provided in Appendix E. This budget assumes that the facility
would capture the processing needs of all of the self-identified customers in its first
year and then grow its annual capacity. The budget assumes the facility would need
to borrow $200,000 for 5 years at 9%. Sources of equity are not identified. Given
the identified market for its services, the facility is neither profitable nor does it cash
flow in its first three years. Increased sales definitely help to improve profitability. If
space for such a facility could be leased, the major capital costs would include
processing equipment and the costs associated with installing the requisite
refrigeration, freezer and fabrication space as well as any needed overhead storage
rails. Most slaughterhouses have a chill room (aka the “hot cooler”) for reducing
Co-location with a food preparation facility such as the Food Venture Center, the
Farmer’s Diner planned commissary or a training facility such as UVM or the New
England Culinary Institute (NECI) could offer the potential for sharing some of the
costs and expertise related to refrigeration, management and market and product
development. Initial discussions with NECI, the Food Venture Center and the
proponents of a farmer-owned milk processing facility indicated an interest in
continued exploration of this idea. NECI is planning to relocate its existing meat
fabrication facility on its Montpelier campus within the next year. However, the
targeted new location is not large enough to accommodate co-location.
APPENDIX – SAMPLE LAYOUT OF CUT SHOP
APPENDIX – PROCESSING FACILITY CAPITAL
BUDGET
(Based on international standards)
Anything in a shaded box is an
assumption
Equipment - Processing Cost/unit Unit size Cost Sub-Totals
Leasehold Improvements sq. ft
Floor/ Wall resurfacing 1.0 5,000 5,000
Ventilation 1 5,000 5,000
Sub-
Total 10,000
General Equipment
1 Meat Saw/Grinder 500 300rpm 500
1 Grinder/mixer 1,250 1 hp 1,250
1 Hand Cuber 400 400
1 Sausage Stuffer & Adapter 950 25# 950
1 Meat Mixer 300 50# 300
1 Patty machine 100 100
1 Platform scale 1,600 1,600
1 Scales, hanging carcasses 250 250
1 Scales, Pricing digital 450 450
1 Smoker 25,000 600# 25,000
1 Feed Slicer 2,800 12', 1/2 hp 2,800
1 Bacon slicer 1,375 1,375
1 Ham Pumper 1,300 1,300
1 Pumping table 600 600
1 Sterilizer - knife 70 70
1 Sharpening Stone 200 200
3 Stainless Steel Tables 370 1,110
1 Double sink & faucet 800 800
1 Hand sink 200 200
1 Rollers & rails 200 200
1 Steam Kettle 7,700 40 gallon 7,700
1 Heater, Ht water 900 900
1 Knee-pedal andwashing 300 300
1 Pressure Washer 840 840
1 High-temp dishwasher 5,200 5,200
1 Racks & shelving 1,000 1,000
1 Lugs & Tubs 100 100
1 Shelving 200 200
1 Trays & Racks 1,000 1,000
1 Misc. & Utensils 5,000 5,000
Sub-
Total 61,695
APPENDIX – SAMPLE OPERATING BUDGET
(Based on international standards)
Anything in a shaded box is an assumption
Assumptions Hours/animal Source Year 1 Year 2 Year 3
Beef Processed 8.75 Shepstone 150 250 400
Lamb Processed 2.5 Shepstone 1,000 1,200 1,500
lbs sausage produced 10,400 14,100 18,000
Work hours/year 2,000
50 weeks, 40
hrs 4,293 6,088 8,450
Inflation 103%
Ave. Dressed
Revenues weight Price/# Year 1 Year 2 Year 3
Beef Processed 564 $ 0.60 50,760 84,600 135,360
Lamb Processed 42.5 $ 0.60 25,500 30,600 38,250
Smoking 36 $ 0.65 3,744 7,020 9,360
Sausage See above $ 0.35 3,640 4,935 6,300
TOTAL INCOME 103,804
164,95
5 239,670

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Slaughterhouse feasibility Report

  • 1. Slaughterhouse Feasibility Report COURSE TITLE: PROJECT MANAGEMENT SUBMITTED BY:
  • 2. MuhaMMad Zeeshan aZaM (123220) MuhaMMad asad bin asif (112345) ali Musyab naqvi (112301) SUBMITTED TO: Mrs sadaf latif Name, Job title Company name Date someone@example.com TABLE OF CONTENTS Muhammad Zeeshan Azam (123220).........................................................................................................................2 Muhammad Asad bin Asif (112345)...........................................................................................................................2 Ali Musyab Naqvi (112301).........................................................................................................................................2 ..........................................................................................................................................2 TABLE OF CONTENTS.................................................................................................2 EXECUTIVE SUMMARY.............................................................................................2 BACKGROUND..............................................................................................................3 PROJECT PARAMETERS............................................................................................3 CRITERIA...................................................................................................................................................................3 REGULATORY ISSUES................................................................................................3 Food Safety and Labeling...........................................................................................................................................3 Water Supply...............................................................................................................................................................4 Environmental Considerations...................................................................................................................................4 BUSINESS FEASIBILITY.............................................................................................5
  • 3. MISSION.....................................................................................................................................................................5 BUSINESS DESCRIPTION.......................................................................................................................................5 PRODUCTS AND SERVICES...................................................................................................................................6 MARKET.........................................................................................................................6 EXISTING FACILITIES AND COMPETITION........................................................7 General Environment:................................................................................................................................................7 The quality of meat .....................................................................................................................................................8 BUSINESS COMPETITION..........................................................................................9 OPERATIONAL CHALLENGES...............................................................................10 POTENTIAL OPTIONS...............................................................................................10 BRIEF PROFILE OF SECTOR...................................................................................10 BUILD A NEW FACILITY...........................................................................................11 DEVELOP COMMERCIAL CONSTRUCTION FACILITY..................................11 OPERATING COSTS MEASUREMENTS................................................................12 Executive Summary In this project report, we have support to establish the slaughterhouse in the Pakistani region. The report contains almost every sort of data which might be able to inculcate the importance of running the sector of livestock. The slaughterhouse would be of international standards and would be able to fulfill the regional laws based on the Livestock and Slaughter sector of the country. The sector contributes to: GDP, Income capita, Employment and in overall growth of the country. The business of slaughterhouse is very important if it is based upon scaling, keeping an eye on every step, and also by keeping in view the events in which meat is needed by nation. The
  • 4. meat can be exported to other countries as well. The business development which we have tried is based in Punjab region of Pakistan. BACKGROUND The slaughterhouses in Pakistan are much of the critical cases. They are either having dirty places to store the meat, or they also have poor premises for their operational activities. The thing which we wanted to implement through our project of “slaughterhouse” is to have different operations, activities and many sort of processes which are to be carried-on under the hygienic environment where no doubt of cleanliness is to be noticed by any of the institutions. A large number of small slaughterhouses are scattered all over the country, some are licensed and others are not. A majority of licensed places lack modern amenities which are built and controlled by the municipal committees providing anti-mortem and post- mortem facilities under qualified veterinary officer. The unlicensed slaughterhouses are spread in the villages without any proper plan. They do not provide any facilities and are devoid of a qualified veterinary officer. The slaughtering of livestock in cities like Karachi, Hyderabad, Lahore, Rawalpindi and Peshawar is done in the municipal slaughterhouses, and at times in the streets and at shops. Butchers prefer to slaughter animals at their convenience. PROJECT PARAMETERS CRITERIA As a cooperative, farmers would theoretically have three relationships with the business – as users, as owners and in its governance and oversight. Key information about each of these constituencies and the identified criteria are detailed in the table below REGULATORY ISSUES Food Safety and Labeling The Pakistan Standards, Punjab Food Authority and the Punjab Animals Slaughter Control Act, 1963 as well as State laws govern the slaughtering and processing of meat
  • 5. and poultry for human consumption. Pakistan’s food safety and inspection services are responsible for ensuring that meat and poultry are safe, not adulterated and properly marked, labeled, and packaged. These federal acts define the process for pre- and post- mortem inspection as well as specific marking, labelling and packaging requirements. Generally, federal inspectors oversee facilities that slaughter and process meat and poultry. Food safety authorities have cooperative agreements with all provinces in Pakistan, including Punjab, that allow state inspectors to enforce requirements “at least equal to” those imposed under the federal acts for state-inspected facilities. Regardless of how a facility chooses to operate, federal and Punjab food law require it to be licensed if it is engaged “in the business of buying, selling, preparing, processing, packing, storing, transporting or otherwise handling meat, meat food products or poultry products…” Exemption from federal inspection requirements (i.e. an inspector does not need to be present when animals are slaughtered or processed) are provided for “custom” slaughtering for “personal, household, guest and employee use.” Federal law dictates that these custom facilities be licensed and examined by state inspectors on a periodic basis. Meat packed as “custom” must be marked “not for sale.” Operators of commercial slaughtering facilities often do custom work after hours since inspectors require overtime pay for days longer than eight-hour shifts. Since the timing and packaging requirements of custom slaughtering and processing are more flexible and less-labor intensive, many slaughtering facilities charge less for custom processing than commercial processing. Meat customers who purchase live animals prior to slaughter effectively take advantage of this exemption. In addition, the federal regulations provide exemptions for small-scale poultry producers. Producers slaughtering no more than 1,000 birds annually are exempt from the federal act as long as: 1. All of the poultry was raised, slaughtered and sold on the producer’s own farm; 2. The poultry producer is not in the business of buying or selling poultry products other than those produced from their own birds Water Supply In order for commercial slaughtering and processing facilities to provide meat or poultry that is clean and fit for human consumption, they must have access to drinkable hot and cold water including “conveniently located” sanitary facilities (i.e. toilet and washing facilities) for the inspector. Commercial facilities require permits as a “non- public” water system. In Punjab, the sanitary facilities requirement has been understood to mean that these facilities need to be accessed on-site. Inspectors in other states have allowed the use of farmhouse facilities for the inspector assigned to mobile slaughtering facilities.
  • 6. Environmental Considerations Slaughtering and processing facilities need to meet Global environmental regulations. Expansion of an existing facility or building a new facility usually will require permits related to the appropriate disposal of wastewater and solid waste. The project may also be subject to local community regulations and (although the facility may qualify for an agricultural exemption if it is located on a farm and engaged in an “on-farm activity.”) Solid waste regulations seek to prevent or mitigate the disposal of materials that emit noxious odors and/or compromise the waters of the State. With a slaughtering facility, solid waste regulators are concerned about the proper disposal of rendered material and other residuals including hides, bones, feathers, blood, and animal fat. Much of this material may be composted on-site if the property has sufficient available land, appropriate soils and good setbacks from waterways and neighbors. When looking at the land availability, Operators disposing larger amounts of slaughtering waste need to file for certification of the facility and comply with the Solid Waste Management Rules. The disposal of wastewater presents some additional considerations. If the wastewater was to drain into a municipal sewage treatment plant, it is highly probable that the treatment plant would need to request an amendment to its operating permit. Said amendment would detail the conditions or management approach required to accommodate the high nutrient value in blood waste. An alternative approach would be to compost as much blood as possible by designing appropriate drains and collection systems. If an on-site system were to be used, an indirect discharge permit would be required unless the waste is less than 6500 gallons per day or the wastewater is afforded an agriculture exemption. This agricultural exemption is allowed for wastes generated solely from products or processing of materials produced on the same property. BUSINESS FEASIBILITY MISSION After reviewing the criteria, we have identified our mission as follows: The goal of this cooperative is to enhance the economic viability and sustainability of member farms by ensuring access to affordable, reliable and high-quality slaughtering and processing services. BUSINESS DESCRIPTION The proposed corporation will be operated as a member cooperative. This means that it is designed to act on behalf of and be controlled by the livestock producers who use its services. The actual corporate organization may be a cooperative or a limited
  • 7. liability company. The company will contract as a single entity on behalf of all of its customer/members for slaughtering with one or more existing slaughterhouses and either own, co-own or be actively involved in creating a new commercial fabrication facility that meets the criteria outlined by the steering committee. PRODUCTS AND SERVICES The Steering Committee identified the following potential products and/or services of the cooperative, in priority order: 1. Slaughterhouse services – i.e. slaughtering, processing and wrapping 2. Marketing Venue/Brand for lower quality cuts of meat - this will require quality standards 3. MARKET
  • 8. The size of the market for any slaughtering facility is generally dictated by the distance farmers are willing to have their animals travel prior to slaughtering. This is impacted by the ease, duration and cost of transport as well as how the stress from travel affects the quality of the meat. Most farmers in the group preferred a distance of an hour or less although many already travel further in order to obtain the professional quality services they are seeking from their processing facility. If the transportation issues can be resolved, the market for a quality processing and fabrication facility might be substantially larger. Sales include animals sold for slaughter and consumption as well as those sold between farmers. Sales data for hogs, ruminants and poultry is likely to correlate relatively well with the number of animals slaughtered. Simple correlations are not as easy with cattle and calves, which take longer to reach maturity and are compounded by the number of dairy cattle sent to slaughter.
  • 9. EXISTING FACILITIES AND COMPETITION General Environment: The slaughtering of livestock in cities like Karachi, Hyderabad, Lahore, Rawalpindi and Peshawar is done in the municipal slaughterhouses, and at times in the streets and at shops. Butchers prefer to slaughter animals at their convenience. According to the West Pakistan Slaughter Control Act 1963, the slaughtering of small and large ruminants should be strictly by undertaken in the recognized places with ante- and-post-mortem veterinary inspection. Presently, for small and large ruminants, it is done in the recognized areas, municipal and cantonment and private slaughterhouses, and in the backyards. Municipal corporations operate majority of such places with few operating in the private sector. In general, the existing facilities are insufficient for the requirements. The problem is severe in Karachi, Lahore and Faisalabad. Due to the shortage of facilities, the number of animals slaughtered outside is much higher than those within the boundaries. Therefore, official statistics greatly understate the number of animals slaughtered. The houses can be referred to as mere slabs with no arrangement of hygiene and sanitation. These premises facilitate butchers and traders (not licensed) for the slaughter of livestock at a fee of Rs10 for small and Rs20 for large animal. There are no storage and quality control measures available. Meat rots, especially in the summer season. The problem is intensified when meat is sold through butchers to consumers. If all meat is not sold in daytime, there arises the problem of freezing. Slaughterhouses are situated in thickly populated localities and the present facilities are not reasonable due to congestion on roads. There is no space to examine the animals and the water, drainage and electric facilities too, are limited. The slaughterhouses have no roof but only walls and floor with no arrangements to dispose of the waste material. The place is not properly cleaned, washed, and disinfected. The slaughtered meat is transported to retailers’ through horse-driven carts, auto rickshaws, or pickups. While in the case of small ruminants, butchers take the meat on foot to the shops located nearby. Livestock slaughtering is an important part of meat marketing. Butchers buy animals for slaughtering. They convert them to edible and non-edible and other useful products in merchandising channels through which they move on to consumers. As for the quality, only ante- and post-mortem examination is carried out by the inspectors and the carcass fit for human consumption are stamped as passed. While in rural areas there exists no such system. At retail level, the food committee representatives rarely visit the butcher shop for quality inspection. In urban areas, the inspector does not have the authority to condemn the whole carcass; only disease portions are rejected. It was also observed that all slaughter, carcass
  • 10. dressing and product handling are done in the same space. In addition to this, the facilities of drainage system, waste disposal and handling of by-products are inadequate and sometimes non-existent, resulting in the contamination of the carcass. The quality of meat The quality of meat, particularly of cattle and buffaloes, is generally low but varies widely from locality to locality. The poor quality of beef is because of very old or young animals. Special breed for beef as evolved in other countries does not exist in Pakistan. As a result, the average dressed carcass weight of cattle in countries rearing meat animals is over 500kg, whereas in Pakistan it is about 300kg. Similarly, the average dresses carcass weight of goat and sheep in Pakistan is about 15.9 g and 12.3kg, respectively. The livestock producers keep most of the stock on their own preferences. They never think of consumers whose choice reflects on the price of the stock. Fair prices can be assured by standardization and gradation. Cooperative associations play a positive role for the livestock sector development. Such associations can accelerate the standardization and gradation, improve the distributive process and maximize the producer’s income. According to the Pakistan Slaughterhouse Act of 1983, the killing of animals outside the boundary of slaughterhouses is prohibited. Recognized slaughterhouses usually provide separate buildings for slaughtering large and small animals. A majority are now located in thickly populated areas. The slaughtering, carcass dressing and by-product handling are done in the same space. Business Competition In Pakistan, there is a much sort of Viral Competition among slaughterhouses and every slaughter has to follow the rules and regulations but unfortunately many of them do not meet to follow the rules and laws issued by the Punjab Food Authority and other federal laws and authorities. Pakmeat Halal Sourcing Pakistan Herbancepura Lahore Sadiq & Saddique Enterprises Pakistan Gpo Haji Camp Road Rawalpindi Umh Industries Pvt, Ltd. Pakistan Gujrānwāla Daska Road Sialkot Punjab
  • 11. Malik Textile Industries (Pvt) Ltd Pakistan L-30 Block-22 Industrial Estate Federal "B" Area Karachi Smmexport Industries Ltd Pakistan Green Wood St Sialkot Punjab Azlan International Pakistan 625/a Hawks Bay Road Karachi Agriculture Welthing Surgical Company Pakistan Sialkot Punjab Anaco Sports Pakistan Sialkot Cantt Pakistan RS International Trading Co Lahore 3-a Board of Revnue Sociaty Johar Town Lahore Punjab Syntronics Limited Pakistan Mandviwala Chambers Talpur Road Karachi Sindh Operational Challenges All of the slaughterhouses visited by the steering committee experience seasonal variations in the demand for their services. The busiest months are generally from mid- August through January with significant slowdowns in May and June. Having sufficiently skilled staff in the busy months and keeping full-time staff occupied through the slower months can prove challenging for these facilities. As a result, slaughterhouses welcome arrangements that better spread the demand for services over the year. The operation of the kill floor is highly dependent on the skill and speed of the people staffing and managing the process. In most cases, the owner of the facility is actively managing this process. Finding qualified staff remains a challenge for these operations. Most of the facilities only slaughter animals one or two days each week. In other words,
  • 12. the factor that limits increased activity and sales is often the hanging and processing capacity NOT the availability of slaughtering facilities. Although many of the State’s slaughterhouses offer a meat counter, few have focused on aggressive marketing or selling their product into niche markets. If this were to change, it could create significant competition for farmers who are direct selling into these markets. POTENTIAL OPTIONS The group realized that purchase of an existing slaughterhouse was one of a number of options that could be considered in order to achieve their goals. Other options included building a new state of the art facility, building and operating a mobile facility, building and operating a commercial processing facility, contracting as a group for services. BRIEF PROFILE OF SECTOR There is a huge shortage of slaughter animals for meat supply. The animal growth cycle needs a certain period to fill the gap made by slaughtered animals but rapid increase in daily use, change in consumption patterns, use of more meat in food table and economic up lift has increased the demand by many folds resulting in slaughtering of premature animals, poor carcass quality and quantity wise and increase in price. If this practice continued, there would be a huge gap between supply and demand, forcing the import of meat at large scale. At present small ruminant i.e. sheep and goats are mainly coming from the range/rain fed areas such as southern Punjab. Southern Punjab has a cultural and economic tradition of sheep and goat breeding. The tradition can be converted into profitable business activity capable of creating sustainable employment opportunities. Poultry industry can get better organized if their produce is purchased by the processing industry from their door steps. Build a new facility The construction of a new slaughtering and processing facility would require at least $600,000 (Rs600 million) in capital costs. This cost is based upon estimates included in a recent feasibility study conducted for the Hudson Valley and corroborated by John Wing of Over the Hill, LLC. In addition, the operation would need to secure all
  • 13. environmental and zoning permits and deal with all of the challenges faced by any start- up including the need to identify and secure its market and engage qualified management and staff. We question whether the potential market in the region north of Route 2 is large enough, especially in light of the existing facilities in the region, to support the construction of a new slaughter and processing facility. We would also note that the permitting process could become fairly onerous if neighbors were opposed to the idea. Develop commercial construction facility Some of the biggest concerns facing potential members are the need for firm slaughtering dates and the desire to obtain finished product with the professional and consistent cutting, packaging and presentation that is required in specialty and niche markets. This is particularly challenging during the busy fall and winter months when a facility might bump a lamb producer in favor of a custom customer with four or five head of beef. The consensus opinion is that Punjab region needs additional ISO9001- licensed fabrication capacity. Such a facility would only be able to assure certification if the slaughtering occurred under federal inspection. Challenges include chilled transport of carcasses, finding slaughterhouses willing to provide slaughtering without processing, finding butchers willing to staff such an operation and making certain than the final pricing is competitive. Ideally, the facility would be managed by someone with experience in food service and meat processing. This experience could potentially help farmers maximize the value of their animals by optimizing the cutting, developing value-added products such as sausages, marinated meats and products that were pre- seasoned and ready for cooking. Operating costs measurements Operating costs would depend on staffing needs and the source of financing. A sample operating budget is provided in Appendix E. This budget assumes that the facility would capture the processing needs of all of the self-identified customers in its first year and then grow its annual capacity. The budget assumes the facility would need to borrow $200,000 for 5 years at 9%. Sources of equity are not identified. Given the identified market for its services, the facility is neither profitable nor does it cash flow in its first three years. Increased sales definitely help to improve profitability. If space for such a facility could be leased, the major capital costs would include processing equipment and the costs associated with installing the requisite refrigeration, freezer and fabrication space as well as any needed overhead storage rails. Most slaughterhouses have a chill room (aka the “hot cooler”) for reducing
  • 14. Co-location with a food preparation facility such as the Food Venture Center, the Farmer’s Diner planned commissary or a training facility such as UVM or the New England Culinary Institute (NECI) could offer the potential for sharing some of the costs and expertise related to refrigeration, management and market and product development. Initial discussions with NECI, the Food Venture Center and the proponents of a farmer-owned milk processing facility indicated an interest in continued exploration of this idea. NECI is planning to relocate its existing meat fabrication facility on its Montpelier campus within the next year. However, the targeted new location is not large enough to accommodate co-location. APPENDIX – SAMPLE LAYOUT OF CUT SHOP
  • 15.
  • 16. APPENDIX – PROCESSING FACILITY CAPITAL BUDGET (Based on international standards) Anything in a shaded box is an assumption Equipment - Processing Cost/unit Unit size Cost Sub-Totals Leasehold Improvements sq. ft Floor/ Wall resurfacing 1.0 5,000 5,000 Ventilation 1 5,000 5,000 Sub- Total 10,000 General Equipment 1 Meat Saw/Grinder 500 300rpm 500 1 Grinder/mixer 1,250 1 hp 1,250 1 Hand Cuber 400 400 1 Sausage Stuffer & Adapter 950 25# 950 1 Meat Mixer 300 50# 300 1 Patty machine 100 100 1 Platform scale 1,600 1,600 1 Scales, hanging carcasses 250 250 1 Scales, Pricing digital 450 450 1 Smoker 25,000 600# 25,000 1 Feed Slicer 2,800 12', 1/2 hp 2,800 1 Bacon slicer 1,375 1,375 1 Ham Pumper 1,300 1,300 1 Pumping table 600 600 1 Sterilizer - knife 70 70 1 Sharpening Stone 200 200 3 Stainless Steel Tables 370 1,110 1 Double sink & faucet 800 800 1 Hand sink 200 200 1 Rollers & rails 200 200 1 Steam Kettle 7,700 40 gallon 7,700
  • 17. 1 Heater, Ht water 900 900 1 Knee-pedal andwashing 300 300 1 Pressure Washer 840 840 1 High-temp dishwasher 5,200 5,200 1 Racks & shelving 1,000 1,000 1 Lugs & Tubs 100 100 1 Shelving 200 200 1 Trays & Racks 1,000 1,000 1 Misc. & Utensils 5,000 5,000 Sub- Total 61,695 APPENDIX – SAMPLE OPERATING BUDGET (Based on international standards) Anything in a shaded box is an assumption Assumptions Hours/animal Source Year 1 Year 2 Year 3 Beef Processed 8.75 Shepstone 150 250 400 Lamb Processed 2.5 Shepstone 1,000 1,200 1,500 lbs sausage produced 10,400 14,100 18,000 Work hours/year 2,000 50 weeks, 40 hrs 4,293 6,088 8,450 Inflation 103% Ave. Dressed Revenues weight Price/# Year 1 Year 2 Year 3 Beef Processed 564 $ 0.60 50,760 84,600 135,360 Lamb Processed 42.5 $ 0.60 25,500 30,600 38,250 Smoking 36 $ 0.65 3,744 7,020 9,360 Sausage See above $ 0.35 3,640 4,935 6,300 TOTAL INCOME 103,804 164,95 5 239,670