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