Professional Documents
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Al Sami Agro Products Private Limited acquired Ac. 10.00 cents land at
Ramannapalem village, Vajrakutam Panchayat, Sankhavaram Mandal, east
Godavari. Dist. Andhra Pradesh in 2009 with intention to establish an integrated
slaughter house, meat processing unit and a Rendering plant.
The proposed site is located in an isolated place surrounded by hills with
good slope and is away from the village habitation. It is also close to National
Highway (NH5) about 18 to 19 KMS with good black top road connecting the
1\11-15 and is about 20 22 KMS away from ANNAVARAM town. However the
site is connected with the village blacktop road to some extent and the connecting
road between the village road and the proposed site is a kachha road which needs
to be converted into all-weather proof road for regular transportation purpose as
several heavy vehicles are expected to visit the unit. The total area is 32.50 acres
of land and a small bit of 0.50 cents is allocated for rendering plant adjacent to
bio-filtration plant for water disposal. The company has also procured 18.00 more
acres land abetting the present location to cater to the future needs. The land is
sufficient for the Slaughter House, Processing unit and Rendering unit. The
surroundings are free from pollution. The green belt is enough to create art eco
friendly environment.
Project Justification:
Hygiene of slaughter house is very important to prevent contamination of
meat. Meat easily perishable and contamination of meat can lead to serious health
issues. The contamination of food will lead to various diseases many, even causing
death. In a hamburger case, the Escherichia coli inside the meat survived due to
short period heating which caused illness and death in children. All conditions and
measures necessary to ensure the safety and suitability of meat at all stages of the
food chain are needed Ensuring hygiene is the shared responsibility of the farmers,
manufactures and consumers. Al Sami is way ahead in this direction.
Slaughtering of animals also generates wastes consisting of non edible offal
like lungs, large intestines, various glands, animal tissues, organs, various body
parts, etc.; stomach / intestinal contents dung bones etc. Large quantity of waste
water is also generated during washing. The average quantity of unusable wet
solid waste produced by slaughtering (excluding dung) is estimated as 12kg per
cattle / buffalo, 4kg per pig, 2.5 kg per goat, and 0.6 kg per poultry. The present
practices in most of the slaughter sheds and chicken stalls are to dispose the wastes
to the rivers, streams or water bodies. The unit is establishing highly efficient
Effluent Treatment Plant, so that the waste will not create environmental
problems. Further, tissue waste rendering plant is also being set till for generating
Meat Bone Meal and Tallow from non edible waste.
Lairage:
Lairage is for keeping the animals indented for slaughter,., well in advance
for observation and convenience. For providing water and feed to the animals,
arrangement shall he there in the Lairage. The Lairage should have anti mortem
facility to check each animal for physical disease or pregnancy.
AAPL designed establish 2 Lairage sheds with specification, of 25 X 120 each
with sufficient ventilation and water facilities. To maintain hygiene, drainages are
linked to underground sewage system to effluent treatment plant.
Slaughter Hall:
Separate provision shall be made for slaughtering large and small animals..
Separate space shall be provided for stunning, bleeding and dressing-.of carcass.
Animals shall not be slaughtered in sight of other animals. Dirty area consists of
bleeding and dressing section and clean area for meat cutting inspection and
dispatch. Pedal operated Water taps and wash basin shall be provided in the
slaughter hall. At the bleeding area, the blood is to be collected in stainless steel
basin for further processing / disposal. The collected blood is to be stored in tank
for heating and drying for manufacture of blood meal. Stainless steel wheel
barrow is to be provided in the slaughter hall to collect and remove waste itemslike large bones, tail, intestine etc into the strippers outside-and dispose the same
on completing the slaughter of the day.
Stunning Area:
As per PCA Rules a stunning area is to be provided for large animals. Floor level
of stunning box need be in an elevated Plane than that of the bleeding area. One
side of the stunning box shall be with hinged plate. Immediately after stunning,
the animal falls on the side wall of the stunning box, and the hinged plate will
open and the animal slips on to the bleeding area. The bleeding area need be
positioned in such a way that, art animal in the stunning box will not see the
bleeding animal. In the case of HALAL slaughtering, separate cubicles made up Of
RCC wall and with ceramic tile in walls shall be utilized. Sufficient drains and floor
slope shall be provided for easy drainage of blood from the cubicles. Bleeding is
done by hoisting the animal to a height of 5 in rail system and blood collection
vessel with funnel shall be used for collection of blood .
washing
DESPATCH
LAIRAGE
LAIRAGE
POST MORTEM
MORTEM
POST
ANTI MORTOM
CARCASS WASHING
STUNNING
/ HALAL
STUNNING
/
SLAUGHTER
CARCASS SPLITTING
HALAL
SLAUGHTER
BLEEDING
CARCASS WASHING
EVISCERATION
DEHIDING
HEAD REMOVAL
The main emphasis of the process is to segregate Waste at different stages and to
recover resources from it and use minimum quality of Water. For this, the slaughter
house requires sufficient good quality water round the year. This is for consumption of
animals, its washing before slaughtering, washing the meat, human consumption,
washing the floor and other areas etc. if water supply is available connection can be
taken and overhead PVC Water tanks can be provided for this purpose. Otherwise a
bore well can be constructed, and shall be provided with pump. A solar water heater
shall be installed for the purpose Of hot water. Hot Water shall be used for Washing
slaughter hall and for sterilizing tools.
Waste Management:
Effective waste management can reduce environmental problems associated with
slaughter house. The strategy followed is to reduce waste by segregating resources from
different types of waste generated in the Slaughter houses. Solid waste is the main waste
product from the slaughter house. Solid waste from slaughter house can be divided into
two main groups, namely edible & inedible. Organs such as brain, liver, heart are the
examples of edible by-products. Hooves; horns, hair, gall bladder, ears, skin, bones etc.
are the inedible by products. The components left recovered forms are the solid wastes.
In a modern slaughter house most of the solid wastes can be recovered as by-products.
Success of material recovery depends on how slaughtering is done and how the facilities
are provided the slaughter house.
Annexure IV
PROCESS FLOW CHART OF SAFE AND HYGENIC MEAT PRODUCED IN MEAT PLANTS
RECEIVING
HOLDING
RE
ANTIMORTEM
CCP - 1
LAIRAGE
ANIMAL RACE WASHING
HALAL
Typing of
oesophagus
CCP - 2
WASHING
WEIGHING
CHILLING
CCP - 3
DEBORING
PROCESSING
PACKING
MATERIAL
QC INSPECTION
WEIGHING OF PACKED CARTONS
PACKING, CARTOONING &
SHINK WRAPPING
METAL DETECTOR
CCP - 4
FREEZING
CCP - 5
COLD STORAGE
CCP - 5
DESPATCH
Slaughtering activities:
A slaughter house or abettor is a facility where animals are stunned for consumption as
food products. Arrangement will be provided in slaughter house for humane
slaughtering. Large animals will be stunned mechanically by pistol. In case of goat, sheep,
and pig, electric stunner will be used.
The blood collected from the slaughter houses will be collected and sent to the rendering
plant. Sat the slighter house adequate tools will be provided for de-hiding of the animals,
hides and skins will be supplied to the tanning Industry. Legs, bones, hooves, etc. will
also be removed and send to the rendering plant.
Hence, all solid wastes arising in the slaughter house shall be properly graded and
disposed of to the rendering plant.
In the discussion on slaughter activities, the focus will be on the slaughtering of cattles.
These types of animals make up almost 3 to 4 tons meat production. The discussion of
the slaughtering process and the waste production. In the slaughter process basically the
following by-products and waste products become available:
Manure, contents of rumen and intestines.
Edible products such as blood and liver;
Inedible products such as hair, bones, feathers;
Fat (recovered from the wastewater by means of fat-separators) and
wastewater.
In most developed countries, slaughtering is a centralized activity. The consumer in
these countries has a preference for lean meat and a few selected buffalos only, such as
brain, kidney, sweetbread, tongue, etc. For this reason, the carcass is often deboned at
the slaughterhouse and cooled before being sent to retail outlets. As a result, large
quantities of by-products (bones, lungs spleen, esophagus etc.) are left behind at the
slaughterhouse. They fall in the category of inedible offal. For economic and
environmental considerations, these need to be suitably processed and utilized. Clean
fatty tissues such as kaul and mesentery fat may be processed into edible fat. Other tissues
may be used to produce composite bone-cum-protein meals or individual products like
bone-meal, meat-meal and blood-meal. In principle all edible and inedible by-products
can be processed and put to further use (e.g. human consumption, pet food, feed
industry or fertilizer). Modern abattoirs are well equipped and are in the possession of
running water, steam, power, refrigeration, transport and other facilities. These facilities
make it also possible that glands are preserved for the production of glandular products.
In developing countries a large variety of slaughter sites exists. Slaughter sites vary from
simple slaughter slabs to very modern slaughterhouses. Large scale industrial processing
units are imported from developed countries, often without rendering or waste
treatment facilities. Many slaughterhouses (of various types) are insanitary and pose
threats to health, particularly around rapidly expanding population areas. Often old
slaughterhouses discharge blood and untreated wastewater. The elimination of sick
animals and subsequent destruction are frequently carried out inappropriately. Blood
may coagulate in drains where it putrefies, causing bad odour and sanitary and
environmental problems. Edible and inedible by-products are frequently wasted during
the slaughtering and further processing owing to amongst others:
(1) Insufficient skills and discipline in slaughtering;
(2) poor quality of slaughtering equipment in the slaughterhouse, slaughtering on the
floor, no slaughter line, lack of adequate maintenance and lack of spare parts;
(3) A non-cost-effective processing of by-products either because of the small quantities
involved, the high costs of processing or the low value of the end product;
(4) Lack of equipment for the processing of by-products; and
(5) Lack of regulations on the discharge of wastes or the inability of the authorities to
enforce regulations.
Charges for slaughtering in abattoirs are often kept low to prevent illegal slaughtering.
Furthermore, slaughter fees constitute a source of income for the municipality. As
however these funds are not used for the operation and maintenance of the abattoir,
abattoirs have difficulties in maintaining certain standards.
Approximately 80 percent of the population in developing countries lives in rural areas.
The great majority of animals are likely to be slaughtered and processed domestically or
in small slaughter slabs. The processing and the utilization of offal require a technology
and capital lay-out which are completely different from those in developed countries.
Huge capital investments in infrastructure of plants and machinery, as is the case in
developed countries cannot be justified. In developing countries also most of the soft and
fat tissues are used for consumption purposes. This reduces the amount of offal with 1015% of the live weight killed (LWK).
The incidence of natural death of livestock in developing countries is relatively high. This
rather leads to sanitary problems than to environmental problems as most of the dead
animals are scattered over large areas.
The raw material for the unit i.e. barren buffalo (after lactation), draught animals
which farmers sell for slaughtering due to their low economic yield and unproductive
buffaloes, which are available abundantly in North Coastal Andhra Pradesh.
Meat
processing units purchase meat from these approved slaughter houses for processing. By
setting up slaughter house at the present location will save transportation cost to these
units besides improved quality due to proximity of the unit to the processing plants. The
promoters have made necessary study regarding the availability of animals and the study
revealed that the present plant could cater only to the extent of 25% of available stock.
Further, with construction of rendering plant, the unit providing complete solution for
the waste management and by-product development and marketing.
Manufacturing Process:
Animals received from the mandis and market will be received at the reception
place and will be inspected by the veterinary doctors (appointed by the company).
Lairage is for keeping the animals indented for slaughter, well in advance for observation
and convenience. It will have arrangement for providing water and feed to the animals
and also anti-mortem facility to check each animal for physical disease or pregnancy.
M/s. AAPPL is establishing 2 lairage sheds with 17848 sq. ft. each with sufficient
ventilation and water facilities. To maintain hygienic, drainages are linked to
underground sewage system to effluent treatment plant.
Separate provision is made for slaughtering large and small animals. Separate space for
stunning, bleeding and dressing of carcass is provided. Animals will not be slaughtered in
sight of other animals. Dirty area consists of bleeding and dressing section and clean area
comprises of meat cutting, inspection and dispatch. Pedal operated water taps and wash
basin shall be provided in the slaughter hall. At the bleeding area, the blood is to be
collected in stainless steel basin for further processing. The collected blood is to be stored
in tank for heating and drying for manufacture of blood meal. Stainless steel wheel
barrow is to be provided in the slaughter hall to collect and remove waste items like
large bones, tail, intestine etc. in to the striper outside and dispose the same on
completing the slaughter of the day.
As per PCA Rules a stunning area is to be provided for large animals. Floor level of
stunning box needs to be in an elevated plane than that of the bleeding area. One side
of the stunning box shall be with hinged plate. Immediately after stunning, the animal
falls on the side wall of the stunning box, and the hinged plate will open and the animal
slips on to the bleeding area. The bleeding area needs to be position in such a way that,
an animal in the stunning box will not see the bleeding animal.
In case of Halal
slaughtering, separate cubicles made up of RCC wall and with ceramic tile in walls shall
be utilized. Sufficient drains and floor slope shall be provided for easy drainage of blood
from the cubicles. Bleeding is done by hoisting the animal to a height of 5 mt rail system
and blood collection vessel with funnel shall be used for collection of blood.
Dressing:
Dressing is carried out in rails fitted at a height of 3 Mts. Adequate means and tools for
de-hiding or belting or the animals should be provided. Hides or skins should be
transported either in a closed wheel barrow or by a chute provided with a self-closing
door. Means for immediate disposal of legs, horns, hooves etc. should be provided
through spring load floor chutes or side wall doors or closed wheel barrows.
Evisceration:
Adequate space and suitable and properly located facilities shall be provided for
inspection of the viscera of the various types of animals slaughtered. This area shall have
adequate facilities for hand washing, tool sterilization and floor washing and
contrivances for immediate separation and disposal of condemned material. Adequate
arrangements may be made for identification, inspection and correlation of carcass,
viscera and head.
Tanning processes:
According to the FCI, 78% of all processed hides come from cattle and buffalo, 15%
comes from sheep and 7% from goats. In the present report, the discussion of the
tanning process is restricted to the tanning of the above mentioned hides and skins.
The tanning process can be partitioned in three processes:
Beam house operations;
The tanning itself; and
The finishing activities.
Some factories only carry out beam house operations, others only finishing activities. A
third group of tanneries carries out all three activities. Hides are usually tanned twice.
The first tanning is a mineral or vegetable type of tanning. These days mineral tanning is
the most popular method for large-scale tanning because it acts quickly and produces
leather with desirable physical and chemical properties. Of the minerals, chromium is the
most frequently used chemical (95%). For the retaining, a combination of agents is used,
mostly of vegetable compounds. For traditional vegetable tanning, barks and nuts are
used instead of chromium. Probably a small portion is oil-tanned, mainly for the
production of chamois leather. Of the worlds output of tanned material, 60% is
assumed to be tanned with chromium while 10% is tanned by means of vegetables. The
remainder is estimated to be treated with aniline or other ingredients. In the United
States, over 20,000 hides are tanned per day of which 23.5% with vegetable tannins
and 76.5% with chromium.
In most developing countries, tannery effluents are discharged into sewers or inland
surface waters and/or brought onto the land with irrigation water. The high
concentration of salt and hydrogen sulphide in tannery wastewater affects the quality of
water and may cause bad taste and odor. Suspended matter (lime, hair, fleshing, etc.)
makes the surface water turbid and settles eventually on the bottom. Both processes
create unfavorable conditions for aquatic life. Mineral tannery wastewater that is
discharged on land will affect the soil productivity adversely and may cause land to
become infertile. As a result of infiltration, the quality of the ground water is affected
adversely also. Discharge of untreated tannery effluents into the sewer system causes
deposition of calcium carbonate and choking of the sewer.
In developed countries the tannery effluent is treated intensively before it is discharged
into surface water. As a result of wastewater purification the chromium and BOD levels
of the purified water is relatively low. The sludge in the waste water systems has to be
brought to special dumping grounds because of its chromium content.