Journal of Cleaner Production 17 (2009) 1200–1205

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Journal of Cleaner Production

journal homepage: www.elsevier.com/locate/jclepro

Cleaner production in the management of water use at a poultry

slaughterhouse of Vale do Taquari, Brazil: a case study
Lourdes Teresinha Kist, Said El Moutaqi, Ênio Leandro Machado*
Department of Chemistry and Physics, Universidade de Santa Cruz do Sul – UNISC, Avenida Independência, 2.293, CEP 96815-900 Santa Cruz do Sul, RS, Brazil

a r t i c l e i n f o a b s t r a c t

Article history: This study included the layout characterization for the production process of a poultry slaughterhouse
Received 23 December 2008 using qualitative and quantitative flow charts for water management; analysis of general parameters for
Received in revised form pollution load in the wastewater produced in critical stages of the production process and assessment of
31 March 2009
environmental impact indicators. Prognoses for cleaner production based on water management were
Accepted 7 April 2009
established. The diagnostic stage revealed that the scalding, pre-chilling, separated points of wastewater
Available online 20 May 2009
disposal for the wastewater treatment plant and disposal of treated and non-reused wastewater were
critical for water management. Dissolved oxygen depletion and eutrophication account for the major
Keywords:
Water environmental impacts of these wastewaters, resulting in an environmental pressure index of 32.1. The
Slaughterhouse opportunities for cleaner production implementation resulting from this study include the reuse of
Cleaner production wastewaters from pre-chilling and chilling for pre-washing of carcasses, since average temperatures of
these wastewaters range between 4 and 16  C. This will contribute to lowering the oil and grease
pollution load. Another strategy concerns the standardization of cleaning procedures with rational water
use in all work shifts and implementation of water meters on a sector-by-sector basis. In the latter case,
which has already been implemented, water consumption was reduced by 13%.
Ó 2009 Elsevier Ltd. All rights reserved.

1. Introduction
The poultry slaughtering industry in Brazil has enormous
economic importance as the country ranks among the world’s
biggest chicken meat exporters. According to the Brazilian Associ-
ation of Poultry Producers and Exporters (ABEF), 3.3 million tons of
whole chicken and chicken cuts were exported to major markets in
Asia, European Union and Middle East in 2007, with an export
revenue of approximately US$ 5 billion. The company under anal-
ysis exports 27,000 tons of chicken cuts and of whole chicken
especially to the Middle East, Asia, Central America and Africa.
However, the environmental impact caused by this productive
sector is strong, chiefly due to water consumption, whose averages
exceed 10 l per slaughtered fowl, with a eutrophication potential of
372 g TKN m3 [1] and a BOD5 pollution load of 0.14–0.18
kg BOD5 kg1 [2].
Environmental problems brought about by poultry slaughter-
houses in the Vale do Taquari region in the state of Rio Grande do
Sul (RS), southern Brazil, are based on the end-of-pipe approach,
according to which every production process results in waste
* Corresponding author. Tel./fax: þ55 51 37177545.
E-mail address: enio@unisc.br (Ê.L. Machado).
products, which shall be treated later on. Several chicken slaugh-
tering facilities are established in this region of RS, some of which
employ partial water reuse only for truck washing. Nevertheless,
most of them do not have a systematic cleaner production (CP), and
eventually lose nutrients, large potentials for wastewater reuse and
energy in their effluents, thus corroborating that studies on water
use management play a major role in CP implementation.
The methodology for the implementation of the CP program was
developed by the United Nations Industrial Development Organi-
zation (UNIDO) and by the United Nations Environmental Program
(UNEP), based on the European know-how about waste manage-
ment and about the misuse of energy and materials [3,4].
The Brazilian Center for Clean Technologies of the state of Rio
Grande do Sul (CNTL) aims to create a network comprised of
organizations and professionals, in order to expedite the transfer of
information and technology to companies, allowing for the
implementation of CP techniques in their environmental manage-
ment systems. This transfer of information and of knowledge is
targeted at enhancing CP actions [5].
Studies on CP involving slaughtering facilities have investigated
simple procedural changes in poultry slaughter, such as longer
exsanguination time for better blood collection and rational use of
salt for the preservation of poultry skin. Other important CP options
include the use of water pressurizers for cleaning and the use of

0959-6526/$ – see front matter Ó 2009 Elsevier Ltd. All rights reserved.
doi:10.1016/j.jclepro.2009.04.006
 L.T. Kist et al. / Journal of Cleaner Production 17 (2009) 1200–1205
cooled water for reducing the oil and grease pollution load in
wastewaters during carcass washing [2]. In addition, the possibili-
ties of separation and treatment of wastewater produced by the
chiller were assessed, considering membrane filtration so as to
allow for its reuse and non-disposal into the wastewater treatment
plant (WTP) [1]. Improvements in wastewater treatment by means
of sequential nitrification/denitrification reactors instead of
lagoons also have been suggested [6], and some authors have
adopted reuse procedures for fertigation and cleaning of areas
where the animals that will be slaughtered are received [1].
Therefore, the major goal of the present paper is to develop
a strategy for water use management, in compliance with the
Brazilian laws, in order to offer alternatives to the reduction in
water consumption and wastewater production at a poultry
slaughterhouse in southern Brazil. More specifically, water
balance by measurement of water consumption and of the
punctual and overall production of waste products; the charac-
teristics of environmental impact associated with water use and
the alternatives to the reduction, recycling and direct and indirect
reuse of water.
2. Methodology
2.1. Monitoring of industrial activities and analytical parameters
The production process and the main procedures used at
a poultry slaughtering facility in southern Brazil were monitored
throughout one year. The methodological sequence sought to
reproduce the environmental diagnostic and prognostic phases of
SENAI-CNTL, established by UNEP and UNIDO [3,5,7].
All sectors, including receiving, stunning and exsanguination,
scalding and defeathering, evisceration, pre-chilling, cut-up area,
packaging and shipment, in addition to the wastewater treatment
plant, were checked during the visits.
The monitoring of industrial activities allowed for the identifi-
cation of sites and sectors with higher water consumption and
wastewater production. These sites were sampled to determine the
chemical oxygen demand (COD), the biochemical oxygen demand
(BOD5), oils and greases, total nitrogen and total phosphorus. Based
on these parameters, the pollution load of the separated waste-
water streams and the efficiency of the treatment system were
assessed, giving priority to eutrophication index and to rates of
dissolved oxygen depletion. Collections were carried out in April,
July and December so as to contemplate different seasons. The
selected sampling sites were the scald tank, the pre-chiller, the raw
WTP influent and the final treated wastewater.
Collections, preservation and analysis of the samples were
performed according to the APHA/AWWA/WEF-Standard methods
for the examination of water and wastewater 2005 [8].
2.2. Qualitative and quantitative determination of environmental
impact indicators
2.2.1. Leopold matrix
The first step for the determination of environmental impact
indicators in the poultry slaughtering industry was a qualitative
one. The data were obtained using the interaction matrix derived
from the Leopold matrix [9,10].
’The impacts upon the physical, biotic and anthropic envi-
ronments caused by activities or actions contemplated and rep-
resented in the interaction matrix were listed considering the
environment specified in sample collection. The identification of
impacts was made by the relationship between the previsional
action and the environmental factor considered and its qualitative
characteristics.
1201
The qualification of the environmental impacts was based on
the following criteria: value (positive and negative impacts); order
(direct and indirect impacts); space (local, regional and strategic);
time (short, medium and long term); dynamics (temporary, cyclical
and permanent) and plasticity (reversible or irreversible).
2.2.2. Environmental impact indicators
For assessment of environmental impact indicators, the method
and software program developed by the System for Environmental
Assessment of Industrial Processes – SAAP [11] were used. SAAP
complies with ISO 14000 standards. Eutrophication index (EI), rate
of dissolved oxygen depletion (RDOD) and environmental pressure
index (EPI) were determined. The references regarding the legal
limits followed the Resolution of the State Environmental Council
(CONSEMA No. 128/2006) [12] and the recommendations of Dos
Santos [13].
The environmental pressure index included the determination of
the weights of two environmental impact indicators (EI and RDOD),
established by the SAAP software program. The program compiles
the indicators automatically and calculates the weights [13].
2.2.3. CP measures
Based on the diagnosis, the critical points of environmental
impacts were defined, considering correction measures, optimiza-
tions or changes in products, processes or services. These measures
also follow the SENAI-CNTL standards, established by UNEP and
UNIDO [3,5,7].
3. Results and discussion
3.1. Characterization of the site of study
and environmental diagnosis
The meat processing industry under analysis is characterized
by chicken slaughtering and processing of special chicken meat
cuts. The analyzed meat processing plant slaughters 103,000
chickens and has a maximum capacity for 120,000 chickens per
day. The company markets several products, which total 139
types and are sold frozen or chilled to the domestic or foreign
market.
In this industrial plant, water is used in virtually all stages,
especially for cleaning the sectors, equipment and facilities; several
sectors of the slaughtering plant do not have ways that allow
determining how much water is consumed. Fig. 1 shows the whole
slaughtering process and the final destination of water in all of the
stages. The normal average slaughtering rate amounts to
8000 chickens/h. None of the sectors of the slaughtering plant has
ways to determine water consumption.
However, by observing the activities in the different stages of
slaughtering, it was possible to perceive higher water consumption
in the scalding and pre-chilling stages.
The slaughter plant is cleaned only with water, according to
necessity during the slaughtering process. At the intervals in
between, the slaughter plant is cleaned with detergents and chlo-
rine. And at night, the plant is totally cleaned, as there is no
slaughter in this period.
3.2. Characterization of wastewaters
The quantitative profile of water use by the slaughterhouse
analyzed is shown in Table 1.
The average total consumption of water in the industrial unit
corresponds to 1800 m3 day1. The percentage rates obtained for
water use indicate losses of 20% between the inflow and outflow at
the end-of-pipe for treatment at the WTP. The main water use in
1202 L.T. Kist et al. / Journal of Cleaner Production 17 (2009) 1200–1205
Chickens and trucks
Receiving
Acclimatization
Cleaning
Slaughter and
exsanguination
Water
Scalding
Defeathering
Evisceration
Carcass rinsing
Pre-chilling and chilling
Packing and freezing
Expedition
Fig. 1. Flow chart showing the slaughtering process.
poultry slaughtering concerns the cleaning and disinfection of all
sectors and equipment during the slaughtering process. Examples
include the receiving of poultry, washing of cages and trucks,
scalding, defeathering and carcass washing.
’Wastewaters were collected at the sites with the highest
water consumption, during the scalding and pre-chilling stages.
Assessments of WTP efficiency were made, especially because
this plant is exclusively used for treating wastewaters from this
slaughterhouse, which follows end-of-pipe policies for water use
management. Table 2 shows the values with regard to the
collection of wastewaters generated during the production
process in April, July and December 2007. These time periods
were chosen in an attempt to better represent the oscillations in
foreign demands, as exports oscillate around 11% throughout
these months. The number of poultry slaughtered every day
during these months amounted to 93,442 in April, 102,520 in July
and 103,977 in December. However, the treatment plant has
enough capacity to treat the additional pollution load, as shown
in Table 1. The values indicate the eutrophication potential and
demonstrate the inefficiency of the system in removing total N
and P, since they are above the limit established by Resolution No.
128/2006-SSMA of CONSEMA [12].
The largest pollution loads from scalding are related to the
remainders of blood and fats produced by exsanguination.
Exsanguination is referenced in the literature as a critical opti-
mization procedure for the elimination and recovery of blood
residues [2].
Manure Composting
Blood
Industry of animal feed
Viscera,
feet and WTP
heads
Packing waste Recycling
3.3. Qualitative and quantitative diagnosis of anthropic actions
Data obtained from visits to the site of study were used to build
the matrix. These data included the identification, analysis and
assessment of major actions, processes and environmental impacts
caused by direct and indirect anthropic actions. The analyses and
assessments were made based on the identification of processes
related to different forms of water use in the industry, with
consequent development of processes and impacts on the physical,
biotic and anthropic environments.
The identification and the qualitative characterization of
impacts were made using the interaction matrix derived from the
Leopold Matrix [9].
At the company where the study was carried out, the stages with
larger water consumption during production were divided into pha-
ses in order to better identify the environmental impact, as follows.
PHASE 1 – Scalding: after exsanguination, the chickens are hung
by their feet from metal shackles on a moving rail and immersed for
about 1 min and 26 s into the water of a scald tank at a temperature
of 58–65  C. Scalding, which may be regarded as the first rinsing
operation, is targeted at removing impurities and the blood from
the outer surface, and mainly at making defeathering easier. The
water is chlorinated at 0.4–2.0 ppm, and continuously changed at
a rate equal to or greater than 8000 l for 8 h per shift. After scalding,
the chickens are placed in a scald tank that specifically handles
chicken heads, with constant water replacement, where they are
submerged for 6 s at a temperature of approximately 70  C.
 L.T. Kist et al. / Journal of Cleaner Production 17 (2009) 1200–1205 1203

Table 1
Main uses of water at the slaughterhouse analyzed.
Process Flow (m3 day1)
Receiving/slaughter/exsanguination 1466
Scalding 24
Pre-chilling and chilling 300
Treated wastewater 1500
The main environmental problems observed in the scald tank
are the following: increase in room temperature and moisture;
generation and emission of noise and of particulate materials; risks
of accidents and worker-related health problems; production of
wastewater and reduction in worker’s capacity, and misuse of
water and raw materials.
PHASE 2 – Once evisceration is complete, the carcasses are
dropped from the transporting hooks into an open tank filled with
water at room temperature. Pre-chilling is carried out in two
stainless steel tanks, equipped with a worm conveyor and driven by
an electric motor with a geared motor system in order to take the
carcasses to the next stage, using or not the bubbling system. Pre-
chilling is divided into two stages: pre-chilling and chilling.
The carcasses are mechanically uncoupled from the rail and
dropped into the pre-chiller, where they remain for at most 30 min,
being transported by the worm conveyor. At this stage, the
maximum water temperature allowed is 16  C and the tempera-
ture of the incoming cold water should be 4  C. Water renewal
rate is 1.5 l per carcass, operated in counterflow, and water
chlorination occurs at 0.4–5 ppm.
The carcasses are mechanically taken into the chiller by the
worm conveyor and remain therein for at least 40 min. In this stage,
the maximum water temperature allowed is 4  C and the
temperature of the incoming cold water should be 4  C. Water
renewal rate is 1.0 l per carcass, operated in counterflow, and
water chlorination occurs at 0.4–5 ppm.
Carcass temperature at the pre-chilling system outlet is at most
7  C and water absorption of at most 8% of the carcass weight.
The main environmental problems found in pre-chilling are:
emission of noise and of particulate materials; misuse of water and
raw materials and production of liquid wastes.
PHASE 3 – Gross wastewater and treatment processes: the
wastewater volume that is disposed of into the WTP amounts to
1500 m3 day1, with a retention time of 10 h. To treat such volume,
the lagoons have a retention time of 10 days. Physicochemical
analyses of the wastewater are regularly performed in order to
meet the levels required by inspecting bodies.
The process refers to the preparation of wastewaters from
several production sectors for treatment before disposal or reuse.
In this stage, all wastewaters are channeled into the WTP. At the
WTP, the treatment of wastewaters from the slaughterhouse is
Percentage based on a biological system preceded by pretreatment operations
82% that are essential to the removal of feathers, viscera, oils and
1.3% greases and suspended solids. These operations involve the
16.7% following.
–
Sieves – They separate and retain feathers and coarser solids,
which are reused in the digesters of flour mills.
Retention of oils and greases – Retention of oils and greases,
which are reused in flour mills.
Primary decanters – tanks for sedimentation of pollutants, with
production of organic sludge.
Activated sludge systems – process whereby microorganisms in
the presence of oxygen provided by aerators consume the polluting
organic matter and mineralize it.
Secondary decanters – tanks for sedimentation of mineralized
organic matter, with production of mineralized sludge.
Treatment lagoon – stage in which the action of winds and solar
energy completes the treatment by removing the last organic
particles from the water through microorganisms.
Polishing lagoon – Stage in which wastewaters are submitted to
final polishing and in which treated and good-quality water is
expected to be obtained.
At the raw wastewater inlet, the major environmental problems
are: emissions of unpleasant odors; misuse of raw materials;
production of liquid wastes and increase in wastewater treatment
costs. And at the outlet of the wastewater treated at the WTP:
emissions of noise and heat; contamination of the receiving body;
generation of noise, odors and liquid waste and reduction and loss
of local fauna.
The application of actions at the Leopold matrix indicates 475
possible relationships of impacts, and identification of 277 impacts.
Among the 277 impacts identified, the following results were
obtained as subsidy for the proposal of minimizing or potentiating
environmental measures:
 Of the impacts listed, 58.5% were negative and 41.5% were
positive, according to the value criterion (Fig. 2);
 with regard to the order criterion, 40% were direct and 60%
indirect (Fig. 2);
 according to the spatial criterion, 83.8% were local and 16.2%
regional (Fig. 2);
 for the time criterion, 91.3% were short-term and 8.7%
medium-term (Fig. 2);
 according to the dynamics criterion, 73.2% were temporary
impacts and 26.8% were permanent impacts (Fig. 2);
 with regard to the plasticity criterion, 87% were reversible
impacts and 13% were irreversible (Fig. 2).

Table 2
Parameter results for the months of April, July and December 2007.

Steps Parameters

BOD5, mg l1 O2 COD, mg l1 O2 Total phosphorus, mg l1 Total nitrogen, mg l1 Oils and greases, mg l1
April Packing 682.5 1527 67.65 2.7 10.3
Pre-chilling 668.5 968 13.69 36.2 191
Raw wastewater 2000 2400 14.33 456.9 17.6
Treated wastewater 85 124 10.06 30.9 17.6
July Packing 1752.4 5990 108.08 392.8 10.0
Pre-chilling 396 660 7.15 23.2 71
Raw wastewater 1451.9 2610 14.20 77.9 187.7
Treated wastewater 79.4 98 9.2 31.1 <1.0
December Packing 1801 4731 30.10 449.8 9.8
Pre-chilling 318 425 3.50 30.5 <1.0
Raw wastewater 990 2373 6.0 90.0 448.8
Treated wastewater 21 116 4.80 42.8 8.3
Emission Standards CONSEMA’s Resolution – RS 128/06 120 360 1.0 10 30
1204 L.T. Kist et al. / Journal of Cleaner Production 17 (2009) 1200–1205

Fig. 2. Qualitative assessment of environmental impacts based on the different criteria.

As to quantitative assessments, the major environmental
impacts were those related to wastewater disposal, which are
associated with the results obtained for the rate of dissolved oxygen
depletion (RDOD), eutrophication index (EI) and environmental
pressure index (EPI).
The impact indicators shown in Tables 3, 4 and 5 were deter-
mined based on the data presented in Table 2.
The larger impact for water use management in the poultry
industry is the EI, with 75% of pollution load, whereas RDOD
corresponds to 25% of the pollution load. The EPI improved in
December (summer in Brazil), and this can be explained by the
increase in temperature, with consequent better performance of
the biological system, including activated sludge systems and
facultative lagoons.
Considering that the ideal environmental pressure value ranges
between 0 and 1, the results obtained are above the desired levels,
including that for treated wastewater.
3.4. CP measures
After identification of environmental impacts, some CP
measures were proposed to minimize the negative impacts and
enhance the positive ones, in addition to assigning responsibilities
for the establishment of these prognoses. The following measures
were considered:
 Dry removal of residues from trucks, floors and equipment for
later washing;

Table 3 Table 4
Environmental impact indicators for water use in April 2007. Environmental impact indicators for water use in July 2007.

Indicators Packing Pre-chilling Raw wastewater Treated wastewater Indicators Packing Pre-chilling Raw wastewater Treated wastewater
RDOD 4.24 2.68 6.66 0.34 RDOD 16.63 1.83 7.25 0.27
EI 252.65 81.93 301.60 48.58 EI 655.85 48.23 139.63 45.32
EPI 190.54 62.12 227.87 36.53 EPI 496.04 36.63 106.54 34.06
 L.T. Kist et al. / Journal of Cleaner Production 17 (2009) 1200–1205
Table 5
Environmental impact indicators for water use in December 2007.
Indicators Packing Pre-chilling Raw wastewater Treated wastewater
RDOD 13.14 1.18 6.59 0.32
EI 402.53 34.35 113.27 36.80
EPI 305.18 26.06 86.60 27.68
 Standardization of cleaning procedures with rational water use
in all work shifts and implementation of water meters on
a sector-by-sector basis;
 Reuse of waters from pre-chilling and chilling for carcass pre-
washing, as the average temperatures of these wastewaters
range between 4 and 16  C. This will contribute to lowering the
oil and grease pollution load.
 Automated water management so that water flow is inter-
rupted and wastewater is channeled into troughs and sinks at
the end of the slaughtering processes;
 Enlargement of bleeding trough and tunnel, in order to maxi-
mize the amount of blood collected;
 Adoption of an environmental management policy by the
company, focusing on water conservation and minimization of
wastewater disposal;
 Installation of fans and windows to improve ventilation;
 Training of workers and education about the importance of
wearing personal protective equipment (PPE) and collective
personal equipment (CPE);
Standardization of cleaning procedures with rational water use
in all work shifts and implementation of water meters on a sector-
by-sector basis were some of the measures that had already been
adopted and assessed with emphasis on CP. The measures allowed
reducing water consumption by 13%. In this context, the installa-
tion of water meters at inlet and outlet points of higher water
consumption and the monitoring of inflow and outflow rates at
these points showed a waste of 9000 l h1 of water.
Given the importance of WTP in the production process, some
more specific measures can be adopted.
Considering the slaughterhouse analyzed in this paper and its
treatment system, which has a wastewater volume of
1500 m3 day1 for the production of 103,000 chickens a day, the
treatment system may be regarded as simple. However, there is
power consumption to maintain the aerators in operation around
the clock, in addition to discharge of biological sludge in compli-
ance with environmental regulations. An anaerobic reactor could
be installed in association with an aerobic system, reducing aera-
tion energy, recovering energy, and producing less sludge. Another
measure for the configuration of the WTP should include the
aeration of activated sludge tanks per sector, allowing for the
creation of oxic and anoxic areas for better removal of eutrophi-
cation agents. This would also lead to less power consumption,
1205
since it would reduce the number of motors in operation during
aeration.
4. Conclusion
The qualitative assessment of environmental impacts of the
poultry slaughterhouse revealed that most CP measures would be
efficient in the short run, as the impacts are predominantly
temporary, reversible and local.
The study conducted in this slaughterhouse showed inadequate
removal of nutrients from the treatment system of the WTP,
especially of total phosphorus and total nitrogen, and consequently,
an increase in their concentrations in the receiving body, thus
contributing to eutrophication.
Among CP measures, one should highlight the adoption of dry
cleaning procedures, control over the amount of water used on
a sector-by-sector basis, better collection of exsanguination resi-
dues, automation of the water system and change in the configu-
ration of the WTP through the use of an anaerobic reactor and
a sequential oxic/anoxic system for reduction of the eutrophication
effect of the final wastewater product. Anaerobic conditions would
allow reducing costs with power consumption and the necessity for
sludge disposal.
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