STEPS IN SLAUGHTER AND DRESSING OF CATTLE

 The steps in slaughter involves the following

o Holding
o Stunning
o Sticking
o Flaying – this involves
 Heading,
 Shanking or Legging,
 Siding,
 Opening and
 Rumping
o Evisceration
o Backing
o Halving
o Washing and
o Shrouding

HOLDING

 Animals are held off feed for 24 hours prior to slaughter, but ample water is
provided.
 Slaughtering techniques will be easy and the yield of waste will be lower on
holding animals off feed.
 Dirt and manure are washed from the animals.

STUNNING

 Stunning may be done in a stunning pen or the animal may be stubbed to ring in
the floor.
 Mechanical stunner like stunning pistol are often used.

FLAYING

 The art of removal of hide is known as flaying

 Lines of ripping is done on the animal before flaying
 These are lines of demarcation for starting the flaying.
 For this the sharpest knife possibly is used.
 HEADING

 The hide is opened from the horn to the nostril and the dorsal aspect of the face
is skinned out .
 The opening is continued from the sticking point down through the centre of the
jaw and the lateral aspects of the face is skinned out .
 The head is turned and the ventral aspects are skinned.
 The jaw is graspped in one hand, the head is bent back on its poll and the head is
removed by cutting at the atlanto-occipital joint, leaving the hide of the head
attached to the hide of the carcass

SHANKING

 Removal of the shanks is known as Shanking.

o The animal is rolled on the skinning rack by placing it under the withers.
 Ripping lines are to be made by a ripping knife in a straight line from the neck or
slaughter incision line, along the middle of the dewlap and belly to the end of the
tail.
 Fore shank
o The tendons are cut on the posterior surface close to the hoof head and
again about nine inches further up the leg. This will leave the leg limp. The
hide is opened around the coronet and holding the knife flat, an incision is
made from the hoof head to the point of the arm on the medial aspect of
each leg. This incision is continued up to the brisket. The shank is skinned
out and removed at the flat joint.
 Hind shank
o The tendons are cut in manner similar to that of the fore shank. The hide
is opened around the coronet, and holding the knife flat, an incision is
made from the heel to the point of the hock on the medial aspect. This
incision is continued up to the inguinal region. The shank is skinned out
and removed at the flat joint.
 An incision is made at the mid line on the belly from the neck (sticking wound) to
the bung.

SIDING

 The hide is opened from the point of the original incision made when sticking,
over the brisket and lung the midline to the rectum.
 The flesh over the brisket to the bone is cut, the thymus removed, and the trachea
and esophagus are loosened.
 The hide is skinned over the brisket and down the sides.
 The hide should be held tight over the knife and the pressure of the knife should
be against the hide.
 Endeavored to use long smooth strokes and short jerky strokes with the knife are
avoided.
 Hide is split from about the midpoint of the brisket on the lower point of the
shank, and from the flank to the side of the hock.
 The beef is sided down as far as possible.

OPENING

 The penis is loosened in case of steers and bulls.

 The breastbone is sawed.
 The midline is opened from the posterior end of the brisket on the aitchbone;
from this point the white connective tissue to the aitch is followed.
 The aitchbone is split.
 In most cattle this can be done with a knife, but in older cattle it may be
necessary to saw the aitchbone.
 With steers, heifers, and dry cows, the split is to make through the middle of the
cod or udder but with cows the udder, but with wet cows the udder should be
removed before opening down the middle.
 The caul fat (Paunch fat) is removed.

RUMPING

 The tendons are split at the hock and spreader or trolley hooks are inserted.
 The carcass is hoisted until tail is about waist high.
 The bung is cut around and dropped into the body cavity.
 The hide is split down the under side of the tail and hide is stripped from the tail.
 The tail may be removed at this time or later.
 The flanks and rump are skinned out and the carcass raised as required for
convenience of skinner.

EVISCERATION

 Evisceration is commenced simultaneously with rumping, by cutting the

abdominal wall just ahead of the pelvis taking care not to puncture the intestines.
 The carcass is opened in the midline and eviscerated as the carcass is lifted.
 The fat and membrane that hold the bung, gut and bladder are loosened.
 The intestines and stomachs are pulled out, leaving kidney fat in the carcass.
 Liver is removed, the gall bladder pulled off, then liver washed, weighed and
hung on a hook.
 Stomachs and intestines are weighed and ruffle fat from intestines stripped.
 The diaphragm membrane is removed and pulled.
 The lungs, heart, trachea and esophagus are removed.
 Heart is removed from thoracic entrails, washed and weighed.
 Pluck is also weighed.
 Skinning is completed over the shoulders and neck.
 The hide is pulled off, weighed, salt applied and placed in hide room.

BACKING

 The hide attached to the outside round (leg) is either pulled or pounded off.
 The backing operation consists of running the knife around the back between
the hide and the carcass and letting the hide drop of its own weight.
 The hide may also be removed by cutting in from either side as a completion of
the siding operation.

HALVING

 Splitting the beef into sides by sawing or chopping through the exact centre of the
back bone is begun before the forequarters of the carcass are off the floor.
 A beef splitting saw or large cleaver is used.
 Standing on the belly side of the carcass,the caudal vertebrate is sawed
through to the sacram.
 Then the opposite side of the carcass is positioned and sawed through the sacrum
and lumbar vertebrae.

WASHING

 All the blood should be washed off both the inside and outside of the carcass.
 Cold or luke warm water is used to wash the carcass.
 Carcass is washed completely and weighed.

TAGGING AND CHILLING

 Each side of carcass is tagged, indicating carcass number, hot weight and the
date.
 Rolled into chill room to cool and set.
 First and second stomachs are cleaned for tripe if desired
 Intestines are cleaned if desired for casings.
Room Finishes
Room finishes are important for most food processing facilities. Floors, walls and
ceilings must be constructed in a manner that promotes operational and
functional cleanliness.
Elements that require specific attention include:
Floors
Production areas undergo constant wash down and exposure to blood and
cleaning chemicals. Floors will often wear down from the constant cleaning and
washing. Common industry practice is to finish the floors with a slightly
roughened slip resistant concrete. As the floors wear down they are typically
covered with a urethane or epoxy floor coating. Non production areas such as
storage or maintenance areas are usually finished concrete (slip resistant) and
office, welfare and admin areas will be finished with a vinyl composition tile.
Walls

Walls that are durable, impermeable to moisture, and vapor tight are the most
desirable in a food processing facility. Walls are typically constructed from
insulated metal panels, CMU or precast concrete. Insulated metal panel finishes
consist of stainless steel or white kynar
finishes. CMU walls need to have pores filled epoxy fillers and coated with epoxy
paints/coatings. Precast walls require a smooth, hard finish. It is important that all
surfaces be cleanable.

Ceilings
Ceilings in a meat and processing facilities are constructed using Insulated
Metal Panels (IMP). They are typically hung from the roof system and form an
access space to run utilities, ventilation and process lines. This area is commonly
known as a USA space. Process areas typically use a stainless steel or kynar finish
on the panels.
Roof System
Leaks can shut plants down so a complete, tight, and durable roofing system is
required for meat and poultry processing facilities. Most plants use low slope roof
systems and thus, a built up type roof system performs the best under these
conditions. The best roof system is an SBS Modified bitumen system. Other
systems such as single ply adhered membrane systems have been used to cover
roofs. No matter what system is selected attention must be paid to detailing to
prevent air and vapor infiltration.

PLAN AND LAYOUT OF BYPRODUCTS UTILIZATION PLANT

 Due to our vast livestock population, it is very important to harvest animal

byproducts for their economic value as well as to provide employment to
marginally educated masses.
 In our country, livestock density demands the setting up of atleast one animal by
products processing plant at each 50 km range.
 Establishment of animal by products processing plant within or in the vicinity of
each abattoir will also alleviate the pollution problem.
 The biogas production unit for the mutual benefit could utilize the resultant
waste from both.
 Important considerations during the establishment of a byproducts utilization
plant are: In tropical and subtropical countries, a byproduct plant should be
established adjacent to the slaughterhouse or it may be a part of the same
building connected through chutes or gravity pipes. In earlier case, the passage
between slaughterhouse and by product plant must be constructed with concrete,
stones or bricks and the slope should be towards byproduct plant. The
establishment should preferably be away from inhabited area. As far as possible,
there should be provision of overhead rails from slaughterhouse to the byproduct
plant. A byproduct plant should have its own-screened drainage with a gully
fitted with individual grease traps. The byproduct plant should have clear clean
and unclean sections. Charging platform or raw materials inlets form a part of
unclean sections whereas processed and sterilized byproducts are prepared,
stored and disposed of from clean section having separate exit point.
 The floor, walls and ceiling should be made up of smooth and concrete material
so that these can be easily and frequently washed. A floor slope of ½” per ft. is
generally recommended.
 A byproduct plant should invariably have a hide/skin salting room, renderers,
tripery, boiler, manure bunker, store besides common amenities.
 The plant building should be open and ventilated to prevent humidity build up
leading to corrosion of equipment and building. It will also check the growth of
moulds and bacteria in the building. The roofing material may preferably be
corrugated asbestos sheeting. There should be provision of exhaust fans from
each partition.
 The equipment to be installed should cope up with the byproduct or offal
accumulation expected each day. Renderer, fat settling tank, fat expeller, blood
press, grind mill etc., are essentially required. A boiler of suitable capacity is
inevitable for processing as well as cleaning operations. It should have a steam
pressure of > 80 psi.
 At the initial stage, processing of one or two byproducts can be taken up. The
operations can be further extended in stages.
 A byproduct plant should have the following main sections:
 Hides and skins section with salt store.
 Tripery/Gut processing section with cleaning tables, water taps etc.,
 Carcass utilisation plant with renderer, bone digester, fat settling
tank, fat expeller and adjoining milling room and store.
 Besides boiler, worker lockers, amenities and adjacent manure pit
are other important requirements.
 The boiler should be of suitable capacity keeping in view the
availability of raw material; and consumption of renderer.
 The requirement of steam has been worked out to be 1.25 lb per lb
of raw material to be processed.
 RECEPTION AREA (MICADRA)

 The animals are received and subjected veterinary inspection before passing to
lairage.
 Ramps for unloading of animals from trucks shall be provided.
 Office room for veterinary inspector should be located in the reception area.
 A suitable office for reception area staff is essential for maintaining slaughter
records.
 Adequate holding area shall be provided according to the class of animals to be
slaughtered. The area should be separate for different animals.
 The holding area shall have water and feeding facilities.
 The resting grounds should have overhead protective shelters.
 Separate isolation pens shall be provided for animals
o suspected to be suffering from contagious and infectious diseases, and
o Fractious animals, in order to segregate them from the remaining animals.

 The off-loading dock should be about 1.2 m high to permit careful offloading,
especially of stock carried on upper tiers of Lorries. The slope should not be more
than 30o.
 Sufficient room should be allowed for manure and temporary parking.
 The entry point to the meat plant for livestock should have a display board
containing ‘All stock must be handled gently and quietly’.
 Irregularities in transportation can be noted at the reception area and the
appropriate action taken.

Facilities

 The ramps must slope up rather than down.

 Drain inlets in the centres of passageways should be avoided.
 Sharp corners should be avoided and projections of any kind and gates should
preferably be placed at the end, not in the middle of the pen side.
 The horizontal bars should be correctly spaced to prevent strangulation if tubular
partitions are used.
 Strident voice and noises, dark objects (especially if these are moving), sudden
movements of personnel, drain openings in the centres of passage was sharp
corners, etc., are contraindicated.
 The final drive races should have solid sides, non-slip floor surfaces and lighting
to encourage the animals to go forward.
 In larger plants it is necessary to have two single-line crushes for cattle to allow
for stock movement so that an animal fall in one race.
 Side gates should be installed to handle such emergencies and also to provide
escape gates for personnel in the drive race when they are confronted with wild
animals.
 The length of the final race is determined by the overall throughput of the meat
plant.
  In a large plant this race can be 36 m long, with stop gates to prevent the animals
going backwards, 80 cm wide, and reach to about waist height.
 Catwalks must be provided alongside the race to enable handlers to control stock
movement, check identification etc.
 Equipment used should be noise-free.
 Gates located in the drive race and sliding or one-way gates in the single file race
should be made of expanded metal or closely spaced bars to enable the animals to
see through them.
 Constant vigilance is requiredto ensure that there is
o No bullying by dominant individuals and
o No females in oestrus.
o Horned stock must be kept separate.

STUNNING AREA

 The area in front of the stunning pen should be at least 3 m in width to the
opposing wall or bleeding trough and be fitted with upright bars 5 cm in diameter
and 1.2 m high, spaced at 40 cm intervals for safety purposes should improperly
stunned animals regain their feet.
 The floor must be properly drained and possess high-impact and non-slip
properties.
 A raised sturdy frame of expanded metal on to which the animal is ejected aids
cleanliness and reduced wetness.
 Effort to be made to reduce hide contamination.

FLOOR AND WALL FURNISHES

 All parts of the meat plants must be able to clean easily and the floors and walls
should be non-toxic and non-absorbent. The floors should be non slippery.
 It is recommended that walls should be coated with a smooth, durable,
impervious material to a height of not less than 3 m from the floor.
 Surface materials should be capable of withstanding impact, doors should be
wide enough to allow easy passage of personnel.
 Good ventilation, insulation and easily cleaned surfaces will minimize the
disruption of routine works.
  Abattoir operations entail wet floors on which are usually present quantities of fat
and blood. While floor finishes should be easily cleaned, they should also non-
slip.
 Walls and floors may be made of concrete or tiles. Wall sheets are often used in
the form of plastic laminates, aluminum, polished asbestos, PVC-faced rust less
metal or stainless steel.

Preslaughter handling
Preslaughter handling is a major concern to the livestock industry, especially the pork industry.
Stress applied to livestock before slaughter can lead to undesirable effects on the meat produced
from these animals, including both PSE and DFD (see Postmortem quality problems).
Preslaughter stress can be reduced by preventing the mixing of different groups of animals, by
keeping livestock cool with adequate ventilation, and by avoiding overcrowding. Before
slaughter, animals should be allowed access to water but held off feed for 12 to 24 hours to
assure complete bleeding and ease of evisceration (the removal of internal organs).

Lairage

After transportation, animals are usually kept in lairage (holding pens) for a period before
being slaughtered. One purpose of lairage is to maintain a reserve of animals so that the
processing line in the abattoir can operate at a constant speed and not be affected by
variation in the rate of delivery of livestock. When lairage conditions are good it also
gives animals a chance to rest and drink.

In slaughterhouses animals are received and kept around in stockyards and pens for 1 day. The
animals are watered, but in most cases not fed unless they are kept more than 1 day.

Slaughtering
The animals are then driven from the holding pens to the slaughtering area where the following
activities take place:

- Stunning;

- Suspension from an overhead rail by the hind legs;

- Sticking and bleeding over a collecting trough. The collected blood may be sewered or
processed;

- Hide removal (cattle)

- Decapitation;

- Opening of the carcass by cutting;

- Inspection of the carcass;

- Evisceration (removal of intestines and internal organs);

- Splitting and cutting of the carcass; and

- Chilling or freezing.

SLAUGHTER HALL

 The place where actual slaughter and dressing animals take place after stunning.
 Form of ‘bays’ or ‘booths’ of 6.5m x 6.5m or in the form of an open hall with
generous floor space, well ventilated and lighted.
 The space requirements of this chamber will depend on the kill @ 3 sq. m per
cattle and 0.5 sq. m per sheep or goat.
 The transfer of animals from lairage to slaughter hall will be easy in a well
designed abattoir
 In upper kill floor the animals are walked directly on the slaughter floor by a
ramp provided with battens and a catwalk
 Cattle and sheep and goat can readily be driven up a ramp as steep as 1 in 6
 If animals are stunned on the ground level then hoisted after bleeding for
subsequent dressing on the top floor.
 Cattle and sheep can be slaughtered in the same slaughter hall provided such
operations are conducted at different periods.
 Hot water and steam facilities should be available for washing and sterilizing
purposes.
 Floors should be impermeable, non-slip, monolithic screed, sloping at 1:50 into
screened drains.
 The walls should be of solid construction, finished in a smooth impermeable
granolithic screed and be tiled, grouted with a impervious material or covered
 with an epoxy resin paint designed to function as a ‘tile’ to a height not less than 2
metres.
 Above this level, the walls should be finished in flake free high quality, light
coloured lead and arsenic free gloss paint.
 Ceilings and superstructures similarly finished.
 All floor/wall/ceiling junctures are rounded or coved.
 The illumination requirements are 220-lux units in the slaughter hall and 540 lux
units in place where inspection is done.
 Overhead rails should be 3.3 m high for cattle dressing, although 4.5 m would be
required for the bleeding rail.
 Small stock and pigs may be slaughtered and dressed from a 3 m rail.
 The overall height of the building should not be less than 6 m at the point of the
cattle bleeding.
 Floor levels should slope in such a way that water and materials on the floor flow
into drains from clean to dirty areas.
 Water should not flow from one room to another.
 The slaughter hall should be provided with conveniently placed chutes for
disposal of offal.

DRESSING AREA

 Platforms are fixed at suitable positions and heights for operatives and inspectors
to work efficiently and without unnecessary stooping and labour for subsequent
leg, hide or fleece removal, evisceration, carcass splitting, inspection, kidney and
channel fat (KKCF) removal, carcass washing and shrouding stations.
 The position of the viscera inspection table is of particular importance
 For adult cattle where the size of the top of the table should be about 2.7 m x 1.5
m wide.

LAIRAGE

 Lairage is a place near to the slaughterhall to give rest prior to slaughter for a
period of 6 to 36 hours.
 Period of rest before slaughter has marked beneficial effect on the meat and
subsequent marketability of the carcass.
 Consist of pens for live animals.

CATTLE LAIRAGE

Dimension of pens
  7.6 m x 6 m - to hold 20-25 cattle.

Facilities

 Drinking water must be always available to animals with a gravitational force.

 One cistern sufficient to feed three troughs.
 Automatic water bowls.
 In tie-up type lairage long water troughs satifactory for easy cleansing than
individual troughs or bowls.
 Hayracks to be provided.
 Animals are fed twice daily except on the day of intended slaughter or from the
afternoon preceding the morning of intended slaughter.
 Hydrant points are placed conveniently so that all parts of the lairage can be
reached.
 An estimated amount of about 680 litres of water per cattle slaughtered is
sufficient for cleaning.
 Passage should be wide enough to admit entry of a vehicle for the removal of
manure and dead animals.
 Ease of cleaning, comfort for the animals and ease of handling to be emphasised.

LAIRAGE AREA

Species Area
Cattle 1.7m2/head
Pigs/Sheep .35m2/head
Goats .25m2/head

SHEEP & GOAT LAIRAGE

Dimension of pens

 Sheep and goat pens should be 0.9 m high with passages 0.9 m wide between
them

Facilities

 Rails should not to be more than 15 cm apart to prevent strangulation.

 Double-hinged gates to facilitate entry and exit of stock
 Sliding gate provided between the pens to accommodate an overflow of animals.
 Water troughs are placed some 50 cm from the floor to prevent fouling.
 Hay racks provided above the level of the sheep and goat heads.
 Straw provided for solid floors to help keep the sheep and goats dry.
  Clean or expanded metal floors to keep clean and dry.
 Cattle and sheep and goats or pigs and sheep & goats lairages can
be accommodated in the same building

Ante-mortem (AM) inspection facilities

 Ample natural or artificial lighting which is even and diffuse.

 An isolation pen with a crush for clinical examination of animal.

Pen size

The following pen sizes are recommended for housing of livestock in abattoirs.

 Cattle
o Loose - 2.3-2.8 m2 /animal.
o Tied - 3.25 m2 /animal.
 Pigs
o Bacon and small porkers - 0.6 m2 /animal
o Heavy pigs and calves - 0.74 m2 /animal
 Sheep and goats
o 0.56 m2 /animal

A further 30% - added for reception areas and passageways.

Lairage sizes have been calculated to hold one day’s average kill.

BLEEDING AREA

 Blood is collected in shallow trays or basins or a separate channel be constructed.

 The bleeding trough should be at least 1.5 m wide, possess a good gradient, side
walls of the same height, and two drains, one for blood only and the other for
water.
 The length of the bleeding line depends on throughput and the system of
conveying carcasses
 The bleeding trough has two points for the reception of blood: one at the actual
point of sticking where the greater volume of blood will be handled; and
thereafter a longer gradual slope that collects ‘drip’ blood classed as inedible.
  The bleeding trough must have smooth impervious surface, often a suitable grade
of stainless steel.
 For hygienic bleeding for edible purposes, the stainless hollow knife combined
with cleanliness and a sodium citrate/phosphate anticoagulant is used.
 The knife is held in the wound by hand, by a rotating endless screw; or by other
means.
 For small meat plants individual containers are used for holding the blood
 For large throughputs and high rates of slaughter several blood draining knives
(as many as 14) can be used in a ‘carousel’ which rotates synchronously with the
bleeding conveyor.
 Arrangements to be made for routine sterilization of the knives and adequate
staff to man this additional operation.
 The hollow knife is made of stainless steel in two sizes, for cattle and pigs.
 Consist of a tubular handle with a defector plate and two blades set at right angles
to each other.
 They are easy to strip for sharpening and cleaning and are combined with an
anticoagulant dispensing tube.
 The broad blade should be directed in the longitudinal direction of the animal
 A collagen tubing connects the knife to containers where the blade is cooled prior
to collection.
 A system which correlates each batch of blood to the carcass from which it
originates must be operated so that if a carcass is subsequently condemned the
blood from that animal may also be condemned.
 In the bleeding trough for sheep and pigs both sides are enclosed and have a
width of 1.1-1.2 m.
 For sheep the overhead bleeding rail is 2.7 m high, and dressing rail is 2.3 m
high.
 For pigs the overhead bleeding and dressing rails should be 3.4 m high.

AREA SIZE

 The size of the site should be given a careful consideration with allowance for the
various buildings and traffic circulation.
 Modern livestock and meat transport vehicles have very large turning circles: 14
m for a vehicle 15 m long.
 Completely separate routes for stock and meat vehicles should be provided.
 Approach roads should be at least 6 m wide.
 When all the various buildings are considered, it will be realized that a large area
is necessary.

Area requirement
  Generally for a small abattoir (up to 30,000 units*/year) the area required will be
about 1-2 acres.
 For a medium plant (50,000+ units*/year) about 2-4 acres will be required.
 A large abattoir handling over 100,000 units* annually will require about 4-6
acres of land.

*One livesotock unit is equivalent to ONE adult bovine or TWO pigs, THREE calves
or FIVE sheep.

DRAINAGE

 The floors in wet areas should slope uniformly to drains with a gradient of 1:50.
One drain is for each 40 m2 of floor area. The internal drainage should be in the
form of open concrete channels leading to open gullies, situated immediately
outside and connected to closed drains.
 Low places where water and blood could collect are to be guarded against. Where
blood tends to collect, e.g. under dressing rails, special provision must be made to
supply drainage valleys at a gradient of at least 1:25. The valleys themselves
should be 60 cm wide and should continue under dressing lines for the collection
of all blood and bone dust.
 Catch Basins - Catch basins must be provided on drains for grease recovery.
 Traps and Vents - Traps and vents must also be provided on drains, properly
sealed and easily cleanable and the latter to be effectively vented to outside the
building.
 Special arrangements have to be made for dealing with stomach and intestinal
contents, the drains for bovine material to be at least 20 cm in diameter and for
the smaller species 15 cm.
 All drains in the slaughter hall be trapped with 4 mm screens, to prevent the
possibility of contamination of the effluent.
 Grids covering drains should be made of cast iron or other approved material.

For 50 heads per day sheep and goat line

Waste Management

MACFAST will follow the strategy of segregated collection and source reduction. Waste will be

disposed at the source itself and used for energy production. Broadly, wastes in slaughter

house can be divided into two; viz: solid and liquid. Solid waste is the main waste product from

slaughter house. It can be divided in to two, namely edible and inedible. Inedible materials are

to be disposed appropriately to prevent contamination of the environment and constituents

thereof from its discharge, deposition, injection, dumping and spillage. Solid wastes can be

converted into energy or recovered as bi – products.

Biogas plant and Aerobic Compost System

It has the capacity to process around 700 - 750 kg solid waste per day. This can be treated in a

bio gas plant with 50m3 capacity. The generated bio gas will be used for lighting/cooking/heating
purpose of the slaughter house.

Equalization Tank for Waste Water Collection

To avoid leakage and environmental contamination waste water will be treated/managed

scientifically. About 10m3 per day of effluent is generated from this modern slaughter house.

This waste water will be treated through anaerobic treatment followed by dispersion trench.

This can be also used for bio gas generation.

VENTILATION

 Adequate ventilation should be provided to prevent excessive heat, steam and

condensation.
 Ventilation prevents the accumulation of odours, dust, etc., but it should not
excessive, that may cause draughts and thus problems for staff.
 Openings of the ventilators and windows should be screened and sills sloped.

DOORS

 These should be wide enough to allow passage of product without contact with
the doorway.
 A width of 1.37 m (4.5 ft) is usually adequate.
 Doors must be constructed of rust-resistant material. If made of wood, they
should be covered with rust-resistant smooth impermeable material.
 Double-acting doors should have a glass (reinforced) panel at eye level.
 Plastic strip doors are not much suitable for fitting in abattoir because they are
difficult for proper cleaning.

SMALL ABATTOIR UNITS

 Smaller plant is cost effective can be located in remote areas close to production
areas thereby reduction in transport costs.

The FPE plant (Food Processing Engineering Plant)

  A prefabricated unit conisiting of a slaughter section with dimensions of 9.14 m
(30 ft) length, 3.7 m (12 ft) width and 4.6 m (15 ft) height.
 This is combined with refrigeration, cutting and boning and by products facilities,
etc.
 Capacity of 10 cattle, 20 sheep and 10 pigs daily.

Mobile slaughter facility

 Many animal welfare organisations are coming up with such mobile units with
slaughter facilities aimed to hygienic meat processing cum humane aspect of
slaughter particularly for the birds.
 Based on a large trailer unit on an a vehicle.
 Fitted with a stunning box, hoists, bleeding area, dressing cradles, chill room,
storage for by-products, detained and effluent material.
 The unit operates from a home base and visits farms on request
 The farms provide basic facilities of water, electricity, lairage pens, toilet and
changing rooms.
 Careful attention is given for animal welfare and organization of ante-mortem
and post-mortem inspection.

TOILET ROOM

1. Must be equipped with sanitary flush-type toilet, acceptable foot- or knee-operated washbasin, liquid
soap dispenser, disposable towel dispenser, and metal receptacle for used towels.

2. The door must be self-closing.

3. If toilet opens directly into a workroom, it must be separated by an intervening vestibule with a self-
closing door. Natural or mechanical ventilator must be provided.

BUILDINGS AND THEIR DISPOSITIONS

The slaughterhouse may consist of (a) main department and (b) accessory department.

Main department

This department may have the following units

 Lairage Weighment room

 Stunning chamber
 Slaughter hall
 Cooling hall
 Hide and skin store
  Manure house
 Detention room
 Condemned meat room
 Boiler house
 Facilities for Personnel
 Mess rooms
 Bath rooms
 Veterinary Office
 Office accommodation
 Superintendent’s office and
 Veterinary Laboratory

Accessory department

 The accessory department may consist of the following units

o Gut and tripe room
o Red offal room
o Edible Fat room
o Cutting rooms
o Inedible Area
o Equipment Wash
o Digester room
o Blood drying yard
o Fresh Meat Dispatch Area
o Residential quarters
o Isolation block
 It will be observed from the above list, that each of the rooms is intended to serve
certain special needs in the slaughter, dressing and subsequent disposal of food
animals’ carcasses in the order of operations taking place here.

1. Livestock receiving area: It is the area where animals are received. Receiving area must have

watering, feeding and animal inspection facilities. Animals are to be inspected by a Veterinarian. Healthy
animals are sent to lairage while sick and injured animals are to be sent to isolation pen.

2. Lairage: Place where animals are provided rest before slaughter. Rest is to be provided up to 24 hours
to overcome the physiological stress involved in transportation of animals. Sheep have to be kept off
feed up to 12 hours before slaughter in lairage to reduce the gut contents thereby reducing the chances
of contamination during dressing of carcasses. Space requirement for lairaging of sheep is 0.6 m2 per
animal.

3. V race: It is the pathway that connects lairage with the slaughter hall. Length of the V race can
be up to 36 m. Pathway will be tapering with width of 50 cm and 80 cm in bottom and at the top
respectively.

4. Slaughter hall: Premises where stunning, bleeding and dressing of carcasses takes place in the
abattoir. Animal need to be stunned before slaughter for painless killing. To ensure proper and safe
stunning a restrainer has to be provided which will hold the animals firmly while stunning. Stunning will
be followed by bleeding which has to be done on a bleeding trough of 1.1 to 1.2 m width for small
ruminants. Dressing of the animals has to be done on rail for ensuring hygiene. Height of the overhead
rails has to be about 2.7 m at bleeding area and 2.3 m at dressing area.

5. Tripe and gut room: Space for cleaning of stomach and intestine. Proper water supply and

provision for disposal of gastro intestinal contents has to be provided at the tripe room. 6. Byproduct
store room: Space for storing fat, skins, head and feet.

7. Offal room: Place for trimming and storing of liver, lungs, kidneys etc.

8. Isolation pen: Place for accommodating sick or suspect animals.

9. Chilling room: For chilling of carcasses after dressing. Temperature maintained in carcass store room
will be 70 C and that of offal will be at 30 C.

10. Cutting room: Room where carcasses are cut into cutup parts/ retail packs and packed as per

consumer requirement. Temperature maintained at cutting room will 100 C. 11. Freezer room: Storage
of packaged meat at – 17 to – 200 C till dispatch.

12. Veterinary room: Section for Veterinarians who undertake ante and post mortem of animals.

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(b) Have a separate room for the emptying and cleaning of stomachs and intestines, unless the
competent authority authorises the separation in time of these operations on a case-by-case basis;

(c) Ensure separation in space or time of the following operations:

(i) stunning and bleeding; (ii) in the case of porcine animals, scalding, depilation, scraping and singeing;
(iii) evisceration and further dressing; (iv) handling clean guts and tripe; (v) preparation and cleaning of
other offal, particularly the handling of skinned heads if it does not take place at the slaughter line; (vi)
packaging offal; and (vii) dispatching meat;

7. If manure or digestive tract content is stored in the slaughterhouse, there must be a special area or
place for that purpose.

Ensure separation in space or time of the following operations:

(i) stunning and bleeding; (ii) plucking or skinning, and any scalding; and (iii)
dispatching meat

Floors Floors
• Floors are made of non-absorbent, impervious and non-toxic materials that
are easy to clean, disinfect and maintain. See also drainage section at 1.3.2
above.
Floor surfaces should be non-slip without compromising hygiene, especially in
wet areas. Suitable materials include sealed concrete, epoxy resin. Avoid
materials that require high levels of maintenance or are not durable. Vinyl is
acceptable

Junctions – junctions between floors and walls should be smooth, sealed (using
an impervious mastic) and rounded to facilitate cleaning. Integral coving is
preferred.

Walls Walls
• Wall surfaces are made of nonabsorbent, impervious and non-toxic materials
that are easy to clean, disinfect and maintain.
B1b
• Smooth wall surfaces extend to a suitable height above the working area.
B1b
Suitable wall surfaces include ceramic tiles, plaster or rendering coated with
washable paint (not recommended for walls that are close to work surfaces or
equipment), plastic coated board (not recommended for wet areas or where
impact damage may occur), plastic cladding, stainless steel sheet, epoxy resin
coating and insulated panelling.
Avoid materials that require high levels of maintenance or are not durable.
Such surfaces will increase costs over time and may cause product
contamination (e.g. from paint, rust, peeling laminate surfaces).
Colour – ideally wall surfaces should be light coloured to reflect light and so that
dirt can be seen easily
Height - extend smooth wall surfaces to ceiling height where possible but, as a
minimum, extend to well above the level that food is either being worked on or
stored to avoid exposed food being next to hard to clean surfaces.
Lighting
 In practice adequate lighting means at least:
 540 lux at inspection points

 220 lux in workrooms

 110 lux in other areas

Lighting should not distort colours so that any discoloration of meat can be identified easily.

High intensity lighting is recommended except where, for poultry welfare reasons, blue
lighting is used in hanging on bays, although here too lighting needs to allow adequate
inspections to be performed

Enclose fluorescent tubes or light bulbs in waterproof and shatterproof covers for ease of
cleaning and to minimise the risk of contamination of food by glass fragments if there are
breakages.

Drainage

• The drainage system is capable of disposing of waste water and effluent effectively. In addition it has sufficient
capacity to cope with the maximum quantities produced at any time.

Drainage systems need to be able to handle material such as fat and blood as well as water.
Connect wastes from wash basins, sterilisers, other washing facilities, production room cleaning
facilities, carcase and offal showers and, refrigeration equipment to drains so that water does
not flow freely on floors. Effluent in drains should flow away from the product flow.

Provide floor drainage in wet areas with enough capacity to prevent overflow. Lay floors so that
waste water and effluent is directed down slopes into drains and pooling does not occur.

Rodent screens should be fitted to drains that open to the outside of the building to prevent the
entry of pests.
Open drain channels should have removable gratings to facilitate cleaning and maintenance.

Traps - protect the system by effective water traps or sediment traps that are easy to clean and
do not allow foul air or effluent to enter food-handling areas.
• Water traps deal with smells and assist with rodent control.

• Sediment traps are buckets to prevent excess solid materials entering the lower drainage
system where they can result in blockage or smell creation and cannot easily be accessed for
cleaning. Sediment buckets should be easily removable for cleaning
Manholes - avoid the use of internal drain inspection chambers (manholes), but if this is not
possible ensure they are doubly sealed and secured so that overflow cannot occur.

Changing facilities

Provide enough lockers and seating so that staff can store outdoor clothing and belongings and can change clothing and
footwear without getting protective clothing dirty. The use of changing facilities as a mess room, a canteen or a storage room
is unacceptable.

Changing facilities should be properly separated from the toilets, access to the food handling area from the changing room
should be through a lobby provided with washing facilities for hands, knives, boots and aprons and hangers for aprons.

The number of operatives and the nature of the operation should determine the facilities provided in the lobby. Some will
have a simple boot wash and hand wash facility while others will include ‘wet’ hygiene area for apron washes and apron
hanging facilities.

Storage for cleaning chemicals Storage for cleaning chemicals

• Cleaning agents and disinfectants Keep cleaning chemicals and utensils in a

are stored away from food handling
areas so that chemicals do not
contaminate food.
separate room or, exceptionally in small
premises, in a cupboard that can be locked and
is used only for this purpose.

A9

Floors
• Floors are made of non-
absorbent, impervious and
non-toxic materials that are
easy to clean, disinfect and
maintain. See also
drainage section at
Floors
Floor surfaces should be non-slip
without compromising hygiene,
especially in wet areas. Suitable
materials include sealed concrete,
epoxy resin. Avoid materials that
require high levels of maintenance or
are not durable. Vinyl is acceptable

1.3.2 above.
B1a
in changing rooms but not in
production areas. Wood is not a
suitable flooring material in food-
handling areas. Floors with grouting
are likely to require more frequent
repair. Such surfaces will increase
costs over time and may cause
product contamination.
Junctions – junctions between floors
and walls should be smooth, sealed
(using an impervious mastic) and

Walls
• Wall surfaces are made of
nonabsorbent, impervious
and non-toxic materials that recommended for wet areas or where
are easy to clean, disinfect impact damage may occur), plastic
and maintain.
B1b
• Smooth wall surfaces
extend to a suitable height
above the working area.
B1b
Ceilings
rounded to facilitate cleaning.
Integral coving is preferred.
Walls
Suitable wall surfaces include
ceramic tiles, plaster or rendering
coated with washable paint (not
recommended for walls that are close
to work surfaces or equipment),
plastic coated board (not
cladding, stainless steel sheet, epoxy
resin coating and insulated panelling.
Avoid materials that require high
levels of maintenance or are not
durable. Such surfaces will increase
costs over time and may cause
product contamination (e.g. from
paint, rust, peeling laminate
surfaces).
Colour – ideally wall surfaces should
be light coloured to reflect light and
so that dirt can be seen easily
Height - extend smooth wall surfaces
to ceiling height where possible but,
as a minimum, extend to well above
the level that food is either being
worked on or stored to avoid exposed
food being next to hard to clean
surfaces.
Ceilings
• Ceilings or interior surfaces
of the roof and overhead
roof fixtures are made
and finished so that they
prevent the accumulation of handling areas. Corrugated roofs and
dirt, and minimise
condensation, growth of
mould and shedding of
particles.
B1c, A1b
Suitable ceiling surfaces include
plastic cladding and sealed concrete.
Polystyrene or acoustic ceiling tiles
are not suitable for ceilings in food
exposed asbestos surfaces are
difficult to clean and are not suitable
surfaces. However, where such
surfaces are already in place and
remain intact, no action need be
taken. But, where these surfaces are
damaged the particles may pose a
risk from inhalation and
contamination of food. As a minimum,
arrangements need to be made to
replace or cover damaged areas.
Avoid materials that require high
levels of maintenance or are not
durable. Such surfaces will increase
costs over time and may cause
product contamination (e.g. from
paint, rust, peeling laminate
surfaces).
Overhead Fixtures - if overhead
fixtures and services in food-handling
areas are hard to clean they may be
boxed in. Fitting a suspended ceiling
made of a washable material (e.g.
plastic cladding) with overhead
fixtures, pipes and other services
above it may be an alternative but
may create other problems such as

Windows
• Windows (and other
openings such as skylights)
are designed and fitted to
prevent the accumulation of
dirt.
condensation, which may need extra
ventilation, and a space for pests.
Junctions – junctions between the
ceiling and walls should be smooth,
sealed [using an impervious mastic]
and rounded to facilitate cleaning.
Integral coving is preferred.
Colour - ideally ceilings should be
light coloured to reflect light and so
that dirt can be seen more easily.
Windows
Avoid windows in workrooms where
possible as they can compromise
temperature control. Where windows
are not needed for ventilation, it is
preferable that they cannot be
opened.
• Where open windows
would result in
contamination, they should
remain closed and fixed
during production.
• Removable insect-proof
screens are fitted where
necessary to prevent pest
entry – see Chapter 5 ( Pest
Control ).
B1d
Doors
• Doors and door furniture
have smooth non-absorbent
surfaces that can be easily
cleaned and disinfected.
B1e, B1f
• Openings (such as external
doors) are designed and
fitted to prevent the
accumulation of dirt.
B1d
Doors
Suitable surfaces include steel
(stainless or coated) and plastic
panelling. Wooden doors are not
recommended as the bottoms rot from
exposure to water and are easily
damaged by fork lift trucks, for
example. If used they need to be clad
or sealed and waterproofed e.g.
sealed with good quality gloss paint.
Door furniture - handles and push
plates also need to be smooth,
washable and resistant to cleaning
chemicals – see surfaces below.
Door openings – these need to be
wide enough to allow the easy
movement of staff, equipment and
vehicles.
External doors – these need to be tight
fitting (i.e. light is not visible around
the frame when closed). Where doors
are in frequent use (e.g. loading bays)
additional measures (e.g. overlapping

Other interior surfaces
• Surfaces in food handling
areas are made of smooth,
washable, corrosionresistant
and non-toxic materials.
They are easy to clean,
disinfect and maintain.
B1f
plastic strips) may help to minimise
pest activity.
Other interior surfaces
Working surfaces need to be smooth
and continuous, avoiding crevices,
pits and hard-toclean corners or
joints. Suitable surfaces include
stainless steel and food-grade
plastics.
Galvanised metal is prone to
corrosion, however
where such surfaces are already in
place and remain uncorroded, no
action need be taken. Wood is
generally not acceptable as a food
contact surface as it is difficult to
clean and disinfect and may shed
splinters, but may be acceptable for
cutting blocks as long as the surface
is smooth and well maintained.
 • If handled in a
slaughterhouse, approved for other
species, precautions are taken to
prevent contamination by separation
in time or space of operations
carried out on different species.
F7
• Separate facilities are
available for the reception and
storage of unskinned carcasses of
farmed game slaughtered at the
farm and for unskinned wild game.
F7
For red meat, there is separation of:
 Stunning and bleeding;
 For pigs: scalding, depilation,
scraping and singeing;
 Evisceration and further
dressing;
 Cleaning and handling of guts
and
tripe;
 Preparation and cleaning of
offal, particularly handling of
skinned heads if this is not done
at the slaughter line;
 Packing offal;
 Dispatching meat.
G6a, G6c
 There is a separate room for
the emptying and cleaning of
stomachs and intestines to
prevent contamination of meat
with gut contents, unless
Competent Authority authorises
separation on time separation on
a case-by-case-basis.
G6b
A ‘straight line’ layout leading from dirty to clean
areas is preferable and allows easy physical
separation of operations and materials. In older
premises there may be crossovers or a doubling
back in the layout. If this is the case it may be
necessary to install barriers to prevent
contamination. The layout should make it
difficult for staff to pass from dirty to clean areas
without washing hands and changing protective
clothing.
Examples of dirty areas:
? Lairage
? Green offal (i.e. Stomach and intestine)
emptying room
? Unfit meat holding facility
? By-products
Examples of transitional areas where clean
and dirty operations meet:
? Stun/stick
? Slaughter hall
? Detained meat loop and chiller
? Equipment wash rooms
? Staff amenities
Examples of clean areas:
? Red offal preparation and packing
? Carcase
chiller ?
Despatc
h
Green offal - time separation for emptying and
cleaning green offal may be authorised at the
premises, providing the OV agrees ( and signs
for the record) the operator’s written procedure
on how this operation will be carried out.
Entrances/Exits -- slaughterhouse layouts
should
Hand washing
 Hand washing facilities for staff
handling exposed meat are fitted
with taps designed to prevent cross
contamination
F4
Storage of unfit/detained meat
• Separate secure facilities are
provided for the storage of meat
declared unfit for human
consumption and for detained meat.
• Meat detained for further
inspection is kept in refrigerated
storage.
F5
• Hazardous and/or inedible
substances are stored in separate
and secure containers.
D4
Facilities for the Veterinary Service
• There are adequately
equipped
lockable facilities for the exclusive
use of the veterinarian and meat
inspection staff.
F6
Hand washing
 Hand washing facilities for
staff handling exposed meat
are fitted with taps designed
to prevent cross
contamination i.e. they are
not controlled by
Hand washing
Staff handling exposed meat should not use taps
controlled by conventional hand operated taps
as this may lead to re-contamination.
Elbowoperated taps should not be used as staff
may use hands to operate them. Install taps that
can be activated using knees or feet or
automatically by sensors.
Storage of unfit/detained meat
There is no opportunity for cross contamination
between fit and unfit meat. See Chapter 10
(Waste Management)
An adequately equipped detained meat facility
capable of being locked should include separate
drains and a rail system. In premises
slaughtering small numbers of young stock it
may be sufficient for the detained facility to be a
secure cage marked ‘detained meat’ with
separate drainage within a chiller. Its
acceptability will depend on the normal method
of operation. It is not acceptable if its use
interrupts / interferes with the normal operation
of the chillers.
Facilities for the Veterinary Service
Make available a lockable room or rooms
sufficient for the number of official veterinarians
and/or meat inspectors working at the premises,
for their exclusive use. Exceptionally, a separate
room may not need to be provided in small
premises where a single official is normally
working for only a few days a week.
Provide an appropriate number of desks or
tables; chairs; storage for outdoor and protective
clothing, lockable storage for official records,
(health marks if used) and personal belongings;
with power points
Hand washing
Staff handling exposed meat should
not use taps controlled by
conventional hand operated taps as
this may lead to re-contamination.
Elbowoperated taps should not be
used as staff may use hands to
 conventional hand operated operate them. Install taps that can be
taps. activated using knees or feet or
I4
automatically by sensors.

Meat Technology
Plant Management

Personal hygiene of the meat handlers has profound effect on the quality of the product. The
workers should be motivated and trained to follow good hygiene practices.

 The clothing should be clean and in good repair.

 No staff member working with meat should wear any kind of jewelry, badges or buttons
that may come loose and accidentally fall on the product.
 All the staff members working with exposed meat should have clipped nails and their head
should be completely covered with a clean cap or hair net to prevent the hair falling on the
product.
 Aprons and mesh gloves worn during work must be clean and in good repair.
 No one should smoke or use tobacco anywhere in the plant area when handling meat,
workers should not scratch their heads, place their fingers in and around the nose or mouth
or sneeze and cough on the product.
 Hands should be washed frequently to remove all visible soiling.
 No person suffering from infections or contagious disease shall be allowed to work in the
factory.

As we know a modern abattoir is highly advanced and organized industry for its successful running
on day-to-day basis we require skilled workers and dedicated technical staff.

The following requirements are important in abattoir management:

Proper maintenance of livestock yard and lairage: These are the areas where animals are
exposed to environmental stress. It is necessary that there should be proper arrangement of
unloading ,weighing and receiving stock.The animals are kept in lairage house for proper rest and
replenishing meat as the glycogen level is depleted during journey which directly affects the meat
quality. Lairage should be provided with sufficient drinking water and feed.

Organization of animal owners: In general there may be two types of slaughtering practices as
per owner organization.
(i) Butcher slaughtering their own animals: Here butcher himself is the owner of animal
slaughtered. S/he used to purchase the stock from nearby village and then slaughter at market place
to sell it.

(ii) Service slaughter on payment: Here the animal owner himself brings the animal to slaughter
place. S/he pays some nominal charges and get its animal slaughtered by skilled butcher in abattoir
premises. S/he either took away the meat for own consumption or sell it at the same place.

Inspection of Livestock: It is of prime importance that only healthy animals should be passed for
slaughter. A thorough antemortem check for health/disease condition of animal should be
performed by a qualified veterinarian.

Proper maintenance of plant and equipment: The abattoir has to be maintained properly
throughout the year. Clean, calm and aesthetic environment in working area must be ensured. All
the equipment whether in uses or not must be cleaned and examined regularly.

Training of staff: The meat production from live animals involves a number of skilled workers.
All the workers should be given proper training according to assigned work. It ensures efficient
production of quality product.

Production schedule and target for daily slaughter: According to reason, available stock,
manpower and capacity of abattoir, target of daily slaughter and meat production must be fixed.
Such type of systematic approach helps in meeting the target of production and therefore, further
necessary planning.

Handling of carcass and products: In a modem abattoir with rail system the unnecessary
exposure of carcass can be reduced easily. Whatever the system, it must be taken care that
unnecessary manual touch to carcass, exposure of carcass to direct open climate, a higher
temperature zone or contaminated carcass could be prevented.

Post-mortem inspection: Once the animal has been slaughtered and carcasses as well as viscera
are being presented for examination, careful postmortem inspection in a systematic manner should
be performed to correlate the results of antemortem report. It should be taken care that viscera
belong to same carcass which is being examined.

Quality control laboratory: Now a days in every modern abattoir there is a quality control
laboratory which examine the meat sample for biological, chemical and physical hazards.
Particularly for export purpose it is necessary to enclose a detailed report from quality control
laboratory.

Maintenance of plant hygienically: To ensure the quality of meat same regular cleaning and
disinfection's of plant premises and equipment's is brought in practice. Fumigation, sterilization
by flame or hot water also performed in some plant. The slaughterhouse should have provisions
for the cleaning and disinfection of trucks, trolleys, gamblers, hooks, inspection tables and similar
equipment's at the end of each working day. Foot-knee activated or timed hand washing facilities
should be provided and should be located so that personnel can readily wash their hands. Liquid
or other dispensable type of soap, paper towels in suitable dispensers and receptacles for used
towels should be provided. Besides these the plant workers must be told about hygienic practices
in detail and persons with habits of spitting and other malpractices must be removed.

Rendering of non-edible products: As discussed earlier a huge amount of byproduct is also

produced besides main product i.e., meat as a result of slaughter. Some of these byproducts are
utilized for specific purpose and have great value. Therefore, it is necessary to utilize these
products in judicious way. Rendering of non-edible products is one of commonly used practices
where fat is separated with the help of heat and rest is used for animal feed and fertilizer.

Processing of byproducts: It has been correctly said that each and every part of an animal is
utilizable except the last cry. Only meat production from slaughtered animals can not be a
profitable business and therefore, all the byproducts must be processed and utilized for economic
operation. Byproduct of meat industry can be defined as everything from the abattoir which is not
directly sold as food i.e., everything produced from the animal except dressed meat may be termed
as byproduct. Trimmings, bone, blood, liver are good source of proteins and several compounds
such as enzymes, hormones etc. can be recovered from the organs which are required by
pharmaceutical and other industries. Bone meal, meat meal preparation, use of skin and hide for
leather goods etc. are example of ideal utilization of byproducts. If these byproducts are left in the
abattoir without any processing then they may lead to unhygienic condition. Therefore, proper
handling storage and utilization of meat byproducts is not only important from economic point of
view but also essential to prevent the pollution in and around the factory.

Social welfare of staff: As discussed under heading utility block some basic requirements related
to staff-welfare must be fulfilled. Proper care for health of the workers should be ensured. They
must have some recreational facilities also.

Supervision of regulation of HACCP and IS0 standards: The quality of product should be of
standard level and as per limits fixed. Hazard analysis critical and control point (HACCP) should
be supervised and regulated. To meet the export quality we should try to stick to the International
Standard Organization (ISO) norms and limits.

Noise Control: Noise barriers such as screens around noisy equipment and operations should be
provided. All ventilation and extractor fans should be fitted with silencers. If the slaughterhouse
is located near the dwelling or noise sensitive place, then perimeter noise barrier walls of 2-4 m
high and off site noise barrier wall of 3 m high should be provided.

Pest Control: All windows and other exterior openings that could admit insects, birds, bats etc.,
should be equipped with screens. Fly chaser should be provided over outside doorways where
screening is not practicable. Expanded metal or wire with a mesh should be embedded in the walls
and floor at their junctions.

Manpower Requirement

Manpower requirement of a regular abattoir for slaughter of about 30 to 100 large animals or 150
sheep/goat per day are presented in the following table.
 Manpower Requirement in an abattoir

In an integrated modern abattoir, the key personnel involved in the plant management are as
follows:

General Manager

A general manager is responsible for:

 Production planning, achieving sustained output of assured quality and maintaining cordial
relations with the workforce.
 Controlling resources both men and material and reducing wastage and direct them to
proper use.
 Making endeavours to maintain consistent productivity levels and meeting production
targets.
 Examining every contract for its feasibility of compliance with respect to the specifications
of the product and meeting the delivery schedules.
 Enforcing the quality policy and the quality objectives and constantly monitoring their
compliance and sorting out all the interdepartmental problems.
 Ensuring conformity of all the quality parameters mentioned in the contract, entering into
the contract with the customers and market research for export market.
 Ensuring customer satisfaction, attending to their complaints and initiating corrective and
preventive action for all customers complaints.
 Identifying the customer's needs and ensuring that all the requirements of the customers
including those implied needs are adequately defined and documented.
 Motivating the departmental managers to create a climate of quality at all levels.
 Goal setting and monitoring performance of the managers and sectional In-Charges
concerned in achieving the plant's objectives.
  Introducing and implementing good manufacturing practices.
 Monitoring performance of production executive and maintaining consistency in
production output.
 Ensuring cleanliness of premisess and equipment coming into contact with meat and meat
products.

Production coordinator

A production coordinator is responsible for:

 Overall planning, scheduling, monitoring and management of product production

processes and maintaining consistent quality of product, monitoring productivity levels and
quality standards.
 Production of finished products as per specifications of the customer and meeting the
delivery schedules.
 Quality of inputs and all the technical parameters at each step of the processes.
 Evolving the parameters for control of processes and ensuring their adherence before the
product is transferred from one process to the next.
 Enforcing suitable controls necessary to prevent production of sub-standard products and
damage and deterioration during handling of products.
 Proper packing and handling of products.
 Ensuring segregation of non-conforming product to avoid inadvertent mix-up/further
processing.
 Ensuring timely corrective action of non-conformity appearing in the system and
preventive measures to eliminate recurrence of non-conformity.
 Monitoring resources both men and material and reducing wastage and direct them to
proper use.
 Maintaining consistent productivity levels and meeting production targets.

Manager administration

Manager administration is responsible for:

Policy making regarding industrial relation, collective bargaining and matters related to growth of
the organization, giving direction and providing coordination and support to administration.
All statutory obligations for operation of the plant.
Development of appropriate HRD policies in line with the organization's objectives, values, vision
and mission and also facilitation, implementation of the same.
Introducing effective concepts of management practices like total quality management, strategic
planning, etc. and to facilitate their implementation by creating resources and training others.
Interacting and interfacing with all the sections and activities to develop faultless inter-personal,
inter-sectional coordination for harmonious and effective industrial relations in the plant.
identifying the training needs of all new personnel and ensuring that they are adequately trained
with reference to the operational features of the machines, and also quality of the product.
Identifying the on going training needs of the employees with effective interactions with
department/section heads. Arranging training, monitoring and recording the same.

Manager Quality Assurance (Veterinarian)

A manager quality assurance:

 Ensures that all the required inspection and tests are carried out in accordance with the laid
down procedures and techniques.
 Ensures that quality assurance personnel take necessary samples that they require using the
correct sampling procedures.
 Ensures that test methods are strictly adhered to and test reports are forwarded to the
designated authority.
 Identifies and organizes calibration of inspection, measuring and test equipment to
maintain their continued suitability.
 Ensures that the final product conforms fully to the laid specifications provided.
 Ensures that corrective action are timely on non conformity appearing in the system and
institute preventive actions to eliminate recurrence of non- conformity.
 Checks the cleaning and hygienic conditions in the process hall and abattoir and prepares
check report.
 Being nominated person under Prevention of Food Adulteration Act, 1954, S/he is
responsible for all statutory obligations for quality of products.
 Facilitates and monitors implementation of systems introduced'and the Total Quality
Management (TQM).
 Ensures adherence to cleaning schedules for maintaining proper hygiene.

Veterinary Officers

A veterinary officer is responsible for:

Organizing animal health programmes in the animal procurement areas.

Ensuring that only healthy animals are accepted for slaughter and performing ante-mortem
examination of animals.
Proper maintenance of lairage and cleanliness of animals before sending for slaughter.
Ensuring that only healthy and disease free carcasses are taken for processing through hygienic
slaughter and effective postmortem examination.
Ensuring proper disposal of condemned carcasses and record keeping.
Examining the animals in isolation pen and under quarantine.

Manager Commercial

A manager commercial is responsible for:

Assessing, evaluating and appointing subcontractors for supply of materials and services.
Procuring of live animals.
Preparing raw material purchase statement and subcontractor payment balance sheet and day to
day production costing report.
Arranging byproducts sale and executing the related activities.

Manager Purchase and Stores

A manager purchase and stores:

Codifies all items of store including accessories and spares.

Receives items of stores and keep records of all items.
Issues all items with proper documentation and updates all stocks and issue of material.
Returns all rejected material to suppliers.
Coordinates with purchase and all other user departments for proper flow of material.
Maintains proper inventory control, plans proper storage to prevent damage and
deterioration,check receipts for right quality and quantity.
Stocks the required items of the consumer departments properly.
Supervises day to day administration and function related to all purchase activities.
Develops specification for different materials including packaging material, consumables, spare
parts etc.

Rendering Plant In-Charge

The In-charge will ensure that the inedible offals are received in covered trolleys to the rendering
plant and are processed on the same day.
The In-charge ensures that bone meal, meat meal, tallow etc. are to be properly packed, stored and
marketed regularly.

Effluent Treatment Plant In-Charge

The In-Charge ensues that the waste water containing faeces, urine, blood washing and meat
material from abattoir are led to the effluent treatment plant (ETP) after screening of grease, solids
etc. S/he also ensures that the anaerobic fermentation is followed by aerobic fermentation and
finally the treated effluent has a BOD of 30 ppm and the water is utilized for irrigation.

General Plant Design Considerations

LOCATION AND SITE

A minimum site area of 1800 square metres will be required to accommodate all modules. The
abattoir layout presented is based on a rectangular site 30 metres by 60 metres.
Only general guidance as to location and siting can be given in a report such as this. Points to
consider in selecting a suitable site are listed below. In practice compromises will inevitably be
needed when selecting a site.

In presenting this check list it has been assumed that a general locality for the abattoir will
already have been established based on sources of stock supply, location of markets, and taking
into account transport methods and infrastructure availability.

Water Supply

An adequate water supply is essential.

Inspection Office

 The minimum office space requirement shall be 5m2 for one inspector and
1.4 m2 for each additional inspector.
 There shall be provision for lockable cabinet and adjoining toilet
 There shall be provision for fixed glass window for viewing.

MESS ROOM/CANTEEN

There shall be provision for a separate area for eating outside the
Slaughter house Building

By products room
By products room products room shall be provided for temporary storage of
hides, feet, head and tail.

Dispatch area
The dispatch area shall be adequate in space and shall allow orderly and
efficient loading of meat. Electronic weighing scale shall be provided

Toilet and Shower Room

Changing/Locker room

 Changing/locker room shall be separated but Accessible directly with

Wash rooms.
  Individual lockers shall be provided for employees

Administration office
 The minimum office space requirement shall be 5sq. meter for one office
personnel and 1.4 sq. meters for each additional personnel.
 There shall be provision for locker cabinet and adjoining toilet.
 There shall be provision for fixed glass window for viewing.

Sanitation
 Foot bath shall be provided before entering the working area. Foot bath
shall be 4-6 inches depth with plug and drain.

 Hand washing facilities (knee operated) shall be provided along the

workers entrance to the slaughterhouse and offal cleaning rooms and
shall be capable of supplying water and directly drained. Location shall
be located where the personnel can readily wash their hands and beside
the footbath.
 Boots washing facility area shall be provided with faucets in both offal
rooms and at the workers entrance
 Wheel bath shall be provided and constructed at the entrance gate
Measuring 6” H x3m W x 3m L. Wheel sprayer is recommended in the
absence of wheel bath.

Employee Welfare Facilities

Employee welfare facilities include dressing rooms, toilets, shower baths, and
lunchrooms.
When both sexes are employed, separate dressing rooms and toilets are
required. If suitable restaurants are not available nearby, a plant may be
required to provide a lunchroom. The slaughter plant layout includes a dressing
room and toilet room for the female employees and a dressing room and a
combined toilet and shower bath room for the male employees.

Spice Room
Plants that make sausages, cured meats, or meat products containing binders or
extenders need an ingredient storage area. If only pre-weighed packages of
ingredients are used, shelf space set aside for these packages in the dry storage
room is adequate. A separate spice room is suggested when ingredients are
purchased in bulk and are measured, weighed, or mixed prior to use. The room
should be well constructed to keel out dampness, dirt, and insects, and be easy
to clean. Ingredients must be stored at least 12 inches above the floor on either
metal racks, shelves, or pallets, or on wooden ones if they are kept in good repair
and are easily cleanable . In addition to storage space, the room needs a table,
scales, and measuring and mixing equipment. The spice room location in the
slaughter plant layout is not as convenient to the cure work area as the one shown
for the non-slaughter plant. This relatively distant location is acceptable, however,
since the cure worker should be able to obtain all the ingredients needed for a
day’s operation in one trip.

Offal Room
An offal room in a small meat plant which is used to store inedible byproducts
temporarily. In slaughter plants, viscera, feet, condemned parts, bones, excess
fat, and other items not for human consumption are stored in this room. If hides
are sold green or if blood is caught during bleeding, these containers may also
be stored in the offal room. If offal is not picked up daily, the room should be
artificially cooled to about 40° F. In low-volume plants, the offal room is used
almost entirely for the storage of inedible byproduct containers. The smallest
practical paunch worktable is about 4 by 9 feet. A paunch truck wash and sterilize
area requires a space about 7 by 8 feet . The amount of floor space needed to
store byproduct containers can be determined roughly if the approximate
amounts of byproducts to be

Hide Room
Many livestock slaughter plants have a room for curing cattle hides. The hides are
put into the curing area as they are removed or at the end of the day’s slaughter.
Ideally, the hides are trimmed and cleaned, and then spread out hair side down
in a curbed area, covered with coarse salt, at the rate of about a pound of salt
to each pound of hide, and cured for about 30 days before they are sold. The
temperature of the hide room should be about 50° to 55° F, with a relative
humidity of 85 to 95 percent to get the best cure (1) . Some slaughterers sell hides
“green.” Green hides are placed in containers in the offal room, and a buyer
picks them up several times a week. The hide-curing area can be located
adjacent to the slaughter floor, in the basement, or in a separate building (figs. 27
and 28). There are advantages and disadvantages to each location. A hide room
near the slaughter floor is most convenient for disposing of the hides, but is usually,
the most costly because of the type of construction required by meat inspection.
Another disadvantage is that in hot weather a disagreeable odor from the hide
room may penetrate the entire plant. A basement room is naturally cool, and
hides can he dropped through a vented chute from the skinning area to the hide
room, but a basement hide room can be expensive because of the extra
excavation and building foundation required, unless the plant is located on a
hillside. A separate hide house can be built of relatively inexpensive materials in
almost any configuration. The major disadvantages of a separate hide house is
distance from the slaughter floor, which makes for discomfort for workers
transporting hides in inclement weather. A suggested design for a separate hide
house is shown in figure 29. The drawing shows the pit below ground level;
however, it could be located at or above ground level if necessary. Hides located
below ground level should be cooler in summer. To prevent saltwater from leaking
into the surrounding soil the pit floor and walls should be waterproofed. When the
pit is emptied of hides, the standpipe can be removed and the walls and floor
cleaned before a new hide cure cycle is started. The 2-foot-high standpipe allows
brine to accumulate around the hides in cure. The ventilators at each end of the
roof allows air to circulate through the building. Since salt is very corrosive, either
wood or rustresistant ventilators are recommended. The walkway, on two sides of
the pit, is for temporary storage of hides and salt storage. The hide house door
can be of treated wood or noncorrosive metal. A galvanized-metal or aluminum
roof is suggested. The pit size shown will handle hides from average-size cattle and
provide space for a narrow walkway on two sides. Based on a storage factor of
about 1 cubic foot per hide, it should hold around 300 hides. A separate hide
house similar to the one shown in figure 29 is suggested for the slaughter plant in
figure 5. This plant will produce about 120 hides in a 30-day cure cycle; a hide pit
depth of between 1 1/2 and 2 feet will handle that volume and allow for a modest
increase as well.

Product Shipping and Receiving

A dock for shipping customer orders and one or more receiving docks are
needed at most plants. If carcass meats are purchased, the shipping dock also
can be used for receiving meats. A dock not in use for loading or unloading
meats can be used for receiving dry storage supplies, plant equipment, and
similar items. A dock can extend out from the building or be located inside the
building near a recommended for shipping and receiving carcasses because it
is usually less expensive than interior space, and the plant door can be kept
closed except when products are passing through. The outside dock floor
should be concrete, sloped down toward the outer edge at about one-eighth
inch per foot. A dock height of about 24 inches should be adequate for serving
small trucks and automobiles, and from 42 to 48 inches, for refrigerated trucks. To
protect meat products from inclement weather, a roof is required over an
outside dock (11). If the dock roof extends beyond the edge of the dock floor,
the lowest part of the roof should be at least 12 feet above the driveway to
clear refrigerated bodies on small trucks, or 14 feet to clear trailer trucks. A
covered dock is shown in both the slaughter plant layout (for loading meats into
customer trucks and receiving supplies) and in the non-slaughter plant layout
(for receiving carcass quarters and wholesale cuts). Both docks have an
overhead rail for moving meat cuts hung on trolleys. Both layouts have a
corridor that connects the dock to the plant storage and work areas. A track
scale is located in the corridor for weighing meats hung on trolleys. To help keep
insects out of the plant, a fly-chaser fan, air door, or other device should be
installed over the doorway (11).

COOLER

Cooler space for one beef will provide space for 1.5 to 2 hogs, sheep, or goats.
When painting or touching up expoxy, it is critical to seal the area off from the
rest of the plant to avoid contamination of food materials, finished products,
and packaging.

Rendering

Rendering is a heating process for meat industry waste products through which fats are separated
from water and protein residues for the production of edible lards and dried protein residues.
Commonly it includes the production of a range of products of meat meal, meat-cum-bone meal,
bone meal and fat from animal tissues. It does not include processes where no fat is recovered.

There are basically two different rendering processes:

- High temperature rendering: through cooking or steam application (5 systems are known: (1)
simple cooking; (2) open pan rendering; (3) kettle rendering; (4) wet rendering; and (5) dry
rendering.)

- Low temperature rendering (around 80°C). This process requires finely ground material and
temperatures slightly above the fat melting point. It results in a better quality lard. The rendering
at low temperatures is a highly sophisticated process requiring large throughputs and trained
personnel. For many developing countries the system is not suitable. (Kumar, undated).

Animal Holding Areas

Construction of animal holding areas should address the following:
1. Unloading of animals.
2. Design of animal paths for fluid movement.
3. Ample space for animals of all sizes.
4. Availability of water for each animal.
 5. Ventilation to provide proper cooling/ heating.
6. Lighting.
7. Contact your regional Iowa State University Extension Livestock Specialist for more detailed
information.

Slaughter Areas
Construction of slaughter areas should address the following:
1. Is there a sterilizer in the slaughter room?
2. Is the knock box in the slaughter able to withstand the animals that it is intended to hold?
3. Is there an adequate inspection pan and head loop for official slaughter rooms?
4. Do you have 50 foot candles at the inspection station on the slaughter floor?
5. Are the rails in slaughter and coolers located at an adequate height for the purpose intended? Is
the bleeding rail height adequate?
6. Are toilet facilities located near slaughter floor to prevent slaughter room employees from
traveling through plant.

Inedible Areas
Construction of inedible areas should address the following:
1. Inedible rooms need to limit access to the facility (e.g. an interior door for the
establishment to place inedibles in the room and an exterior door for the rendering truck to pick
up the inedibles without entering the plant).

Receiving and Shipping Areas

Construction of receiving and shipping areas should address the following:
1. Load out areas should be located so that product is not transported back through production areas.
2. Receiving and shipping areas should not open up into a processing room.
3. Receiving and shipping areas should be adjacent or close to where products/supplies are being
stored.

Coolers and Freezers

Construction of cooler and freezer areas should address the following:
1. Are there separate coolers for storage of raw and cooked products?
2. Do the coolers have drains in them and are they adequately sized?

Storage Areas
Construction of storage areas should address the following:
1. Is there adequate storage for dry and nonmeat ingredients.
2. Is there adequate storage for packaging and labeling supplies?
3. Is there storage for equipment?
4. Is there storage for maintenance tools?
5. Is there separate storage for cleaning tools, supplies, and chemicals—away from food?
6. Is there storage for employee belongings?
Processing Areas—
RAW, COOKED, SMOKEHOUSE
Construction of processing areas should address the following:
1. Are there separate areas for processing cooked and raw products?
2. Is the processing room refrigerated?
3. Is the smokehouse in a room by itself with a drain?
4. Do carcass rails lead all the way into the processing areas for convenience and safety of dropping
carcasses to tables or work areas?
5. Are floors sloped to drains?
6. Consider placement of equipment for ease of transition from one machine to another, e.g., meat
saw close to boning table.

Employee/Welfare Areas
Construction of welfare/employee areas should address the following:
1. Do the bathrooms have separate sewer
lines until outside the building or is there a backflow preventative device?
2. Does the restroom have a self-closing door and ventilation that is turned on with the light?
3. Is there a bathroom that customers can use easily?
4. Is there a separate break area for employees?
5. Is there a separate storage area and refrigerator for employee food?
6. Consider the location of the management office within plant—should it be closer to the retail
area, employee welfare area, production area? Where does management spend most time? Is other
office space necessary?
7. If you operate under FSIS-inspection, a separate office area is needed. If Iowainspected, a work
area and place to store plant files is needed.

Retail/Customer Areas
Construction of retail/customer areas should address the following:
1. Is the retail area sufficiently separated from processing areas?
2. Can customers pick up their products without causing contamination of processing areas?
3. Are finished product storage areas (e.g., freezer, ready-to-eat cooler) located close or adjacent to
retail area (and/or to shipping area)?

Traffic Patterns
Traffic pattern items that should be considered:
1. Is the flow of the product from animal arriving to packaged meat leaving
adequate to prevent contamination of areas or products?
2. Is the traffic flow for delivered goods adequate to prevent contamination in processing areas?
3. Are traffic patterns planned to retain separation of cooked and raw products— including people
(employees and nonemployees), equipment and product?
4. What paths do delivery or pick-up persons take within your plant? How do you prevent
contamination from the outside?
Sewer and Water
Sewer and water items that should be considered:
 1. Do you have a sewer certificate?
would come from the city.) 2. Do you
annually? Does your city?
3. What is the source of the water for the
4. Are sewer pipes from toilets/welfare areas
5. Is there proper water disposal (sewer) to
contamination—backflow devices?
General Construction Considerations
1. Are the floors, walls, and ceilings in wet
cleanable?
2. Are doors and hallways wide enough for
equipment movement—e.g., smokehouse
3. Are there hose bibs in wet areas so that
4. If there are windows, are the windowsills
(no ledges is preferred)?
5. Do the floors in wet areas slope toward the
drains have adequate traps?
6. Are the hands-free handwash sinks
located in areas where they will be easily
7. Is the lighting adequate for the purpose
8. Is there a three compartment sink for
9. Will there be curbing around the rooms?
constructed to ensure cleanability and a good
10. Consider which direction doors open—
11. Consider what type of doors are needed—
12. What type of security is needed?
13. Determine the volume of your business
size of coolers, freezers, processing, storage
14. Determine how plant can grow in the
15. Air flow (ventilation, heating, cooling,
positive and negative air pressure are balanced
odor from animal holding pens/offal/slaughter
packaging area should be positively
plant.
16. Will any other operations be happening in
Catering? Retail sales of nonmeat foods and
operations?
(If hooked up to a municipal system, this
have the water tested at least
plant? City water (public) or private well?
separate from sewer pipes from production areas?
protect food production areas from
areas smooth, impervious to water, and easily
the intended purpose—people, product, and
trucks?
proper washing can be performed?
built to prevent accumulation of debris and dirt
drains and are the drains adequate in size? Do the
accessible and useable?
and is it protected?
cleaning equipment?
What will it be constructed with and how will it be
seal at the junction where the wall meets the floor?
freezers, coolers, etc.
swinging doors, lockable doors?
and growth of your business when determining the
areas, and retail areas.
future with building additions.
etc.) inside the plant should be addressed so that
and do not cause adverse situations in the plant—
area filtering to other parts of the plant. The retail
pressurized to push air out into the rest of the
the plant? Other non-meat food processing?
other items. What space is designated for those