Design and construction of Abattoirs & processing plants
Principles of design and construction of Abattoirs & processing plants
The first stage of planning an abattoir or meat/poultry processing facility is to do a feasibility study.
This is followed by drawing up a plan for the plant’s interior and exterior design, calculating capital and operating costs, and, finally, approaching a meat plant designer to make sure all bases have been covered
The feasibility study must address the number of livestock/carcasses to be processed; type of product to be prepared; markets to be served; the management system required (which will take account of specialised labour requirements); costs of materials, services and labour; equipment and spare parts; and methods of waste disposal (in the case of abattoirs).
Provision must be made for capital costs (land, buildings, pieces of equipment and their instillation) and operating costs (personnel, water and electricity, fuel, maintenance and spares, insurance, cleaning chemicals, and sundries such as packaging materials and office supplies).
Management and staff
In the case of an abattoir, the exact management system – Public Service, commercial or wholly private – must be established in the initial planning stages, as this will have a bearing on design and the equipment to be installed.
Likewise, the system of management of staff must be considered from the outset. This entails full-time, part-time and contracted staff.
Design
The following information is crucial to assist with the design of the meat /poultry plant:
• The number of livestock/poultry to be slaughtered, their type and weight, and over what time period (in the case of a processing plant, the number of carcasses/boxed meat/poultry cuts bought from producers or abattoirs, type of meat/poultry products produced, and their packaged weight);
• The availability of stock for slaughter and its seasonality;
• The ownership of the livestock at each stage, e.g. will the abattoir buy them from producers or at auctions; will it slaughter for producers or wholesalers; will it sell processed meat /poultry to wholesalers or through its own outlets. These factors influence the carcass identification systems and space requirements;
• What parts of the carcass are considered edible and inedible, e.g. chicken feet, unused in many parts of the world but
considered a delicacy in others such as South Africa. This will assist with by-product and effluent plant design;
• The slaughter system to be considered appropriate, e.g. overhead railway system; and
• The level of technology to be employed.
Location
Transport distances between the processing plant and livestock producers and the marketplace must be short so that transport costs and livestock stress and mortality rates are reduced.
The site for a processing plant should be chosen with care, with main consideration given to the provision of services. There should be easy access to adequate water and electricity; gas, if required; and communication systems. A qualified, readily available workforce to operate, manage and maintain the plant is also vital.
Abattoirs release unpleasant odours; and fumes, smoke and steam, as well as particulate matter from other manufacturing processes or housing, such as feed millings and sawdust. Therefore they should be situated far from housing developments and other food processing facilities.
For drainage reasons, the best sites are those situated on a gentle slope, with soil that drains well or, alternatively, is rock hard. In addition, one of the most important services to the plant, namely effluent disposal, relies on effective handling that is facilitated through a sufficient gradient and soil type. The effluent disposal system should be designed so that the water source for industrial and personal usage is not contaminated.
Buildings
As trucks will frequently enter and exit the premises, ample space should be available around the meat processing plant for parking / turning and vehicle wash areas, as well as waste disposal and effluent treatment systems, and ancillary buildings and facilities such as office areas and livestock holding pens.
As for the main building, attention must be given to the space required for the processing and staff areas.
Processing areas comprise “clean” and “dirty” operations – with meat handling locations considered “dirty” – and are therefore separated from each other. Rooms include a reception area, slaughter hall, dressing rooms, chilling and freezing facilities, processing rooms, offal and by-product processing rooms, packaging areas, storage rooms (chilled, frozen and dry), and a dispatch area.
Staff facilities include offices, toilets and changing rooms, a canteen, and first aid room. A wholesale shop open to the public may be made available.
Depending on the type and size of the operation, not all of these areas will be required, but more than one will be needed in others, for example a reception area for chilled meat/poultry and another for dry ingredients.
It is very important to remember to make provision for the whole building to be proofed against insects, rodents and birds.
Equipment
Machinery must be chosen based on the technology best suited to the livestock being slaughtered and the estimated maximum throughput envisaged for the foreseeable future, with scope for expansion in line with business growth.
Design plans should show an uncluttered, logical flow of equipment along the processing line, with minimum distances between operations and processing materials close to the applicable processing equipment, for instance, packaging materials should be close to the packaging machine.
Doors and windows
Window and door frames should be made from non-corrosive materials such as metal alloys. Window sills must slope so that items of clothing and knives cannot be stored on them, and doors should have impermeable surfaces.
Ventilation
In abattoirs and meat processing plants the emission of airborne particles with pathogenic and spoilage microorganisms can create high airborne concentrations. These must be carefully controlled through adequate ventilation to guarantee product quality and safety, as well as the health and wellbeing of plant workers.
Service runs
Again, our article on HVAC can be a useful reference when designing a meat processing plant’s service runs and ducting, which need special consideration.
Pipework should be simple and straight, preferably buried in the walls or floors, or run down an outside wall before it passes into the room where it is required. Where pipes buried in a wall emerge into a room, stainless steel should be used as the pipes tend to corrode at this point, which makes repair very difficult and expensive.
Pipes that run inside a production room should be made of stainless or galvanised steel and mounted in wall spacers so that they are 50mm from the wall. Suspended pipework should not be located over product lines, as, should they need repair, production and product quality will be affected.
If they cannot be situated outside production areas, electrical fittings, fixtures and switches should be of waterproof standard, able to withstand the force of water from a hose pipe or steam lance.
Companies that can assist in South Africa include Abattoir Supply Company, JF Equipment, Jarvis, DFS Process Equipment, and LA Steel Supply .
Abattoir Supply Company – Turnkey abattoir design and development services and equipment suppliers for small to large scale operations.
Our turnkey solutions cover all aspects of the abattoir and livestock slaughtering industry, and our know-how ensures impressive quality. Our process design extends from the animal entering the facility, right until the product is dispatched for retail. We are dedicated to providing quality and affordable products that are best suited to our clients.
Process Design
Custom design and formulation of optimal operational processes and production lines.
Architectural
We provide Architectural Design and manage the municipal plans submission procedure.
Engineering
Professional engineering services, including Civil, Structural, Electrical and Mechanical.
HVAC Systems
Design and installation for all Refrigeration and Mechanical Ventilation systems.
Compliance
Provision of Environmental Impact Assessments, and Water Use Licensing.
Comprehensive offering.
Our service is fully comprehensive, and offers great value for money. Our client centric approach takes all unique requirements into consideration, while providing the most optimised solution in terms of work flows, efficiencies, and compliances. Our process design extends from the animal entering the facility, right until the product is dispatched for retail.
⁃ Single or combined lines for all types of livestock.
⁃ Highly effective cutting systems.
⁃ Optimal exploitation of by-products.
⁃ Tubular track technology for optimised meat transportation.
⁃ Custom-made systems that meet regulation standards.
Why choose us?
We are dedicated to providing quality and affordable products and services that are highly optimal and cost effective.
Highly focused on customer service.
We embrace the philosophy that our customers are the most important people in our business, and in this regard, every effort is made to give clients the best products and service at competitive rates. We are committed to ensuring that our clients receive reliable and personal service that exceeds expectations.
We are committed to expand to meet the growing needs of our customers. It is for this reason that the sale does not stop at the final installation, but becomes the beginning of a long association whereby the equipment is serviced and monitored to ensure maximum life.
We have the ability to set and maintain the desired quality standards expected by all our customers, thus we are committed to change in accordance with their needs and expectations.
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As a specialist for customised, complete abattoir system solutions, including the processing of by-products, cutting systems, logistics and refrigeration, we have made a name for ourselves in sub-saharan Africa. Our customers particularly value our first-class solutions, combined with vast experience in regional markets.
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We have been in the industry for many years, so we have had ample time to learn our way around the marketplace, and have become reputable in providing clients with the most suitable value for money products. We continue to compliment our offerings as we explore new opportunities and expand into the local market.
Passionate
We provide products that have you, the customer, and your unique requirements in mind. Our passion in our business and our people skills make us ready for any challenge. From impressive customer service and strong supplier partnerships, we have you covered for a long-term mutually rewarding business relationship.
Great Support
Customer service is always a top priority for us. We give customers peace of mind through a transparent and enriched customer experience. Our excellent support reassures our customers that we are serious about our business, and we always go the extra mile to make your experience with us a pleasant one.
High-End Equipment Suppliers
We supply a wide range of equipment and consumables to the abattoir industry, and have been appointed as an official supplier of FREUND – German Quality Slaughter Tools. For far more than 100 years FREUND has been developing and producing machines and equipment for humane and economic meat production and cutting.
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