Abattoir Practices and Animal Products Technology

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.