Meat Processing

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Meat Processing

Text of Meat Processing

  • MEAT PROCESSING PLANT

    [Pre-feasibility Study]

    Prepared by

    ARCH VISION Consulting

    Engineers Environmentalist & Architects

    UPDATED BY

    PUNJAB BOARD OF INVESTMENT&TRADE (PBIT)

    LAHORE

    2011.

  • [MEAT PROCESSING PLANT] September 7, 2011

    [PBIT] Page 1

    DISCLAIMER

    The purpose and scope of this Pre Feasibility Study is to introduce the Project and provide a

    general idea and information on the said Project including its marketing, technical, location and

    financial aspects. All the information included in this Pre-Feasibility is based on data/information

    gathered from various secondary and primary sources and is based on certain assumptions.

    Although, due care and diligence has been taken in compiling this document, the contained

    information may vary due to any change in the environment.

    The Planning & Development Division, Government of Pakistan, M/s. Arch Vision Consulting

    Engineers who have prepared this Pre-feasibility study, or National Management Consultants

    (Pvt.) Limited who have quality assured this document do not assume any liability for any financial or

    other loss resulting from this Study. They have granted permission to PBIT to update and disseminate

    to potential investors.

    The prospective user of this document is encouraged to carry out his/ her own due diligence and

    gather any information he/she considers necessary for making an informed decision.

    The project document outlays project costs as estimates obtained from primary and secondary data

    sources. However, it is strongly recommended that a detailed feasibility study shall be carried out to

    develop project financials.

  • [MEAT PROCESSING PLANT] September 7, 2011

    [PBIT] Page 2

    ESTABLISHING MEAT PROCESSING FACILITIES

    Pakistan does not have a modern meat processing plant due to which the country suffers as

    current facilities are unable to pass the stringent health requirements of the European and the US

    health authorities. This effectively shuts Pakistan out of the lucrative Halal markets of the world

    where a large expatriate Pakistani community lives. The processed meat industry incorporates

    a range of activities, from simple slaughtering and butchering of various species for human

    consumption through to complex cooked, preserved and fermented products. These processes

    add value to the product by dividing it into smaller units or transforming them into more complex

    products. As part of the project it is proposed to have a modern meat processing unit which will

    process 150 cattle head per day along with 1,000 goats and sheep.

    LOCATION OF THE PLANT

    It is proposed to locate the meat processing plant near the cattle farm in Lahore near the area of

    airport like kanna Nao. The cattle and the sheep/goats will be purchased from the local animal

    markets the biggest of which is located about 30 minutes from the proposed location. The

    processing plant will be located on the road which leads to the main cattle market and through

    which nearly 90% of the animals which are sold in the Lahore Cattle Market pass. It is hoped

    that in a short period of time, the Plant can develop into a first stop for traders heading for the main

    market trying to sell directly to the Plant. In addition, the plant is proposed to be located in an

    area which is well connected to the international markets as the International Airport would be

    less than an hours drive from the Plant, this will ensure that export shipments fully comply with

    international requirements. The main market for domestic meat is located in Lahore which has

    got a thriving food catering/ restaurant/hotel business in addition to a population of more than

    16.0 million inhabitants, having the highest levels of education and international exposure. It is

    expected that the market will readily accept the packaged meat concept.

    THE MEAT PROCESSING PROCESS

    The live weight of the cattle slaughtered for meat can vary from 250 kg to 600 kg depending

    on the age and the breed of the animal. The basic slaughtering procedure for beef cattle

    has become more automated and efficient over the past few decades. Most improvements have

    occurred in slaughtering, hide removal, evisceration and splitting techniques.

  • [MEAT PROCESSING PLANT] September 7, 2011

    [PBIT] Page 3

    The basic process for the slaughtering and processing of cattle is shown in Figure 1;

    FIGURE - 1

    THE MEAT SLAUGHTER & PROCESSING PROCESS

    Delivery and holding

    of livestock

    Slaughtering under

    Islamic Method

    Hide removal/

    Dehairing

    Boning

    Trimming and

    Carcass

    washing

    Evisceration

    Chilling

    Packaging

    Cold storage

  • [MEAT PROCESSING PLANT] September 7, 2011

    [PBIT] Page 4

    Pre-handling of Cattle: Cattle are delivered to the abattoir in trucks and unloaded into

    holding pens, where they are rested for one or two days before slaughter. Any cattle classed as

    dirty are washed. Veterinarians will subject the animals during rest period to ante-mortem

    examination; only after approval the animals will be slaughtered.

    Dhabia or zabiha of the Animal: Prior to the slaughter, the animal's eyes and ears are

    checked to ensure that the animal is healthy and suitable for slaughter. If the animal is deemed to

    be healthy, it is first given water to drink (in order to quench its thirst) and is then pointed towards

    Mecca to be slaughtered. According to Islamic tradition, the conventional method used to

    slaughter the animal involves cutting the large artery in the neck along with the esophagus and

    trachea with one swipe of a no-serrated blade. This method of slaughter serves a dual function:

    it provides for a relatively painless death and also helps to effectively drain blood from the

    animal. The latter is important because the consumption of blood itself is forbidden in Islam.

    This method of killing the animal is cleaner and more merciful to the animal. During the blood

    draining process, the animal is not handled until it has died. Once the animal has died, it is then

    shackled by a hind leg and hoisted on to the overhead rail or dressing trolley any blood still left in

    the animal is collected in a trough.

  • [MEAT PROCESSING PLANT] September 7, 2011

    [PBIT] Page 5

    Dressing and Hide Removal: The bled carcasses are conveyed to the slaughter hall where

    dressing and evisceration takes place. The first stage of the process, dressing, can be

    performed as the carcass hangs from the overhead rail, or the animal can be unshackled and

    laid in a cradle. The head and hoofs are removed, the head is cleaned with water and the tongue

    and brain are recovered, hide is then removed and conveyed to the hide processing area

    where it is preserved by salting or chilled in ice. Evisceration: The carcasses are then opened to

    remove the viscera the stomach (paunch) and intestines are emptied of manure and cleaned in

    preparation for further processing. Edible offal (tongue, lungs, heart and liver) is separated,

    washed and chilled. The carcass is then split, rinsed and conveyed to a cold storage area for

    rapid chilling.

    Cutting and Boning: Carcass cutting and boning often takes place after chilling since a carcass

    is easy to handle and cut when it is chilled. Boning is the term used to describe the process of

    cutting meat away from the bone

    Inspection: Carcasses and viscera are inspected to determine if they are suitable for human

    consumption. Each carcass and its components are identified and kept together wherever possible

    until inspection is complete.

    By-products: At various stages in the process, inedible products such as bone, fat, heads,

    hair and condemned offal are generated. These materials are sent to a rendering plant for

    rendering into feed materials.

  • [MEAT PROCESSING PLANT] September 7, 2011

    [PBIT] Page 6

    MEAT PROCESSING TECHNOLOGY

    Meat processing technology comprises the steps and procedures in the manufacture of processed meat products. Processed meat products, which include various different types and local/regional variations, are food of animal origin, which contribute valuable animal proteins to human diets. Animal tissues, in the first place muscle meat and fat, are the main ingredients, besides occasionally used other tissues such as internal organs, skins and blood or ingredients of plant origin.

    All processed meat products have been in one way or another physically and/or chemically treated. These treatments go beyond the simple cutting of meat into meat cuts or meat pieces with subsequent cooking for meat dishes in order to make the meat palatable. Meat processing involves a wide range of physical and chemical treatment methods, normally combining a variety of methods. Meat processing technologies include:

    Cutting/chopping/comminuting (size reduction) Mixing/tumbling Salting/curing Utilization of spices/non-meat additives Stuffing/filling into casings or other containers Fermentation and drying Heat treatment (see separate chapter page 87) Smoking

    EQUIPMENT USED IN MEAT PROCESSING

    In modern meat processing, most of the processing steps can be mechanized. In fact, modern meat