Processing Meat

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MEAT PROCESSING PRACTICES AT Keels Food Product LimitedMinuwangoda Road, Ekala , Ja-ela.

By B.M.W.G.Jayawardhana, (02/AG/A/009) 2008

Department of Livestock Production Faculty of Agricultural Sciences Sabaragamuwa University of Sri Lanka. Belihuloya.

MEAT PROCESSING PRACTICES AT KEELS FOOD PRODUCT LIMITED BYB.M.W.G. Jayawardhana. (02/AG/A/009) This report is submitted in partial fulfillment of the requirement of the degree of B.Sc. (Agricultural Sciences) (Specialized in Livestock Production) Of Faculty of Agricultural Sciences Sabaragamuwa University of Sri Lanka Belihuloya Sri Lanka 2008 Approved by

Internal supervisor, Dr. T.S.P.Jayaweera, Senior Lecturer, Department of Livestock Production, Faculty of Agricultural Sciences, Sabaragamuwa University of Sri Lanka Belihuloya. ..

External supervisor, Mr. Anton Kalubowila, Purchasing Manager Livestock, Keels Food Products Limited, Ekala, Ja- Ela. .. Dr. Anil Gunaratne, Head of the Department, Department of Livestock Production, Faculty of Agricultural Sciences, Sabaragamuwa University of Sri Lanka Belihuloya. ...................... Date: .................

SynopsisKeells Food Products Limited Ekala, is the todays leader of the meat processing industry in Sri Lanka which has 70% of market share. KFPL produces processed meat products as Keells range products and battered and crumbed products as Krest range products. Sausages, meat balls, ham, bacon, bomb products, fresh meat cuts etc. are some Keells range products, and Chinese rolls, drumsticks, nuggets, fish burger, fish finger etc are some of the Krest range products. I had a great opportunity to do my in-plant training in those factories and I gained ample knowledge about processing and quality control practices of processed meat products. The factory has a receiving bay in which all raw meat are received and dry ingredients are bought through dry stores and other ingredients are sent to freezes or chiller. They also receive live pigs and slaughter them in the slaughter house in the factory premises. After slaughtering pigs and other received carcasses are sent to de- boning section for de- bone according to the

production requirement. From that variety of products are made and stored in freezers until sent to Finley cold stores. In krest factory, battered and crumbed meat products are produced and marketed as Krest range products. Further more the factory has its own waste water and water treatment plant and waste disposal system which does not release hazards to the environment Apart from that quality control department of KFPL is doing a great job to assure the safety of customers via maintaining the quality of the food. They perform microbiological, chemical testing according to SLS methods and sensory evaluations to ensure product safety. I got familiarized with all the production procedures are well as quality assurance in KFPL. Apart from that I carried out many case studies and most of those were based on swab sample testing method.

Acknowledgement

I would like to express my deepest gratitude to my internal supervisor Dr. T.S.P. Jayaweera (Senior lecturer, Department of Livestock Production, Faculty of Agricultural sciences, Sabaragamuwa University of Sri Lanka) for giving his assistance to undertake this study and his valuable guidance in carrying out this training successfully. At the same time , I wish to acknowledge my gratitude to the external supervisor Mr. Anton Kalubowila (Manager Livestock Purchasing, KFPL) for his valuable guidance, constructive criticism and invaluable assistance given for the successful completion of this program. Secondly I would like to thank Dr. Jagath Munasinghe (Coordinator- industrial training program, Department of Livestock Production, Faculty of Agricultural Sciences, Sabaragamuwa University of Sri Lanka) , Dr. D.M.A. Gunaratne , Head of the department of Livestock Production and all the academic non academic staff of the Faculty of Agricultural Sciences, Sabaragamuwa University of Sri Lanka for their guidance and help extended me in numerous ways. I offer my special thanks to Mr. Lasath Ratnayake (Head-Qulity Assurance of the KFPL) and all the executives, supervisors and workers of the KFPL for their valuable contribution and necessary advices in completing my training period. Finally I would like to extend my sincere thanks to parent, my colleagues for their kind cooperation to make this study progressively.

Table of content Content Page number

Synopsis i Acknowledgement ii Table of content ............................................................................................iii List of figures iv List of tables ..v Chapter 1 1.1Introduction 1.2 History of the company 1.3 Organization structure of the Keells Food Products Limited .. 1.4 Policies of the company 1.5 Management Hierarchy of the company .. 1.6 Objectives . 1.7 Nature of the training . 1.8 Distribution and marketing of Keells products . Chapter 2 Receiving bay, Slaughter house and de-boning section of KFPL 2.1 Receiving bay 2.1.1 Purchasing of live animals . 2.1.2 Purchasing of raw meat and fish 2.2 General procedure while receiving live animals and raw meat. 2.2.1 Receiving of live animals 2.2.2 Receiving of pork carcasses (leg and loin) and beef carcasses (forequarter hindquarter) and mutton .. 2.2.3 Receiving of beef 2.2.4 Receiving of chicken .. 2.2.5 Receiving of fish . 2.2.6 Receiving of non meat ingredients . 2.3 Ingredients used in processing of meat products 2.3.1 Non meat Ingredients .. 2.4.2 Special steps that are strictly controlled in slaughter house .. and

2.4 Slaughter house operations 2.4.1 Slaughtering of animals in KFPL .. 2.5 De-boning of carcasses Chapter 3 Processing section of Keells factory 3.1 Meat processing equipments and utensils .. 3.2 Meat processing methods . 3.3 Different meat products .. 3.4 Processing of Krest products .. 3.4.1 Production of formed products . Chapter 4 Packing Section 4.1 Concept (FIFO) 4.2 Good manufacturing practices at KFPL .. 4.3 Equipments used in packing section 4.4 Packing materials . 4.5 Processes involve in packing 4.6 Color code system for finished product bundles. Chapter 5 Handling and storage of raw materials and finished products at KFPL 5.1 Concept: First In First Out (FIFO) 5.2 Handling and storage of raw materials 5.3 Handling and storage of half processed products 5.4 Handling and storage of finished products 5.5 Steps should be followed when products are stored in plate freezer

Chapter 6 Quality Assurance Department 6.1 The routine schedule of quality assurance department 6.2 Media preparation 6.2.1 Potato Dextrose agar (PDA) media 6.2.3 Baired Parker media 6.2.2 Mac Conkey Broth 6.2.3 Baired Parker media 6.2.4 Peptone Broth 6.2.5 Sellanite Cystene broth 6.3 Microbiological Tests 6.4 Chemical Analysis 6.5 Sensory Evaluation

Chapter 10 Discussion 10.1 Strengths 10.2 Weaknesses 10.3 Recommendations

List of figures Figures Page numbers

Figure 1: Contribution of different sectors to John Keells Holdings group.

Figure 2: Contribution of different sectors to Food and Beverage sector of JKH Figure 3: Management Hierarchy of John Keels Holdings Group .. Figure 4: Operational involvement of different units if KFPL Figure 5: Role of nitrite, ascorbate and heat in cured meat pigment formation Figure 6: Ingredients used in KFPL for the production of processed meat products.. Figure 7: Zones of hygiene in pigs slaughtering and processing .. Figure 8: Pork primal cuts Figure 9: Different types of casings . Figure10: Different meat product at KFPL Figure 11: Flow of production of formed products Figure 12: Flow of production of formed products Figure 13: Waste water treatment system at KFPL Figure 14: Potable water treatment system at KFPL

List of tables Table Page number

Table 1: Color code system for finished product bundles .. Table 2 : Different types of chillers and freezers in the factory .. Table 3: Microbial counts of samples with brine A (Purac) sodium lactate Table 4. : Microbial counts of samples with brine B sodium lactate

List of abbreviation

AOAC FIFO HACCP IPA ISO KFPL LAB MDM MSM PDA SLS SLSI TPC TVP

- First In First Out - Hazard Analysis Critical Control Point - Iso Propyl Alcohol - Keells Food Products Limited - Lactic Acid Bacteria - Mechanically De-boned Meat - Mechanically Separated meat - Potato Dextrose Agar - Sri Lanka Standards - Sri Lanka Standards Institute - Total Plate Count - Texturized Vegetable Protein

Chapter 1 1.1 IntroductionJohn Keells Holdings PLC (JKH) specializes in the sectors of Food & Beverage, Transport, Leisure, Information Technology, BPO, Financial Services, Property Development, Plantation and Investor Services. JKH preserves the identity of each sector group, yet successfully bring them together as John Keells Holdings PLC. The Food & Beverage Sector Group is home to a portfolio of leading brands in the Beverage, Frozen Confectionary, and Processed Meats categories which include "Elephant" carbonated soft drinks, "Elephant House" Ice Creams, and the "Keells" and "Krest" ranges of Processed Meats. All brands are market leaders in their respective categories and are supported by a well-established distribution channel of almost 80,000 Outlets Island wide. Keells Food Products PLC is presently Sri Lankas market leader in the processed meat industry and enjoys a market share of approximately 70%. A subsidiary company of John Keells Holdings, KFP PLC started its operations in the year 1983, and today takes the pride being solely responsible in developing the Sri Lankan Processed Meats industry to its current heights. KFP PLC have kept abreast of the industry through strategic investments in state-of-the-art food processing technology, quality control systems, an aggressive companywid