UNIVERSITY OF NAIROBIDEPARTMENT OF ENVIRONMENTAL

AND BIOSYSTEMS ENGINEERING

FEB 461: PROCESS AND FOOD ENGINEERING

TERM PAPER

TITLE: PROCESSING OF MEAT.

AUTHOR: MATILU URBANUS NDUNDA

REG. NO: F21/0026/2005

SUBMITTED TO: MR. E.B.K. MUTAI

1

DATE: 4TH FEB 2009

TABLE OF CONTENTS1. INTRODUCTION ............................................................................1

2. INDUSTRY STRUCTURE................................................................1 2.1. BEEF PRODUCTION.....................................................................................2 2.2. SUPPLY OF LIVESTOCK...............................................................................2 2.3. SLAUGHTERHOUSES.............................................................................3

3. MEAT PRODUCTION.......................................................................3

4. MARKET CONDITIONS...................................................................3 4.1. THE EXPORT MARKETS....................................................................... ….3 4.2. THE DOMESTIC MARKET.................................................................... …..4 4.3 DOMESTIC CONSUMPTION ………………………………………...........5

5. MEAT PROCESSING…………………………………………………….7 SLAUGHTERING AND PROCESSING…………………………………………….........................7 MEAT PRODUCTS…………………………………………………………………………….8

6. WASTE MANAGEMENT………………………………………………...9 BY-PRODUCT WASTE……………………………………………………………….……………………..9 WASTEWATER………………………………………………………………………………………….……..9 ENVIRONMENTAL CONDITIONS……………………………………………………………………..10

7. CONCLUSION................................................................................10

8. REFERENCES…………………………………………………………..10

2

1.0 INTRODUCTIONMeat can be defined as the flesh of an animal that is considered edible, especially that of a mammal or a bird. In Kenya meat production falls in the Agricultural sector which is the dominant sector in the Kenyan economy accounting for approximately 24% of the country’s Gross Domestic Product. With the Livestock sub-sector contributing about 3.3% of the Gross Domestic Product (GDP) and accounting for over 30% of farm gate value of agricultural commodities. Livestock production is a major economic and social activity for the communities that live in the high rainfall areas for Intensive livestock dairy production and in the arid and semi-arid areas (ASALS) for meat production. The population of major livestock species in 2003 was estimated at 9 million Zebu cattle, 3.5 million exotic and grade cattle, 9.9 million sheep, 11.9 million goats, 895,000 camels, 415,200 pigs, over 25 million chicken and 470,000 rabbits. The major livestock products exported from Kenya are beef and dairy products. As mentioned earlier, the livestock sector contributes 3.3% of the GDP and comprises mainly of dairy and meat production, eggs, hides, skins and wool from cows, sheep, goats and poultry. Red meat, comprising beef, mutton, goat and camel meat, accounts for over 80% of all the meat consumed locally. About 67% of the red meat is produced in the arid and semi-arid lands (ASALs) under pastoral production system. Pastoralists keep about 70% of the national livestock herd, estimated at about 9.7 million beef cattle, 9.6 million goats, 8.3 million sheep, and 0.8 million camels. White meat, which includes poultry and pig meat, accounts for about 19% of the meat consumed in the country. There are two main players namely Kenchic and Farmers Choice for poultry and pork production respectively. The contribution of game meat, on the other hand, is negligible accounting for less than 1% of the total meat consumed in the country. At present Kenya restricts marketing and export of game meat due to fears that legalizing it could stimulate demand for illegal bush meat and poaching. However there are a few licensed dealers in game meat especially hotels and restaurants. Kenya’s main export markets for meat products include United Arab Emirates (UAE), Tanzania and Uganda, while the main markets for hides and skins are Germany, United Kingdom, Netherlands and Italy. The value of meat products exported increased from Kshs.190 million in 1999 to Kshs.285 million in 2002 while the quantity of hides and skins exported increased from 7,302 tons in 1999 to 13,910 tones in 2003. Kenya’s competitive advantage as an investment destination for the meat industry is supported by various investor friendly factors, which include availability of beef cattle, stable political environment and market access to local and regional markets. Game meat is a new area, which has a very wide investment scope in Kenya.

3

2.0 INDUSTRY STRUCTURE2.1 Beef ProductionBeef production in Kenya is practiced primarily in the ASAL areas of the country. Although Zebu cattle in the ASAL dominate the national beef herd, there is a significant proportion of beef coming from dairy bull calves and cull cows. The marketing of beef animals currently is conducted on ad hoc basis with pastoralists, middlemen and butchers playing a major role. Theincrease in beef consumption is higher than the increase in production and demand is expected to outstrip supply in the near future. This will lead ultimately to an increase in consumer prices. Beef is derived from three major livestock production systems i.e. Extensive Pastoral Beef, Dairy Bull Calves and Commercial Beef Production System. Kenya’s beef cattle population stands at over 9 million, most of which are kept in the rangelands. Currently, most of the beef produced is consumed locally. There is high potential for export whose exploitation is limited by market accessibility and diseases. The main potential markets for Kenya meat and meat products are other African countries Middle East and Europe. The distribution of beef cattle in Kenya is influenced by rainfall patterns. Most animals are kept in ranches in the Rift Valley province - Nakuru, Trans Nzoia and Kajiado.

2.2. Supply of LivestockIn Kenya the domestic market for livestock consists of primary, secondary and the terminalmarkets. Stock change hands either once or twice before reaching the terminal markets.The market for livestock supplies is increasingly expanding both locally and regionally. Nearlyall the cattle sourced at Moyale and some of the cattle and goats purchased at Manderamarket originates from the Borana and Somali regions of Ethiopia. Small numbers of cattleoriginating from Eastern Equatoria of South Sudan and the Southwestern part of Ethiopia arerouted to Eldoret and Nairobi through Lokichogio and Lodwar. A significant proportion of thecattle in Garissa market come from Somalia. Similarly livestock from Tanzania are routedthrough Kuria to Migori and then to the terminal markets in Nairobi.

2.3. SlaughterhousesThere were 65 operational slaughterhouses in Kenya in the year 2000. Sixty-three of theseslaughterhouses dealt with red meat. The other two, namely, Farmer’s Choice and Kenchic,slaughtered pigs and poultry respectively. Kiamaiko and Mlolongo dealt exclusively with goatsand camels respectively. Only two out of the 65 slaughterhouses, i.e., Hurlingham andFarmer’s Choice, are export standard slaughterhouses; the rest serve the local meat market.The annual output capacity of Hurlingham and Farmer’s Choice is 10,000 cattle and 20,000pigs respectively and both are privately owned companies. Out of 63 slaughterhouses that deal in red meat, 32 are private owned and the remaining are public owned by various local authorities, with annual average capacity of 18,344 and 9,774 respectively.OwnershipNumber

4

3. MEAT PRODUCTIONOver the years the total value of meat and meat products produced indicated an upward trendwith the value of products from cattle and calves increasing from KShs 8,886.4 million in 1999to KShs 11,476.1 million in 2003. Red meat production in Kenya is estimated at 362,815 metric tones (MT) with the bulk of the supply coming from Arid and Semi-Arid areas. A small proportion of beef supply also comes from dairy herds. The value of annual red meat production in Kenya is estimated at KShs 43.2 billion with the value of beef estimated at KShs 34.4 billion, combined goat meat and mutton at KShs 8.2 billion and camel meat at KShs 0.66 million. The total heads of livestock purchased for slaughter has been decreasing over the last 4 years from 7,631 thousand heads in 2000 to 6,133 heads in the year 2003. The total number of beef cattle decreased from 2,870 thousand in 2000 to 1,669 thousand in 2003. Sheep and goats formed the bulk of animals purchased for slaughter contributing over 60% o the total heads bought for slaughter. In the local market, beef is more popular than other types of meat e.g. pork, mutton or poultry.

4. MARKET CONDITIONS4.1. The Export MarketsKenya currently produces meat and meat products both for export and local consumption.The country exports both live animals and processed meat in the form of tinned meat andPreparations, bacon etc , mostly to East Africa and Middle East regions. Kenya has been exporting more of pork products than beef, mutton and goat meat combined in the last few years. Kenya’s total exports declined in 1985 as a result of the closure of the Kenya MeatCommission, who at the time was the leading exporter of canned meat.Table 1: Kenyan Exports, 1999 – 2002, (Figures in KShs “000”)ProdLive animals, chiefly for food

30,320 20,456 44,040 77,417

Tinned meat & preparations

36,240 40,776 36,069 70,010

Bacon 27,560 94,512 97,498 90,565Other products 102,020 28,528 44,358 47,343777 Total 88 190,140 184,272 221,965 285,335[Source: Statistical Abstract, 2003 by Central Bureau of Statistics, Ministry of planning and National Development]

Over the years the value of meat and meat products exported from the country has indicatedan upward trend with live animal exports increasing from KShs 30.3 million in 1999 to KShs77.4 million in 2002. The value of export of bacon and other pork products also increasedfrom KShs 27.6 million in 1999 to KShs 90.6 million in 2002.

4.2. The Domestic MarketLivestock trading has been the domain of the private sector following the liquidation of theKenya Meat Commission (KMC) and the exit of the Livestock Marketing Division (LMD) from

5

the markets. The domestic market comprises of several other markets which are discussed below.

1) Primary MarketLivestock traders in pastoral areas operate in a variety of ways. Some buy young cattle, keepthem for about two years and sell them later. Stock traders based in Garissa buy animalsfrom Wajir, Elwak or Mandera and trek them to Garissa market. There is also unofficial cross border livestock export from Southern Sudan to Kenya for the local market.

2) Secondary MarketMiddlemen from Nairobi buy cattle from Garissa or Isiolo markets and truck them to Nairobi.At the same time, Somali traders from Garissa or Mandera trek large number of cattle toMombasa and Malindi, allowing the animals to graze and put on weight in the process. Thesetraders may also rent ranches for a certain period to fatten the animals before disposing ofthem (there are about 35 ranches between Nairobi and Mombasa) in the terminal markets.

3) The terminal marketsA number of terminal markets are located close to large urban areas. The terminal markets inKenya include Nairobi, Nyahururu, Isiolo, Meru and Nyeri for the North-central axis; Kisumu,Kisii, Eldoret, Nakuru, Naivasha and Nairobi for the North- western axis; and Nairobi andMachakos on the Southern axis. The coastal terminal markets are on the Northwestern andNorth-central axis and to a minor extent on the Southern axis (Kajiado).

4.3 Domestic ConsumptionThe Ministry of Livestock and Fisheries Development estimates that in the year 2000 total beef production was 287,000MT, which rose to 300,000MT in 2003. This estimate is close to that of FAO for years 2000 and 2001 estimates at 290,000MT. Given that Kenya has not been exporting any significant amount of beef in the last decade, it can be assumed that this beef production presents a fair approximation of domestic beef demand. However, considering the number of hides produced in the country per year (1.5 million), it would appear that this is an overestimation and that the correct figure is around 200,000MT. Recent marketing studies estimate that total beef consumption in Nairobi and Mombasa is 91,000MT and 15,000MT respectively per annum. This translates to about 850,000 animals per annum. In terms of corned beef, the country is currently relying on imports to supplement that processed by KMC which was closed but now not yet operating at its full capacity. The estimated national demand for canned beef in Kenya is 40,000 cases of 24 can each (333MT). Each head of a mature bovine produces four cases of corned beef. Thus to meet the national demand for corned beef, you require 10,200 mature bovines per year.

5.0 MEAT PROCESSING5.1 SLAUGHTERING AND PROCESSING.

6

The cattle are mostly transported by means of vehicles to the slaughter houses. On arrival the animals are received by veterinary doctors who diagnose and check whether the animals are healthy. If any are found to be sick the necessary action is taken such as treating or disposing them if the sickness is a dangerous one. The healthy animals are then starved for about eight to twelve hours before they can be slaughtered. During slaughtering the animals are led into the slaughter house and a stunning gun used to hit them on the brain so that they become unconscious.

On becoming unconscious the animals fall into another room where a sharp panga is used to cut their throats before they regain consciousness. After that they are shackled and hoisted on rails and transported to another chamber mainly known as the bleeding line where the animals are allowed to bleed and then their horns are removed. After dehorning the animals are skinned and their trotters removed. Pneumatic machines are used for breaking of bones and then treated water used to remove any bone particles that might have remained on the meat. From there the animals are moved to the rescration table where the intestines are removed and the carcasses are moved onto another special head table where the heads are cut and the carcasses further inspected by veterinary doctors and then numbered.

The carcasses are then split, the quarters weighed and quality determined by the amount of fat content. At this stage the hump and breast fat are removed and used later to process caned beef. From there the sides are taken into chillers where they are arranged according to quality in different rails. Also at this stage the principle of “first in first out” is followed and the sides are required to stay in the chillers for a minimum of 7 days and a maximum of 21 days for them to attain the desired flavor and color. In the chillers the temperatures range from 0 - 40c. From the chillers the sides are then taken to the value addition department where bones are removed and the meat packed. The bones and the blood collected from the bleeding line are used in manufacturing of bone meal. The skins and the hides are on high demand and so the customers collect them even before they are treated. In order to observe cleanliness and safety of the products, employees have the appropriate personal protective clothing such as lab coats, gumboots, having footbaths and also keeping the floor wet. The footbaths are mostly on each entry and exit to ensure that there are no chances of harmful organisms entering any room and they are not only for the workers but also the cattle and vehicles. Other safety factors include minimal handling of the meat by human to avoid contamination; in this case the meat is transported from one section to another by means of rails. After the meat has been packed it is stored in a room where the appropriate temperatures of about -300c so as to prevent breeding of bacteria. It’s not in all slaughter houses where the above procedure is followed but it depends on the capacity of the slaughter house and the destination of the beef. For example, the above process is used in KMC.

7

The characteristic feature of Kenya's livestock is the dominance of primary production. There is very little on-farm and off-farm processing of livestock products; which translates to low income for farmers and less jobs for Kenyans.

Reasons for encouraging agro-processing:-

It improves rural incomes by adding value to products thereby saving on transport cost by delivering high-value/low volume products and creating opportunities for the use of by-products as inputs in other farm operations such as animal feeds, manure, and fuel.

It provides an opportunity for reducing farm losses through the conversion of perishable products into more durable products.

It will help create jobs in the rural areas thereby contributing to the reduction of both poverty and rural-urban migration.

Processing and value addition of livestock products prolongs shelf life and enhances packaging with increased earnings. To increase value addition, the following measures will be taken:

Providing appropriate incentives for the establishment of agro-industries in the rural areas.

Focus research on value addition especially processing, storage and packaging of the livestock products.

Promoting partnership between smallholder farmers and agribusiness. Encouraging the development of supportive infrastructure services such are rural

access roads, electricity, water and telecommunications. Capacity building of farmers and farmer organizations in value addition and agro-

processing.The major livestock products for value adding are milk, Red meat, White meat, hides and Skins; Honey/bee wax, whereas the relevant livestock products for value adding food products are milk, Red and White meat, and Honey.

5.2 Meat ProductsThere is great potential to increase meat production through:

Improved disease Control and Management to reduce mortality rate and increase growth rate.

Breeding for quality in terms of size and growth rate. Intensification of production.

Poor market outlet for the country's livestock has been disincentive for investment to exploit the potential. Some of the factors that have contributed towards the inability of our livestock and livestock products to access international markets are:-

Run down disease control and marketing infrastructure. Inefficient production that make our products not competitive in the internal market. Stringent sanitary and phytosanitary measures imposed by importing countries as

technical barrier to trade. Unfair competition in the world market from highly subsidized production from

developed world.

8

In meat industry there is a need to invest in the following areas: Development of quality abattoirs for meat processing particularly in the production

areas. Focus on enhanced productivity and profitability by producers to produce according to

market demands and agro-processing initiative to be in accordance to the set standards. The promotion of private/public sector and trader/producer partnerships.

This will ensure access to markets of value added livestock products. Strengthen animal health services for increased productivity and high quality products.

Establishment of disease-free zone to facilitate access o the E.U. market for animal and animal products.

Provision of credit facilities. Value addition in various forms and packaging.

6.0 WASTE MANAGEMENT6.1 By-Product WasteThere is an estimated 59% yield from live weight to carcass weight. Of the remaining 41%, approximately 6% is the weight of the hide, and a further approximately 5% can be sold as by-product for human consumption or pet food. The balance, including blood, becomes inedible offal. Solid or by-product waste typically consists of inedible offal, blood, paunch manure, blood, hides, and trimmings. Inedible offals must be properly stored to prevent contamination of edibles. Disposal of inedible offal generally depends on different slaughter houses. Some can sell as raw materials for making bone meal to other factories or it can also be used to make biogas. Solid waste averages approximately 400 pounds per animal.

6.2 WastewaterWastewater and sludge result from washing carcasses and surfaces, and can include blood, tissue, fat, urine, manure, dirt, feed, hair, sanitizers and cleaning agents. Fats, oils and grease (FOG) can cause problems for waste treatment systems (coating and clogging pipes) and generally must be removed through a pre-treatment system. Blood in particular has a very high Biochemical Oxygen Demand (BOD), meaning that as it breaks down, it uses high quantities of oxygen. Nowadays as it is necessary to protect the environment slaughter houses are required to provide efficient disposal mechanisms for their wastes before they are licensed by NEMA. Slaughter houses which don’t meet these requirements face the risks of being shut down like what happened to Dagoreti slaughter house not long ago. For example KMC has little waste to deal with i.e. the waste water since other waste matter is used to make bone meal. The waste water is drained to a basin where fertilizer is removed and then directed to a wet land.

6.3 Environmental conditions.Unless good care is taken of the slaughter houses and handling of their wastes monitored, their emissions can have advance effects on the environment. For example the sludge which results from the Dagoreti slaughter house, pollutes the Nairobi River hence affecting aquatic life

9

downstream. Also unless cleanliness is observed the meat can be contaminated hence becoming unfit for consumption. This can also lead to monetary losses and also loss of jobs.

7.0 CONCLUSIONS Expanded beef processing in Kenya is challenging. The greatest potential opportunities

relate to cow beef and niche markets, from both a market access perspective and in terms of cost structure.

Because of the importance of economies of scale, existing processors are more likely to consider expansion of their existing facilities than development of new ones.

Both cow beef and niche markets require market development beyond the country. Because of the high capital costs associated with a processing plant and the perishable nature of the product, long ramp up periods may not be possible financially. Clearly defining the product, establishing a market, and confirming suitable supply prior to major capital investment will be important to increase the likelihood of success.

In addition to market development, significant expertise is required to effectively manage a federal facility and profitably market product. Securing this expertise early in the process of establishing a plant will be fundamental to the success of the project.

Over the long term, alternatives for by-product disposal must be developed to enable a sustainable beef processing industry in Kenya.

REFERENCES.Statistical Abstracts, 2003 by Central Bureau of Statistic, Ministry of Planning and National DevelopmentEconomic Survey, 2004 by Central Bureau of Statistic, Ministry of Planning and National DevelopmentAn Audit of the Livestock Marketing Status in Kenya, Ethiopia and Sudan Prepared by Yacob Aklilu, 2002Livestock farming in Kenya, www.kenyaweb.com, 2003

10