Proposal to GOI for Poultry Processing Plant

Transcription

1 APTEC Technology Consulting Tags: poultry processing plant, plant design, budget, model plant design, slaughterhouse Proposal to GOI for Poultry Processing Plant APTEC Technology Consulting is located at C-60, Amaltas, Alstonia Estate, Sigma IV, Greater Noida , India. This name and APTEC are the registered property of Alok's Poultry Technology Private Limited. Telefax Website Document dated Oct 30, 2011 Rev 1 dated 18 March 2012

2 Budget Poultry Processing Plant - Page 2 of 5 1 Reference In a bid to upgrade hygiene, standardize production, eliminate waste and gradually introduce traceability the Government of India has decided to encourage the installation of a large number of poultry processing plants spread across the Country. This plan has been prepared by APTEC, and relates to a model budget poultry processing plant in fulfilment of the above objective. By definition this plant layout is not designed for expansion. All equipment constituting the related offer may, however, be rearranged on a bigger plinth to form part of an expanded plant e.g BPH expandable to 4000 BPH, at the existing plant compound or at another nearby location. If the expansion is contiguous, on the same plot, the old plinth area can be incorporated into the final building, forming, for instance, the expanded portioning/deboning/packing area or part of a future frozen store. If the future expansion shifts to another site, this plinth can form part of a future hatchery. This design feature has been introduced because it is believed that as time passes, the per capita consumption of poultry will increase from its present low level, in keeping with recommended protein intake levels and in response to increasing per capita income. Having an upgradable ensemble of equipment will thus prevent obsolescence and capital waste on a nationwide scale. It is important to note that locally fabricated small plants comprise machinery which is not upgradable a plant based on such machinery must necessarily sell its old machines before it can buy new larger machines. Because this is an entry-level plant, the design has been kept simple, with the minimum of permanent construction. 2 Salient Features of The Proposed Plant Capacity 1000 BPH, Singles or double shift operation. Not expandable, but entirely relocatable with enhanced capacity Product Chilling Broilers, average weight 1800 grams live. Fresh chilled only. Available as whole wicket bagged carcasses, tray and bulk packed portions and deboned meat. If blast freezing facility is required, it can be incorporated as a customized component Water chilling Summary Manpower Hanging 1 Killing 1 Pinning 1 Evisceration 9 Hocks 4 Deboning, filleting 14 Handling, supervision 3 TOTAL 33 Area Total plinth area 309 SqM Capacities Overall 1000 BPH Portioning 700 BPH Tray-packing 150 packs/hr Bulk packing Variable Whole carcass bagging 300 BPH Chilling storage (-1 to +4 o C) tonnes (Assuming one reefer in standby mode)

3 Budget Poultry Processing Plant - Page 3 of 5 Features Construction Total panel construction, easily relocatable Steel superstructure Minimal, GI sections bolted onto floormounted columns Approx connected load 22kW in process areas 3 Design Philosophy Compressed air Dry compressed air approx 6 bar. Vacuum Approx bar Water 25 Kl/hr for duration of primary processing Chilled water Approx deg C Shell ice for chilling Approx 675 Kg/hr Shell ice for packing Approx 675 Kg/hr Poultry processing technology has graduated through the following design stages over the years in a bid to lower unit processing cost, eliminate waste, improve yield and hygiene and allow a progression towards traceability: Stage 1 Stage 2 Stage 3 Stage 4 Bleeding cones, LPG heated scalding tanks, drum pluckers, table-top evisceration and ice sludge tank chilling Simple carrousel or conveyor type non-expandable, non-upgradable plants incorporating on-line plucking and evisceration with ice-sludge tank or simple spin chilling with or without counter-current flow Modern overhead conveyor type plants fully upgradable and expandable to retrofit online chilling for traceability Plants permitting full traceability. Worldwide, the typical median plant design lies somewhere between Stages 3 and 4. In India the typical locally fabricated plant lies between Stages 2 and 3. There are an estimated 15 such plants in operation today, in addition to scores of Stage 1 plants. Approximately 14 imported plants conforming to Stage 3 are also in operation. Altogether the processing industry on-stream has a capacity of some 56,000 birds per hour, accounting for some 6% of the poultry consumed at present. The design presented here belongs to Stage 3 of plant design evolution except that it offers expandability and upgradability upon relocation. With this compromise, we have reduced the capital outlay without in any way limiting the redeployment of the entire hardware without any obsolescence to achieve Stage 4. This design requires the plant building blocks to be bolted together at site not welded. Such plant building blocks are available. Line Configuration Operating Mode Arrival To reduce capital cost we have provided a common killing cum evisceration line, no hock cutter - you cut hocks using pneumatic shears over the spin chiller. Likewise no hock unloader - you do it manually. The track length has been kept to an absolute minimum (69 metres) consistent with reasonable working and movement space around the machines. The plant design allows cost-effective operation as service slaughter houses provided the smallest batches requiring processing are of the order of one carrier load. If the carrier load is assumed to be a small truck such as the Piaggio Ape or the Tata Magic, the batch size will be of the order of 500 birds. It is assumed that birds will arrive in trucks with fixed cages as this is the norm for supply of birds in mandis and the wet market in general. For this reason the arrival and hanging department is aligned as shown. This arrangement does away with the need for capitalizing a large inventory of cages and providing

4 Budget Poultry Processing Plant - Page 4 of 5 conveyors and crate washers in the arrival department, without in any way compromising retrofitting possibilities. Scalder Plucker Chiller, Ice maker Jacuzzi scalder with heat exchanger and a two pass design to ensure a high product quality. The scalder is supplied without canopy as we feel that in India the weather is generally quite warm and energy loss is not an issue when the canopy is eliminated. The design includes a 32 disk plucker which has a peak capacity of approximately 1300 BPH. This is necessary for peaking capacity. Since this seriously affects product shelf life, we have not compromised with dwell time in the chiller for peak capacity and thorough chilling. The design includes a 3 metres, 2.1 m diameter counter current and air agitated spin chiller which gives a large dwell time and produce carcasses with core temperature of 4 o C, conforming to the best international standards. The chiller will need a 2 o C water supply and also shell ice added manually. We have opted for shell ice in this design because one shell ice maker can serve both technical chilling in the spin chiller and use for packing chilled product for shipment to stores. Since shell ice cannot have a continuous discharge production, it will have to be received in a bin and manually added to the chiller. After production, the same ice maker will generate ice for packing and shipment. Portioning & Deboning Since portions and deboned meat fetches a higher return, we have included a 6.7 metre cone deboner and a disc cutter in the design The disc cutter is sourced locally. Using nine workers, the cone deboner can process 3000 carcasses in half a day, leaving them free to debone/trim and pack the same in the other half. Alternatively the plant can operate 2 shifts of portioning/deboning and packing and with the single disc cutter working 2 shifts it is possible to convert approximately 3000 carcasses into curry-cuts every day. Refrigeration plant As against the design philosophy adopted for normal processing plants, incorporating a common ammonia configuration to serve most needs, here we recommend use of distributed R22/134 etc based self-sufficient units. The last voyage reefers incorporated in the design, or walk-in chill-rooms sourced locally, have a 3 phase 5-6 kw connection, so they are independent. Water chilling is to be done by a skid mounted R22/134 etc unit with a plate heat exchanger, designed to supply approx 3375 kl of water at 2 o C per hour into the screw chiller for the duration the chiller runs. The shell ice maker is likewise connected to its independent skid-mounted R22/134 etc compressor unit which allows it to produce 675 Kg of shell ice per hour for the duration it runs. Space cooling (22SqM within the chilling/portioning/packing area) may need additional cooling besides the cooling that would naturally occur due to the presence of the spin chiller. This can be done by using split unit air conditioners. Hocks We have observed an increasing demand for hocks in the overseas markets. However, this plant cannot benefit from the overseas demand because there is no blast freezing capacity.

5 Budget Poultry Processing Plant - Page 5 of 5 Should the local demand pick up, we have considered the possibility of using local built LPG fired scald tank and drum plucker assembly to prepare hocks for the market. Weighing Arrivals & Yield Tracking Because plants built to this model are expected to be located up-country with supplies of live birds coming from many contract farms, it may be necessary to maintain good record of weights arrival of live birds and yield after evisceration. Since we cannot use coops, we need to make use of a public weighbridge facility for weighing incoming and outgoing trucks for doing so. Additionally, the empty trucks will need to be washed after delivering live birds in public truck-wash facilities which need to be located close to the public weighbridge, and a system implemented to ensure that trucks are washed after being tare-weighed. Blast Freezing Laboratory Facilities Rendering We have not considered a blast freezer or a frozen store in this design. However, should the need arise, one of the reefers may be shifted to accommodate a single blast freezing chamber in between. Then that reefer may function as a small frozen store. Scope depends on local availability. We expect that the Government will encourage the establishment of more such facilities through subsidies. A dedicated rendering plant constitutes a big investment in the form of the plant, large capacity boiler and dedicated offal transport circuit. One solution involves establishment of a number of centralized merchant rendering plants which will process feather transported from feeder slaughterhouses. In this event we can design the offal circuit to allow separate discharge of wet feathers for this purpose, while all other offal may be used in fish and/or pig farms as feed. Such a design approach requires active Government participation towards encouraging the concurrent growth of merchant rendering plants. Another approach is to downsize the rendering captive rendering plants to cater only to feather waste, while all other offal may, as stated above, be used in fish and/or pig farms as feed. Raw water Wastewater No plans made yet for treating raw water. Design will be site-specific No plans made yet for treating and disposal of wastewater. Design will be sitespecific. However, Government intervention is required to permit discharge of treated wastewater, conforming to realistic BOD levels for the purpose of crop irrigation in adjoining farmlands