Cover
FAO ANIMAL PRODUCTION AND HEALTH PAPER 98





Small-scale poultry processing




CONTENTS

by
D. Silverside
M. Jones

The designations employed and the presentation of material in this publication do not imply the expression of any opinion whatsoever on the part of the Food and Agriculture Organization of the United Nations concerning the legal status of any country, territory, city or area or of its authorities, or concerning the delimitation of its frontiers or boundaries.



M-24
ISBN 92-5-103145-2



All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechani- cal, photocopying or otherwise, without the prior permission of the copyright owner. Applications for such permission, with a statement of the purpose and extent of the reproduction, should be addressed to the Director, Publications Division, Food and Agriculture Organization of the United Nations, Viale delle Terme di Caracalla, 00100 Rome, Italy.

FOOD AND AGRICULTURE ORGANIZATION OF THE UNITED NATIONS Rome, 1992
© FAO


FOREWORD

Poultry production is big business throughout the world. It has become a standard form of cheap protein. It is also a highly competitive industry and feed suppliers, producers, processors, manufacturers of equipment etc have all appreciated the economies of scale and gone on to develop bigger and more automated systems of operation than ever before to supply an insatiable market.

The production of poultry on a small scale is very important in less developed countries, particularly in places some way from the main commercial and industrial centres. There continues to be a need for small scale processing facilities. Unfortunately many manufacturers of small scale equipment have not survived with the march of time and commercial developments. This book has been written however, to show that it is still possible to establish a small operation with the appropriate equipment and facilities.

Slaughter of poultry in suitable surroundings by hygenic methods is essential for the production of wholesome meat, extension of the shelf life of the product, reduction of post harvest losses and protection of public health. This book addresses these issues and hopes to persuade the producer of poultry on a small scale that it is worthwhile to establish the proper facilities.

The book is divided into five parts. The first puts poultry into context by giving a general background and description of poultry production and processing throughout the world. The second chapter outlines the general principles of planning, economics, design and construction of small scale poultry processing plants. The concept of the three models is developed and plant layout and construction details, including that of effluent treatment are given. The third chapter describes how it is intended that these models are to be operated. It covers most aspects of poultry production from transport of the live bird to the factory, to the dispatch of packed poultry to the market. Chapter four is devoted to health, hygiene and routine maintenance. These three subjects are put together to emphasise the routine nature of these important aspects of food production. It gives some emphasis to the microbiology of production systems but leaves the veterinary aspects of poultry health to the veterinarian. A schedule of activities is given in the hope that the production of clean, wholesome poultry in a clean factory will be assured with minimal delay in operation. The final chapter discusses the theory of marketing and offers some advice on the importance of planning a proper strategy. It should give an introduction to market development.

The reader is advised to seek comprehensive advice if he wishes to build new facilities or redesign existing buildings. The book is but a guide-line to poultry processing and cannot be written with every circumstance in mind. Nevertheless it has a tropical flavour and attempts to be realistic in its approach to the tropical situation.

Acknowledgements

Some of the information presented in this book stems from the publications listed in the Further Reading section to which the reader is directed.

The authors also acknowledge gratefully the contributions made by the companies, Poultryman Machines, Botley (Southampton/UK) for drawings on pages 16, 40, 41, 44–49, 51, 53–57 and 100–104, Cope and Cope, Reading/UK for the drawings on page 43, and the British Chicken Information Service, London, for photographs 1–10 in Annex 6 “Poultry Portioning”, as well as Ernest West & Benyon, Bromley (Kent/UK) and Environmental Engineering, Spalding (Lincolnshire/UK) for their contributions on refrigeration and effluent treatment equipment.

Hyperlinks to non-FAO Internet sites do not imply any official endorsement of or responsibility for the opinions, ideas, data or products presented at these locations, or guarantee the validity of the information provided. The sole purpose of links to non-FAO sites is to indicate further information available on related topics.

CONTENTS

CHAPTER 1
INTRODUCTION TO POULTRY PROCESSING
 Poultry Production
 Poultry Consumption
 Poultry Rearing Systems
 Poultry Hygiene
  Poultry rearing hygiene
  Preslaughter inspection
  Vehicle and transport hygiene (including cages)
  Personal cleanliness and habits
 Marketing of Live Poultry
  Harvesting and transport systems
  Transport to market
  Display methods
  Sales methods
 Poultry Slaughter and Marketing
  Systems of operation of poultry processing plant
  Ownership of birds
  Production methods
  Type of product
  Packaging
  Refrigeration
  Transport to market
  Display & sales
  Customer use
CHAPTER 2
DESIGN & CONSTRUCTION OF SMALL POULTRY PROCESSING PLANTS.
1GENERAL DESIGN PRINCIPLES
 Planning
 Economics
 Management
 Location of Plant
 Facilities Required
 Flow Diagram
 Equipment and Machinery
 Hygienic Principles of Design
  Clean and dirty areas
  Product flow
  Equipment
  Drains
  Floors, walls and ceilings
  Doors and windows
  Service runs
  Lighting
  Ventilation
 Facilities Required in Specific Areas
 General Building
  The building
  Roof
  Walls
  Insects
  Wood
  Water and steam
  Drainage
 Outside Areas
 Livestock Reception Area
 Reception Loading Area
 The Slaughter hall
 Evisceration and Chilling Room
 Packing Room
 Chilling Rooms
 Freezing Rooms
 Dispatch
 Dry Stores
 Offal Room
 Staff Facilities
 Hand and Boot Wash
 Laundry
 Offices
 Inedible By - products and Waste Disposal Facilities
  Solid by - products
  Effluent treatment
2PLANT LAYOUT & CONSTRUCTION DETAILS
 Introduction
 Development of the Models
 Model 1 Very Small Scale Abattoir - 50 birds/day
 Model 2 Very Small Scale Abattoir/Processing Room - 200 birds/day
 Model 3 Small Scale Abattoir - 350 birds/hour
 Notes on the Drawings
CHAPTER 3
OPERATION OF SMALL SCALE POULTRY PROCESSING PLANTS
 General Operational Procedures
  Bird species
  Appearance of the final product
  Transport and reception of live birds
  Evisceration
  Packaging
  Refrigeration
  Dispatch
 Specific Operational Procedures
 MODEL 1 – 50 BIRDS/DAY
  Stunning and slaughter
  Defeathering
  Refrigeration
 MODEL 2  – 200 BIRDS/DAY
  Stunning and slaughter
  Defeathering
  Evisceration
  Cooling
  Packing and grading
  Refrigeration
 MODEL 3 – 350 BIRDS/HOUR
  Stunning and slaughter
  Scalding and defeathering
  Evisceration
  Cooling
  Cutting
  Packing and grading
  Refrigeration
CHAPTER 4
HEALTH, HYGIENE AND ROUTINE MAINTENANCE
 Poultry Rearing Hygiene
  External contamination
 Inspection of Live Birds before Slaughter (ante mortem inspection)
 Microbial Implications of Slaughter and Processing
 Inspection of Live Birds after Slaughter (post mortem inspection)
 Staff Health
 Plant Sanitation and Maintenance
  plant sanitation
  plant maintenance
 Sanitation and Maintenance Schedules
CHAPTER 5
POULTRY MARKETING
 Role of the New Abattoir in a Marketing System
 The Definition of Marketing
 Marketing Activities
 The Importance of Marketing
 Poultry as a Product
 The Poultry Market
 Marketing your product
  Research and analysis
  Decision making
  Implementation of decision

TABLES
Table 1: World population of poultry in selected regions
Table 2: Poultry meat production
Table 3: World poultry meat consumption
Table 4: % Protein content and consumption of some common foods
Table 5: World consumption of hen eggs in shell
Table 6: 1989 % World distribution of the three most important poultry species
Table 7: Effluent characteristics of the three plants

ANNEXES
Annex 1 Poultry Processing: Flow Diagram
Annex 2 Separation of Clean and Dirty areas
Annex 3 Equipment for Poultry Processing Units Model 1: 50 Birds/day: NYD
Annex 4 Equipment for Poultry Processing Units Model 2: 200 Birds/day: Chilled whole poultry carcases
Annex 5 Equipment for Poultry Processing Units Model 3: 350 Birds/hour: Chilled whole poultry carcases and portions
Annex 6 Evisceration, Trussing and Portioning Poultry Carcases
Annex 7 Plan of Baffled Sedimentation/Flotation Tank
Annex 8 Alternative Layouts For Small Scale Poultry Processing Plants

DRAWINGS
Drawing 1: Poultry processing plant for 50 Birds/day
Drawing 2: Poultry processing plant for 200 Birds/day
Drawing 3: Poultry processing plant for 350 Birds/hour using ice/cold water chilling
Drawing 4: Poultry processing plant for 350 birds/hour using air chilling
Further Reading
Equipment Suppliers