INTRODUCTION As per the curriculum of B.V.Sc &A.H 5 th semester , Prof. Dr. Dainik Bahadur Nepali, courseteacher of the subject” Animal Product Technology” took us (students of B.V.Sc & A.H -5th semester ) for a day tour to Kathmandu valley on Mangshir 26 th 2070 B.S. The objectives of the tour was to visit the Valley Cold Store and Alpine Livestock & Bio Trade Private Limited in order to collect information on the way they deal with the transportation, processing, storage and marketing of the carcass, meat and meat products. The tour was focused on getting the ideas on modern and advanced working mechanism of meat processing and storage in Nepal.
VALLEY COLD STORE Our first visit was to valley cold store located at Indrayani road of Nayabazar, Balaju. Mr.Shree Krishna Ghimire, the project manager of valley Cold Store gave us information about this organization and its recent activities. The valley cold store was established in the year 2038 B.S. (1981 A.D.). Its formal registration was made in the department of cottage and small industry, HMG of Nepal. These are 3 directors of this organization, Mr. Shree Krishna Ghimire, Mr. Sanu Babu Bindukar and Mr. Hari Krishna Rawal. Other members are Baburaja Rawal, Sakshyam Ghimire, Raj Bindukar The valley cold store basically processes the poultry meat. It is the edbst producer and largest supplier of the poultry product in the Nepal. Dr. Karna Bahadur Bohara is a doctor in valley cold store. The store prefers to buy a truck- load (5000-6000 broilers) at one stop rather than part of a load at several stops. They save time with fewer stops and the poultry is more uniform when less lots are available. Trucks with broilers are weighed and weight of total birds is taken. This is recovery and holding area. There are 2 machines: 1. Boiler- having water 2. Recovery plant –feathers and intestine are cooked at 3200 C and turned to powder as feather meal and meat meal which can be used as feed and pet food. Thus nothing will go as waste and all parts of a bird will be utilized. The poultry processing plant of the valley Cold Store consists of different places and equipments which are described as follows: 1. Hanging areas Birds are hung on the shackles. 2. Electric stunner It is used to make the birds unconscious by passing electric current in the bath full of water. This is done to immobilize birds. But the machine killing is not done keeping in view the welfare of Page | 1
the animals. The killing is done by bleeding. The jugular vein is cut from outside with a sharp bleeding knife by holding the head between the thumb and forefinger with the left hand, and making a cut through the skin and jugular vein at the junction of head and neck. The time taken for a bird to expire through bleeding varies from <1 minute for small bird to >2 minute for large turkeys. Blood makes about 4% of the live weight of the poultry. A bird which had been poorly bled will have a pink or reddish appearance after the removal of feathers. Birds with fever (systemic disturbance) like a cute cholera or black head may not bleed well. These should be condemned before slaughter. 3. Picking (Wet picking) The birds are immersed in hot water and the feathers are removed by hand or mechanical pickers. Feathers account for 5-8% of the live weight of the poultry. Females have more plumage then males, and waterfowl more then chickens. 4. Scalding Scalding means the passing of birds through the hot water after they have been killed and bled, which is normally done to facilitate the removal of the feathers by relaxing or expanding the muscles around the base of feathers. The aim of scalding is to open the follicular (in which the shaft of the feather is held), so that these can be removed easily. While scalding the broilers, the high temperatures usually used for short period, but for old birds, the temperature is usually higher and longer time. Scalding rate is 1500 birds/hour. If the speed increases, the temperature also increases. The shackled birds are moved along conveyor line. They are passed through the hot water. The speed at which the conveyor line is moving depends on the temperature of the water. Longer tanks are used to increase the time of scalding. The agitation of the birds in the tank is completed by equipment which rolls then over, pushes them up or down, and forces streams of water against the carcass.
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Types of scalding
Types scalding
of Temperature of Time of Immersion water (C) (secs)
1.Hard Scalding
71-82
30-60
2.Sub Scalding
59-60
30-75
3.Semi Scalding
50.5-54.5
30-75
Usefulness
Others
-suitable for ducks geese and chickens meant for canning. -facilitates the removal of the feather and thin epidermal layer of skin. -Removes the epidermal layer. -Feathers (including pin feathers) removed by mechanical pickers.
-causes discolouration of skin in broilers. -Hard scalded birds darken quickly when exposed to air.
-Epidermal layer of carcass remains intact which aids in retarding the dehydration from the carcass surface. -Requires additional labour after mechanical picker to remove the remaining feathers.
-Birds retain the original colour and “bloom” so semi-scalded birds have more “eye-appeal” than those scalded at high temperature.
-Provides desirable shiny appearance to the carcasses provided carcasses are kept wet during holiday period -Sub-scalded birds darken only when surface is moist.
5. Picking/ Plucking It should be done immediately after scalding. It is done by passing birds through the task mechanical pickers to remove the feathers. It can e done by hand at home. 6. Pinning: Birds should be free from the in feather. Pin feathers are removed by hands using a pinning knife. The operator grips the pin feathers between the edge of the blade and the thumb and pulls outwards. Scrapping of the pinning area should be avoided. Page | 3
7. Singeing It follows the final pinning operation to remove the hair like feathers found on the some birds, especially old ones. A gas flames envelops the birds momentarily as they are signed on the shackle line. In small operation, they are hand signed. 8. Neck- breaker The birds are then loaded into the neck breaker to remove the neck parts like crop, gullet and trachea. 9. Vent cutter Vent cutter is used to make a hole in the abdomen. Then evisceration is done and postmortem is done together. Evisceration It is done manually but not mechanically. It is done by using the tools. 1) A hydraulic cutter is used to cut and remove the neck and legs. The feet are cut off at the hock joint. 2) The oil (preen) gland at the base of the tail is removed by a “scooped-out” cut through the skin. 3) A transverse cut is made into the body cavity at the rear of the keel and another cut around the vent. The bird is cut along each side from the rear of the keel to the sternum and the breast is pushed forwards to expose the viscera. 4) The viscera is pulled out through this cut without breaking intestine, gallbladder, crop and wind pipe, etc. the lung, ovary, ovi-duct, or testis and kidneys are removed. 5) The following procedures may be followed in removing the giblets (liver, heart and gizzard): a) Liver and heart should be clipped from the viscera with scissors. The gall bladder should be removed carefully without breaking it. The heart should be freed of blood and adhering blood vessels. b) Gizzard is removed by first cutting the oesophagus just above the glandular stomach. Both openings of gizzard must be trimmed clean. The gizzard should be cut open with scissors and washed from inside and outside. The inner lining of the gizzard should be completely removed. Giblet make up 4.5-13% of the ready to cook weight of the different species. After evisceration, cleaning is done. Page | 4
Postmortem A separate pre-mortem and postmortem lab is constructed. Pre-mortem is done before processing and post-mortem is done during the evisceration, as soon as viscera are exposed. The viscera may be left attached to the bird as it is suspended from the shackle or the viscera may be loosened and held beneath the bird in a pen until the examination is completed. The speed with which the birds may be exposed in the line operation varies from about 300 to 15,00 per hour, depending upon their age and the condition. Line operations at the point of inspection may be slowed down if the birds are routed in 2 or more lines from the point of viscera exposure and examination by an inspector. Cooling The dressed chickens are now cooled immediately after the slaughtering and evisceration to retain the fresh composition longer. The dressed chicken are kept in chilling vat (temperature<5C) for half an hour. The ice water is used as coolant. Within half an hour, the internal temperature of dressed chicken should be<5C. Deboning After cooling, deboning is done in a table having steel at the middle and cemented on the two sides. Grading poultry Factors considering in grading includes: 1) Confirmation 2) Fleshing 3) Pin feathers 4) Cuts and tears 5) Discolouration 6) Freezer burn Freezer burn is shown by dehydrated areas on the skin. It develops on unpackaged or poorly packaged birds held in cold storage longer than 2/3 weeks. Cold Storage After grading, these birds are ready for dispatch. But till the time of dispatch. The proper storage is done by 2 types of cold storage: 1) Blast storage The bird are stored here at -40c and stored till they freeze completely.
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2) Holding Container Now the birds are transferred to the holding container which is a cold room having walls, ceiling and floor of stainless steel. The floor has checker blades to prevent the slipping. Dressed chicken are first kept in a rack stamped with a batch no. and then racks are transferred to the cold room. When it is time for dispatch, then the racks containing dressed and graded birds are transferred from the holding container to the refrigeration containers kept outside the plant building. The refrigeration Containers have the capacity of storing 10 tons. The refrigeration container is meant for supplying by attaching to a vehicle. Hygienic methods applied inside the plant building: 1) The entrance to processing plant building has two doors: 1 st glass door which is followed by the next after leaving some space. This is done to prevent the entrance of pollutants like dust and especially the flies. Fly repellants are kept in between 2 doors on the ceiling above to discourage the entrance of flies. 2) After making the entrance through 2nd gate, the visitors and the workers have to pass through a small shallow area having medicated water so as to disinfect the slippers and shoes. This is done to prevent the chance of contamination by workers and visitors. 3) There is a facility of different type of tap which is opened by pressing a button on the floor by feet. This is to avoid the contamination of the tap if it was made to open using the hands. The workers and the visitors are to use the tap before entering the main processing unit and after leaving it. 4) The bottom edge of the walls are curved which enhances their proper cleaning.
ALPINE LIVESTOCK & BIO TRADE PRIVATE LIMITED We all 41 students of B.V.Sc & A.H 5 th Semester of veterinary 16th batch visited Alpine Livestock and Bio Trade Private Limited located at Bhumesthan-8, Dhading. It’s main office in Dhapasi -9, Kathmandu. We visited alpine livestock and slaughter house in 27 th of Mangshir under the supervision of our course teacher of Animal Product Technology, Prof. Dr. Dainik Bahadur Nepali. Alpine Livestock & Bio-Trade Pvt. Limited is established on 26 March, 2010 (13 Chaitra 2066 BS). Main objective of the company are to operate a modern slaughter house and to provide the consumers best quality hygienic meat. The company will also develop improved goat farming around project area to assure market and improve economic conditions of farmers Project also aims to assist the identified farmers in their income generation activities like dairy products, Page | 6
organic vegetable farming and distributing, herbal farming and producing of herbal medicine etc. Company also plans to establish slaughter house and four modern hygienic meat shops in Kathmandu Valley. In future the company intends to involve in goat framing and exporting of the goat meat. Alpine meat situated in Dhading is the only industry to prepare frozen meat in Nepal. It processes chevon and motton. When we reached slaughter house and processing plant of alpine meat, we were greated by management staff .13 share holder run this alpine livestock and bio trade pvt. Ltd. Medical doctor is Dr. Kedar Karki. The slaughter house was defined and equipped perfectly. It was semiautomatic type of plant. It also has transporting and holding facilities. The wall and floor were all paved with white tiles and working table were all made out of metal i.e hooks and overhead rails were all galvanized. There was a slope in the region where blood would be drained. There was separate compartments for processing herd, intestinal content and skin.
Objective ALPINE LIVESTOCK & BIO TRADE PVT.LTD. is registered under the Companies Act 2065 B.S. The main purpose of this company’s are
to establish a modern slaughter house and cold stores. to provide hygienic meat for consumers.
to improve public awareness regarding meat borne diseases.
Company Background Agriculture is the most important sector in the overall development of Nepal. More than 60 % of the total population in Nepal is dependent on agriculture. Basically Nepal is still practicing traditional way of farming and pace of development in the field of horticulture and animal husbandry is quite slow. According to the income levels Nepali people are considered among the poorest in the world. In spite of several development program and projects implemented by the government in agricultural sector, since decades, it has hardly been able to meet the food demand of increasing population. However, in the absence of other employment opportunities there is no alternative to agriculture for the nation’s development. This is the reason that this sector is receiving top priority in national development plans and programmers. There has been slow but gradual increase in the livestock and poultry farming in various parts of the country. As crop production does not provide full time employment to the rural people they are also involved in rearing livestock and poultry which helps them in augmenting their income. It is estimated that the agriculture sector alone provides the livelihood to more than 80 percent of Page | 7
the population. On the national GDP side, agriculture is contributing about 32 percent, among this poultry and animal framing has contributed about 15 %. Their main products are milk, meat, egg, hide & skin, compost manure etc. Needless to say, major source of high quality protein in the human diet is being available from milk, meat and eggs. This nutritious animal protein plays a vital role in the growth of human body and is a vital component in the balance diet. So livestock and poultry have been regarded as an important sector of agriculture for contributing nutritious component in the general public’s diet. Nepal has struggled too long to embark on a fast economic growth path. However due to various reasons its development is far from satisfactory. People are still suffering from hunger and malnutrition. It can be said that well managed farming, both crops and animal husbandry, is the need of present day Nepal’s agricultural development. It can only help to obtain sustained economic growth by upgrading people’s livelihood. Nepal is a multi-cultural, multi- religious country with different types of living conditions and varied settlements. Similarly food habits of the people are also diversified. Regarding meat consumption some community prefer buffalo meat while others like pork or chicken but the most common meat item is the goat meat. The meat industry in Nepal is in primitive stage of development. We can see some improvement in chicken and buffalo meat industry. In recent years some organized sector have come forward in establishing cold stores mainly dealing in chicken varieties. Also in the market we can find dry buffalo meat packages prepared with some hygienic viewpoint. However, there is a lack of organized processing, packaging of the goat meat or even rearing of goats on a massive scale is not practiced yet in Nepal. The public-private partnership era of development has now opened door for so many industrial ventures. Also the private entrepreneurship has been emerging in the country. It has been most waited field to start a meat processing industry in private sector. Alpine Live Stock & Bio-Trade is established with that objective – to promote modern meat industry in Nepal.
Promoters and Management Team The company is promoted by diversified promoters team. Current promoters and management team members are Mr Madhav Prasad Aryal, Mr Ijan Kumar Baral, Mr Indra Lal Sapkota, Mr Govinda Bhattarai, Mr Narayan Prasad Pandey, Mr Keshab Bahadur Rayamajhi, Mr Bhim Lal Paudel, Mr Arjun Gautam, Mr Gokul Prasad Shrestha, Mr Mahendra Bahadur Rayamajhi and Mr Cheef Bahadur Thapa. Mr Ramesh Kaphle is the chief executive officer of the company.
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A Rendering Plant The project has constructed a rendering plant of well equipped Slaughter House including a Meat Processing Plant & Cold Store separately at Khayarghari, Bhumesthan VDC-8, Dhading district, Bagmati zone. Capacity of the plant is to slaughter maximum of 300 goats per day in 8 hours duration at the beginning . Alpine Live stock and Bio Trades Pvt. Ltd. is one of the unique meat processing industry and it is considered that the major raw materials will be solely from agriculture and allied sector. As per cost calculation above 60 to 70 percent of the cost of production will be for primary processing. To ensure adequate acceptable quality, availability and procurement it is suggested to run the project as an integrated unit. The proper utilization of byproducts and the production of the value added goods both would substantially improve the financial viability of the project. The project has been conceived in order to gear up the established slaughterhouse and meat processing plant to its optimum capacity. Industry had its own chilling unit. Pieces are made in machine in 6o second by 900 rounds. Columns of -5C, -7C. Storage facilities at -18C ,-22C . Pacakaging facilities also available. It had separate antemortem, postmortem examination room, doctor’s room, changing room and locker for staffs.
Market Analysis a) Marketing Objective Marketing objective of project should be: “to satisfy consumer needs with social responsibility “. It is the needs of the consumer that should dictate the type of the product to be produced. The company should be guided by social responsibility before marketing of its products. Also the company will equally maintain and control the quality of its products. b) Benefits of the product The output of the project will be prepared by the special scientific technique considering its grade and quality. Every product should be guaranteed for its hygienic value. c) Advantage of the product Better quality product/ export market possibility
Bulk supply.
Wastage of materials avoided or minimized.
Guaranteed products. Time required for the shopkeeper will greatly reduce.
Organization at site is more streamlined. Page | 9
d) Existing similar Industries in Nepal This industry is really the first proposition of its kind .The volume and the range of the products will be added advantage. Now in existing goat meat market, so many non-organized personal level meat shops (butcher houses) are providing the service. The manual method of slaughter is being practiced. The proposed industry’s proposal to provide meat-products will really enhance to upgrade the quality of the service. It can be expected that the guaranteed supply of sufficient quantities to required outlets and supply centers can boost demand expected in near future. Photograph snapped at Alpine Livestock and Bio Trade Private Limited
Conclusion Tour was informative and enjoyable beyond my expectation. I learn all techniques of chicken and chevon processing. I learn about frozen meat and packaging. I was keen on visiting a slaughter house to see how it operates and I got a chance to visit one. I would like to thank my course teacher for his efforts in making this tour really informative.
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