P LANT D ESIGN AND C OSTING

A SSIGNMENT #1
Piyush Pastor
Roll No 18113038
5th Semester

Design and Set up considerations for meat

processing plant

Introduction
The meat-processing industry consists of establishments primarily engaged
in the slaughtering of different animal species for obtaining meat to be sold
or to be used on the same premises for different purposes. Processing meat
involves slaughtering animals, cutting the meat, inspecting it to ensure that
it is safe for consumption, packaging it, processing it into other products
such as sausage or lunch meats, delivering it to stores, and selling it to
customers.

Processing involves taking the meat in its raw form and turning it into
another product that is marketable, safe for consumption, and attractive to
consumers.

Elements of Meat Processing Facility are :

1. Live Hold & Receiving,

2. Kill & Evisceration,

3. Raw Processing,

4. Further Processing,

5. Cold Storage & Shipping,

6. Utilities & Maintenance,

7. Admin and Welfare.

Facility Planning Considerations
Proper planning is an important aspect of long-term profitability for any Agri-
industrial facility.. It is important to minimize capital and operational costs to
increase value for owners and shareholders. A major part of effective planning is
considering items such as: (1) Regulatory Issues, (2) Animal Supply, (3) Utilities
and Water (4) Long Range Planning, (5) Economic Factors, (6) Labor Supply, (7)
Location/Site/Zoning, (8) Technology, and (9) Facility Layout. Optimal planning
should lead to lower life cycle costs for the entire plant.

• Regulatory Issues. All the regulatory issues should be taken care of and required
permissions, licenses and certifications like fssai need to be taken.

• Animal Supply. Meat processing is highly dependent on a sufficient supply of

animals for slaughter. Hence the animal supply chain need to be established with
local farming communities.

• Utilities and Water. Food processing operations are energy and water intensive.
Adequate electrical power for processing equipment is necessary. Processing meat
requires huge amounts of water and often this water must be pretreated because of
high Biological Oxygen Demand BOD prior to entering the municipal waste system.

• Long Range Planning. Long range or strategic planning is a function of the strategic
vision and objectives of an organization. It generally reflects the mission of the
company and how it will proceed toward achieving its business objectives. For
optimization of long-range profitability, capital spending on new facilities needs to
reflect the strategic planning objectives of the organization.

•Labor Force. The meat and poultry processing industry is not as highly automated
as other food processing industries. This makes it is very dependent on an available
labor supply

•Location/Site/zoning. Selection of an appropriate site is an important

consideration for the profitability of a meat and poultry processing facility.
Locations close to applicable transportation and infrastructure are essential for
facility operation.. Additional site issues can include drainage, wetlands, water, and
other similar items.

•Facility Layout. Facility layout and design is a key consideration in the operation of
a functional facility. The relative location between physical locations of the receiving
and load out can play a role in the operational costs of running the facility. The type
of construction and the amount of available land can have major role in the physical
layout of the facility. Additionally, the layout of individual pieces of equipment can
have an effect on the total labor and power requirements of the facility.
Design considerations

1. Animal Holding Areas

Construction of animal holding areas should address the following:
1. Unloading of animals.
2. Design of animal paths for fluid movement.
3. Ample space for animals of all sizes.
4. Availability of water for each animal.
5. Ventilation to provide proper cooling/ heating.
6. Lighting

2. Slaughter Areas
Construction of slaughter areas should address the following: the
rails in slaughter and coolers located at an adequate height for the
purpose intended, sterilizer in the slaughter room, etc.

3. Receiving and Shipping Areas

Construction of receiving and shipping areas should address the

following:

1. Load out areas should be located so that product is not

transported back through production areas.

2. Receiving and shipping areas should not open up into a

processing room.

3. Receiving and shipping areas should be adjacent or close to

where products/supplies are being stored.

4. Coolers and Freezers

There should be separate coolers for storage of raw and cooked
products and must be adequately sized

5. Storage Areas

Construction of storage areas should address the following:

1.Adequate storage for dry and nonmeat ingredients.

2. Is there adequate storage for packaging and labeling supplies?

3. Storage for equipments and maintenance tools?

6. Processing Areas—
Construction of processing areas should address the following:
 1. Separate areas for processing cooked and raw products

2. Whether processing room is refrigerated

3. Is the smokehouse in a room by itself with a drain?

4. Do carcass rails lead all the way into the processing areas for
convenience and safety of dropping carcasses to tables or work
areas?

5. Floors sloped to drains

6. Placement of equipment considered for ease of transition from

one machine to another, e.g., meat saw close to boning table.

Other considerations
They include sewer and drainage, general construction considerations, transport, market
and retail etc.