MODERN SLAUGHTER HOSUE

MODERN SLAUGHTER HOUSE

1 Department of Civil Engineering, SIST

1. INTRODUCTION

A slaughterhouse is an industrial facility where animals are processed for

consumption as food products. Slaughterhouses act as the starting point of the meat

industry, where stock come from farms/market to enter the food chain. They have

existed as long as there have been settlements too large for individuals to rear their own

stock for personal consumption. In United States, around 10 billion animals are

slaughtered every year in 5,700 slaughterhouses and processing plants employing

527,000 workers. In 2007, 28.1 billion pounds of beef were consumed in the U.S. alone.

In Canada, 650 million are killed annually. In the European Union, the annual figure is

300 million cattle, sheep, and pigs, and four billion chickens. There are countries where

horses and camels also are commercially slaughtered for human consumption.

India is endowed with the largest resource of livestock population in the world,

with 204.5 million cattle, 84.2 million Buffaloes, 50.8 million Sheep, 115.3 million

Goats, 12.8 million Pigs and 307.1 million poultry (Ministry of Agriculture, Govt. of

India). Livestock available for slaughtering comprises of animals namely, buffaloes,

cattle, sheep, goats, pigs and poultry. In the year 1992-93, meat production was 1.5

million tonnes which increased to 2 million tonnes in 1997-98. The Indian Meat

Industry is currently on the track of a remarkable leap forward. The global demand for

Indian meat and meat products is increasing considerably during the past few years. We

also have one of the largest domestic markets for our meat and meat products. The

reported per capita availability of meat in India is about 1.4 kg per annum, which is

rather low compared to 60-90 kg in European countries.

As reported by the Ministry of Food Processing, as of 1989, a total of 3616

recognized slaughter houses slaughter over 2 million cattle and buffaloes, 50 million

sheep and goat, 1.5 million pigs and 150 million poultry annually, for domestic

consumption as well as for export purposes. Of these, a large number of the slaughter

houses are very old and lack in basic amenities such as lairage, waste disposing

systems, proper flooring and water supply. These slaughterhouses in India are mostly

service oriented performing only slaughtering and dressing. Slaughter houses, besides



catering to the needs of consumers, serve as source of raw materials for a wide range of

industries such as tanneries, bone meals, gelatine, glues, livestock/ animal feed

processing units and pharmaceuticals.

1.1 CURRENT STATUS OF SLAUGHTER HOUSES IN INDIA

In India, the slaughter houses come under the purview of the Animal Husbandry

Division of Ministry of Agriculture, for the purpose of funding towards expansion and

modernization activities, the respective local bodies are responsible for day-to-day

operation/maintenance. Most of the slaughter houses in the country are service-oriented

and, as such, perform only the killing and dressing of animals without an onsite

rendering operations. Most of the slaughter houses are more than 50 years old without

adequate basic amenities viz. proper flooring, ventilation, water supply, lairage, waste

disposing facilities, transport etc. In addition to these deficiencies, slaughter houses

suffer from very low hygiene standard posing a major public health and environmental

hazards due to discrete disposal of waste and highly polluted effluent discharge.

Unauthorized and illicit slaughtering has also increased manifold and thus the related

problems.

1.2 PROBLEMS DUE TO CURRENT SLAUGHTERING PROCESS

In India mostly slaughtering of animals is done either by way of halal or jhatka

method. Halal is the method preferred by Muslims and jhatka by the

Hindus/Christians/Sikhs, etc. To slaughter the animals in a humane way stunning of the

animals is prescribed, but in most of the cases stunning before slaughtering has yet not

been adopted due to certain religious feelings. In both methods of slaughtering, blood

collection is not done immediately on slaughtering and most of the blood goes down

into municipal drains causing pollution. Due to lack of means and tools, dehiding of the

carcasses is done on the floor itself, which causes contamination of the meat. The hides

and skins are spread on the floor of the slaughtering area. Similarly legs, bones, hooves

etc. are not removed immediately from the slaughtering area. Evisceration process

during slaughtering generates maximum amount of waste. The butchers who carry out

illegal slaughtering of animals generally throw visceral material at the community bins

and wash the small intestines at their shops itself and thus create pollution problem. The

wastes from slaughter houses and packaging houses are almost wholly organic, having



dissolved and suspended material. The principal deleterious effect of these wastes on

streams and water courses is their de oxygenation.

1.3 INITIATIVES TO IMPROVE SLAUGHTER HOUSE MANAGEMENT

The Supreme Court of India, High Courts in States and Lower Courts have taken

serious view on environmental pollution and have in several cases ordered closing down

of existing slaughter houses and flaying units and other such highly polluting industries.

The slaughter houses are normally controlled by local bodies, which should follow the

standards prescribed, but due to non-existence of modernized slaughter houses,

environmental pollution arising out of the slaughtering activities cannot be controlled.

Department of Animal Husbandry, Ministry of Agriculture, Government of India is

providing substantial financial assistance for setting up of modern slaughter houses and

carcass utilization centres. Many State Governments and Urban Local Bodies initiated

plans for modernization of slaughter houses.

Central Pollution Control Board (CPCB), India has brought out “Draft

Guidelines for Sanitation in Slaughter Houses” during August, 1998. The guidelines

contained in the Manual on Sewerage & Sewage Treatment (Ministry of Urban

Development, 1993) should be followed for the treatment of liquid waste/ effluent from

slaughter houses. The standards prescribed in the Environment Protection Act, 1986,

must be adhered by each slaughter house. The mandatory legal acts/rules need to be

followed by each slaughter house includes Water (Prevention and Control of Pollution )

Act, 1974; Air (Prevention and Control of Pollution) Act, 1981; Environment

(Protection) Act, 1986; Municipal Solid Waste (Management and Handling) Rules,

2000; Prevention of Cruelty to Animals (Slaughter House) Rules, 2001 and the

respective Municipal Bylaws. The Bureau of Indian Standards has also brought out the

Indian Standard, IS: 4393- 1979, as basic requirement for Abattoir and IS: 8895- 1978

guidelines for Handling, Storage and Transportation of Slaughter House By- products.

1.4 CURRENT STATUS OF SLAUGHTER HOUSE IN TRIVANDRUM

The only legal slaughter house in Trivandrum Corporation is at located at

Kunnukuzhi, implemented in 1992. Both small animal and big animal has been

slaughtered here. Another legal institution known as KEPCO is situated at Pettah where

only small animals are slaughtered legally. Only 20% of the total meat consumption



was processed at Kunnukuzhi when it was working on its full swing. It has been

reduced to 5-8 % from the last few years. Solid waste produced in both the places was

moved into Vilapilshala waste treatment plant, and liquid waste produced was sent in to

ETP unit which is within the respective compounds. But as now Vilapilshala waste

treatment plant has been closed for last two years, solid waste produced in slaughter

houses is been simply dumped in to pits creating public disturbances such as health

problems, contaminating nearby wells, creating foul smell etc. Function of ETP units

has also been very pathetic. Due to public protest slaughter house in Kunnukuzhi was

forced to shut down.

1.5 APPROACH TO THE PROJECT

Apart from the construction techniques, one of the most important areas of civil

engineering is the field of waste management. Also in the present society we are facing

a lot of problems due to improper waste management. So we thought of reducing the

waste management problems in our corporation through our project. On October 22nd

we noticed an article on Malayala Manorama newspaper (figure 1.1) that the

government was forced to close the slaughter house in Trivandrum city due to defective

waste management system, so we thought of introducing modern techniques in

managing the waste from slaughter houses.

Figure 1.1 Newspaper cutting from Malayala Manorama on October 22nd

2012



1.6 PROJECT OBJECTIVES

Main objectives of the project are:

1.6.1 Development of slaughter houses

The traditional method of slaughtering has been followed by the local butchers

which affects the environment and quality of meat. This project aims to develop a

modern slaughter house with best quality of meat and protection of environment with

use of advance machinery and techniques.

1.6.2 Zero waste concept

The wastes produced in most of the slaughter house are dumped in pits and

thrown in water bodies. Due to this pollution is a major effect of present slaughter

houses. This project aims in recycling the complete waste produced into useful by-

products.



2. CASE STUDY

(Visit to Meat Products of India, Koothattukulam)

Figure 2.1 Meat product of India, Koothattukulam

2.1 WHAT IS MPI?

Meat Products of India Ltd (MPI) is a Public Sector undertaking of Government

of Kerala. Established in the year 1973, the company holds a category license from the

Ministry of Food Processing Industries, Government of India for the manufacture and

marketing of meat and meat products. The products of MPI are derived from young and

healthy livestock and are processed by the help of sophisticated technology to ensure

high standards of hygiene, longer storage time and more nutritive value.

Products of MPI range from beef, buffalo, pork, mutton, rabbit and poultry. The

processed and semi-cooked products include corn beef, meat loaf, sausages, curries,

bacon, ham, cutlet-mix, chicken-n-ham and salami. Sausages, one of the most popular

of the MPI products range come in varieties such as cocktail sausage, pork sausage,

chicken pepperoni sausage and masala sausage. In tune with the varied demands of the



market, the above ranges of products are available in different weights and quantity in

polypackings and cans.

Meat Products of India Ltd. is a Kerala Government owned company engaged in

production and marketing of various meat and meat products derived from pork, beef,

chicken, mutton, rabbit and quails. It is holding MFPO Licence No.1 under A. The

products are manufactured under strict Veterinary Supervision from selected animals

free from zoonotic disease. MPI products are available with all leading supermarkets

and cold storages throughout Kerala and other states.

2.2 FACILITIES IN MPI

1. Electric stunning unit

2. Effluent Treatment Plant Unit

3. Biogas Plant

4. Waste utilization around 70 percentage

2.3 DEFECTS FOUND OUT IN MPI

1. Feather, simply dumped into pits

2. Burning of waste, creating public issues

3. Processed water is not at all utilized

4. No byproducts from fats



3. LOCATION OF SITE

3.1 SUITABLE LOCATION FOR A SLAUGHTER HOUSE

A minimum site area of 8000 square meters will be required to accommodate all

modules. In order to minimize the cost, rectangular shape and level grounds are

preferred. The site should be free draining and not subject to water logging or flooding

to avoid costly foundation such as pile or well foundation. Points to consider in

selecting suitable sites are listed below:

a. Distance from Urban Development:- It should not be located close to dwellings,

educational institutions, worshipful places and other public or commercial buildings due

to possible nuisance from noise, smell, congestion etc. Likely future commercial and

residential developments should also be taken into account.

b. Accessibility:- The site should be accessible from a permanent road to allow ready

transport of both livestock and meat.

c. Water Supply:- An adequate water supply is essential. Quantity of 100 litres/small is

desirable. In some areas it may be necessary to rely on rainwater collected from the

roofs. (Under these circumstances water usage will need to be much lower than given

above and ‘dry’ slaughter systems should be adopted.)

d. Electricity:- Connection to a public electricity supply is desirable especially if

chilling of carcasses is being considered or on site water pumping is required.

e. Effluent disposal:- Should have open ground with sufficient number of trees and

vegetation mainly for irrigation purpose

f. Solid waste disposal:- The site should have enough space for burial and biogas plant.

g. Parking Area:- Adequate parking area is required.

3.2 SITE LOCATION

GIS (geographic information system) technology is used for finding suitable

location.



3.2.1 What is GIS?

A geographic information system (GIS) integrates hardware, software, and data

for capturing, managing, analyzing, and displaying all forms of geographically

referenced information. Geographic information system (GIS) is a system designed to

capture, store, manipulate, analyze, manage, and present all types of geographical data.

The acronym GIS is sometimes used for geographical information science or geospatial

information studies to refer to the academic discipline or career of working with

geographic information systems. In the simplest terms, GIS is the merging

of cartography, statistical analysis, and database technology.

A GIS can be thought of as a system which digitally creates and "manipulates"

spatial areas that may be jurisdictional, purpose, or application-oriented. Generally, a

GIS is custom-designed for an organization. Hence, a GIS developed for an application,

jurisdiction, enterprise, or purpose may not be necessarily interoperable or compatible

with a GIS that has been developed for some other application, jurisdiction, enterprise,

or purpose. What goes beyond a GIS is a spatial data infrastructure, a concept that has

no such restrictive boundaries.

In a general sense, the term describes any information system that integrates,

stores, edits, analyzes, shares, and displays geographic information for

informing decision making. GIS applications are tools that allow users to create

interactive queries (user-created searches), analyze spatial information, edit data in

maps, and present the results of all these operations. Geographic information science is

the science underlying geographic concepts, applications, and systems.



3.3 LOCATION DETAILS

Location: Trivandrum Corporation

Figure 3.1 Trivandrum Corporation ward map



3.4 STEPS TO BE FOLLOWED FOR SUITABLE SITE LOCATION

CRITERIA 1:

The location of slaughter house should be within 0.1 km from roads. Figure: 3.2

show location of roads and in Figure: 3.3 the position of the areas within 0.1 km from

roads are shown below.

Procedure:

Buffer the roads for a distance of 0.1km using buffer tool.

Clip those buffered areas using clip tool.

Figure: 3.2 Location of roads of Figure: 3.3 Position of areas

Trivandrum corporation within 0.1 km from roads



CRITERIA 2:

The slaughter house should be 0.5km away from water bodies. Figure: 3.4

shows the position of water bodies and 2nd

Figure: 3.5 shows areas suitable for the

location.

Procedure:

Buffer the water bodies for a distance of 0.5km using buffer tool.

Erase those areas using erase tool.

Figure: 3.4 Areas after buffering the water bodies Figure 3.5 Position of water bodies



CRITERIA 3:

It should be 0.5km away from tourist spots &worship places. Figure.3.6 shows

the major tourist spots and worship places and Figure.3.7 shows the buffered area.

Procedure:

Buffer the important spots for a distance of 0.5km using buffer tool.


Figure: 3.6 7Position of important spots Figure 3. Required site after

spots important spots



CRITERIA 4:

It should be 1km away from railway stations.Figure.3.8 shows the important

railway stations and Figure.3.9 shows the required site.

Procedure:

Buffer the important railway stations for a distance of 1km using buffer tool.


Figure: 3.8 Position of important railway Figure 3.9 Required site after buffering

stations railway stations



CRITERIA 5:

The slaughter house must be 5km away from airport.Figure.3.10 shows the

airport and Figure.3.11 shows the required area.

Procedure:

Buffer the airport area for a distance of 5km using buffer tool.


Figure: 3.10 Position of Trivandrum airport Figure 3.11 Required site after

buffering airport area



CRITERIA 6:

Its location must be 0.5km away from hospitals & schools .Figure.3.12 shows

the site for schools and hospitals while Figure.3.13 shows the suitable location.

Procedure:

Buffer the hospitals and schools at a distance of 0.5km using buffer tool.


Figure: 3.12 Position of schools and Figure 3.13 Suitable location after buffering

hospitals



CRITERIA 7:

The suitable soil type is sandy and gravelly clay.Figure.3.14 shows the areas of

corresponding soil type and Figure.3.15 shows buffered map.

Procedure:

Select the sandy and gravelly clay soil using select option.

Clip those areas using clip tool.

Figure: 3.14 Areas of corresponding soil type Figure 3.15 Areas with suitable soil type



PROPOSED SUITABLE AREA MAP

CRITERIA 8:

The required area should be of low slope.Figure.3.16 shows the areas and their

corresponding slopes.Figure.3.17 shows the low slopping areas.

Procedure:

Select tool is used to find the low slope areas.

Those areas are clipped using clip tool.

Figure: 3.16 Areas and their corresponding slope Figure 3.17 Suitable low slopping areas



Figure.3.18 Suitable site map



3.5 LAND AVAILABILITY FOR PROPOSED PROJECT

Using GIS technology Sreekaryam, Chempazhanthi and Chellamangalam wards

were found as the appropriate places for slaughter house. In order to find the extend of

area data from Sreekaryam and Uliyazhathara village offices were collected. From the

information obtained, found out that there is no free land under government sector but

there is land which can be acquired from the private by ‘land acquisition’ method.

Land Acquisition in India refers to the process of land acquisition by the central

or state government of India for various infrastructure and economic growth initiatives.

Several controversies have arisen with claims that land owners have not been

adequately compensated.

Land acquisition in India is currently practiced under the Land Acquisition Act,

1894. Since 2011, the country has proposed and its parliament has been considering a

new law, named Land Acquisition and Rehabilitation and Resettlement Bill.

If land cannot be acquired, as a final remedy the project can replant in existing

slaughter house at Kunnukuzhi.

http://en.wikipedia.org/wiki/Land_Acquisition_Act,_1894

http://en.wikipedia.org/wiki/Land_Acquisition_and_Rehabilitation_and_Resettlement_Bill



4. CAPACITY OF THE SLAUGHTER HOUSE

First survey was done within our friends, family and neighbours. From that we

tried to find out the total meat consumption of the Trivandrum Corporation. But it was

not finding satisfactory. So we went to the present slaughter house in Trivandrum city

and consulted the doctor. He told us that in 2011 when the slaughter house was working

in full swing, they were able to slaughter 20% of the total meat consumption. That is

about 600 chicken and 100 goats per day. Due to lack of maintaence and improper

waste management, they were not able to produce this much meat nowadays

So we thought of doubling the capacity of present slaughter house. That is 40%

production of meat. For that we will be designing a slaughter house which has a

capacity of slaughtering 1500 chickens and 300 goats.

4.1 CALCULATION OF MEAT PRODUCTION

As people in Trivandrum city consume more chicken than any other type

animal, we fix the capacity of slaughter house as 1500 birds and 300 goat.

i. 1500 Chicken @ 1.75kg/bird = 1500 x 1.75

= 2625 kg

ii. 300 Mutton @ 15 kg/goat = 300 x 15

= 4500 kg

Total meat produced daily = 2625 + 4500

= 7125 kg



5. STATUTORY REQUIREMENTS AND BASIC FACILITIES FOR

A MODERN SLAUGHTER HOUSE

While considering the basic facilities of a slaughter house, both the facilities to

be provided as part of animal rights and those for hygienic and scientific slaughtering

are to be taken care of. In the Indian context, the present situation is deplorable in both

these areas. Quality and hygiene levels in the meat production are low in our country

due to primitive and crude slaughtering, imperfect bleeding, improper de-feathering

techniques, lack of water supply, absence of power supply, facilities for flaying and

hanging carcass and improper handling during transportation of carcass. The hygiene

level of the slaughterhouse workers also is poor. Establishment of modern

slaughterhouses will largely improve the situation.

5.1 BASIC FACILITIES FOR A SLAUGHTER HOUSE

The basic facilities for a slaughter house having a capacity more than 20 big

animals or 40 small animals are given below:

1. Reception area for animals

2. Lairage (Resting place for animals)

3. Room for Veterinary Doctor for performing anti-mortem and post-mortem

examination.

4. Place for isolated resting place for diseased animals.

5. Stunning place / Halal slaughtering place

6. Bleeding place (for removal of blood)

7. Removal of skin and washing place

8. Evisceration place (removal of contents from stomach)

9. Meat removal and examination place.

10. Storage facilities for skin, bones, blood, fat etc.

11. Administrative building

12. Waste disposal facilities

13. Refrigeration room

14. Laboratory



5.2 BASIC REQUIREMENTS FOR A MODERN SLAUGHTER HOUSE

5.2.1 Land

a. A minimum of 0.5 acre of land will be required for a slaughterhouse.

b. The land should be level ground, dry and rectangular or square in shape.

c. The location should be outside or on the periphery of a city or town (but not too

far away from the city) and shall be away from an Airport (IS 4393-1979).

d. It will be ideal if the there is more land area available, which could be used for

buffer zone and green belt.

5.2.2 Road

a. All-weather road connectivity should be provided to the site.

b. It should satisfy the road standards.

5.2.3 Water

a. Water (pipe water, surface water or ground water) should be sufficiently

available to meet the requirements.

b. The water should be safe and potable.

c. There should be adequate pressure for floor washing (with water jet of 200 to

330 kPa pressure) and carcass washing (1000 to 1700 kPa pressure).

d. Supply of clean hot water should be available in the slaughter hall and work

rooms during the working hours.

e. Availability of hot water not less than 820C for sterilizing equipments and

secondary floor washing.

f. Suitable facilities for washing of hands (including adequate supplies of hot and

cold running water, nail brushes, soap or other detergents).

g. Non-potable water for fire fighting purpose.

The slaughter house requires sufficient good quality water round the year. This

is for consumption of animals, washing animals before slaughtering, washing the meat,

human consumption, washing the floor and other areas etc. If water from a water supply

authority is available, connection can be obtained from them and stored in overhead

tanks. Otherwise water could be pumped and stored from a bore well or open well

constructed for the purpose. Sufficient number of leg operated water taps are also to be



provided. A solar water heater shall be installed for the purpose of hot water. Hot water

shall be used for washing slaughter hall and for sterilising tools.

5.2.4 Power Requirement

a. It is estimated that 15kW connected load power is required in the slaughter

house. A three phase power supply is essential for the purpose.

b. Apart from electric connection, a standby generator set for continuous supply of

electricity to the slaughter house is essential for the proper functioning of

equipments and lighting.

5.2.5 Waste disposal facilities

a. Proper sewage disposal facilities should be made available.

b. Facilities to avoid foul smell should be avoided

5.2.6 Lairage

a. Lairage is for keeping the animals indented for slaughter.

b. There will be facilities in the lairage for providing feed and water to the animals.

c. The lairage should have antimortem facility to check each animal for physical

disease or pregnancy.

5.2.7 Slaughter hall

a. There will be separate provision for slaughtering different types of animals.

b. Separate space shall be provided for stunning, bleeding and dressing of carcass.

Animals shall not be slaughtered in sight of other animals.

c. Pedal operated water taps and wash basin shall be provided in the slaughter hall.

d. At the bleeding area, the blood is to be collected in stainless steel basin for

further processing/ disposal. The collected blood is to be stored in tank for

heating and drying.

e. Stainless steel wheel barrow is to be provided in the slaughter hall to collect and

remove waste items like large bones, tail, intestine etc into the stripery outside

and dispose the same on completing the slaughter of the day.



5.2.8 Screens and insect control

a. All windows, doorways and other openings that may admit flies should be

equipped with effective insect and rodent screens.

b. ‘Fly chaser’ fans and ducts or air curtains shall be provided over doorways in

outside wall of meat handling areas that are used for despatch or receiving.

5.3 EQUIPMENTS USED IN A SLAUGHTER HOUSE

5.3.1 Stunning box

Figure 5.1 Stunning box

a. Stunning place should be separated with a cross wall

b. An animal shall not be slaughtered in sight of other animals

c. Stunning box manually operated for large animals (statutory requirement)

d. Electric stunning box for small animals (statutory requirement)

As per PCA Rules a stunning box is to be provided for large animals. Floor level

of stunning box need be in an elevated plane than that of the bleeding area. One side of

the stunning box shall be with hinged plate. Immediately after stunning, the animal falls

on the side wall of the stunning box, and the hinged plate will open and the animal slips



on to the bleeding area. The bleeding area need be positioned in such a way that, an

animal in the stunning box will not see the bleeding animal.

In the case of halal slaughtering, separate cubicles made up of RCC wall and

with ceramic tile in walls shall be utilised. Sufficient drains and floor slope shall be

provided for easy drainage of blood from the cubicles. Bleeding is done by hoisting the

animal to a height of 5 m rail system and blood collection vessel with funnel shall be

used for collection of blood. Blood collected shall be dewatered by heating in a vessel

using stove of LPG and methane from biogas plant. Dried blood with rice bran can be

sold as fish feed / cattle feed or as manure.

5.3.2 Continuous rail arrangement in the slaughter hall

A continuous rail arrangement should be provided on the top of the animal

slaughter hall and is fixed on to the roof slab with supporting structures. The rail

arrangement covers the bleeding area and hanging area for the smooth and convenient

movement of the carcass for processing.

5.3.3 Electric hoist

There should be an electric hoist on each rail for lifting animals. Primary

objective of electric hoist is to bring the animal to a height of 5 m for bleeding purpose.

Each is having capacity of one ton. In addition to electric hoist there should be at least

one unit of manually operated moving hoist. The hoist can operate with the pendant

switch hanging by the side. A ladder arrangement should be there to access to the hoist

and rail for maintenance. The electric hoist is running on three phase power supply. The

carcass can be lifted conveniently with the hoist for processing at different stages. After

hoisting, carcass can be moved manually. The throat is cut and the blood is collected in

stainless steel trough.

5.3.4 Dressing

Dressing is carried out in rails fitted at a height of 3 m. Transferring of animal

from 5 m bleeding rails to 3 m dressing rail is done using the electric hoist. Adequate

means and tools for dehiding of the animals should be provided. Hides or skins should

be transported either in a closed wheel barrow or by a chute provided with a self-closing

door. Means for immediate disposal of legs, horns, hooves etc should be provided



through spring load floor chutes or side wall doors or closed wheel barrows. In case

wheel barrows or trucks are used, care should be taken that at no point wheel barrow or

truck has to ply under the dressing rails and a clear passage is provided for movement of

the trucks.

5.3.5 Evisceration

Adequate space and suitable and properly located facilities shall be provided for

inspection of the viscera of the various types of animals slaughtered. There should be

adequate facilities for hand washing, tool sterilization and floor washing and

contrivances for immediate separation and disposal of condemned material. Adequate

arrangements may be made for identification, inspection and correlation of carcass,

viscera and head.

5.3.6 Captive bolt pistol

As per PCA rules, a captive bolt pistol should be provided for stunning the

animal inside the box. The pistol should be specially made for stunning animals. It is a

trouble free pistol and is in use in slaughter houses in India and abroad. As it is a

statutory requirement it is to be procured even though most of the slaughter houses in

Kerala practises halal type of slaughtering.

5.3.7 Stainless steel chute

Stainless steel chute are to be provided on the side wall of the slaughter hall.

Through this chute waste can be deposited to the stripery outside. When the slaughter of

the day is over, the waste can be collected from the stripery. Since the chute is made of

stainless steel, it will last long and it will be easy to keep it clean.



Figure 5.2 Various equipments used in modern slaughter house

5.3.8 Hanging of goat

At small-animal slaughter hall, stainless steel pipe shall be fixed at convenient

height having length from one end to the other end of the hall for hanging and

processing the small animals. Chain with hook is provided on the pipe for hanging the

carcass. The size of the stainless steel pipe is 3”. The slaughtered animal is hanged on

the pipe with chain and hook. After removing the skin, intestine etc it is put on trolley

having stainless steel top and moved to the despatch area.



5.3.9 Wheel barrows

Wheel barrow shall be made available in the animal slaughter hall for movement of

waste and materials. It can be used for leading the dung, waste etc to the pit / biogas

plant.

5.3.10 Diesel generator set

A diesel generator set to supply power for the electric hoists, lighting purpose

etc shall be installed. Since slaughtering of animals commence in the early morning,

electric power is needed for lighting. For operation of the hoists / crane power is

needed. Therefore it is necessary to install a DG Set in the slaughter house.

5.3.11 Meat cutter

There could be a motorized meat cutter for cutting the carcass of large animals

into pieces of convenient size before dispatch. This will ease the work of butchers in

slaughter house.

5.4 BASIC ACCESSORIES NEEDED IN A SLAUGHTER HOUSE

5.4.1 Compound wall

There should be a compound wall constructed in such a way that the slaughter

house and its surrounding are not visible to the public easily. The compound wall also

helps to keep away the stray dogs. It can be constructed with rubble basement and

hollow bricks super structure.

5.4.2 Gate

A steel fabricated gate having sufficient width for the passage of vehicles is

necessary. Entry of stray dogs through the closed gate should not be possible.

5.4.3 Green belt

A green belt of sufficient width with suitable species of trees shall be developed

around the compound.



5.4.4 Office & rest room

An office for the veterinary doctor and health inspector and rest room for the

workers are to be included with sufficient space.

5.4.5 Toilet

Toilets for the staff and the visitors are to be provided. It will have flush, wash

basin, floor with tiles, light fittings etc.

5.4.6 Plumbing work

The slaughter house is to be provided with sufficient number of water taps, wash

basin, pedal operated water taps etc. Flexible hose can be used for easy cleaning of the

slaughter hall.

5.4.7 Unloading platform with ramp

An unloading platform with ramp suitable for easy unloading of animals from

truck may be provided.



6. SLAUGHTER HOUSE FACILITIES

6.1 CONCEPTUAL DESIGN

A minimum site area of 2000 square meters will be required to accommodate all

components. In order to minimize the cost, it will be ideal if the site selected is level

ground and rectangular in shape. The site should be free draining and not subject to

water logging or flooding to avoid costly foundation such as pile or well foundation.

Based on scale of operation, slaughter house have been classified into three categories

namely, large, medium and small.

6.2 BASIC AMENITIES FOR A SLAUGHTER HOUSE

The slaughter house shall have the following essential facilities:

6.2.1 Production modules

Includes reception area or resting ground, lairages, and slaughter building. The

Slaughter building should have an Inspection area, Processing area, Slaughter floor,

dressing area, Fresh blood processing, Drying yard, Storage facilities, and Refrigerated

room.

6.2.2 Reception area

It is at this place, animals or birds are received at the slaughterhouse. A green

ambience with trees and vegetation should be provided. Number and type of animal/bird

received should be entered in the prescribed register. It is essential that crates and

vehicles used to transport birds/livestock are thoroughly cleaned between collections, to

reduce the spread of any infection which may be present. Facility for proper unloading

should be provided.

6.2.3 Lairage

Generally the lairage should be sized to hold the expected daily kill. This will

allow stock to be held overnight before slaughter. In some special cases a greater

capacity may be required although the holding of stock at the slaughter house for an

extended period before slaughter should not be permitted. The size of lairage, thus, will

depend on the size of the daily kill and the duration of keeping the animals in the



lairage. If the practice is keeping the animals brought from the farm in the

slaughterhouse lairage, the size of the lairage should be proportionately large. Lairage

areas for each specific slaughterhouse should therefore be assessed relative to expected

throughput.

6.2.4 Slaughter building

Slaughter building consists of preparation room, slaughter floor, fresh blood

collecting facilities, dressing area, hide and skin removing place, waste disposing area,

skin storage room, meat delivery place, refrigerating room and staff room. There should

be sufficient height for holding hooks & pulley block for free movement of the

slaughtered animal for dressing. Slaughter floor is constructed with non-slippery white

granite or marble slab with sufficient gradient for collecting fresh blood in one point.

6.2.5 Dressing area

It must be impervious, of good quality marble slab, ceramic tiles or granite.

Walls up to 2.0 to 2.5m from floor should be surfaced with approved quality white

glazed tiles or equivalent material. Sufficient ventilation and lighting system should be

provided. It should have adequate drainage system for draining out effluent & cleaning

purpose. There should be rails with hooks & pulley block with suitable rust proof metal

for bleeding, dressing & hanging of carcasses in slaughter house.

6.2.6 Waste disposal area

Waste disposal area should be near to the dressing area. The floor should be

surfaced with approved quality white glazed tiles or other equivalent material.

Sufficient ventilation system should be provided. It should have adequate drainage

system for draining out effluent and cleaning purpose.

6.2.7 Skin storage room

It should be near to the dressing area. The floor should be surfaced with

approved quality white glazed tiles or other equivalent material.



6.2.8Mmeat delivery area

This is the last point of the dressing room. It should have easy access to public

and vehicles.

6.2.9 Service modules

Includes Administrative building with Doctor’s room and Laboratory (optional),

Solid waste disposal, Effluent disposal, Watchman shed, Toilet facilities, Internal roads,

Storm water drainage, Water supply & electricity, Compound wall and gate, Rainwater

harvesting, Parking ground, and Site work and vegetation.

6.2.10 Administrative building

The administrative building mainly consists of office, doctor’s room and toilet.

The minimum area will be at least 30 m2.



7. SHEEP SLAUGHTER HOUSE

7.1 WORKING GRID AT SLAUGHTER AREA

For Halal method killing a working grid for butcher to stand and handling the

killed animal for elevating.

7.2 ELEVATOR FOR LIFTING THE CARCASS ON THE RAIL

Elevator which elevates a carcass, suspended from bleeding chain, upto the

bleeding buffer rail.

Technical description: Elevator with single hinged, galvanized chain fitted with push

fingers.

The chain runs on nylon rollers through a hot dipped galvanized guide and support

frame made from double UNP sections. A 2” tube rail is fitted under the frame. The

sprocket wheels are galvanized and fitted with shafts and bearings. The elevator

comprises: drive unit; tensioning station with spindle tensioners required conveyor chain;

required hot dipped galvanized hanger supports to the beams up to 500mm above the

elevator; required fastening material rail for transport of carcasses along de-bleeding

station to the transfer area.

7.3 BLEEDING RAIL

Galvanized rail track with track beam for de-bleeding of the carcasses

7.4 BLEEDING SHACKLES RETURN

Gravity hot dipped galvanized rail for return of bleeding shackles to the

shackling position

7.5 DRESSING CONVEYOR

Conveyor to transport the carcasses along the working stations towards the

inspection area. For the pre-dehiding of lower parts and final dehiding the conveyor

elevates and lower the carcasses.



The conveyor comprises:

a. 1 drive station with frequency variable drive

b. 11 tensioning station

c. 50 carrier hooks for goats carcasses

d. 50 hooks for red organs

7.6 SHEEP DEHIDER

For the mechanized pulling of sheep/goats skins. The legs, flanks and back of

the carcass are pre skinned till a free hanging flap hangs underneath the nose. The free

skin flap will be manual attached to the drum of the dehider, the rotation is activated

and the skin is pulled from carcass. For the release of the skin the reverse rotation is

activated and the skin will be removed.

The dehider comprises a, two floor mounted columns with height adjustable

frame with skin drum, drive and foot switch to activate the rotation of the drum. Drive

painted. Pneumatic components in standard finish.

7.7 RAIL TO COOLING AREA

Rail for transport of carcasses from dressing area to the Chillers/cooling area .



MEAT

RECOVERY

CHILLING OF CARCASSES

WEIGHING/QUALITY

GRADING SHEEP

SUPPLY

ANTE MORTEM

Blood, skin

& heads

STUNNING/BLEEDING

LEG HANGING

LEG PREPARATION

DE-HIDING

Intestines

EVISCERATION

POST MORTEM

COLLECTION &

Bones

WASHING

TRANSPORT OF CARCASSES

PROCESSING

OF BY-

PRODUCTS

CHILLING

Meat PORTIONING

DEBONING

FURTHER PROSESSING

PACKAGING & LABELLING

INTERNAL LOGISTICS /

CHILLING STORAGE

DISTRIBUTION

Flowchart no:7.1 Various stages of sheep slaughter house



8. POULTRY SLAUGHTER HOUSE

8.1 ELECTRIC STUNNER

a. Fibre Glass water bath with electric stunning

b. Complete with adjustable stainless steel framework to suit various sizes

of birds

c. Totally enclosed in control panel box

8.2 KILLING & BLEEDING TROUGH

a. Suitable for 2 minutes bleeding

b. Made up of stainless steel constructed to collect blood hygienically

during slitting.

8.3 SCALDING TANK WITH AIR AGITATION

a. Scalder for 1.5 m scalding, including heavy gauge stainless steel with

temperature digital display.

b. Air agitation system must be installed.

c. Heating by direct steam injection automatically.

d. Stainless steel bird guide baffles.

e. Over flow for controlling water level.

f. Water drain on one side with stainless steel ball valve.

8.4 16 DISC PLUCKER

a. 16 Quick release discs, with 9 fingers on each disc.

b. Heavy gauge stainless steel construction.

c. Double side high efficiency, belt driven, shackles guiding and water

pipe with stainless steel ball valve.

d. Height and distance adjustments should be available



8.5 ELECTRICALS AND PANEL BOARD

a. stainless steel constructed 1.2 thick sheets.

b. Easy openable door, Separate contractor and overload relay for each

equipment.

c. Earth leakage circuit breaker.

d. Switch fuse unit for operate panel.



EVISCERATION

POST MORTEM

HARVESTING/PROCESSING

GIBLETS AND NECKS

CHILLING OF CARCASSES

WEIGHING/QUALITY

GRADING BIRD

PORTIONING

SUPPLY

INSPECTION OF BIRDS

STUNNING / NECK CUTTING

SCALDING

PLUCKING

Blood, feather,

head, hock

COLLECTION &

TRANSPORT

PROCESS OF BY-PRODUCTS

,RENDERING

UNIT

CHILLING

DEBONING

FURTHER

PROCESSING

PACKAGING AND LABELLING

INTERNAL LOGISTICS /

CHILLING STORAGE

DISTRIBUTION

Flowchart no:8.1 Various stages of poultry slaughter house



9. PRELIMINARY SURVEY

In order to find the impact of illegal slaughtering in Trivandrum city a

preliminary survey was conducted.

For that data was collected from nearby hotels and found that there are around

1000 hotels (average calculation considering 10 hotel per ward) in Trivandrum city

includes small, medium and large hotels. In a small hotel less than 75 kg of meat is

consumed in a day. For a medium hotel about 100-150kg of meat is consumed while for

large hotels around 200kg of meat is used. But as per corporation records less than 100

kg of meat is produced in a day legally. So we found that the rest is produced by illegal

slaughtering which creates waste management issues and we aims to reduce this

problem through our project.



10. WASTE MANAGEMENT IN A SLAUGHTER HOUSE

Carcass is the product of slaughterhouse. Other items are byproducts. Most of

the byproducts are capable of material recovery. In fact the material recovery

determines the quantity of waste generated in a slaughterhouse. The strategy followed

should be to reduce waste by segregating resources from different types of wastes

generated. Byproducts from slaughter house can be divided into two main groups,

namely edible & inedible. Organs such as brain, liver, heart are the examples of edible

by-products. Hooves, horns, hair, gall bladder, ears, skin, bones etc. are the inedible by-

products. The components left unrecovered form the solid wastes.

The importance of waste management in industries hardly needs any emphasis.

Effective waste management not only reduces environmental problems but also

increases productivity of industrial activity. Slaughter house generates substantial

quantity of solid wastes. Waste management in regard to this category of units has

special significance because their wastes tend to form an ideal breeding ground for

pathogenic micro-organisms. Such wastes attract flies, dogs, birds and other vermin,

thus causing public nuisance and also accompanied by the danger of spreading disease

if disposed of without proper care. Burning or burying of wastes leads to the total loss

of potential by-products. Waste processing and disposal has to be economical and

environmentally acceptable. It needs to be noted that almost all the wastes generated by

a slaughter house can be processed to obtain various products which have commercial

value.

10.1 SOLID WASTE GENERATION

Ruminal, stomach and intestinal contents constitute the solid waste of a

slaughterhouse. Besides this, stomach and large intestine are also disposed of as waste

in most of the slaughter houses. Soft meat pats such as lungs and pancreas are collected

in large slaughter houses for sale to poultry feed processing units, whereas these offals

are disposed as waste in medium and small slaughter houses. Horns and hooves are

generally collected for sale. Average solid waste generation from bovine slaughter

houses is 275 kg/tonne of live weight killed (TLWK) which is equivalent to 27.5 per

cent of the animal weight. In case of goat and sheep slaughter house, average waste

generation amounts to be 170 kg per TLWK which is 17 per cent of animal weight.



Solid waste generation from pig slaughtering is 2.3 kg/head equivalent to 4 per cent of

animal weight.

It is observed that there is no organised system for disposal of solid wastes in

most of the slaughter houses. The entire solid waste is collected and disposed of as land

fill. In some slaughterhouses, dung and rumen digesta are collected separately for

composting.

Slaughter house waste contains mostly biodegradable matter. Characteristics of

solid wastes from goat and sheep slaughtering are given below.

10.2 REDUCTION IN POLLUTION LOAD

Reduction in pollution load will reduce the required treatment plant capacity and

the operation costs for on-site treatment. In addition, introduction of measures for the

reduction in pollution load mostly leads to the recovery of valuable by-products

improving the overall profitability of a unit. Technically feasible pollution load

reduction measures are given below:

Table 10.1 Characteristics of slaughter house waste

Parameters Value

Moisture, % 69.45

Total solids, % 30.55

Volatile solids, % 87.95

Fixed solids, % 12.05

Org. carbon, % 23.32

Total nitrogen, % 2.71

Phosphorous, mg/g 4.19

Potassium, mg/g 6.9



10.3 COLLECTION AND SEPARATE DISPOSAL OF STOMACH AND

INTESTINE CONTENTS

Discharge stomach and intestinal contents to the wastewater substantially

increase the TSS and BOD & COD load to the wastewater treatment system.

Introduction of dry procedures for the collection of stomach and intestinal contents,

therefore, is strongly recommended. The collected solids can be reused by farmers as

fertilizer or soil conditioner. A 10% reduction in total waste load by dry collection of

stomach content alone is quite possible.

10.4 SEPARATION OF HAIR, FEATHERS AND SOLIDS FROM

EVISCERATING WASTEWATER

Hairs, feathers and other screenable solids should be removed from the

wastewater as close to the place of generation/discharge as possible. Wastewater

streams containing high content of these solids should be segregated and pre-treated by

a self-cleaning screen system prior to combination with the remaining wastewater of the

unit.

10.5 SEGREGATION AND PRE-TREATMENT OF WASTEWATER FROM

VISCERA AND INTESTINE WASHING ACTIVITIES

Minimising water consumption, segregation and effective oil/grease removal

will effectively reduce the pollution load from this activity. Installation of an effective

self-cleaning type screening system at wastewater streams with high-suspended solids

content is strongly recommended for all types of the above industries. This will

substantially reduce the overall BOD and COD load to the wastewater treatment plant

and avoid choking of sewer lines in cases where only pre-treatment is required prior to

sewer discharge.

10.6 BY-PRODUCT RECOVERY

Incorporating one or all of the above-mentioned techniques can substantially

reduce pollution load from slaughterhouse. The separated “wastes” can be converted

into valuable by-products by the following technically feasible methods:

a. Blood is used by pharmaceutical companies for manufacturing haemotonic

preparations. Hence this should be collected. Alternatively blood plasma could be



used in sausage preparations. Blood can also be converted into blood meal, which,

after mixing and drying with rumen digesta, can be used as animal feed.

b. Rumen digesta contains 10-20% proteins, vitamins and essential minerals which,

after processing/drying is an ideal animal feed. Alternatively rumen digesta can be

used as manure after composting.

c. Rendering: Fat should be collected separately and rendered into tallow or lard by

using wet or dry rendering processes. Indirect heat is used to melt fat evaporate

moisture from the animal tissue. Tallow and lard is a valuable raw material for

several chemical industries.



11. WASTE WATER PROCESSING

The slaughter house in Trivandrum city is service-oriented and, as such,

performs only the killing and dressing of animals without an onsite rendering

operations. Lack of appropriate slaughtering facilities and unsatisfactory slaughtering

techniques have caused unnecessary losses in meat quality. As valuable by-products are

not recovered this has resulted in another heavy loss. Animals are slaughtered in places

which are frequently polluted with blood, intestinal contents and dirty effluents, and

which are not protected against insects, rodents and dogs. Meat produced under such

conditions will quickly deteriorate due to the bacterial load and could cause food

poisoning. In the absence of inspection, meat from sick or parasite infested animals may

well be a vector for spreading diseases affecting human beings as well as animals in the

city. Furthermore, meat quality is adversely affected by careless handling under

unsanitary conditions in the meat market or shops. In addition, by-products are

not properly utilized and, instead of being an asset, are considered as a nuisance. The

respective local bodies are mainly responsible for day-to-day operation/maintenance of

the slaughter houses. The construction of small-scale modern slaughterhouse in

centralized part (combined system of poultry and large animals) of the city which meets

the environmental and legal requirements is an immediate necessity. Slaughterhouses

are a key element in the meat production and distribution chain. It is also essential

to provide adequate treatment system for the solid and liquid waste generated to

improve slaughter hygiene , meat quality, reduce raw material losses, increase

utilization of by-products, and thereby increase profitability and financial returns to

livestock producers.

In a slaughter house the water is used for drinking by animals during lairage,

washing of slaughtering and bleeding areas, washing of dressing halls, cleaning

intestines, cleaning of knife, axis, tables & any other equipment in the slaughter house.

Further a considerable amount of water is also consumed inside the premises of the

factory for the toilets canteen (for employees of the slaughter house complex),

drinking and hand washing of meat dealers, animal traders, butchers, and transporters.

Except for domestic water consumption and drinking water provided for animals for

lairage, the major portion of the water is discharged as waste water.



The wastes from slaughter houses and packaging houses are similar in terms of

chemically to domestic sewage, but are considerably more concentrated. They are

almost wholly organic, chiefly having dissolved and suspended material. The principal

deleterious effect of these wastes on streams and water courses is their deoxygenating

effect. Slaughter house effluents have a characteristic brownish, blood like appearance

and special repugnant odor .The organic compounds occur as suspended matter and

colloids. The effluent of a slaughter house will also contain pathogenic

microorganisms in addition to other pollutants like BOD, COD and TSS.

11.1 WASTEWATER

Wastewater from a slaughterhouse arises from different steps of the

slaughtering process such as washing of animals, bleeding out, skinning, cleaning of

animal bodies, cleaning of rooms, etc. The wastewater contains blood, particles of skin

and meat, excrements and other pollutants.

Process flow chart for a Modern Slaughter House is given below. Main

emphasis is to segregate waste at different stages and to recover resources from it.

Overuse of water should be avoided.



FLOWCHART

RECEPTION

Water

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

LAIRAGE

ANTIMORTOM

STUNNING / HALAL

SLAUGHTER

BLEEDING

HORN & HOOVES

REMOVAL

EVISCERATION

HEAD REMOVAL

DEHIDING

CARCASS WASHING

washwater

blood

blood

washwater

washwater

RED OFFAL REMOVAL

CARCASS SPLITTING

CARCASS WASHING washwater

POST MORTEM

DESPATCH/

Flow chart no: 11.1 Stages of segregation of waste water



The liquid waste should be washed away by safe potable and constant supply

of fresh water at adequate pressure throughout the premises of slaughtering. The

wastewater from slaughter house lead to heavy pollution and, therefore, it should not

be allowed to mix with the municipal drain system without pre-treatment meeting

sewage standards. Within a series of processes, slaughterhouses produce large

amounts of different wastes and wastewaters. The problems are complex since the

slaughterhouses is located in the cities. Traditional ways of letting the wastes to

drain/sewage / agricultural land are not applicable due to resulting environmental and

ecological problems. Direct disposal of highly polluted wastewater and organic

residues into the sewerage system without prior treatment on the other hand is not

acceptable due to high organic content and solids. Hence, anaerobic processes flowed

by aerobic can contribute in an interesting way to improve the situation.The hard solid

waste has to fed to the rendering plant.

11.1.1 Wastewater quantity

For hygienic reasons, slaughter house use large amounts of water in animal

processing, cleaning, staff usage, thus producing large amounts of wastewater that

have to be treated. Waste water quantity will be always 80% of the total water

consumed per day.

11.1.2 Wastewater characteristics

Knowledge of wastewater characteristics are essential for an effective and

economical waste management programme. It helps in the choice of the treatment

methods, deciding the extent of treatment, assessing the beneficial uses of wastes and

utilizing the waste purification capacity of natural bodies of water in a planned and

controlled manner. The important characteristics are temperature, hydrogen ion

concentration, colour and odour, solids, nitrogen, phosphorous, chlorides, BOD, COD,

toxic metals and compounds The typical wastewater characteristics are given in table

11.1



Table 11.1 Typical wastewater characteristics

Parameter Concentration (g/l)

pH

6.8-7.8

COD

5.2-9.4

TSS

0.57-1.69

Phosphorus

0.007-0.0283

Ammoniacal nitrogen

0.019-0.074

Protein

3.25-7.86



12. PROPOSED WASTEWATER TREATMENT PLANT

The proposed plant is designed based on the following data of wastewater. Water

needed for complete slaughtering process is

i. For chicken : 20 l / bird

ii. For goat : 80 l / animal

Capacity = (1500 x 20) + (300 x 80) x 80

100

Operation hours: 24 hrs

= 43200 l

= 43.2 m3

≈ 45m3

Plant flow rate : 45/24 = 1.88 cum/hr

Design flow rate: 1.88 cum/hr

The plant is designed to attain effluent characteristics as prescribed in the

CPCB standards. The expected outlet Values in relation to the input values are

provided in the Table.12.1, which is the basis of design criteria.

Table 12.1 Design criteria for the proposed plant

Sl.No Description Unit ETP Inlet ETP Outlet Standards

1 PH - 6.8-7.8 6.5 – 7.5 5.5 – 9.0

2 TSS mg/l 1690 <25 < 100

3 BOD mg/l 6000 < 25 < 30

4 COD mg/l 8000 < 200 < 250

12.1 PROCEDURE FOR BOD TEST

A sample is pipetted into a BOD bottle containing dilution water. The

dissolved oxygen content is determined and recorded and the bottle is incubated in the

dark for 5 days at 20°C. At the end of five days, the final dissolved oxygen content is

determined and the difference between the initial D.O. is calculated and used to

calculate the biochemical oxygen demand of the sample.

a. Take fresh water in BOD bottle



b. Add 2ml manganese sulphate and 2ml alkali iodide azide

c. Mix well for at least 15 turns

d. Precipitate formed indicate the presence of dissolved oxygen and allowed to

settle

e. Add 2ml concentrated sulphuric acid (H2SO4) through sides

f. Mix thoroughly and keep for 5 minutes

g. It is then titrated 203ml solution against 0.025 N sodium thiosulphate

h. Note colour change to light yellow

i. Add 1ml starch solution, which turns the solution to blue colour

j. Titrate again till blue colour disappears. Note the reading

12.2 PROCEDURE FOR COD TEST

The Chemical Oxygen Demand (COD) test measures the oxygen equivalent

consumed by organic matter in a sample during strong chemical oxidation. The strong

chemical oxidation conditions are provided by the reagents used in the analysis.

Potassium dichromate is used as the oxygen source with concentrated sulphuric acid

added to yield a strong acid medium. Several reagents are added during the set up of

the analysis to drive the oxidation reaction to completion and also to remove any

possible interferences. Specifically, these reagents are potassium di chromate, ferroin

indicator and sulphuric acid. Mercuric sulphate is added to remove complex chloride

ions present in the sample. Without the mercuric sulphate the chloride ions would

form chlorine compounds in the strong acid media used in the procedure. These

chlorine compounds would oxidize the organic matter in the sample, resulting in a

COD value lower than the actual value. Silver sulphate is added as a catalyst for the

oxidation of short, straight chain organics and alcohols. Again, without the silver

sulphate the COD of the sample would be lower than the actual value. Sulfonic acid is

added to remove interferences caused by nitrite ions. Without sulfonic acid the COD

of the sample would measure higher than the actual value.

12.3 PROCEDURE FOR TOTAL SUSPENDED SOLIDS (TSS)

1. Wash filter paper & dry

2. Cool & weigh filter paper

3. Assemble filtration apparatus



4. Wet filter paper with distilled water

5. Stir sample

6. Pipette 50ml into filter while stirring

7. Filter and wash three times

8. Transfer filtrate to evaporating dish & dry

9. Cool & weigh

10. Calculate in mg/l

11. Repeat steps 1 to 10 using 10 ml aliquot

Calculating total suspended solids (TSS) concentration (ml ) of sample

= (A - B) x 1000mg Suspended Solids /l

where:

A = weight of filter + dried residue, mg

B = weight of filter, mgHP

12.4 DESIGN, CODES AND STANDARDS

a. Basic Design:

1. CPHEEO Manual, Wastewater Engineering treatment and reuse - Metcalf & Eddy

2.All design, inspection, and testing of the plant will be done with respect to the

latest Indian Standards.

3. In case of non-availability of standards, good engineering practice will be

adopted.

b. Process description

The influent is screened through the screen unit to remove the floating solids in

the influent and is then led to equalization tank for equalizing the variation in the

inflow and giving consistency in feeding rate. The effluent from the equalization tank

is let to the anaerobic digester. The BOD will be reduced from 6250 mg/l to 1250

mg/l while the COD will be reduced form 8000 mg/l to 1860 mg/l in the anaerobic

digester. The sludge from the anaerobic tank is pumped to the Sludge drying bed

periodically and then disposed as manure. The digested wastewater is then led to the

Activated sludge process tank where the wastewater is aerated for bacterial growth by

diffused aeration system. The suspended growth of the bacteria removes the organic



pollutants in the wastewater and then the treated water with suspended solids passes in

to the sedimentation tank for separation of water and sludge. The settled sludge from

Clarifier tank is recirculated to the Aeration tank for maintaining the MLSS

concentration. After secondary treatment the BOD & COD will be reduced from 1250

to 250 mg/l and 1860 to 400 mg/l respectively. The excess sludge will be pumped to

the Sludge tank from where it will be pumped to the sludge drying bed. The clarified

water is then led to Chlorine contact tank where NaOCl dosing is done. The

chlorinated water is pumped to Pressure sand filter & Activated carbon filter unit

using Filter feed pump to remove the suspended solids, colour, odour and organics.

The filtration will again reduce the BOD & COD to < 25 mg/l & < 200 mg/l

respectively.



13. TECHNICAL SPECIFICATION AND DESIGN

CALCULATIONS FOR THE EQUIPMENTS

The required plant capacity for the proposed slaughter house is, Q = 45 cum /day.

13.1 BAR SCREEN

Bar screens are typically at entrance of a wastewater treatment plant, bar

screens are used to remove large objects such as offal, hair, rags, plastics bottles, and

solids from the waste stream entering the treatment plant. Bar screens are vital to the

successful operation of a plant, they reduce the damage of valves, pumps, and other

appurtenances. Floatables are also removed at the entrance to a treatment plant, these

are objects that "float" on the surface of the water and if aren't removed end up in the

primaries or aeration tanks.

Figure.13.1 Bar screen



Design:

Working hours =7hrs

Q = 45÷(60x60x7)

= 1.78x10-3

cum/s

Velocity range for bar screens= 0.7-0.8m/s

Assuming velocity = 0.7m/s

Net area, A = Q÷V

=1.78x10-3

÷0.7

= 2.55x10-3

m2

= 25.5 cm2

Assuming width =1 cm, clear spacing= 5cm,

Gross area = 25.5 x (5+1)

5

=30.6cm2

Assume bar 60o

inclined, gross area = 30.6x 2

31/2

= 35.33cm2

Use bar screen of size 10cm x 10cm at 1cm width and with a clear spacing of 5cm

13.2 SKIMMING TANK

Skimming tank is used to remove the fat and other colloidal material present in

slaughtered waste

Design:

Detention period = 4 minute

Surface Area = 0.0062 x Q/Vr

= 0.0062 x 45/0.25

= 1.1196 m2

Assume Depth = 1m

Length = Velocity x Detention Time

= 0.25 x 4 =1m

Width = Surface area/length

= 1.1196/1 = 1.1196m



13.3 EQUALIZATION TANK

Equalization tank is provided for collection of the effluent for dampening the

flow. Flow equalization is method used to overcome the operational problems and

flow rate variations to improve the performance of downstream processes and to

reduce the size & cost of downstream treatment facilities. To prevent flow rate,

temperature, and contaminant concentrations from varying widely, flow equalization

is often used.

Figure 13.2 Equalisation Tank

Design:

Retention time = 10hrs

Flow rate = 45

7

= 6.43m3/day

Volume of tank required = flow rate x detention time

= 6.43x10

= 64.43m3

Assume depth = 3m

Area = 21.43m2

Length = 4.62 m

Breadth = 4.62 m

Depth = 3 m

Tank Size = 4.62 x 4.62 x 3 (FB: 0.3m)



13.4 ANAEROBIC DIGESTER TANK

The wastewater containing very high COD and BOD can be easily

degraded under anaerobic condition by providing appropriate detention time and

create more surface area for the anaerobic reaction to take place. Since the BOD, COD

ratio is less the anaerobic treatment will have the higher efficiency. Simple end

products which are formed in the anaerobic process will be settled and removed

periodically .The major portion of the organic is removed. Standard retention time 3 -

4 days for anaerobic digester. Hence the designed tank is adequate.

Design:

BOD

= 6250 mg/l

Detention Period = 4 days

Volume = 45x4

= 180m3

Assume depth = 4m

Area = 180/4

= 45m3

Length = 10m

Breadth = 4.5m

Tank details = 10m x4.5m x 4m(FB: 0.3m)



13.5 AEROBIC TREATMENT TANK

By bubbling compressed air through liquid effluent in a tank, treatment creates

a highly oxygenated (aerobic) environment for bacteria, which uses the organic matter

as an energy source .The aerobic treatment pre-treats wastewater by adding air to

break down organic matter, reduce pathogens, and transform nutrients. Compared to

conventional septic tanks, aerobic treatment break down organic matter more

efficiently, achieve quicker decomposition of organic solids, and reduce the

concentration of pathogens in the wastewater. In another stage bacteria and solids

settle out of the wastewater.

Figure 13.3 Aerobic treatment tank

Design:

MLSS Concentration : 3000 mg/l

F/ M Ratio : 0.3

No. of Aeration Tanks : 1

Average flow to tank = 45m3

Total BOD entering into tank = 1250mg/l

BOD outlet = 250mg/l

BOD removed = 1250-250

= 1000mg/l

Efficiency = 1000 x100 = 80%

1250

F = Q = Y0

M V Xt

0.3 = 45/V x1250/3000

V = 62.5m3

Depth = 3 to 4.5m (standard values)



Width = 4 to 6m (standard values)

Depth = 3m

Width = 4m

Length = 5m

Design = 5mx 4m x 3m(FB =1m)

Aerator sizing:

BOD5 applied = 1250mg/l

Average flow = 45m3

BOD to be removed = 45 x 1.25

= 56.25kg/day

= 56/24

= 2.3 kg/hr

O2 requirement = 1.2kg / kg of BOD applied

Peak O2 demand = 125%

O2 transfer capacity of the aerator in standard condition = 1.9 kg/kWh

= 1.41 kg/HPh

O2 transfer capacity of aerator at field conditions = 0.7 x 1.41

= 0.9 kg/HP/hr

O2 to be applied to the tank = 1.2 x2.3 x 1.25

= 3.5 kg/hr

In order to treat BOD 3.5 kg/hr oxygen is needed. So for providing 3.5 kg/hr

oxygen two motor each of 1 HP for alternate use and another 1 HP motor as stand by.



13.6 SECONDARY SEDIMENTATION TANK

The secondary sedimentation tanks or settling basins or clarifiers allow the

microorganisms and other solids to settle after secondary or biological treatment. The

part of the sludge is pumped back into the Aerobic treatment for maintaining the

MLSS and the remaining sludge is pumped to sludge drying bed. At this stage the

BOD may be reduced to 75 - 80% of the influent level and suspended solids are

removed.

Figure 13.4 Secondary sedimentation tank



Design:

Quantity of water to be treated = 4500 litres

Detention time = 4 hrs

Assuming

Width = 10 > x > 12 m

Horizontal flow velocity = 0.3 m/minute

Treatment during detention time = 45 x 4/24

= 7.5 m3

Assume depth = 1.5 m

Area = Treatment during detention time/depth

= 7.5/1.5

= 5 m2

Provide Breadth = 2 m

Length = area/breadth

= 5/2 = 0.5 m

Design = 2.5 x 2 x 2 (FB =0.5 m)

13.7 SLUDGE DRYING BED

After most of the organic solids have been digested, the sludge is

pumped to drying beds for removing water in the sludge. The dewatered solids are

then disposed off. The resulting solids are in the range of 18-20 percent solids, these

solids can be applied to agricultural land. The solids can also be taken to a landfill.

The sludge drying beds also provide a means of drying the sludge treated by the

anaerobic digesters. As an alternative, the digested sludge may be pumped to the truck

loading station to be hauled to other locations for drying or for use as fertilizer. Sludge

is a good soil conditioner as well as fertilizer.



Design:

Figure 13.5 Sludge Drying bed

Sludge Loading Rate : 100 kg/day

Specific gravity : 1.015

Solid content : 1.5%

Volume of sludge : 100/1.5 x 1/(1000 x 1.015 )

= 6.568 m3/day

Depth of Each Bed : 0.4 m

Area : 16.42 m2

Length of Each Bed : 2m

Width of Each Bed : 2m

No. of Beds required : 4



13.8 CHLORINE CONTACT TANK

Chlorination is the most common disinfection method for public and private

water systems. This disinfection process is necessary to kill disease-causing bacteria in

the water. In order to be sure the added chlorine is killing the bacteria, the water is

detained in the tank for at least 6 hours. Chlorine Contact Tanks are designed to the

required residence time of the treatment system. Sizing is based on the site restrictions,

available pumping rate, and a minimum required chlorine contact time.

Figure 13.6 Chlorine Contact tank

Design:

Size :

1.5 x 1.5 x 1.5

Length : 1.5 m

Breadth 1.5 m

Depth of liquid :

Volume of effluent :

1.2 m

2.7 m3

Retention time : 12 hrs



13.9 SAND FILTER

Sand filters are beds of granular material, or sand, drained from underneath so

that pretreated wastewater can be treated, collected and distributed to the land

application system. They are normally used to polish effluent from treatment processes

before it is distributed on the land.

Specifications:

Figure 13.7 Sand filter

Specific gravity : 2.5-2.7

Uniformity co-efficient : 1.55

Effective size : 0.55mm

Diameter : 500 mm

Height on straight : 1000 mm

Type : Vertical

No. Provided : 1

Operation hours : 20 hrs

13.10 ACTIVATED CARBON FILTER (ACF)

It is used to remove the minute suspended particles including particulate BOD,

colour odour from the settling tank.



Specifications :

Figure 13.8 Activate carbon Filter

Specific gravity : 2.5-2.7

Uniformity co-efficient : 1.55

Effective size : 0.55mm

Diameter : 500 mm

Height on straight : 1000 mm

Type : Vertical

No. Provided : 1

Operation hours : 20 hrs

Hence the filtration plant (ACF &Sand filter) is adequate for filtering the

effluent. The backwash water from the filters will be led back to effluent collection

tank. The filters will be backwashed by the using the treated water with the help of

filter feed pumps itself.

13.11 TREATED WATER TANK

Quantity : 1 no:

Capacity : 6 m3

Size : 2.0 m x 2.0 m x 1.5 m



Table 13.1 Tank Sizing of the Wastewater treatment system

Sl.

No

Description Quantity MOC Dimension (m)

Length Breadth Depth Free

board

Bar screen 1 RCC 1.0 1.0 0.5 0.2

Equalization tank 1 RCC 4.62 4.62 3.0 0.3

Anaerobic tank 1 RCC 10 4.5 4.0 0.3

Aerobic treatment

Tank

1 RCC 5 4.0 3.0 1.0

Secondary

sedimentation Tank

1 RCC 2.5 2.0 2.0 0.5

Sludge Drying bed 4 BBM 2.0 2.0 0.4 0.3

Chlorine contact

tank

1 RCC 1.0 2.5 1.5 0.3

Pressure sand filter 1 MS-

FRP

0.5 Dia 1.0 height

Activated Carbon

filter

1 MS-

FRP

0.5 Dia 1.0 height

Treated water tank 1 RCC 2 2 1.5 0.3



14. RENDERING PLANT

Solid wastes are any discarded (abandoned or considered waste-

like) materials. Solid wastes can be solid, liquid, and semi-solid or containerized

gaseous material. Such materials are to be disposed of appropriately so as to prevent

contamination of the environment by them or constituents thereof from their discharge,

deposition, injection, dumping and spillage.

Rendering is a useful method for the physical separation of fats from solids and

water. All the animal matter such as inedible offal, tissues, meat trimmings, waste and

condemned meat, bones etc. can be processed in a rendering system as the main

constituents of animal matter are fat, water and solids. Rendering is affected by heating

and rupturing connective tissue of individual fat and muscle cells so that raw fat and

other material bound within is freed. In rendering, fat recovered is used for industrial

purposes, such as soap and greases.

Fat recovered from flesh of healthy parts can also be used for edible purposes. Solid

portion, which is known as meat meal or bone meal, is utilized for the manufacture of

stock feed and fertilizers. All the animal matter i.e. type II wastes such as inedible offal,

tissues, meat trimmings, waste and condemned meat, bones etc. can be processed in

rendering system. The main constituents of animal matter are fat, water and solids. The

objective of rendering process is to physically separate the fat, the water and the solids.

This is affected by heating and rupturing connective tissue of individual fat and muscle

cells so that raw fat and other material bound within is freed. In rendering, fat recovered

is used for industrial purposes, such as soap and greases. Fat recovered from flesh of

healthy parts can also be used for edible purposes. Solid portion, which is known as

meat meal or bone meal, is utilsed for the manufacture of stock feed and fertilizers.

Rendering is carried out in dry rendering or wet rendering plants. In both the

processes, large pieces such as heads, bones etc are reduced in size by shredders or

other machinery. Large soft offals are also cut to size before processing. Intestines,

stomach and similar soft materials contain manure and, therefore, they are

opened and cleaned before feeding to rendering plant.



14.1 CALCULATION OF SOLID WASTE

Number of goats slaughtered = 300

Number of chickens = 1500

Waste generated from goat = 13 x 300 = 3900 kg

Waste generated from chicken = 0.5 x 1500 = 750 kg

Total waste generated = 4650 kg ~ 5000 kg

14.2 EQUIPMENTS

1. Pre breaker : It is used to thoroughly mix and finely grind the solid waste

2. Double jacket steam cooker: It is used to cook the solid waste at high temperature

3. Fat removing tank : It separates the suspended fat on top of cooker

4. Hammer mill : The rendered waste is finely crushed in Hammer mill

5. Condenser unit : The rendered waste is at high temperature. In order to

cool it a condenser unit is used

6. Boiler : The heat required for working of double jacket steam

cooker is provided by the boiler



15. WASTE UTILISATION

15.1 BLOOD

a. 7% of live weight, 50% collected

b. Mixed & cooked with bran as feed

c. Blood meal, pharmaceutical products, leather finishing agent, plywood adhesive,

Fertilizer.

15.2 BONE

a. 20 – 30% of live weight

b. Gelatin: photographic, pharmaceutical, food, explosive,

c. Tallow: soap, cosmetics, food, feed,

d. Bone ash: ceramics

e. Glue: adhesive

15.3 HIDE, INTESTINE

a.

b.

Hide: Leather, Collagen, Glue, Gelatin

Dialysing Intestine: Making sausages

c. Casings: edible, surgical sutures, musical

material – collagen sheets membrane.

strings, sports guts, Prosthetic

Figure 15.1 Making of sausages using intestines



15.4 HORN &HOOF, HAIR

a. Horn & Hoof: Horn meal, Neats foot oil, fire extinguisher, protein hydrolysate

in food.

b. Hair & Wool: Carpets, Felt, Upholstery, packing material, amino acids, brushes.

15.5 PHARMACEUTICAL USES

a. Stomach: Rennin used in dairy industry

b. Lungs: Heparin

c. Brain: Cholesterol

d. Fat: fatty acids, cosmetics, greese,lubricants, Tallow

e. Pancreas: Trypsin, Insulin,

f. Liver: Liver extract, Vitamins

g. Adrenaline, Pituitary hormones, Sex hormones , DNA

h. Intestines : making surgical threads

Figure 15.2 Manufacture of surgical threads



15.6 TREATED WATER UTILISATION

a. Lairage washing

b. Vehicle washing

c.Gardening

d. Sewage farming

15.7 BY PRODUCT UTILISATION

Economic feasibility assessment of establishing byproducts based industries-

generally requires huge investments .Consider

a. Availability of raw material

b. Facilities to collect by-products

c. Investment required to set up the industry

d. Demand and cost of end product

e. Labour cost and its marketability.



16. SCOPE FOR THE FUTURE STUDY

Our project consists of both structural design and waste management. We have

completed the waste management side successfully. To complete the whole project the

structural design also have to be designed. Due to lack of time and the size of project

we have not designed the structure. But we have given a scope of future study by

designing the plan of our slaughter houses and by presenting a model of a slaughter

house.



17. CONCLUSION

The slaughter house has been designed with the most modern equipments and

treatment plant. Also we developed a plan for both poultry and sheep slaughtering

house. Both solid and liquid waste are efficiently treated and converted to useful by-

products i.e., zero waste concept. By this we can reduce a portion of illegal slaughtering

in our Trivandrum city.



18. REFERENCES

1. CPHEEO Manual

2. Metcalf and Eddy, Waste water management, pg 167, 228-387

3. S.K Garg, Environmental engineering volume 1, pg 326- 512

4. S.K Garg, Environmental engineering volume 1, pg 425- 535

5. Water Supply And Sanitary Engineering – S.C.RANGWALA (pages 548-577)

6. “Solid waste treatment in slaughter house” https://www.cedindia.org/wp-

content/uploads/2011/03/slaughter-house-waste-managment.pdf

7. (accesedon december 2012)

8. The Kerala Municipality Act 1994 – 452,453-arrangement of SHs & licensing

9. The Kerala Panchayat Raj (Slaughter Houses and Meat stalls) Rules, 1996

10. The Prevention of Cruelty to Animals(Slaughter House rules) 2000 under PCA

Act 1960

11. The Municipal Solid wastes (management and handling) Rules, 2000 under

Environment (Protection) Act 1986

12. The Water (Prevention & Control of Pollution) Act 1974

https://www.cedindia.org/wp-%20content/uploads/2011/03/slaughter-house-waste-managment.pdf

https://www.cedindia.org/wp-%20content/uploads/2011/03/slaughter-house-waste-managment.pdf

MODERN SLAUGHTER HOSUE

Engineering

Transcript of MODERN SLAUGHTER HOSUE