Plant layout for poultry processing

S.R.SWAMINATHAN BTF 06-027 TNAU

Poultry industry Vs india India is the world's fifth largest egg producer (45,200 million eggs) and the eighteenth largest producer of broilers (1,400 million chickens). Production of eggs and broilers has been rising at a rate of 8 to 10 % perannum. Per capita availability of poultry meat is 1.6 kg.

Cont Leading large scale poultry processing in india Venkateswara Group, Pune Suguna Poultry Farms Ltd, Coimbatore Pioneer Poultry Group, Coimbatore Godrej Agrovet Ltd, Mumbai Sky Lark group, North India

The broiler industry is well dominated in southern states in our country with nearly 60-70% total output coming from these states

Indian poultry export potentialPeriod 2003-2004 2004-2005 2005-2006 2006-2007 Qty metric tonnes 4 1 5 2 2 8 .1 7 2 7 7 7 4 4 .4 6 1 4 5 8 8 9 .0 0 7 1 0 8 8 0 .1 2 Value in rs crs. 2 0 2 .4 0 1 6 0 .7 9 1 6 7 .5 8 3 1 5 .9 0

There is a large scope in poultry Poultry processing level is low - 6% , as against 60-70% in developed countries. Government's offer for developing poultry Excise duty is reduced from 16% to 8% setting up of Meat and Poultry Processing Board funds of Rs1095 crore for poultry development during the 11th Plan and Rs 30,000 crore for the entire livestock sector Poultry farmers to get maize on

400 birds / day

SMALL SCALE POULTRY PROCESSING UNIT

Location of the plant Naduppalayam, coimbatore. Guideline value : 19rs/squarefoot 20 km away from collector office coimbatore

Source: www.tnreginet.com, google map

Management The system of management of staff must be considered from the outset To assist with the design of the facilities, management should include: Number of birds to be slaughtered Nature of the products Slaughter system Level of technology

StaffingStaff Reception/sticker Scalder plucker Evisceration Truss/packer Manager/dispatcher Cleaner/laborer Number of person 1 2 2 2 2 1 2 Rs. Salary/person 4000 5000 5000 5000 5000 10000 4000

Total

12

62000

Poultry Plant Productsc ic h en kry ur C t cu

Wh

le o

lo

li l

op p

Dr k

ms u

ic t

Bo

el n

ss e

br

as e

Flow diagram

Water tank

Total area : 0.2023 ha / 0.5 ac Total build up area : 20%

Greenery

Rest room Securit and toilet y

Parking

5 17 4 3 2

6

8 7

13

9 10 17 18 16

12

11 18

1 14 15

1.Reception 2.Stunning table 3.Cone stand 4.Scalding machine 5.Defeathering 6.Head and leg removal 7.Evisceration table 8.Giblet station 9.Carcass washer

10. Ice tank 11. Packaging machine cum table 12. Chill room 13. Freezer 14. Office 15. Store room 16. Processing table 17. wash basin for carcass 18. Hand wash

Equipment for poultry processing unitDepends on the level of technology used. Small scale plant semi automatic machineries

1.Poultry crates X 100 2.16 cone killing stand 3.Stunner/sticking knife 4.Waterfall dip tank,with thermometer 5.Flight feather remover

8.Feather bins X 5 9.Mobile racks X 3 10.Evisceration table 11.Evisceration tools , 5 sets 12.giblet station X 1 13.Carcase washer 14.Sink unit/ sterilizer X 4

15Wash hand basin X 2 16Icemaker, for use with ice tank only (optional) 17Ice tank or spiral washer chiller 18Packing table X 4 19Shelving 20Offal truck 21Scale

22Dry store room 23Cold storage 24Freezer storage 25Insect electrocutors 26Office equipment 27Bagging machine 28Boot wash 33Cleaning equipment (higher pressure power washer)

30

Economics Economics of establishment and operation of the venture are the first considerations when designing poultry plant Capital cost Operating cost

Capital costsParticulars Land Buildings Plant and equipment Contingencies Working capital One time Investment Reasons (Rs) 0.5 acre at 19rs/sqft 4,50,000 1000rs/sqft 10 cent 45,00,000 building + fence + Cold storage, 15,00,000 parking production, wiring,ice Paper work, 20,000 bagging machine, registration, license, Procurement of birds 50,000 61,00,000 featherfan, etc,. table , remover, and first month Giblet station, etc,. operating cost

Total

Operating costsPersonnel Maintenance and spares Water and sewage Electricity Packaging materials Sundries Contingencies Cost (Rs.)/ month 62,000 2,000 2,000 10,000 10,000 2,000 10,000

Total

98,000

rice and profit estimation 0 0 b ird s/ d a y 4 Price of farm live chicken :Rs. 50/ Average weight of live chicken : 2 kg Price of slaughtered carcass : Rs. 90/ Average weight of one carcase: 1.5 kgy hl nt Mo e ur it nd pe ex

8 0 0 K g /d a y 4 0 , 0 0 0 R s/ d a y

6 0 0 kg / d a y 5 4 , 0 0 0 R s/ d a y

Pro fi t 1 4 , 0 0 0 R s/ d a y25 ys : da king W th o n or

Pro fi : 3 , 5 0 , 0 0 0 R s/ m t0 0,0 1,0 0 Rs

Pay back period Period of recovering investment cost Payback period = investment / annual net profit = 61,00,000/30,00,000 = 2.033 = 2 years (app)

Conclusion

Type of industry: small scale poultry processing Location : Naduppalayam, coimbatore. Staff : 12 members Products : whole chicken (with skin and without skin), curry cut, boneless breast, drumstick, lollipop. Area required: 0.5 acre Capital cost : 61,00,000 Rs Operating cost : 98,000 Rs/month

Reference

Annual report 2007-2008 mofpi http://www.mofpi.nic.in/ http://www.apeda.com/apedawebsite/six_he www.ansci.umn.edu/ poultry/.../small-scale_production.htm Poultry processing, manpreet singh, anburn university attra.ncat.org/attrapub/poultryprocess.html www.fao.org/docrep/003/t0561e/T0561E00.