Poultry Plant Layout -swami

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 potential Period 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

Staffing Staff 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 Products

Wh

lo

i l l

e l o

p o p

c

c i h

y r r u C t cu

n e k

s m u

Dr k

c i t

Bo

l e n

s s e

br

s a 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

8

6

13

7

17 4 9

3

12 10

2

17 16

18

11

1

18 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 unit Depends 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 costs Particulars Land Buildings Plant and equipment Contingencies Working capital

Total

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 wiring,ice production, Paper work, 20,000 bagging machine, registration, license, Procurement of birds 50,000 61,00,000 feather remover, table , fan, etc,. and first month Giblet station, operating cost etc,.

Operating costs Personnel 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 estimation4 0 0 b ird s/ d a y • 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 kg

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

y hl nt Mo e ur it nd pe ex

Pro fit 1 4 , 0 0 0 R s/ d a y

0 0,0 1,0

Pro fit: 3 , 5 0 , 0 0 0 R s/ m

: 25 s y g da n i k r o nWoth

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. • • • •

•