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 % per annum.
• 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 Qty metric tonnes Value in rs crs.

2003-2004 415228.17 202.40

2004-2005 277744.46 160.79

2005-2006 145889.00 167.58
2006-2007 710880.12 315.90
 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 concessional rate to
use it as feed in poultry.
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 Number of person Rs. Salary/person
Reception/sticker 1 4000
Scalder 2 5000
plucker 2 5000
Evisceration 2 5000
Truss/packer 2 5000
Manager/dispatcher 1 10000
Cleaner/laborer 2 4000
Total 12 62000
Poultry Plant Products
Flow diagram
 Water tank

Total area : 0.2023 ha / 0.5 ac

Total build up area : 20%

Greenery Rest room

Security and toilet
Parking
 8
5 6 7 13
17
4
3 9 12
2 10
17

18 16 11

1
18

14 15
1. Reception 10. Ice tank
2. Stunning table 11. Packaging machine cum
3. Cone stand table
4. Scalding machine 12. Chill room
5. Defeathering 13. Freezer
6. Head and leg removal 14. Office
7. Evisceration table 15. Store room
8. Giblet station 16. Processing table
9. Carcass washer 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
6. Holding table, 2X1m
7. Bowl plucker
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
15 Wash hand basin X 2
16 Icemaker, for use with
ice tank only (optional)
17 Ice tank or spiral
washer chiller
18 Packing table X 4
19 Shelving
20 Offal truck
21 Scale
22 Dry store room
23 Cold storage
24 Freezer storage
25 Insect electrocutors
26 Office equipment
27 Bagging machine
28 Boot wash
26 Cleaning equipment
(higher pressure power
washer)
 Economics
• Economics of
establishment and
operation of the
venture are the first
considerations when
designing poultry
plant
• Capital cost
• Operating cost
 Capital costs
Particulars One time Reasons
Investment (Rs)
Land 4,50,000 0.5 acre at 19rs/sqft

Buildings 45,00,000 1000rs/sqft – 10 cent

building + fence + parking
Plant and 15,00,000 Cold storage, wiring,ice
production, bagging
equipment machine, feather remover,
Giblet station, etc,.
Contingencies 20,000 Paper work, registration,
license, table , fan, etc,.
Working capital 50,000 Procurement of birds and
first month operating cost

Total 61,00,000
 Operating costs
Cost (Rs.)/ month
Personnel 62,000
Maintenance and spares 2,000
Water and sewage 2,000
Electricity 10,000
Packaging materials 10,000
Sundries 2,000
Contingencies 10,000
Total 98,000
Price and profit estimation 400 birds/day
• Price of farm live chicken :Rs. 50/- 800 Kg/day
• Average weight of live chicken : 2 kg 40,000 Rs/day
• Price of slaughtered carcass : Rs. 90/-
• Average weight of one carcase : 1.5 kg
600 kg/day
54,000 Rs/day
Net profit
2,50,000 Rs/month
Profit
14,000 Rs/day

Profit: 3,50,000
Rs/month
 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
• Pay back period : 2 years
 Reference
• Annual report 2007-2008 – mofpi
• http://www.mofpi.nic.in/
• http://www.apeda.com/apedawebsite/six_head_
product/animal.htm
• www.ansci.umn.edu/poultry/.../small-
scale_production.htm
• Poultry processing, manpreet singh, anburn
university
• attra.ncat.org/attra-pub/poultryprocess.html
• www.fao.org/docrep/003/t0561e/T0561E00.htm