3/4/2021 Livestock specialist: Operational Manual of Model Butchery in Pakistan

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Operational Manual of Model Butchery in Pakistan
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1 Introduction
▼ 2012 (3)
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Meat is an important source of protein in human diet. Traditionally beef and ▼ January (3)
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mutton are relatively more consumed as compared to poultry meat and fish. In the Operational Manual of Model
existing system, the marketing of beef and mutton starts from slaughtering of Butchery in Pakistan
animals in the abattoirs and in the backyard of butchery. Livestock Market study for
Development Projects in...
In Pakistan, Livestock is an important sub-sector of agriculture as it contributes Current Status of Meat Sector in
51.8 % of agriculture value added and 11% of the total GDP and affects the lives of Pakistan
35 million people in rural areas. Livestock sector contributes 9 % of total export
earning of Pakistan. During last two decades, dairy and commercial Poultry sectors
have shown significant growth over. However, there are some impediments in the Livestock Specialist
optimum productivity of animals for meat production, processing and marketing.
To enhance the quality meat production and processing there is need to establish
modern meat processing system with cold chain facilities to provide hygienic meat
for local and export markets.

Currently retail meat selling is made on conventional butcher shops where Muhammad Mohsin Kiani
Islamabad, Pakistan
traditional practices are followed. Animals are slaughtered early in the morning in
the nearby municipal slaughterhouses and are sold at the same day as fresh warm D.V.M (1st Div)2001 from SAU (Pak),
meat because no chilling facilities are available. At the most butcher’s shops the M.Phil (1st Div)2003 QAU
meat is sold out and business is closed by afternoon the same day. Generally beef (Pak),worked as research fellow in
NARC (ICT), Livestock Technical
(bara ghousht) and mutton (chouta ghousht) selling outlets are separate from one
Advisor (DDF), Livestock Development
another, but some butchers have recently started selling both types of red meat at
Officer (I-LED) USAID, Livestock
the same premises. Development Officer (Ministry of
Livestock and Dairy Development
Transport of the carcass is carried out by various means, like carrying on one GOP). Recently working as Livestock
person (head or shoulder), open horse carts, open donkey carts, bicycle handles, Coordinator (Concern Worldwide
motor cycles and by open / covered Suzuki motor vans etc. All such carriers INGO)Islamabad.
including vehicles are neither clean nor adopted for meat transport. The transport View my complete profile
operators (drivers / others) do not know and observe any hygienic principles for
food and perishable meat commodity. Butchery businesses are 99 % family related
businesses in Pakistan.

Traditional meat shops are sort of platform uncovered and open to all sorts of
contamination from air, unclean water supply , dirty walls and floors of the
premises. Highly dirty blocks of wood are used for chopping, cutting meat and
carcass parts to make stew/chops for customers. .The tools and utensils used are
dirty and the only machine used by common butcher for mincing of meat is
generally dirty and is a major source of contamination. The sold meat is packed in
all types of poor quality and non-food grade polythene bags. The only savior is the
harsh cooking method, which kills almost all bacteria and even hard-to-kill spores.

The traditional butcheries work 5 days week and sell out, mostly before noon’s peak
temperatures. These obviously are of small throughput selling about 10 to 20 small
and one to two large ruminant carcasses. Beef is slow moving product therefore;
traditional butchers usually maintain an affordable ice box or a freezer especially
for reasonably large quantity of beef mince, the preferred mode of beef
consumption by our large middle class.
In recent times as the price of mutton is increasing rapidly, the number of
butcheries selling both mutton and beef in the same premises in big towns and

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metropolitan cities. The disparity in mutton and beef prices is favoring significant
shift of consumers from mutton to beef and poultry.

In our traditional meat marketing system, there is no concept of value addition. With
changing socioeconomic status (particularly in urban areas), the living standards
and
eating habits are changing rapidly. Consequently, there has developed a niche for
quality and value added meat and meat products. This segment has been projected
to expand greatly and rapidly in the impending WTO regime, globalization affects
and socioeconomic progress However, the skilled manpower for this sector is
almost non-existent in Pakistan because there are no training programs on
butchery trade, meat cutting and processing in public or private sector
institutions.

Presently about 15.74 million small and 6.92 million large animals are being
slaughtered
annually (Pakistan Livestock Census 2006), but major portion of the byproducts is
going
in to waste due to lack of modern meat/ byproducts processing facilities. Some of the
major byproducts are as under.

Table 1 Major by-products of Meat

Byproduct Usage
Blood Rich source of animal protein for poultry feeding.
Only about 30% is being utilized.
Gut and Export item for cat gut. Sports. and sausages etc.
stomach etc. 30% is being utilized.
Glands Used in pharmaceutical, leather industries. 90% wastage
Fat Byproduct of more than 10 grades is available. Annually tallow/oil
worth Rs.2.7billion is being imported in to the county for
cosmetics/soap industry, despite slaughtering of about 20 million
small and 3 million large animals per annum.
Meat Meal Protein source for poultry feeding. In efficient utilization.
Skin and Hide Indigenous leather industries and export item, 40% value is
damaged due to poor processing system.
Bones (Allied DCP and gelatin
business)
Rumen Liquor Valuable material for livestock, pet feeding and composting etc.
Contents Presently all wastage.

There is a dire need for aggressive reforms and improvements in this area of retail
and wholesale marketing of fresh meat of good quality and better hygiene. Meat
Development Project has taken initiative to promote this trade through establishing
model butcheries in collaboration with private sector. Technical guidelines have been
made and cost for establishment of model butchery has worked out. It is concluded
that such type of project may set a model for the establishment of similar facilities in
all over the country.

2. Meat Composition, Types and Quality

The word meat comes from the Old English word mete, which referred to food in
general. Meat is mostly the muscle tissue of an animal.

2.1 Composition

Numerous aspects of the biochemical composition of meat vary in complex ways

depending on the species, breed, sex, age, plane of nutrition, training and exercise
of the animal, as well as on the anatomical location of the musculature involved.

Adult mammalian muscle flesh consists of roughly 75 percent of water, 19 percent

of protein, 2.5 percent of intramuscular fat, 1.2 percent of carbohydrates and 2.3

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percent of other soluble non-protein substances. These include nitrogenous
compounds, such as amino acids, and inorganic substances such as minerals.

Muscle proteins are either soluble in water (sarcoplasmic proteins, about 11.5
percent of total muscle mass) or in concentrated salt solutions (myofibrillar
proteins, about 5.5 percent of mass). There are several hundred sarcoplasmic
proteins. Most of them – the glycolytic enzymes – are involved in the the glycolytic
pathway, i.e., the conversion of stored energy into muscle power. The two most
abundant myofibrillar proteins, myosin and actin are responsible for the muscle's
overall structure. The remaining protein mass consists of connective tissue
(collagen and elastin) as well as organelle tissue.

Fat in meat can be either adipose tissue, used by the animal to store energy and
consisting
of "true fats" (esters of glycerol with fatty acids), or intramuscular fat, which
contains
considerable quantities of phospholipids and of unsaponifiable constituents such as
cholesterol.

2.2 Types of Meat

Meat can be broadly classified as "red" or "white" depending on the concentration

of myoglobin in muscle fiber.When myoglobin is exposed to oxygen, reddish
oxymyoglobin develops, making myoglobin-rich meat appear red. The redness of
meat depends on species, animal age, and fiber type. Red meat contains more
narrow muscle fibers that tend to operate over long periods without rest, while
white meat contains more broad fibers that tend to work in short fast bursts. The
meat of adult mammals such as cows, sheep, goats, and horses is generally
considered red, while domestic chicken and turkey breast meat is generally
considered white.

2.3 Nutritional value of meat

The meat, poultry, fish, beans, eggs and nuts group provides the needed protein for
the body to build and maintain all structural components of the body. No other
nutrient can be used for this purpose. Protein is also required to manufacture the
body’s hormones, enzymes and antibodies. This food group also supplies many
essential vitamins and minerals required by the body, such as B vitamins, iron and
zinc.

B vitamins are essential for the body’s ability to use the energy of food for the body’s
energy needs. B vitamins are also needed for growth and maintenance of both
nerves and muscles. Vitamin B12 is mainly sourced from meat products.

Beef and pork are good sources of iron. Iron is lacking in many diets of children and
in women of childbearing age. This deficiency results in tiredness, a shortened
attention span, poor appetite, and decreased resistance to infection. Iron found in
plants and eggs may be bound by phytates and oxalates, which limits iron
absorption into the body.

Zinc is a very important mineral and is involved in over 200 processes in the body.
For example, zinc is a component of the important hormone insulin. Like iron, zinc
is better absorbed into the body from meats than from plants.

As adults, all too often we eat too much meat, while 30 % of children and teens do
not obtain sufficient quantities of the meat group to meet their daily nutrient
requirements.

Pregnant women require more than the 7 oz (198 g) of meat a day to fulfill their 60
g a day protein requirement. A non-pregnant woman requires 44 - 50 g of protein a
day. To obtain 6 oz (170 g) of meat is not difficult. For example, a person may eat 1
egg for breakfast, 1 to 2 oz (28 - 57 g) of meat in a sandwich for lunch and 3 oz (85
g) of meat for dinner. Three oz (85 g) of meat is the size of a medium hamburger
patty, or half a medium chicken breast. An easy way to remember meat serving size
is “A deck of playing cards is about the size of a 3 oz (85 g) portion of meat.

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2.4. Quality of Meat

To the consumer an enjoyable meat eating experience is one that associates meat with being tender, juicy and
flavorsome. Consumer studies show that tenderness and flavor are the most important characteristics
determining the acceptability of meat. However, there is a wide range of other attributes that can potentially
influence acceptability of meat.

Visual appearance is very important in determining the likelihood of purchase.

Bright red in the case of beef and lamb is the desirable color of lean meat. The
amount of fat can also influence meat’s visual appeal.

2.4.1. Factors affecting meat quality

The key factors that affect meat quality have been intensively researched for the
production of consistent eating quality in beef, lean and tender lamb quality.

Age- there is clear differences in the attributes of meat from young and older
animals.
Breed – the observed differences from various breeds are small for cattle and sheep.
Gender – is a factor but modern production methods have reduced variability.
Fat content – marbling (intra muscular fat) can increase juiciness and flavor scores.
Diet – is an important factor in fat type, which in turn affects flavor.
Production systems and pre-slaughter handling – the avoidance of stress in
the live animal is important in livestock production, during transport and when the
animal enters the abattoir before slaughter it can cause dark, firm and dry meat
affecting both tenderness and flavor.

Tenderness There are a number of factors that can influence the tenderness of
meat

Chilling conditions – Rigor mortis (the stiffening of the carcass) occurs naturally
following slaughter. Muscles shorten as they go into rigor and the pH of the muscle
(measure of acidity or alkalinity) falls. The amount of muscle shortening affects the
meat’s tenderness.
If carcasses are enter rigor mortis below 10-12°C, ‘cold shortening’ of the muscle
fibers can occur, causing toughness and preventing tenderization through ageing.
Cold shortening is a problem where rapid chilling systems are used, particularly for
sheep carcasses where the low volume of meat means the muscle cools very rapidly.
Similarly, if carcasses enter rigor mortis above 20°C, ‘hot shortening’ occurs. The
reduction in tenderness is not as appreciable as in cold shortening.

Electrical Stimulation – The application of an electric current to the carcass

following slaughter reduces the pH of the muscle more quickly and hastens the onset
of rigor mortis. Not only can it prevent cold shortening, it can result in early
tenderization.

Hanging – The method of carcass suspension influences the degree of tension

which muscles are under when rigor mortis occurs. Suspending lamb and beef
carcasses from the hip rather than by the Achilles tendon, allows the commercially
more important muscles of the carcass to be stretched, thus improving tenderness. In
beef, correct hanging is more beneficial to meat tenderness than electrical
stimulation.

Ageing (or maturation) – ageing occurs as enzymes present in the muscle break
down proteins post-slaughter. Carcasses are held in refrigerated storage for varying
periods to improve tenderness. The rate of ageing varies by species and by cut.

Flavor Flavor is the combined result of the taste and smell senses and because it
is a subjective property, is difficult to evaluate. Each species has its own
characteristic flavor. The flavor of meat can be influenced by the diet of the animal.
Grass or forage-fed cattle and sheep tend to produce meat with a more intense
flavor than grain-fed animals. Grass-feeding increases certain polyunsaturated fatty
acid concentrations in the muscle and improves flavor.

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Color Color is a major influence on the visual appeal of meat rather than on
quality. The color of meat is primarily dependant on the concentration and
chemical state of the pigment myoglobin, which is responsible for moving oxygen
through the muscle. The amount of myoglobin varies widely between the species,
which accounts for the marked differences in color between their meats. The type of
packaging used at retail and thus the amount of oxygen to which the meat is
exposed, influences the meat’s color and appeal to the customer

3 Hygiene and Sanitation

Hygiene

Hygiene came from the Greek word “Hygienos” which means healthy, clean and
sensible; often equated with “cleanliness”.

Sanitation

Sanitation is the reduction of contamination with foreign matter including

micro-organism to a level harmless to health.

3.1 Meat contamination and its sources

3.1.1 Microbial (biological)

Bacteria
· Fungi
viruses
Parasites

Contamination by bacteria is the greatest threat to food safety. Under ideal

conditions bacteria can multiply by dividing into 2 every 20 minutes; in this way a
single bacterium could increase to 2,097,152 within 7 hours.

What bacteria need to grow?

Bacteria can live any where a human can live. Infact, they can even survive extreme
temperature better than people. Generally, bacteria live well in potentially
hazardous foods because these foods are often warm, moist, protein rich, and
neutral or low in acid.

These conditions can be remembered by the acronym FAT-TOM:

F (Food) - although different types of food poisoning bacteria can live on a range of
food, most bacteria prefer something that is moist, and high in protein. These foods
are prone to bacterial growth even if they are cooked and served cold later.

A (Acidity) - acidity is measured on a scale from 0 (very acidic) to 14.0(very

alkaline, basic). A solution with a pH (acid-alkaline measurement) of 7.0 is neutral.
Most potentially hazardous foods have a pH level between 4.6 and 7.0. However,
high acid foods, such as citrus fruits, rarely allow the growth of harmful bacteria.
Adding vinegar or lemon juice to food items will help slow bacterial growth- but it
does not ensure control and should not be used as the only defense against bacteria
growth.

T (Time) - highly perishable foods should not remain in the temperature danger
zone for more than four hours during the entire food handling process.

T (Temperature) - the temperature danger zone for potentially hazardous food is

4.4C to 60C (40F-140F) However, since bacteria can survive at (and some bacteria
can grow at) lower temperatures, refrigerating food is not protection against
bacterial growth. Discard food if it is past expiration date.

O (Oxygen) - some bacteria require oxygen to grow, while others require no oxygen.
However, most of the bacteria that cause food borne illness can either grow with or

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without oxygen.

M (Moisture) - the amount available water in food is called water activity(Aw). The
lowest water activity (Aw) at which harmful bacteria can grow is 0.85. Most
potentially hazardous foods have water activity values of 0.97-0.99, which is ideal
for bacterial growth. Water activity can be reduced to safe level by freezing,
dehydrating (removing the water) adding sugar, salt, or cooking. Dry foods such as
beans and rice, become potentially hazardous when water is added.

Table Bacteria causing food poisoning

Bacteria Types of
Description Habitat Cause
Responsible Foods
Staphylococc Produces a heat- Nose and throat of Meat and Poor personal
us aureus stable toxin 30 to 50 percent seafood salads, hygiene and
of healthy sandwich subsequent
population; also spreads and temperature
skin and high salt foods. abuse.
superficial
wounds.
Salmonella Producesan Intestinal tracts of High protein Contamination
intestinal animals and man foods - meat; of ready-to-eat
infection poultry, fish foods,
and eggs. insufficient
cooking
Clostridium Produces a dust, soil and Meat and Improper
perfringens spore and gastrointestinal poultry dishes, temperature
prefers low tracts of animals sauces and control of hot
oxygen and man. gravies. foods, and
atmosphere. recontamination
Live cells must .
be ingested.
Clostridium Produces a Soils, plants, Home-canned Improper
botulinum spore and marine sediments foods. methods of
requires a low and fish. home-
oxygen processing
atmosphere. foods.
Produces a heat-
sensitive toxin.
Listeria Survives adverse Soil, vegetation Raw and Contaminated
monocytogen conditions for and water. Can uncooked raw products.
es long time survive for long meat,Milk, soft
periods. periods in soil and cheeses,
plant materials. vegetables
fertilized with
manure.
Campylobacte Oxygen Animal reservoirs Meat, poulty, Improper
r jejuni sensitive, does and foods of milk, and pasteuriztion or
not grow below animal origin. mushrooms. cooking. Cross-
86o F. contamination.

Enteropathog Can produce Feces of infected Meat and Inadequate

enic E. coli toxins that are humans. cheeses. cooking.
heat stable and Recontaminatio
others that are n of cooked
heat-sensitive. product.

3.1.2 Chemical

Pesticides.
Excess preservatives and additives

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Toxic metals

These are chemicals like pesticides, food additives and preservatives, cleaning
supplies and toxic metals that leech through worn out food wares and equipment.

3.1.3 Physical

Filth- human, insects, rodents.

Foreign matters
Other objects.

Physical hazards are foreign matters such as dirt, metal strips, wood splinters,
broken glass, bone fragments and other objects that accidentally get into food

3.2. Hygiene of Manpower at Butchery

People are common source of pathogenic bacteria, so everyone who works with food
must have the highest possible standards of personal hygiene and personal habits to
avoid contaminating food.

3.2.1 Personnel hygiene

1 Control of disease

A healthy food handler means he is free from:

Disease of the respiratory tract-cold, sore throat, pneumonia and
tuberculosis (TB).
Intestinal disorder-typhoid fever, infectious hepatitis and diarrhea.
Skin disorders- sores, abrasion, lesions, infected ears, boils, scabies and
severe rashes.

Requirements

Pre-employment physical/ medical examination.

Regular medical check-up when employed.
Manager/supervisor should monitor health condition of employees.
Employees should report any illness to supervisor.

Goal Employee health condition should not contribute to food contamination.

2 Attire/ Clothing for Staff

Hair restraint or hair nets.

Apron and uniform. Avoid use of buttons, zipper for aprons/gowns
No pencils or cigarettes in pockets.
Foot wear (gum shoes)
Face mask and gloves

Goal Wearing the prescribed attire will prevent cross contamination.

3 Habits/Workers personal Hygiene

Take a bath daily.

Use an effective deodorant
Shave as needed
Well trimmed nails
Wash and sanitize hands as needed
No eating, smoking, drinking and spitting in the processing area.
Wash hand after sneezing, coughing, scratching, or touching any body
part.
Try to catch sneeze with your elbow.
Do not use teeth as a package opener.
Never blow air by breathing into plastic bags.

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Proper hand washing

· It is very simple practice , but a very powerful food safety tool

· It has been referred to as first step to food safety.
· It helps to prevent cross contamination.

How to wash your hand

Turn on water
Wet your hand
Add soap and lather hands, including the backs, wrist, and up to elbow.
Wash each finger and scrub for 30-60 seconds.
Rinse hands under running water.
Sanitize the hands.
Dry hands with air dryer, or other sanitary hand drying device.
Turn off water using paper towel.
Check hands and finger nails are clean.

When to wash your hands

On arrival at the workplace before starting the work.

After going to toilet.
After handling garbage/container.
After scratching or touching reservoir areas of the body.
Before resuming work.
Before handling cooked or ready to eat foods.
After handling raw foods.
After smoking.
After handling money.

4 Education and training

Appropriate training for expected performance.

Awareness on role/ responsibilities regarding food safety.
Effectiveness of training by evaluation.
Use of signs, poster as reminder.

3.3 Cleaning and sanitizing of Premises

Cleaning is the process of making something free from dirt and

contamination. Detergents help to dissolve grease and remove dirt.
Sanitizing is the reduction of bacteria to low, safe level using different
methods.

3.3.1 What to clean and sanitize

Food contact surfaces.

Hand contact surfaces.
Production areas.

3.3.2 When to clean and sanitize

· Clearing and cleaning up immediately after every task.

3.3.3 Stages of wet cleaning sanitizing

· Pre-clean, remove loose and heavy soiling.

· Main clean, wash with hot/tap water and detergent.
· Rinses, remove any traces of detergent and food particles with clean
hot/tap water.
· Disinfection, use chemical, disinfectant; make sure to leave it on for
the correct contact time.

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· Final rinse, use clean hot/tap water.
· Dry.

3.3.4 Assessment of the cleaning procedure

No Visible dirt.
No greasy or gritty feeling when rubbed.
No off-odor.
Wetting test: no excessive water break.
Microbial assessment.

3.3.5 Cleaning agents

Detergents.
Solvent cleaners or degreasers.
Acid cleaners.

3.3.6 Sanitizing agents

Heat sanitizing.
Chemical sanitizing.

3.3.7 Factor that influence chemical sanitizers

Contact time, usually one minute.

Selectivity.
Concentration.
Temperature.

3.3.8 Benefits of proper cleaning

Minimum product rejection, returns, complaints.

Increase product shelf life.
Reduce risk of involvement in food poisoning.
Facilities preventive maintenance.

Chlorination Levels as a sanitizer for the following areas of concern:

Hand dip 20-30 ppm

Foot bath 250-350 ppm
Floor 250-350 ppm
Equipments 150-200 ppm
(Ppm- parts per million)

3.3.9 Pest control

Basic rules
Good housekeeping and keeping premises clean.
Keeping a lookout for vermin.
Keeping them out.
Use only professional pest controllers.

3.4 Cleaning and Sanitizing of Equipment

3.4.1 Hygiene and sanitation requirements

The highest level of hygiene is required in meat retailing outlet.

Meat can easily be contaminated by

Germs (found in equipment, clothes and bodies)

Moulds.

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Chemicals
Viruses
Dirt
Foreign objects

Contamination will affect the appearance of the meat. Some forms of contamination
may cause illness or even death. Most germs that contaminate food come from
hands, the surfaces and equipment used in processing transport and storage.

All knives and other personal equipment, including clothing, can carry germs and
may cause contamination. It is your responsibility to make sure that every thing
use, touch, prepare and sell is clean and free from contamination

3.4.2 Cleaning and sanitizing procedures

Cleaning and sanitizing are two step processes which aim to control contamination
by eliminating or reducing the presence of germs on the equipment that meat
handler use.

a Cleaning

Cleaning is the first step in this procedure. It is the process of removing dirt and
grease from surfaces. Cleaning could remove all soil and foods build up on
equipment surfaces but it does not guarantee the elimination of germs.
Detergents are substances that lift grease and dirt but do not destroy germs and
their spores.

b Sanitizing

Sanitizing is the second step. It kills most kinds of germs. Different sanitizing
methods include:

Steam or very hot water (80C or above).

Chemicals

Sanitizers are chemical substances specifically produced for the food processing
industry, which are used to kill germs.

a Steps to clean and sanitize

Six steps that should follow when cleaning and sanitizing the equipments.

I Remove solid particles on the surface of the equipments.

II Wash with water, use detergent and hot water (if necessary) to remove the
grease.
III Rinse well with tap water.
IV Sanitize with an approved sanitizer.
V Rinse with clean tap water.
VI Dry tools carefully with a clean dry cloth or air dry.

3.4.3 Chemicals and hazardous substances

When working with chemicals or hazardous substances, it is important to know:

Which chemical you are using.

How to use, handle and store each chemical according to manufacture’s
specification.
What to do when an accident occurs.

Use all chemicals according to manufacture’s specifications.

Wear protective clothing when using chemicals, do not mix chemicals.

4 Establishment of Model Butchery

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A butchery is a place for marketing of fresh, clean and wholesome fresh

meat. Fresh meat is high protein rich food for micro-organisms and can be

spoiled easily. It is highly perishable and expensive food commodity, having

short shelf-life. So, any kind of negligence or lapse in the display, handling

and marketing can lead to spoilage and ultimate wastage of meat. So,

inappropriate handling of fresh meat, at any stage after slaughter, can bring

financial loss to the business.

4.1 Model Butchery

This type of meat shop would be the state of the art for a modern butchery for
installing in big mega cities like Karachi, Lahore, Islamabad, Multan, Peshawar,
Quetta and other similar places. Such butchery would install latest chilled/
refrigerated sale outlets along with the incorporation of the benefits of the latest
scientific developments in the field of retail meat marketing any where in the
world. It will look like as a part of a global order like any other franchise food
outlets of KFC, McDonald, and Pizza Hutt etc. One can see such butcheries
ushering up in Asian mega cities of India, Malaysia, Thailand etc and they are
bound to start here in Pakistan in the near future.

Starting a modern high tech butchery even in big cities, sometimes may not be a
successful business in all areas. So, selection of a suitable site in posh organized
localities of cities for such modern openings must be evaluated carefully and
critically. In fact the high-tech modern butchery causes a value addition to the
same meat being sold in other low tech butcheries elsewhere.

One has to handle and exercise care for the meat in this category from the stage
of slaughter to the stage of consumer’s home and even storage. Strict hygienic
controls in slaughtering, dressing transport and in storage house and butcher
display shop are the hallmark of its retail exposure. Exercising proper
temperature control is critical as it is related to the shelf life of fresh meat. The
whole sequence requires high level of precision management. One can even
obtain HACCP (Hazard Analysis for Critical Control Points) certification for the
promotion / high ranking of the outlet in the market.

4.2 Equipment for Model Butchery

Following equipments are used for model butchery.

1 Meat Band Saw

Band saw is used to cut the mutton and beef carcass into steak and stew according
to the choice of the client. It is fast and time saving equipment. Block man
(butcher) must be expert to run the band saw otherwise it will injure the person, cut
the carcass when it is chilled. Red and green switches are there on out side of the
band saw, which are used to switch off and switch on the
cutter.
2 Meat Grinder

Grinder is used for mincing of meat. It reduces handling and processing time. It
increases the yield, improve particle size, and reduce the bacterial account.

3 Display Unit

Display unit is used to keep the meat cuts for retail in the butchery. So that the meat
remains fresh and customer can buy good quality meat of their choice. Its
temperature
should be maintained at 0C to 5C.

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3 Chiller

Chiller is an important component for modern butchery. It is used to chill the

carcass in the butchery for hygienic reason. It improves the product quality
(juiciness, tenderness and flavor).
Chiller also reduces the microbial growth from the carcass. Its temperature should
be maintained at 0 C to 5 C. Its function is to keep down the carcass temperature.
It is made of sandwich sheet around 120mm, 150mm thickness.

5 Butchery Hooks

Butchery hooks are used to hang the carcass. It is made of food grade stainless
steel.

6 Weighing Balance

Weighing machines are used to scale the product at the shop. Two type of weighing
machines are used at the shop One is industrial computerized scale which can
weight up to500 kg
one time. It is made of stainless steel and hooks are there on the top to hang the
carcass, and its digital screen is fixed on the wall to see the weight. Other type of
scale is used
at the shop for retail customers. It can weight 15-20 kg.

7 Knives

Knives are used for cutting and trimming of meat. It is sharp and made of stainless
steel. Different type and size of knives are used at the butcher shop.

8 Chopping Board

Chopping board is made of food grade plastic. It is 4-6 inch thick. It is used for
cutting and trimming of meat with the help of knife.

9 Air Curtain

Air curtain is used to control the ouseflies enter In he shop.It fixed on top of the door at the
butchery . In the air cutter blades moves with high speed to control the flies enter in the
butchery.

1
0
.
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t
a
i
n
l
e
s
s
S
t
e
e
l
T
a
b
l
e

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Food grade stainless steel table is used to keep the meat on it for further procedure
i.e. cutting etc.

11 Stainless Steel Trays

Stainless steel food grade trays are used for the handling of meat and its products
.These trays are used to display the meat in the chiller.
Geyser

Geyser is used to warm the water for hygienic cleaning of equipments and floor.

13 Sterilizer

Sterilizer is used for the sterilization of knives. In this process fill the sterilizer with
water and
warm the water at 60 C, then keep the knives in it for
sterilization.

14 Meat Scrapper

Meat scrapper is used for the trimming of fat from carcass.

15 Patty Making Machine

It is used to make patties according to mold size.

16 Clipping Machine

Clipper is used for quickly, safely closing small packaged, poly bagged, chub or
netted
product.

4.3 Cost Estimates of Butchery Equipments

Table 3 Equipment Cost Estimates (Model Butchery)

Sr.N Items/ Quantit Unit cost Average Total Cost

o Equipment y (Rs) Estimate (Rs)
d Per Per
Unit
Cost (Rs)
1 Walk in 1 450,000- 550,000 550,000
chiller(8’X8’X 650,000
8’)
2 Display unit 3 112,000- 157,500 472,500
203,000
3 Up right 2 158,000- 209,500 419,000
chiller 261,000
4 Meat band 2 61,900- 144,340 288,680
saw 226,780
5 Meat Grinder 1 32,500- 58,750 58,750
85,000
6 Meat slicer 1 33,600- 49,300 49,300
65,000
7 Wrapping 1 30,000 30,000 30,000
machine
8 Air curtain 1 15,500- 25,250 25,250
35,000
9 Weighing 2 15,000 30,000 30,000
balance

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10 Stainless steel 2 25,000 50,000 50,000

table (5’X2.5’)
11 Knives/ meat 15000 15000
chopping
devices
12 Air 2 ( 1.5 32,000- 38,500 77,000
conditioning tons 45,000
system capacity
each)
Total cost 1,358,14 2,065,48
0 0
4.4 Source of Butchery Equipments

4.4.1 National Supplier

1 Anis Ahmed & Brothers

18- Zamindar Building Campbell St. Karachi

. Tel.021-4536348, 4545912

2 Standard Equipment Company

7-S, Rafi Centre,
30 Abakri Road
New Anarkali, Lahore Tel.042-7231168

3 Kold kraft (pvt) Ltd

247 S, Industrial Estate Kot Lakhpat, LahoreTel.042-5116727-8, 0300- 8451947

4 Dastgir Engineering Co.

12-A,
Lahore Road
, Saddar Lahore Cannt, Lahore Tel.042-6665140,

5 Iqball Engineering Company Gulber Road Lahore

, Tel.042-5710091, 5716626.
6 Ghosia Cooloing Center

Haji street, near shezan Factory,

Bund Road, Lahore
Tel. 042-7414109

7 Technology international
P-29, street # 5-6 Main Talan Walal road, Rahman colony 124J B, Marzi Pura
Faisalabad, Tel.041-2695761

8 Mughal Electric and Machinery Store

62—
Beadon Road, Lahore
Tel.042-6361122

9 Brotherhood
2-S, Rafi Centre,
30- Abkari Road
, New Anarkali, Lahore. Tel.042-6146215

4.4.2 International Suppliers

1 Meat Grinding and Processing Equipment

1604 N. Hwy 14,Aurora NE 68818,USA
Tel. 0800-321-1073 Email:< [email protected].

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2 Food Equipment Australia Limited

Unit 2/8,
Furnis Road
, Landsdale 6065, Western Australia, Australia.
Tel. 00-61-8 9302 2255, Fax 00-61-8 9302 2555

3 Centurion International Corporation

1345 – West State Road 47, Lebanon,Indiana 46052 USA.
Tel. 765-483-0170. Email:<sales#centurionequipment.com
Company Phone Website address
name Fax E-mail address

+31 544 390500 http://www.stork-mps.com

Stork MPS BV
+31 544 375255 [email protected]

Attec Danmark +45 74 407644 http://www.attec.dk

A/S +45 74 407929 attec@attec.

+45 59 450450 http://www.butina.dk

Butina ApS
+45 59 450457 [email protected]

Daanen
+31 485 322952 http://www.daanenpoultry.nl
Import/Export
+ 31 485 330818 [email protected]
Bedr.

Duram Rubber +972 9 7474458 http://www.duram.co.il

Products +972 9 7474479 [email protected]

Tel. +48 (52) 583-95-

Wamma Poland,
27
Bydgoszcz,65-
Fax.+48 (52) 583-95- e-mail: [email protected]
391, ul.
24 www.wamma.pl
Tamawska 1,
Mr.Tomasz Sitarski
Poland.

Meat Processing
Systems,Albert
Schweitzerstraat
Tel.+31 544 390 500
33, www.mps-group.nl
Fax +31 544 375 255
AD 7130
Lichtenvoorde,
The Netherlands

4.5 Modern Butcheries in Pakistan

1. Qureshi Fresh and frozen

F 10 markaz, Kashmir Plaza,
Islamabad
Ph# 0333-5140833

2. Qureshi Fresh Frozen Foods

Kohsar Market, F6/3, Islamabad
Ph# 051-2822275

3. Veal Butchery
G-11 Markaz, Islamabad
Ph# 051-2830232
4. Gulraiz meat mart,
Gulraiz gate#3, Rawalpindi
Ph# 03335253900

5. D-Mart Naheed store,

Bank Chourangi, Bhawadarabad, Karachi.
Ph# 0346-2396460

6. Aghaz Super Market

Clifton, Karachi

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Ph# 0300-3756932

7. Ideal Mart,
Bhadar Commercial street, phase V, DHA Karachi.
Ph # 0345-2431612

8. Mandi Fresh,
Shop # 5, Bhaddar Commercial Area, DHA Karachi.
Ph # 0300 8266004.

Zenith Meat

9 Model Town,
Link Road, Lahore
Ph# 042-5942352

10 ohar Town, Lahore

Ph# 042-5290415

11 Allama Iqbal Town, Lahore

Ph# 042-5431441

12 DHA, Y Block, Lahore

Ph# 042-5090394

13
M. M. Alam Road, Lahore
Ph# 042-5431551

14 Rizwan Garden, Lahore

Ph# 042-2730095

Al-Hilal Meat

15 249-A, Ayubia Market, New Muslim Town, Lahore

Ph# 042-5838627
16
Tajpura Road
, Shadbagh, Lahore
Ph# 0322-4796598

17 SB Super Store, D Ground, Faisalabad

Ph# 0300-7625625

18 E. Mart,
Main Susan Road, Faisalabad

19 Al. Fateh Super Store,

Main Jaranwala Road, Faisalabad

Jan Shopping Arcade

20 Sadar Peshawar
Ph# 091-5270364

21 Ishrat Cinema, Gulbhar, Peshawar City

Ph# 0300-5902068

22 Azad Mega, Azad Chowk,

Mirpur, AJK

23 Select & Save,

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Mian Mohd Road
,
Mirpur, AJK

24 Hanif Beef & Mutton Shop,

Mian Mohd Road
,
Mirpur, AJK

5 Meat Cuts
5.1 Cuts of Beef
Beef is a meat derived from dressed carcasses of bovine animals. It may be
derived from male, female animals or from steers. Dressed carcass means a
carcass from which the skin, head, developed mammary glands, and the feet
have been removed.

Beef carcass is divided into two major portions i.e. fore quarter and hind quarter.

5.1.1 Fore Quarter

It represents approximately 52 percent of the carcass weight and 31 percent of the

live weight. The fore quarter is composed of five wholesale cuts i.e. chuck, Ribs,
brisket, shank and plate

5.1.1.1 Chuck

Means the portion of the front quarter which is separated from ribs, plate, brisket
and shank by
two straight cuts at right angle to each other. First cut passes between the 5th and
6th rib
and separate the chuck, brisket and shank from the rib and plate .The second cut
pass at
a point slightly above the elbow joint and through the cartilaginous juncture of the
first rib and sternum, and separate the chuck from the brisket and shank

5.1.1.2 Rib

Means the portion of front quarter which is separated from the chuck and brisket
by
a straight cut passing between 5th and 6th rib and from the plate by a straight cut
passing
across the ribs at a right angle to the first cut at a point slightly below the centre of
the rib cage.

5.1.1.3 Plate

Means that portion of the front quarter which is separated from the chuck and
brisket by a
straight cut passing between the 5th and 6th rib and from the rib by a straight cut
passing
across the ribs at right angles to the first cut at a point slightly below(ventral to) the
centre
of the rib cage.

5.1.1.4 Brisket (Brisket Point)

Means that portion of the front quarter which is separated from the plate by a
straight cut
passing between the 5th and 6th rib, from the chuck by a cut at a right angle to the
first cut
passing at a point slightly above (dorsal to) the elbow joint and from the shank by a
cut

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which follows the natural contour of the bone.

5.1.1.5 Shank (Fore shank)

Means that portion of the front quarter which is separated from the chuck by a cut
passing at a point slightly above the elbow joint and from the brisket by a cut which
follows the natural seam of the elbow bone.

5.1.2 Hind Quarter

Means the posterior portion of the beef side which is separated from the front
quarter by
a cut passing between the 12th and 13th rib. The hind quarter composed of three
whole
sale cuts (the round, loin and flank) represents approximately 48 percents of the
carcass weight
and 29 percent of the live weight. The hind quarter is composed of three wholesale
cuts i.e.
flank, loin and round.

5.1.2.1 Flank

Means that portion of the hind quarter which is separated from the loin by
a
straight cut passing approximately parallel to the lumbar back bones
(lumbar vertebrae beginning in close proximity to or through the flank
lymph node and from the plate by a cut passing between the 12th and 13th
rib and cartilage.

5.1.2.2 Loin (Long Loin)

Means that portion of the hind quarter which is separated from the flank from the
sirloin
and from the hip by a cut which passes in front of the rump knuckle bone thereby
cutting the
pelvic bone into approximately two equal parts. The loin composed of two whole
sale cut.
5.1.2.2.1 Short Loin

Means the anterior portion of the loin which is separated from the sirloin by
straight cut which passes at a point immediately in front of the pin
bone.

5.1.2.2.2 Sir Loin

Means the posterior portion of the loin which is separated from the short loin by a
straight cut which passes at a point
immediately in front of the pin bone.

5.1.2.3 Round (Full Round)

Means that portion of the hip which is separated from the rump from the sirloin
tip by a straight cut which passes at a point in front of the shaft of the leg bone
and from the heel of round by a straight cut which passes through the base of the
shaft of the leg bone. The cut may extend into the
rump.
5.2 Cuts of Mutton

Mutton

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Means the meat derived from a dressed carcass of an ovine animal. Dressed Lamb
carcas means the carcass of a lamb from which the skin, head and feet at the carpal
and tarsal joints have been removed and the carcass has been eviscerated.

5.2.1 Front Half

Means the anterior portion of the dressed lamb carcass which is separated from the
hind half by
a cut following the natural curvature between eleventh (11th) and twelfth (12th) rib.
The front half is composed of these cuts.

5.2.1.1
Lamb Shoulder Square
Cut Whole

Lamb shoulder square cut whole is a square-shaped cut containing arm, blade, and
rib bones.
The thin paper like outside covering is called fell.

5.2.1.2 Lamb Shoulder Blade Chops

Lamb shoulder blade chops are cut from the blade portion of shoulder and contain
part of the blade bone and backbone.

5.2.1.3 Lamb Shoulder Arm Chops

Lamb shoulder arm chops are cut from the arm portion of shoulder and contain
Cross-sections of round arm bone and rib bones.

5.2.1.4 Lamb Shoulder Neck Slices

Lamb shoulder neck slices are cross-cuts of the neck portion containing small
round
bone. lean meat is interspersed with connective tissue.

5.2.1.5 Lamb Breast

Lamb breast is part of the forequarter and contains ribs. It is oblong-shaped with
layers of fat and lean, with fat usually covering one of the sides.

5.2.1.6 Lamb Breast Rib lets

Lamb breast rib lets are cut from the breast and contain ribs with meat and fat in
layers. The cuts are long and narrow.

5.2.1.7 Lamb Shank

Lamb shank is cut from the arm of shoulder, contains leg bone and part of round
shoulder
bone, and is covered by a thin layer of fat and fell (a thin, paper like covering).

5.2.1.8 Lamb Rib Chops

Lamb rib chops contain backbone and, depending on the thickness, a rib bone. The
chops have a meaty area consisting of rib eye muscle. The outer surface is covered
by fat but with the fell
(a thin, paper like covering) removed.
5.2.1.9 Lamb Rib Crown Roast
Lamb rib crown roast is cut from half of the rib. The rib bone is trimmed one to
two inches from the end. The ribs are curved and secured to resemble a crown
when the roast rests on the backbone.
5.2.2 Hind Half

Means the posterior portion of the dressed lamb carcass which is separated from
the

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front half. The hind half is composed of these cuts

5.2.2.1 Lamb Loin Chops

Lamb loin chops contain part of the backbone. Muscles include the eye of the loin
(separated from the tenderloin by T-shaped finger bones) and the flank. Kidney fat
is on the top of the tenderloin, and the outer surface is covered with fat, but with
the fell (a thin, paper like covering) removed.

5.2.2.2 Lamb Leg Sirloin Chops

Lamb leg sirloin chops are cut from the sirloin section of the leg and contain
backbone
and part of the hip bone, which vary in shape. Muscles include the top sirloin,
tenderloin, and
flank. there is fat on the outside, but the fell (a thin, paper like covering) is
removed.
5.2.2.3 Lamb Leg Whole

Lamb leg whole contains the sirloin section with hip bone and the shank portion
with round bone. The outside is covered with fell (a thin, paper like covering).

5.2.2.4 Lamb for Stew

Lamb for stew consists of meaty pieces of lamb with a small amount of fat, cut into
one to two-inch squares.

Ground Lamb

Ground lamb contains lean meat and trimmings from leg, loin, rib, shoulder, flank,
neck, breast,
or shank. It is mechanically ground and sold in bulk

Posted by Muhammad Mohsin Kiani at 05:00

1 comment:

Anonymous 7 March 2016 at 09:45

Hi,

I came across your interesting blog on meat processing and methods.

I am in USA and I recently bought farm chickens that are referred as "heritage
chicken" here, just as we call them "desi chicken" in Pakistan. The chicken's were
hand slaughtered in a chicken cone, hung upside down. Chickens were no let loose
in a box to flap wings. Chickens were put in hot water before cleaning the feathers.

One of the chickens we cooked the same night was so stiff that we could not even
break or chew the meat, even though we kept it in refrigerator for a couple of hours.

I understand rigor mortis occur to the meat but my question is, why the chickens
purchased from a butcher shop in Pakistan do not seem to have any stiffness and is
skinned off so effortlessly?

Thank you.
Akhter
Reply

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