By: Khaled Ali Ahmed

16R11A0446
ECE-3A
 Objectives

To know the prospects & potential of chicken

processing industry.
To learn the concept of feasibility study.
To know the processing of chicken.
To design & illustrate the layout.
To learn the necessary equipments & machinery.
To see its contribution in perspective to our economy.
 Introduction

Annual poultry production - 3206.33 lakhs.[2016, DLS]

Contribution of poultry meat to the total meat
production is 35.25%.[2]
Poultry meat – lean meat.
Versatile & acceptable.
Relatively cheap compared to other meat source.
 Products To Be Manufactured

Chicken Nuggets
Chicken Pops
Chicken Bullets
Chicken Patties etc.
 General Planning & Design

Planning.
Economics.
Management.
Location of Plant.
Facilities Required.
 Economics
Capital costs: Operating costs:
Land Personnel
Buildings Maintenance and spares
Plant and equipment Water and sewage
Installation Electricity
Contingencies Fuel oil
Working capital Packaging materials
Insurance
Location of Plant - Mirsarai

Economic zone.
Easy access to Dhaka-Chittagong highway.
Access to Chittagong Port through Outer Ring Road.
Export facilities.
Access to railway.
Sufficient amount of poultry farm.
Poultry Processing

• Primary Processing
• Secondary Processing
 Reception

Slaughtering Bleeding

Scalding &
Defeathering

Washing

Evisceration Giblet

Chilling

Cutting

Packaging

Figure: Block Diagram For Primary Processing of Chicken

 Raw Meat

Grinding

Mixing

Forming

Breader

Frying

Packaging

Freezing

Figure: Block Diagram For Secondary Processing of Chicken

Process Flow Diagram For Chicken Processing
 Process Flow Diagram For Primary Processing of Chicken[5]

5 6 8

14
13

2
3 17
4
12
1

9 15
11
10

16 16

Adapted From - Sample factory layouts: 800 birds per hour layout: Poultry Processing Equipment. [online]
1. Reception – Live Bird 10. Hock Cutter
Hanging 11. Leg Unloader
2. Blood Trough 12. Evisceration Trough
3. Scald Tank 13. Giblet Sorting Table
4. Plucking Machine 14. Giblet Chiller
5. Offal Pump 15. Screw Chiller
6. Offal Separator 16. Shackle Washer
7. Vacuum Transport 17. Cutting & Packaging
System
8. Maintenance Room
9. Head Remover
Technical Details For a Primary Chicken Processing System

Product Frozen
Plant type Semi-automatic
Kind of birds Broiler
Average live weight 1,500 Grams
Minimum live weight 1,400 Grams
Maximum live weight 2,000 Grams
Capacity per hour 800 Birds
Bleeding time 2 Minutes
Scalding temperature 60 °C
Scalding time 2 Minutes
Pre-chilling time 40 Minutes
[5]
Process Flow Diagram for Chicken Products
Cutting Table

Mincer
Mixer

Packaging
Table
Fryer

Mixer
Layout of Chicken Processing Plant
 Main Gate

Security
Post Parking
Common Pest Lot
Generator Machinery
Service Room Control
Room Repair Section
Room

Free Space

Administration
Building

Packaging Refrigeration
Non-meat
Washing Material Store Room
Ingredients
Room Room
Room

Processing Area
Cold Storage-1

Unit 2
Q.C Lab
Cold Storage-2
Unit 1

Blast Freezer
Waste Treatment
Specific Areas
Administration Building Processing Area
Quality Control Lab Washing Room
Pest Control Room Non-meat Ingredients
Common Service Room Room
Machinery Repair Section Packaging Material Store
Generator Room Room
Waste Treatment Refrigeration Room
Main Gate Cold Storage 1
Security Post Cold Storage 2
Parking Lot Blast Freezer
 Equipments & Machinery
Primary Processing Secondary Processing

Blood Trough Grinder

Scald Tank Mixer
Inline Plucker Former
Head Cutter Breader
Hock Cutter Fryer
Evisceration Tools Miscellaneous
Giblet Chiller
Screw Chiller
Shackle Washer
 Blood Trough Scald Tank

Inline Plucker Head Cutter Hock Cutter

Offal Pump Offal Separator Vacuum Transport

Machinery For Offal Management

Vent Cutter Neck Skin Cutter Lung Suction Gun

Evisceration Forks
Various Knives

Evisceration Tools
Giblet Chiller Shackle Washer

Screw Chiller
 COMBIgrind 280 (Grinder)

Main Benefits
• Meets the strictest hygiene requirements
• Available with bone elimination system
• Robust design
SPEEDmix Double shaft intermeshing mixing system
(Mixer)

Main Benefits
•Meets the strictest hygiene requirements in
the industry
•Automatic preset mixing programs and
manual control
•Inspection platform
 PlateFormer (Forming Machine)

Main Benefits
• Accurate portioning
• Wide variety of forms and products possible
• High capacity
• Easy changeover to new products
• User friendly operation
• Hygienic production process
 RotoCrumb (Breader)

Main Benefits
•Suitable for the processing of a wide
range of products with a wide variety
of crumb
•Excellent adhesion
•PLC controlled and operated by
touch screen
•Easy to clean
• A minimum of crumb in circulation
 GoldFryer (Fryer)

Main Benefits
• Uniform fried products
• Consistent high quality
• High production capacity
• Energy efficient
• Innovative oil management