FEASIBILITY REPORT ON

SEEKING ALLOTMENT OF LAND

IN DP ANANTHAPURAM,

KASARAGOD FOR SETTING UP A

UNIT MANUFACTURING

CHICKEN MEAT MEAL OUT OF

CHICKEN WASTE

PROJECT REPORT

INTRODUCTION
 THE PROMOTER

MARKET POTENTIAL

PROJECT DETAILS

PROPOSAL
 PROJECT PROFILE

PROJECT FEASIBILITY REPORT TO OBTAIN LAND AT DP ANANTHAPURAM,

KASARAGOD TO SET UP A UNIT OF MANUFACTURING CHICKEN MEAT MEAL

Name of the unit :

Proposed location of the unit :

Name of the Promoters : 1

Experience of the Promoters : For over 10 years
Major Machinery :
Line of activity : Manufacture of chicken meat meal

Total cost of project : Rs.90,00,000/-

 INTRODUCTION

Rapid urbanization and industrial diversification has led to generation of

considerable quantities of municipal, plastic, hazardous and biomedical waste.
Improper disposal of waste often results in spread of diseases and contamination of
water bodies and soils. The impacts of these wastes on the economy cannot be
ignored and managing them has become a major problem. Under the provisions of
the Environment Protection Act, 1986, the Government of India has brought into
force the Hazardous Waste Management Rules, 1989, the Biomedical Waste
(Handling and Management) Rules,1998, the Recycle Plastics (Manufacture and
usage Rules), 1999, the Municipal Waste (Handling and Management Rules), 2000
and so on. In Karnataka, amongst the 3 types of waste generated in 2012, the
largest amount is the is the Municipal Solid Waste at 39,64,950 metric tonnes
followed by hazardous and other wastes.

MUNICIPAL SOLID WASTE

As regards Municipal Solid Waste, on an average 40 to 50 oercent of the total

municipal waste is generated in the SIX Municipal Corporations of Karnataka and
more than 70 percent of Municipal Waste is generated by the residential and
market areas. The domestic waste generated by households comprises mainly of
organic, plastic and paper waste and small quantities of other wastes. While plastic
and glass waste are segregated and collected by rag pickers, remaining waste is
disposed in community bins. Though door-to-door collection of waste were
introduced in Mangalore, Bangalore, Mysore, etc, municipal solid waste is still
disposed off through community bins.
SLAUGHTER HOUSE WASTE

Karnataka produced 1,78,920 metric tons of meat in 2012 with Bangalore

contributing to 20% of production. The meat processing operation consists of
slitting and bleeding, deskinning, evisceration, cleaning and carcass washing which
are all water consuming. The waste generated consists of dung, blood, hair,
condemned parts, skin pieces, fat paunch manure and waste water. Though the
wwastes from slaughter houses came under purview of the Municipal Waste
(Handling and Management Rules), 2000, it is important to note that the waste is
similar to bio-medical wastes in terms of its infectious and bio-hazard nature.

The wastes and waste water is highly infectious and safe treatment is necessary.
In Mangalore stipulated environmental requirements are not adhered to by the
slaughter houses. The stipulated effluent treatment plant is either not installed or
does not operate efficiently. The effluent contain blood, fat, intestinal contents and
pieces of inedible contents which put a high load on the effluent treatment plant
and are therefore many times let into the underground drains.

In Mangalore and other Corporation, waste is dumped in open sites outside the
cities since many years and till now no cities have and engineered landfill with total
recycling system to dispose the non-recyclable municipal wastes. The dumpsite of
Mangalore is only at one location 15kms away with 70 acres of dumpsite which is
always over flown.

The Municipal waste also gets mixed with other wastes such as plastic, chemicals,
etc and turns hazardous causing serious diseases.

Thus, the Promoter who has already installed a unit at Kasaragod District in Kerala
to collect the chicken waste and process it into animal feed, proposes to install a
similar unit at Mangalore in Karnataka to support the cause for waste management.
 THE PROMOTER

The Promoter of the project is Mr.Abdul Rahiman Sadiq B.A, residing at Bayar
Village in Kasaragod District. The Promoter is well experienced in running the
expeller unit. He has worked as machine operator in a large scale unit in Northern
Karnataka. After gaining the operating skills, he installed a similar unit in a small
scale at Beripadavu in Kasaragod District. And the unit is running successfully and
has also set an example in superior chicken waste management in Kasaragod.
Presently, the produce is being sold to his past Employer company in Karnataka
itself.

He has travelled far and wide to learn the technology and skills of operation.
He also undertook thorough study of collecting the waste. Initially the local public
had ambiguity, as they thought that the waste recycling process involves use of
hazardous chemicals which will cause serious diseases. But, after providing
awareness through community meetings and with the help of local bodies, the
public got aware that the recycling process adopted by the Promoter is bio-medical
and organic and it will only help to make the environment clean and healthy. The
Promoter has already earned many accolades and awards from various
organizations and Companies in India and abroad. He is young and dynamic and
proven his ability in setting up a successful waste recycling unit in Kasaragod.

To prove his excellence and the appreciation he earned, a set of photographs

are attached herewith which itself speaks of the capability of this youth. With his
abundant knowledge and experience in the field, he set up the unit named-
BAHRAIN NUTRITECH, at Beripadavu in Kasaragod. Highly sophisticated and
environment friendly imported machinery was installed in the unit which alone cost
over 125.00lakhs. The recycled product obtained is termed Chiken Meat Meal.

Chicken meal is the dry rendered product from a combination of

clean chicken flesh and skin with or without accompanying bone, derived from
whole carcasses of chicken, exclusive of feathers, heads, feet and
entrails. Meal here is used in the sense of "an ingredient which has been ground or
otherwise reduced in particle size." It is mainly used in pet foods.
Chicken meal is ground up chicken meat that has been carefully dried to a moisture
level of 10%. The protein content is 65% and the fat level is 12%. Regular chicken
contains about 70% water with 18% protein and 5% fat. To create chicken meal,
ingredients are placed into large vats and cooked. This rendering process not only
separates fat and removes water to create a concentrated protein product, it also
kills bacteria, viruses, parasites and other organisms. Because meat can be rid of
infectious agents through the rendering process, “4D” animals (dead, dying,
diseased or disabled) are allowable chicken meal ingredients. While not always
present, the possible inclusion of these ingredients makes chicken meal always
considered unfit for human consumption. Chicken meal is mainly used in pet foods.
Its protein content is much higher than regular chicken because most of the water
has been removed.

Typically when it comes to pet food, all of the ingredients (meats, grains, vitamins,
minerals) are mixed together and put through a machine called an extruder. The
extruder cooks the mixture by adding steam and water. The result is the familiar
kibble coming out of the extruder and it is subsequently dried. Fat is added after
drying. (This is the same process for making many breakfast cereals.) The final pet
product has a moisture level of around 10%.

The processing of chicken meat along with the other ingredients essentially is
converting it to chicken meal. However, there are some characteristics of regular
chicken meat that make it less flexible for use as an ingredient compared to chicken
meal. The high moisture content of chicken limits the amount that can be
formulated into a complete finished food. Chicken is generally stored frozen to
minimize microbial growth. The frozen chicken is thawed and made into slurry
before adding to the mix.

Chicken meal, however, can be used in a finished food at levels much greater than
chicken meat. Chicken meal in a finished food provides roughly 4 to 5 times the
nutrients as the same weight of chicken meat because of the differences in
moisture. A pet food made of chicken meat may therefore have only 20% of the
chicken in the final product, providing only 3.6% protein. An equivalent proportion
of chicken meal would provide 13% protein.
 MARKET POTENTIAL

By-products, as defined by AAFCO, are the non-rendered, clean remains of a

slaughtered animal after all the “edible” parts are removed (basically after
everything “human grade” has been taken away). So usually you’re left with things
like feet, internal organs (minus giblets which are usually used in the making of hot
dogs or can, in turn, be sold as edible meats), heads, bones, and in the case of
chickens, their undeveloped eggs. However, this does not include hair, horns, teeth,
or hooves. Now, some of these items aren’t necessarily bad, I mean, my own dog
loves a dried chicken foot or a trachea every now and again, but it really boils down
to the fact that a majority of them are harder to digest than muscle meat and by-
products aren’t usually handled appropriately after slaughter because they aren’t a
“human grade” ingredient. If the by-product is labelled as “meat by-product” on the
ingredients list, it gets even worse. Since there is no specified protein source (an
example of a specified protein source would be “chicken by-product”), they can
contain bits from sources such as euthanized pets, diseased or dying livestock,
dead zoo animals, road kill, or dead on arrival poultry. There is no telling what the
vague “meat” source could be.
Now on to meal. Meat meal is defined by AAFCO as being the clean, rendered tissue
of either mammal, fish, or poultry that may include the skin and sometimes, but
not always, bone. Rendering is a cooking process that basically cooks out all of the
moisture to leave a protein dense powder. This is a huge difference from whole
meat ingredients (like, say, boneless chicken breast) which are basically 70% water
while the meal ingredients are typically 10% water. This allows pet food companies
the ability to make a really protein packed and lower carb food that is biologically
appropriate. Of course, like mentioned with by-products, there is a dark side to the
meal ingredients, and that is when you get the vaguely mentioned “meat meals.”
Again, since there is no specified protein source, who know what the “meat”
actually is. So meals are a perfectly good ingredient as long as the protein source is
clearly defined in the ingredients list.
 With the increased consumption of meat, mainly chicken, the result was the
abundant rise is chicken waste and inspite of measures to curb or recycle the waste
generated, the enormous and exponential growth in population consuming chicken,
could not match with the steps taken to manage the waste. The best possible way
to manage waste, especially chicken waste is to recycle the same and produce meat
meal.

For a dog food, what could contain more protein than whole meat?
Well, surprisingly, a quality grade meat meal can actually be a more abundant source of
protein than the whole meat from which it was made.
Here’s why.
Meat meal is a dried end-product of the cooking process known
as rendering. Rendering is a lot like making stew — except that this stew is
intentionally over-cooked.
With rendering, you start with a meat stew, cook away the water and bake the
residue. And you end up with a highly concentrated protein powder — or meat
meal.
 PROJECT DETAILS

PROCESS OF MANUFACTURING :- The ingredients including raw chicken meat with

blood, parts of chicken such as chicken head, feather, chicken intestine, chicken
leg, whole chicken etc which are atleast fresh for 20 hours are initially collected.
The Promoter shall arrange a collection van which shall be exclusively insulated for
collecting the chicken waste. The raw materials shall be collected in drums specially
arranged for the purpose and procured at the factory.

The raw materials are first processed into the batch cooker or rendering cooker of
2tonnes capacity which is just like an ordinary pressure cooker which on rendering
for a period of 4-5 hours which produces sterilized chicken meat meal only and
there are no other by products. The daily capacity will be 14000kg of the main
product and 5500kg of by product. The said chicken meat meal is packed into bags
of 50kg capacity and dispatched for sale. The process does not result in any kind of
air/water or other kinds of pollution as the resultant product is just like any other
product boiled and steamed.

Just like cooking in a cooker, the raw material is mixed with water and then
using water steamer the cooker is heated by sending steam through pipeline. The
cooker has a pulverizer which will powder the particles in raw materials. As process
of steaming, the water content in the raw material gets evaporated and gets
evacuated through the condenser and subsequently through the chimney of over
100ft height. Normal firewood is used for the steaming purpose.

Hence, the process is very simple and the Promoter has the required knowledge to
operate the production directly,
 THE PROPOSAL

The Promoter proposes to commence a similar chicken meat meal

manufacturing unit at Mangalore in Karnataka.

For the purpose, the Promoter requires a land area of 1.00acre so as to set up the
unit most efficiently. And the Promoter requests that the land be allocated in such
an area which is not residential so that the normal public is not affected. Even
though the waste will be collected in completely covered vehicle in closed drums, to
prevent any ambiguity, the Promoter proposes such an area which is not residential
as ideal.

The Promoter will install most sophisticated technology and the machine will
be imported one. The block of machinery will consist of Stainless steel batch
cooker, stainless steel condenser, stainless steel scrubber, vacuum filter pump,
stocking tank for treatment of water, chiller, cooling tower, boiler, ID blower, dust
collector of 3 different capacities, dust collector, chimney of 100feet, special blower
for cooker sucking, ms tank of two types, collecting bins, 10ton capacity cool
storage, 150kva generator with full fittings.

The Promoter requires 20 workers in total of which 4 must be skilled

workers. The labourers can be easily appointed locally.

Apart from obtaining the land, the Promoter also requests support in being
authorized to collect the chicken waste from slaughter houses, market and traders.

Once the land is allocated, the unit can be set up within 3-4 months and within 6
months production can be started.

The unit will have a capacity to recycle tones of chicken waste per day, which will
support in eradicating the chicken waste and making Mangalore city clean and
healthy.

Hence, the proposal.