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 Qty metric tonnes Value in rs crs.
2003-2004 4 1 5 2 2 8 .1 7 2 0 2 .4 0
2004-2005 2 7 7 7 4 4 .4 6 1 6 0 .7 9
2005-2006 1 4 5 8 8 9 .0 0 1 6 7 .5 8
2006-2007 7 1 0 8 8 0 .1 2 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 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
r y
u r
C t
k e n cu
i c
c h
l e
o
Wh
a s
e
br
s s
l e
n e
p c Bo
p o t i
l i m s
l u
lo Dr
k
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
 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

3.Cone stand machine cum table

12. Chill room
4.Scalding machine
13. Freezer
5.Defeathering
14. Office
6.Head and leg
removal 15. Store room

7.Evisceration table 16. Processing table

8.Giblet station 17. wash basin for

9.Carcass washer 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 One time Investment Reasons
Land (Rs)
4,50,000 0.5 acre at 19rs/sqft
Buildings 45,00,000 1000rs/sqft – 10 cent
Plant and equipment 15,00,000 building
Cold + fence +
storage,
Contingencies 20,000 parking
wiring,ice
Paper work, production,
Working capital 50,000 bagging machine,
registration,
Procurement license,
of birds
Total 61,00,000 feather
table remover,
, fan,
and first etc,.
month
Giblet station,
operating cost etc,.
 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
rice and profit estimation4 0 0 b ird s/ d a y
• Price of farm live 8 0 0 K g /d a y
chicken :Rs. 50/- 4 0 , 0 0 0 R s/ d a y
• Average weight of live chicken :
2 kg
• Price of slaughtered carcass : 6 0 0 kg / d a y
Rs. 90/- 5 4 , 0 0 0 R s/ d a y
• Average weight of one carcase:
1.5 kg
Mo

Pro fit
nt
hl

1 4 , 0 0 0 R s/ d a y
y
ex
pe
nd
it

s : 25
ur

y
ing da
e

Pro fit: 3 , 5 0 , 0 0 0 R s/ m r
o nWothk
1,0
0,0
0 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/attra-
pub/poultryprocess.html
• www.fao.org/docrep/003/t0561e/T0561E00.
•