1. Slaughterhouse Layout and Construction
1.1. A wheel disinfection tank capable of discharging disinfectant is set at the entrance of the live pigs entering the factory, which is the same width as the door, 4m in length, and 0.3m in depth.
1.2. The plant area should have a slaughter waiting room, a slaughter room, an emergency slaughter room, a laboratory, an official veterinary room, and a harmless treatment room (or a temporary storage room).
1.3. There should be a special area for cleaning and disinfection of pigs in the factory, as well as a special area for cleaning and disinfection of product transport vehicles and related tools.
- The raw material receiving area should be equipped with vehicle cleaning and disinfection areas and facilities. And the floor of the car washing platform in the return yard should be equipped with a covered ditch for collecting washing wastewater.
- It has disinfection areas and facilities for product transport vehicles.
- There are special areas for cleaning and disinfection of containers for products and tools for hanging products.
1.4. The layout and facilities of each workshop in the production area should meet the production process and hygiene requirements. The clean area and non-clean area of the workshop should be separated.
- The clean area includes: carcass processing, trimming, heart, liver, and lung processing, temporary storage and delivery room, grading, measurement, division processing, packaging and other places.
- Non-clean areas include: slaughter waiting room, stunned, bleeding, scalding, depilation, singeing, peeling, and intestinal, stomach, head, hoof, and tail processing places.
1.5. The construction area and facilities of the slaughter workshop should be compatible with the scale of production. The processing areas in the workshop should be clearly divided according to the production process, the flow of people and logistics should not interfere with each other, and meet the requirements of the process, sanitation, and quarantine inspection.
1.6. There are pig unloading stations, pig driving lanes, inspection rooms (including weighing rooms), waiting rooms (including shower rooms), isolation rooms, chemical medicine rooms, veterinary studios, etc.
2. Pre-slaughter Facilities
2.1. Slaughter Waiting Room
- Capacity of Waiting Room: Calculated based on (1.0-1.5) class slaughter (each class is counted as 7 hours). The area of each pig is (0.6-0.8) square meters, excluding the pig-driving lane. The shower room is divided into at least two compartments.
- The slaughter room is well ventilated in summer, has sufficient sunlight in winter, and has a rain-proof roof. The floor in the slaughter room is made of impermeable and easy-to-clean materials, the slope should not be less than 1.5%, and slope to the drainage ditch; drinking water facilities are provided inside.
- The slaughter room is equipped with a covered open ditch for collecting washing wastewater.
2.2. Isolation Room
The isolation room needs to be close to the pig unloading platform.
2.3. Emergency Slaughter Room, Harmless Treatment Room
- The entrance and exit of the emergency slaughter room, and the harmless treatment room should be equipped with a disinfection tank that is convenient for the trolley to enter and exit. The disinfection tank should be the same width as the door, not less than 2 meters long, and 0.1 meters deep.
- Emergency slaughter room and harmless treatment room should be equipped with hot and cold water pipes.
3. Slaughter Workshop
3.1. The slaughter workshop includes the pig-driving lane in the workshop, the killing and bloodletting room, the scalding and dehairing room or the peeling room, the carcass processing room, the carcass storage room, the red viscera processing room, the white viscera processing room, the head and foot processing room, the by-product storage room, and the veterinary hygiene Inspection studio and other areas.
Among them, the scalding and depilation room should be separated from the peeling room to prevent cross-contamination.
3.2. There should be locker rooms, toilets, and shower rooms that are compatible with the production capacity and connected to the workshop, and their facilities and layout should not cause potential pollution risks to the products.
3.3. Areas with different cleanliness requirements should be provided with separate changing rooms, and personal clothing and work clothes should be stored separately.
3.4. At the entrance of the workshop, there is a non-manual hand washing and disinfection facility and a shoe disinfection tank.
3.5. Certain utensils and equipment used in the slaughter and inspection process of livestock and poultry, such as slaughter, dehorning equipment, inspection knives, chest opening and dicing saws, quarantine inspection trays for viscera, etc., should be used after each use. The above hot water is cleaned and disinfected.
3.6. The ceiling or suspended ceiling should be made of materials that are smooth, non-toxic, resistant to washing, and not easy to fall off. The surface should be flat and concise, and there should be no gaps, concave corners, or protrusions that are not easy to clean.
3.7. Doors and windows should be closed tightly. The surface of the door should be smooth, anti-adsorption, impermeable, and easy to clean and disinfect. It should be made of impervious, sturdy, and non-deformable materials.
3.8. The walls and wall skirts in the workshop are smooth and flat, made of non-toxic, impermeable, and washable materials, and the color is white or light. If the wall skirt is made of stainless steel or plastic plates, all the joints of the plate seams are sealed.
3.9. The height of the wall skirt of the slaughter workshop shall not be less than 3.0m (the height of the wall skirt of the assassination bloodletting place shall not be lower than the track surface).
3.10. The floor of the workshop should be water-proof, non-slip, easy to clean, and corrosion-resistant.
3.11. A covered open ditch or shallow open ditch should be set up under the track of each processing procedure in the slaughter workshop, and the ground should not be accumulated water.
4. By-product Processing Room
4.1. The processing rooms for by-products such as heart, liver, lung, stomach, intestinal, head, foot, and tail should be set up separately and physically isolated, and they should not be contaminated with each other.
4.2. The gastrointestinal processing room adopts workbenches or belt conveyors and other equipment.
4.3. The head, hoof, and tail processing rooms are equipped with a scalding pool, hair removal machine, washing machine (set), and shaving table. (Do not leave the factory with wool).
4.4. The by-product processing operation table and pool should be smooth, impervious to water, and easy to clean and disinfect
5. Cold Storage
The temperature of the storage warehouse should meet the specific requirements of the product being stored. The temperature of the refrigerated storage should be monitored, and a hygrometer should be equipped if necessary. The temperature of the cooling room is 0-4℃, and the temperature of the freezing room is not higher than -23℃.
6. Equipment, Appliances
6.1. The equipment, utensils, and containers that come into contact with meat should be made of non-toxic, odorless, non-absorbent, corrosion-resistant, non-deformable, non-easy to fall off, and can be repeatedly cleaned and disinfected. They will not interact with meat and clean under normal production conditions. The chemical and disinfectant react, and should be kept intact; bamboo and wood crafts (tools) and containers should not be used.
6.2. The waste container should be made of metal or other impermeable materials. Containers for holding waste and containers for meat should not be mixed. Containers for different purposes should have obvious signs or color differences.
7. Water Supply
According to the needs of the production process, cold and hot water pipes should be set at the water location for slaughter. The temperature of hot water for cleaning should not be lower than 40℃, and the temperature of hot water for disinfection should not be lower than 82℃.
8. Lighting
Lamps installed above the exposed meat should use safe lighting facilities or adopt protective facilities to prevent the lamps from being broken and contaminating the meat.
9. Ventilation Facilities
9.1. There should be good ventilation and exhaust devices in the workshop to remove polluted air and water vapor in time. The direction of airflow should flow from the clean area to the unclean area.
9.2. The vents should be equipped with gauze or other protective and corrosion-resistant materials to prevent the intrusion of insect pests. The gauze or net cover should be easy to load and unload, clean, repair or replace.
10. Draining
10.1. The floor of the slaughter and segmentation workshop should not be accumulated with water, and the drainage flow in the workshop should flow from the clean area to the unclean area.
10.2. A grille of non-corrosive material should be installed at the drain outlet of the open ditch, and there should be anti-rat and anti-odor facilities.
11. Harmless Treatment
11.1. Self-processing facilities and equipment such as the harmless treatment room for diseased pigs and pig products.
The equipment in the harmless treatment room meets the technical requirements of the “Technical Specification for the Harmless Treatment of Diseased Animals and Dead Animals”. And deal with it according to technical requirements.
11.2. If a professional harmless treatment agency is entrusted to deal with it, an independent low-temperature space or area should be set up for the temporary storage of suspicious diseased carcasses or tissues.
There are special temporary storage low-temperature facilities for harmlessness, entrustment agreement, and complete handover records.
12. Production Equipment
12.1. Complete equipment configuration (matched with production capacity and ability to meet relevant requirements of pig slaughtering operating procedures): Stunning equipment (designed to slaughter 300,000 heads and above with three-point hemp motor or carbon dioxide stunner, designed to slaughter 300,000 heads or less can be equipped with two Point type hemp motor,), pre-cleaning device, scalding equipment (excluding open scalding pool), peeling (except for those that do not use peeling process), hair removal machine, splitting equipment (excluding bridge splitting and half sawing (including splitting) Half-saw disinfection device)], carcass cleaning device, viscera synchronous inspection line, hand washing, and knife disinfection device, pole hook cleaning device and other equipment.
12.2. Tracks
- The slaughter production line adopts mechanical conveying track (temporary storage warehouse and delivery warehouse can adopt hand-pushing track). Set up a hanging conveyor on the bloodletting line.
- The height of the bloodletting track from the ground should not be less than 3.5 meters (mandatory clause), and the height of the suspension track from the ground in other processing areas should not be less than 2.5 meters.
- There must be a branch track for the carcass of suspected diseased pigs. A separate door is set between the carcass of sick pigs and leads directly to the outdoors. The place where the suspected pig carcass and the suspected pig carcass are unloaded must be equipped with an impermeable airtight special vehicle, which should be clearly marked. After the pig carcass is re-inspected, a veterinary sanitary inspection and stamping station must be set up.
13. Hygiene Management
13.1. The utensils, gloves, and inner and outer packaging materials that come into contact with meat should be kept clean, hygienic, and safe.
13.2. The facilities and toilet facilities for the operators to wash and disinfect their hands should be kept clean and maintained regularly.
13.3. Rodent, insect, and bird hazards should be prevented and eliminated.
13.4. Take effective measures (such as gauze, gauze, rat-proof board, fly-proof lamp, wind curtain, etc.) to prevent the intrusion of rodents and insects.
14. Inspection and Quarantine
14.1. Each inspection operation point (head, body surface, internal organs, initial inspection, re-inspection, etc.) of the slaughter workshop is equipped with inspection footrests. The length and height of the footrests are suitable for the needs of inspection operations.
14.2. The slaughter workshop should be equipped with a synchronous inspection device, and a special container for collecting repairs and waste should be set up in this interval, and the container should be clearly marked.
Synchronous inspection can be carried out, the three glands can be removed as required, and the repaired materials and waste are stored in special containers.
14.3. The parasite inspection room is set up at the sampling place close to the slaughter production line, and the area meets the inspection requirements. The inspection room should be equipped with workbenches, scissors, tweezers, microscopes, cleaning and disinfection facilities, metal trays, and other utensils.
14.4. The illuminance of each inspection operation point is not less than 500Lx. The illuminance of the parasite inspection workbench is not less than 750Lx. The light should not change the natural color of the processed object.
15. Transportation Equipment
15.1. Live pigs and pig products should be transported in different vehicles.
15.2. To transport slices of pork, special vehicles with hanging facilities should be used, and no open transportation is allowed.
PS: The above information is only for learning reference. For more information please contact to our engineer
