ICAR National Research Centre on Meat PM Formalisation of Micro Food Processing Enterprises (PM-FME) Scheme TRAINING FOR MASTER TRAINERS HANDBOOK OF MEAT AND POULTRY PROCESSING Organized by ICAR National Research Centre on Meat ISO 9001:2015 Certified & ISO/IEC 17025:2017 NABL Accredited Institute Chengicherla, Hyderabad – 500092, Telangana nrcmeat.in In Collaboration with Indian Institute of Food Processing Technology, Thanjavur, Tamil Nadu Handbook of Meat and Poultry Processing 1 ICAR National Research Centre on Meat Handbook of Meat and Poultry Processing 2 ICAR National Research Centre on Meat PM Formalisation of Micro Food Processing Enterprises (PM-FME) Scheme TRAINING FOR MASTER TRAINERS HANDBOOK OF MEAT AND POULTRY PROCESSING Organized by ICAR National Research Centre on Meat ISO 9001:2015 Certified & ISO/IEC 17025:2017 NABL Accredited Institute Chengicherla, Hyderabad – 500092, Telangana nrcmeat.in In Collaboration with Indian Institute of Food Processing Technology, Thanjavur, Tamil Nadu Handbook of Meat and Poultry Processing 3 ICAR National Research Centre on Meat MoFPI sponsored Master Trainers Training on Meat and Poultry Processing 4 to 8 January 2021 HANDBOOK OF M Organized by ICAR - National Research Centre on Meat Chengicherla, Boduppal Post, Hyderabad – 500 092 AND POULTRY PROCESSING Edited and compiled Dr. Rituparna Banerjee Dr.Barbuddhe Published by Director ICAR - National Research Centre on Meat Chengicherla, Boduppal Post, Hyderabad – 500 092 Handbook of Meat and Poultry Processing 4 ICAR National Research Centre on Meat TA B L E O F C O N T E N T S Page No.1 Status, market size and scope of meat production and processing 7 in India 1.2 Livestock and meat supply chain in India 11 1.3 Pre and post harvest loss in livestock produce 17 1.4 Important issues in Indian meat sector 20 1.5 Challenges and suggested solutions for meat sector in India 20 1.6 Way forward for livestock/poultry producers, meat processors 24 and exporters Chapter 2: Plant layout and maintenance 25 2.1 Criteria for selection of site to establish an abattoir 25 2.2 Equipments and specifications of machineries in meat and poultry 31 processing 2.3 Machineries for meat products processing 38 2.5 Cleaning, sanitation and pest control: Equipment and facility design 44 for meat industry 2.6 Primary meat processing 48 2.7 Utilisation of animal byproducts 52 Chapter 3: Value added meat products 57 3.1 Meat processing steps 59 3.2 Ingredients and their role in meat products processing 60 3.3 Different value added meat products 64 Handbook of Meat and Poultry Processing 5 ICAR National Research Centre on Meat TA B L E O F C O N T E N T S Page No. Chapter 4: Packaging of meat and poultry products 83 4.1 Functions of the package 83 4.2 Packaging materials and techniques 84 4.3 Packaging of fresh meat 89 4.4 Packaging of frozen meat 90 4.5 Packaging of cured meat 91 4.6 Packaging of dehydrated meat 91 4.7 Recent advance in packing 92 4.8 Current Indian scenario in food packaging 95 4.9 Important FSSAI regulations on food packaging 96 Chapter-5 Meat food safety regulation and certification 107 5.1 Need and various aspects of food testing and notified NABL, referral 107 and reference labs 5.2 List of notified reference laboratories, referral laboratories and state/ 113 public food laboratories in india 5.3 Food safety regulations and certifications 124 5.4 International organization for standardization (ISO) 127 5.5 Codex alimentarius commission 129 5.6 Food safety and standards authority of india (FSSAI) 130 5.7 Good manufacturing practices and standard operating procedures 132 5.8 Hazard analysis and critical control point (HACCP) 133 5.9 Food safety plan 134 Annextures 137 Handbook of Meat and Poultry Processing 6 ICAR National Research Centre on Meat CHAPTER-1 INTRODUCTION 1.1 Status, market size and scope of meat production and processing in India Livestock play an important role in Indian economy and provide livelihood to two-thirds of rural community. Livestock and poultry including cattle, water buffalo, sheep, goat, pig and chick- en are primarily produced by the masses for milk, meat, egg, draught power and biomass.
Few other species viz, yak, mithun, camel, rabbit, duck, emu, Japanese quail, etc. are also produced in some parts of India as livelihood activities. India has around 42 sheep breeds, 26 goat breeds, 13 buffalo breeds, 40 cattle breeds, 6 pig breeds and 17 chicken breeds registered with Indian Council of Agricultural Research-National Bureau of Animal Genetic Resources (ICAR-NBAGR). India has a huge livestock wealth and ranks 1st, 2nd, 2nd and 4th in the world for water buffalo, cattle, goat and sheep population, respectively during the year 2019 (FAOSTAT).
In the year 2018-19, India has produced 8.1 million tonnes of meat and has the distinction of producing largest amount of buffalo meat in the world (42. It is also the 2nd largest producer of goat meat in the world. Per capita consumption of meat in India still remains relatively low at less than 6.5 kg/person/annum. Meat sector activities includes live animal transport, marketing, slaughtering of animals, pro- cessing, value addition, by-products utilization, disposal of solid and liquid waste, distribu- tion and retailing of meat and offals.
India has around 4000 registered slaughterhouses/plac- es maintained by local bodies, where animals are slaughtered for domestic consumption. Slaughtering is performed in designated abattoirs or slaughterhouses and most of the meat is consumed on the same day or kept in a refrigerator in the households. The meat produced for the domestic market is sold as hot meat (pre-rigor meat without any chilling). Food safety and standards act, 2006 enacted from Food Safety and Standards Authority of India (FSSAI) regulates production of meat for domestic consumption.
An overview of species-wise meat sector contribution in India is presented below. Handbook of Meat and Poultry Processing 7 ICAR National Research Centre on Meat LIVESTOCK & MEAT VALUE CHAIN Genetics Nutrition Meat Animal Slaughtering, animal and Transport processing, value • Retailing Health addition and poultry • E- commerce by-products production Marketing utilization • Export Production Meat Industry Management Important components of livestock and meat value chain 1.1 Buffalo meat sector: India possesses about 109 million buffaloes which are reared mainly for milk purpose. There are no exclusive meat purpose breeds and buffalo meat is sourced as byproducts of dairy industry from the spent animals. Majority of the meat science literature in India mention that only 2 -3 % of the total meat undergoes processing and value addition.
However, more than 21% of the total meat produced in India (8.1million tonnes) undergoes processing and value addition. This is mainly because of buffalo meat in which around 90% of total buffalo meat produced in India (~1.5 MT) undergoes chilling, packaging, freezing and branding and then exported. Most of the buffalo meat is processed at around 82 state of the art export slaughterhouses approved under APEDA. These processing plants have all the facilities for solid and liquid waste management and convert all the inedible waste and byproducts into meat and bone meal, meat meal, blood meal or fertilizer using rendering or composting technique.
Hence wastage from buffalo meat sector in India is limited. Total leather and leather good export from India stood at US$ 5.07 billion during April 2019 to 2020 (Council for Leather Exports). Around 3500 companies are manufacturing or exporting leather and leather products are members of CLE. Around 40% of the leather produced and exported from India comes from buffaloes, whereas 30% comes from goats.
Buffalo meat exports (1.15 MT) from India has contributed Rs. 22,669 crores during the year 2019-20 (APEDA). Handbook of Meat and Poultry Processing 8 ICAR National Research Centre on Meat Overview of domestic and export meat sector in India 1.2 Sheep and goat meat sector: As per 19th livestock census (2012) India possess about 65 million sheep and 135.17 million goats, which is about 12.71 % and 26 % of the livestock in terms of numbers, respectively. Out of estimate total meat production of 8.1 million tonnes, total goat and sheep meat production during 2017-18 was 1.64 million tons, which has a value of about rupees 66,814 Crore (DADF 2020).
There is a huge gap between demand and supply of mutton. Hence, price of mutton is rising continuously. Sheep and goat meat are premium meats in India sold at around Rs. 600-800 per kg across the country.
Most of the edible offal or Handbook of Meat and Poultry Processing 9 ICAR National Research Centre on Meat by-products produced from sheep and goat are also marketed and consumed in India. Hence the wastage from this sector is minimal. However, major chunk of the sheep and goat meat in India is produced in domestic slaughterhouses which are in very poor condition and realisation from inedible byproducts is very less. Organised slaughtering in sheep and goat sector will improve the returns to farmers.3 Poultry meat sector: The poultry Industry in India is a Rs.
The 75% of poultry sector (breeding, feeding, hatcheries and broiler farming) in India is organised with complete integration, however remaining 25% including slaughtering, distribution and retailing is unorganised with predominantly wet market business. This also includes microeco- nomic activity for sustainability in rural areas. The 11% of poultry meat is produced in India from more than 21 large (>1000 birds/hour capacity) and around 20 smaller (<1000 BPH) poultry processing plants. This means almost 90% of the poultry meat in India is produced under wet market conditions through highly scattered roadside poultry processing retail units.
This is resulting in inefficient utilization of all poultry by-products and disposal problems. How- ever, no meat or edible by-products is wasted either at retail or consumer level. Most of the loss in poultry value chain is happening during transportation of live birds (pre-harvest) due to transportation loss, injuries and death of birds. To some extent loss may happen at restau- rants/hotels or in functions where buffet lunch/dinner is served.4 Pig meat sector: Among the various livestock species, piggery is the most potential source of meat production and more efficient feed converters after the broiler.
Apart from providing meat, it is also a source of bristles and manure. Around 150 meat processing plants which are mainly processing pork and pork products like sausages, bacon and ham are func- tioning on small scale in the private sector in India. Most of the production and processing ac- tivities are under unorganized sector. As per the reports there are 25,000 pig farmers in Telan- gana state with 10-500 animals in each.
Punjab has around 400 pig farmers with an average farm size of 50-200 each. Pig producers cooperative federations are coming up in some of the States. India has several indigenous and exotic pig breeds. The commonly used exotic pig breeds in India are Large white Yorkshire, Hampshire, Landrace, Large black and Duroc either pure or their crosses.
Besides these exotic pig breeds, the indigenous pig breed, Ghungroo is also available in few states of NE. Thus the present shortfall of pork in the country is about 0. Pork production and processing can be a profitable enterprise for nutri- tional security and meeting employment generation requirement of ever increasing population. Handbook of Meat and Poultry Processing 10 ICAR National Research Centre on Meat 1.2 Livestock and meat supply chain in India In India, meat production is largely byproduct system of livestock production.
Most of the large animals (buffalo and cattle) utilized for meat production are aged/ spent animals, which have completed their productive and reproductive life. However, goats, sheep, pig and poultry are reared largely for meat purpose. Buffaloes utilized as triple purpose animals in most parts of the country for milk, meat and draught purpose. Cow and bullock slaughter is restricted and it varies from state to state.
Pig is purely a meat animal reared mainly by the weaker sections of the society and tribal people. Broiler chicken is largely contributing to meet the increasing demand of the growing populations.1 Marketing of livestock: The livestock marketing system in India is still in a primitive stage.