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PROPOSAL FOR ESTABLISHING MODERN ABATTOIR
IN TUMKUR, TUMKUR DISTRICT, KARNATAKA

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URBAN INFRASTRUCTURE DEVELOPMENT PLAN
SOLID WASTE MANAGEMENT
21-Apr-14

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A.Siddharth
2100200045
B.PLAN

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IIIrd year – VI semester
SPA VIJAYAWADA

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 CONTENTS

INTRODUCTION

CITY PROFILE 2
BACKGROUND 2
PROJECT OBJECTIVES 2
PROJECT JUSTIFICATION 2
FACILITIES REQUIRED IN A MODERN ABATTOIR 3

Reception area and resting grounds 3

Lairage 4
Slaughter Hall 4
Office & Rest room 5
Compound Wall and Gate 5
Green Belt 5
Water Requirement 5
Accessibility for Cleaning and Maintenance 6
Non acceptable material 7
Waste Management 7

DETAILED ESTIMATE 8

ESTIMATE REPORT
GENERAL ABSTRACT OF ESTIMATE
COMPONENT WISE ABSTRACTS OF ESTIMATE

Slaughter house, Lairage etc

Soak Pit
Overhead Tank
Anaerobic Tank
Compound Wall and
Gate Road and Parking
lot

DETAILED ESTIMATE FOR MODERN ABATTOIR FOR TMC 20

Slaughter house, Lairage, Administrative Building and Watchman Shed

Soak Pit
Overhead Tank and Pump House
Anaerobic Tank
Compound Wall and Gate
Road and Parking lot

RATE ANALYSIS 43

ECONOMIC ANALYSIS 73

OPERATION AND MAINTENANCE 73

ECONOMIC ANALYSIS 73
Expenditure 74
Income 75

CONCLUSION 76

1
1.0 INTRODUCTION

1.1 CITY PROFILE

The Tumkur City Municipal Council (CMC) was constituted in 1975. It is located at a distance of 70 km to
the northwest of the capital Bangalore along with Pune-Bangalore National Highway No. 4. The city is in
close proximity to Bangalore. The population of the city was 2, 48,592 according to 2001 census. The
CMC had 35 wards with equal number of councilors. The district headquarters is located at Tumkur town.
The Government of Karnataka has upgraded the Tumkur City Municipal Council to a City Corporation in
August 2010 after considering the growth of population increasing to over 3 lakhs and the resource
mobilization capacity is crossing Rs. 6 crore annually. The city is surrounded by mountains and hilly
terrain. The famous places of the city include Siddhaganga Mutt, Kaidala Temple, Devarayana Durga,
Namada Chilume, Shiva Gange, Goravanahalli Mahalakshmi Temple, etc. The principal crops grown are
cereals, pulses, millets, oil seed, ragi, paddy, coconut and sugarcane. The total area of the city is 75.4
sq. km (7541 hectares). It consists primarily of elevated land intersected by river valleys. A range of hills
rising to nearly 4,000 feet (1,200 meters) crosses it from north to south, forming the watershed between
the systems of the Krishna and Kaveri.

1.2 BACKGROUND

India is endowed with the largest resource of livestock population in the world. The Indian Meat Industry
is currently on the track of a remarkable leap forward. The global demand for Indian meat and meat
products is increasing considerably during the past few years. We also have one of the largest domestic
markets for our meat and meat products. More than 65% of the Indian population consumes meat and
meat products. About 40 million people are engaged in meat sector, namely, trade of live animals, hides,
bones, casings, horns and hooves etc.. However, the global competency of our products has not
improved considerably in terms of quality and quantity. One of the major lacunae in this regard is lack of
modern infrastructure for production of hygienic meat and for value addition. More scientific organization
of this sector will generate more employment in rearing of animals on scientific lines and processing of
slaughter-house by-products for allied industries.

1.2 PROJECT OBJECTIVES

The objectives of the project are:

I. To establish a modern abattoir in Tumkur in Karnataka and to ensure that the meat supplied to
the public is clean and hygienic.
II. To ensure that the slaughter house wastes generated in the city are processed scientifically.
III. To ensure that the slaughter house wastes are not mixed with the municipal solid waste or
discharged into drains or sewers.

1.3 PROJECT JUSTIFICATION

Hygiene of slaughter house is very important to prevent contamination of meat. Meat is easily perishable
and contamination of meat can lead to serious health issues. All conditions and measures necessary to
ensure the safety and suitability of meat at all stages of the food chain are needed. Ensuring hygiene is
the shared responsibility of the farmers, manufactures and consumers. Slaughtering of animals also
generates wastes consisting of non edible offal like lungs, large intestines, various glands, animal tissues,
organs, various body parts, etc.; stomach/intestinal contents; dung; bones etc. Large quantity of waste
water is also generated during washing. The average quantity of unusable wet solid waste produced by
slaughtering (excluding dung) is estimated as12 kg per cattle/buffalo, 4 kg per pig, 2.5 kg per goat, and
0.6 kg per poultry. The present practices in most of the meat shops are to dispose the wastes to the
drains or sewers. Construction and maintenance of modern slaughter house with Waste Management
Facility is inevitable for maintaining societal hygiene in all urban and rural local bodies. There are
guidelines/ stipulations in the legislations such as the Prevention of Cruelty to Animal Rules 2001, the
Municipality Act 1994 and Water (Prevention and Control of Pollution) Act 1974 etc., insisting minimum
facilities to be provided in a modern slaughter house. Considering the special nature of the State, it may
not be necessary to provide fully automated with highly sophisticated machineries for slaughter houses
that is to be established for Gram Panchayats and Small Municipalities.
In Tumkur, at an average, 36
cattle, 92 goats and 342 chickens are slaughtered every day. At present there is no authorized slaughter
house in Tumkur city operating as per the Pollution Control Board norms. The slaughtering of animals is
done in the premises of meat shops on illegal basis. The waste water after cleaning of waste from these
shops is directly discharged into the open drains and the solid waste is mixed with the municipal solid
waste which is dumped with the other waste without any segregation. The public in this area is looking for
meat processed in neat and clean environment without any dirt and safe for consumption. It is also the
duty of the local bodies to protect and promote human health by providing hygienic meat to the
consumers and ensure proper living environment for the public. Thus a modern abattoir with facilities for
hygienic meat production and waste disposal is an urgently needed in the Panchayat.

1.4 FACILITIES REQUIRED IN A MODERN ABATTOIR

The Prevention of Cruelty to Animals (Slaughter House) Rules, 2001 notified by the Government of India insists the
following basic facilities in a modern abattoir:

1. Reception area for animals

2. Lairage (Resting place for animals)
3. Room for Veterinary Doctor for performing anti-mortem and post– mortem examination.
4. Place for isolated resting place for diseased animals.
5. Stunning place / Halal slaughtering place
6. Bleeding place (for removal of blood)
7. Removal of skin and washing place
8. Evisceration place (removal of contents from stomach)
9. Meat removal and examination place.
10. Storage facilities for skin, bones, blood, fat etc.
11. Proper drainage and facilities for liquid and solid waste management.

1.4.1 Reception area or resting grounds

 The slaughter house shall have a reception area of adequate size sufficient for livestock subject
to veterinary inspection.
 The reception area of slaughter house shall have proper ramps for direct unloading of animals
from vehicles or railway wagons and the said reception area shall have adequate facility
sufficient for feeding and watering of animals.
  Separate isolation pens shall be provided in slaughter house with watering and feeding
arrangements for animals suspected to be suffering from contagious and infectious diseases,
and fractious animals, in order to segregate them from the remaining animals.
 The resting grounds in slaughter house shall have overhead protective shelters.

1.4.2 Lairage

Lairage is for keeping the animals indented for slaughter, well in advance for observation and
convenience. For providing water and feed to the animals, arrangement shall be there in the lairage. The
lairage should have anti-mortem facility to check each animal for physical disease or pregnancy.

1.4.3 Slaughter Hall

Separate provision shall be made for slaughtering large and small animals. Separate space shall be
provided for stunning, bleeding and dressing of carcass. Animals shall not be slaughtered in sight of other
animals. Dirty area consists of bleeding & dressing section and clean area for meat cutting inspection and
dispatch. Pedal operated water taps and wash basin shall be provided in the slaughter hall. At the
bleeding area, the blood is to be collected in stainless steel basin for further processing/ disposal. The
collected blood is to be stored in tank for heating and drying. Stainless steel wheel barrow is to be
provided in the slaughter hall to collect and remove waste items like large bones, tail, intestine etc into the
stripery outside and dispose the same on completing the slaughter of the day.

Stunning Area: As per PCA Rules a stunning area is to be provided for large animals. Floor level of
stunning box need be in an elevated plane than that of the bleeding area. One side of the stunning box
shall be with hinged plate. Immediately after stunning, the animal falls on the side wall of the stunning
box, and the hinged plate will open and the animal slips on to the bleeding area. The bleeding area need
be positioned in such a way that, an animal in the stunning box will not see the bleeding animal. In the
case of halal slaughtering, separate cubicles made up of RCC wall and with ceramic tile in walls shall be
utilized. Sufficient drains and floor slope shall be provided for easy drainage of blood from the cubicles.
Bleeding is done by hoisting the animal to a height of 5 m rail system and blood collection vessel with
funnel shall be used for collection of blood.

Continuous rail arrangement in the slaughter hall: A continuous rail arrangement should be
provided on the top of the large animal slaughter hall. The rail arrangement covers the bleeding area
and hanging area for the smooth and convenient movement of the carcass for processing.

Dressing: Dressing is carried out in rails fitted at a height of 3 m. adequate means and tools for dehiding
or belting of the animals should be provided. Hides or skins should be transported either in a closed
wheel barrow or by a chute provided with a self - closing door. Means for immediate disposal of legs,
horns, hooves etc. should be provided through spring load floor chutes or side wall doors or closed wheel
barrows.

Evisceration: Adequate space and suitable and properly located facilities shall be provided for inspection
of the viscera of the various types of animals slaughtered. This area shall have adequate facilities for
hand washing, tool sterilization and floor washing and contrivances for immediate separation and
disposal of condemned material. Adequate arrangements may be made for identification, inspection and
correlation of carcass, viscera and head.

Waste Grinder: The waste generated is to be grinded / shredded before putting in to the biogas plant.
For this a motorized waste grinder is needed. This is given as an optional item in the project proposal. It
is an optional item.
1.4.4 Office & Rest room

An office for the veterinary doctor and health inspector and rest room for the workers are included in the
project. Toilets are to be provided in the project. It is for the use of workers and for office in the
slaughter house. It is provided with flush, wash basin, floor with tiles, light fittings etc.
A green belt of sufficient width with suitable species of trees shall be developed around the compound.

Electrification: Electrification of the slaughter house shall be done in order to get sufficient light in the
slaughter hall and inspection area. Sufficient number of electric lamp inside and outside the house is
considered.

Plumbing work: The slaughter house is to be provided with sufficient number of water taps, wash
basin, pedal operated water taps etc. Also flexible hose arrangement is there for easy cleaning of the
slaughter hall.

1.4.5 Compound Wall and Gate

The area shall be protected with a compound wall and gate to avoid unwanted persons to enter into
the compound.

1.4.6 Green Belt

In order to provide an aesthetic appearance to the abattoir, the boundaries and open areas shall be
planted with trees like Chempakam (Michelia chempaka), Neem (Azaridca indica), Pongilliam (Pongamia
glabra), Poormouth (Lagerstroemia flos-reginae) etc.

1.4.7 Water Requirement

The process flow chart of activities for a modern abattoir as given in figure 1 shows that, water is required
in the slaughter house at all stages of operation.

The major water uses are:

 Safe, potable and constant supply of fresh water at adequate pressure

 Floor washing with water jet of 200 to 330 kPa pressure
 Carcasses washing 1000 to 1700 kPa pressure
 A constant supply of clean hot water shall be available in the slaughter hall and work
rooms during the working hours.
 Hot water not less than 820C for sterilizing of equipment and secondary floor washing
 Suitable facilities for washing of hands (including adequate supplies of hot and cold running
water, nail brushes, soap or other detergents)
 Non-potable water for firefighting purpose

The main emphasis of the process is to segregate waste at different stages and to recover resources
from it and use minimum quantity of water. For this, the slaughter house requires sufficient good quality
water round the year. This is for consumption of animals, its washing before slaughtering, washing the
meat, human consumption, washing the floor and other areas etc. If water supply is available connection
can be taken and over head PVC water tanks can be provided for this purpose. Otherwise a bore well can
be constructed, and shall be provided with pump. A solar water heater shall be installed for the purpose of
hot water. Hot water shall be used for washing slaughter hall and for sterilizing tools.
 Fig. 1 Process flow chart for Modern Slaughter House

1.4.8 Accessibility for Cleaning and Maintenance

 All parts of the product zone shall be readily accessible to sight and reach for cleaning
and inspection
 Where necessary for proper cleaning and inspection, equipment shall be easily demountable. To
facilitate this dismantling, quick opening devices that require no tools or, such simple tools as a
mallet and an open – end wrench shall be provided. Bayonet joints, butterfly clamps, spring
bolts, and other similar devices are desirable for connecting or closing parts of equipment.
Where parts should be retained by nuts and bolts, the design shall provide for fixed studs with
wing nuts, rather than bolts to a tapped hole
 All bearing shall be located outside the product zone and if adjacent thereto, shall be
constructed with a readily removable seal at the entrance of the shafts, into the product zone
 Interior corners of equipment shall be provided with radii (minimum 6mm), except where
greater radii are required to facilitate drainage and cleaning.
 All welding within the product zone shall be continuous, smooth, even and relatively flush with
the adjacent surfaces
 All parts of the product zone shall be free of recesses, open seams and gaps, crevices,
protruding ledges, inside threads, inside shoulders, inside bolts or rivets and deal
ends.
  Where necessary for sanitary maintenance, equipment shall be constructed and installed so as
to be completely self-draining
 Care shall be taken to prevent contaminating product by lubricants used in overhead
motors, gears, and similar devices. If drip pans are necessary, they should be easily
accessible for inspection and removable for cleaning.
 All safety or gear guards shall be readily removable for cleaning and inspection
 All external surfaces that do not contact with food products shall be free of pen seams, gaps,
crevices and inaccessible recesses.

1.5.9 Non acceptable material

 Copper and its alloys in equipment used for edible products

 Cadmium in any form in equipment handling edible products
 Equipment with painted surface in product zone
 Enamel containers or equipment is not desirable
 Lead
 For elimination of fatigue and comfortable working for laborers the working table should be at
waist height of the worker to work in standing position. If the table is at more height (that is 800
mm to 860 mm) it should have a platform incorporated for the balance height above 860mm.
 Working platform for on-the rail operations should be of such height that the slaughter man has
neither to stoop too low nor stretch himself to his operation zone, and he should be able to reach
operation zone in his natural standing position.

1.4.10 Waste Management

Effective waste management can reduce environmental problems associated with slaughter house. The
strategy followed is to reduce waste by segregating resources from different types of wastes generated in
the slaughter houses. Solid waste is the main waste product from a slaughter house. Solid waste from
slaughter house can be divided into two main groups, namely edible & inedible. Organs such as brain,
liver, heart are the examples of edible by-products. Hooves, horns, hair, gall bladder, ears, skin, bones
etc. are the inedible by-products. The components left unrecovered forms are the solid wastes. In a
modern slaughter house most of the solid wastes can be recovered as by-products. Success of material
recovery depends on how slaughtering is done and how the facilities are provided in the slaughter house.

Biogas Plant for Solid Waste Treatment: Dung from lairage and other wastes in slurry form can be
treated in biogas plant. Slaughter house having a capacity to slaughter 30-40 large and 40 small animals
generates about 750 kg of solid waste per day. This can be treated in a biogas plant with 40m 3 capacity.
For getting more efficiency, and considering the increase in number of animals, in the future two biogas
plants with 25 m3 is envisaged in the present project. Facility for utilizing biogas for generating electricity
for operating equipments in the plant /lighting the plant area is also envisaged in the project.

Liquid Waste Treatment: Wastewater mainly wash water from slaughter house is to be collected and to
be conveyed to a common collection cum equalization tank. About 8m 3 per day of effluent is generated
from a slaughter house with capacity to slaughter 30 - 40 large animals. The strategy adopted is to
reduce pollution load by by-product recovery and use of less quantity of water for washing purpose.
Wastewater mainly consists of wash water can be treated in an effluent treatment plant established in the
site of slaughter house. The process for effluent treatment suggested is anaerobic treatment followed by
dispersion trench.
2.0 DETAILED ESTIMATE

2.1 ESTIMATE REPORT

Sub: Construction of a modern Abattoir at Tumkur.

The proposal is to construct a Modern Abattoir at Tumkur. An extent of 0.40 ha of land comprising in
Tumkur city under their possession is set apart for the above purpose. The components envisaged in this
estimate are:

I. Slaughter House Building.

II. Administrative Building, Refrigeration room, Lairage, Watchman shed and toilet block.
III. Overhead water tank with bore well and pump set.
IV. Boundary wall and gate.
V. Bio gas plant and bio conversion generator kit.
VI. Anaerobic tank.
VII. Soak pit
VIII. Internal road and parking lot.
IX. Water Supply and drainage system.
X. Electrification works
XI. Hot water generation and supply
XII. Stainless steel ladder, bench, wheel barrow, pressure washer, chopper, mixer grinder and hooks.

All the RCC works are proposed as 1:1.5:3 mix. The floor of the slaughter area is proposed to be finished
with white superior quality marble and the remaining area of floor of the slaughter house is proposed to
be finished with fully vitrified tiles. Doors are proposed to be made with Anjili wood and windows are with
glazed steel works. Roof of the slaughter area is proposed with powder coated GI tile profile roofing
sheet. Facilities for refrigeration room are also provided. Provisions for washing and changing room are
also included in the slaughter house.
The conveyance of materials is taken as actual as provided by
Panchayat. The estimate amount comes to Rs.94, 00,000/- including 10% contractor’s profit.

2.2 GENERAL ABSTRACT OF ESTIMATE

No. Details of work Amount (Rs.)

1 Slaughter house, lairage etc 60,63,915.00
2 Soak pit 15,238.00
3 Over head Tank 6,42,541.00
4 Anaerobic Tank 2,23,714.00
5 Compound wall and gate 9,40,142.00
6 Road and parking lot 4,91,935.00
7 Electrification works 3,00,000.00
TOTAL 88,77,485.00
8 Preparation of Design and detailed estimate 2% 1,71,630.00
9 Technical supervision 4% 3,43,260.00
10 Unforeseen Expenses 2,07,625.00
GRAND TOTAL 94,00,000.00

Ninety Four Lakhs Only

3.0 ECONOMIC ANALYSIS

The overall objective of the project to establish a modern abattoir in Tumkur is to ensure the supply of
clean and hygienic meat to the public and to ensure that the water bodies in the area are not
contaminated with slaughter house wastes.

The animals brought in by the registered vendors will be examined by qualified veterinary doctors and
slaughtered in the slaughter house, dressed, sliced in large pieces, washed and will be handed over to
the vendors for transportation to their meat shop and for retail sales.

3.1 OPERATION AND MAINTENANCE

Operation and maintenance of the slaughter house is proposed to be by engaging qualified butchers on
piece rate and sanitation workers on daily wage basis. The activities will be supervised by a health
inspector and the veterinary doctor will carry out the anti-mortem and post-mortem inspections.
Appropriate fees for the slaughtering and waste treatment services will be levied from the meat vendors
so as to meet the O&M costs and for payback of the capital cost.
The proposed slaughter house can handle up to 60 large animals (cattle) and 40 small animals (Goats)
per day. The estimated average slaughtering in Tumkur is 36 cattle and 90 sheep /day. The expected
minimum number of animals in the abattoir is 40 large and 20 small animals per day.

3.2 ECONOMIC ANALYSIS

3.2.1 Expenditure

The costs involved in the functioning of the Abattoir are mainly related to:
 1. Butcher charges
2. Wages to Sanitation workers and security staff
3. Supervision and Veterinary Doctor Charges
4. Electricity Charges
5. Water charges
6. Pollution Control Board Certificate/Renewal etc.
7. Annual maintenance
8. Miscellaneous expenditure
9. The economics of the abattoir is worked out considering the following basic details;
10. Average number of large animals slaughtered per day: 40
11. Average number of small animals slaughtered per day: 20
12. Number slaughter days/year excluding national and state holidays: 350
13. Number of large animals slaughtered per year (50x350): 14,000
14. Number of small animals slaughtered per year (30x350):

7,000 The abstract of expenditure for running the plant is given below:

1. Butcher charges

The butchers are expected to do the following activities in the abattoir:

 Hygienic killing of animals

 Dressing (dehiding, removal of legs, horns, hooves etc)
 Evisceration (removal of contents from stomach)
 Slicing the Carcass into large pieces, washing
 Washing Carcass

Qualified butchers will be engaged for undertaking this activity. The present rate ` 200/- for large animal
and ` 30/- for small animal.
 The cost for this activity will be ` 30,14,000/- (40x350x200+20x350x30)
2. Wages to Sanitation workers and security staff

Two security staff and 5 sanitation workers are required for proper functioning of the abattoir. The security
staff shall be engaged from licensed agencies and the prevailing rate is ` 5,000/month. The sanitation
workers shall be appointed as daily workers at a rate of Rs. 220/day including all allowances.
Thus the total coast for wages will be ` 5,05,000/- (5000x12x2+220x350x5)

3. Supervision and Veterinary Doctor Charges

It is the responsibility of the local bodies to ensure the supply of hygienic meat to public and to protect the
environment for which the local bodies have veterinary doctors and health inspectors. They have other
duties also to perform. However, a part of their salary shall be levied under this activity. The amount will
be around `20,000/month and the total for one year is ` 2,24,000 (4x350x10).

4. Electricity Charges

Electricity is required for pumping water, operating high pressure water jet, aerator motor, lighting lamps
etc. The total power required /day is estimated as 8 units per day of which about 4 units used for
lighting lamps will be obtained from the biogas plant. The amount required for paying the electricity
charges per year at the rate of ` 10/unit will be ` 14,000.

5. Water charges

Water is required for washing the carcass, floor cleaning, lairage cleaning, toilet use, gardening etc. The
average quantity of water required per large animal is around 150 liter and for small animal is 30 liter. The
total quantity of water per day is thus estimated at around 6.5 KLD (kilo liter/day) and 2275 kilo liter/year.
About 50% of this (1175 kilo liter) will be met from the bore well present in the compound and balance
from the public water supply. The amount required per year for this at the prevailing rate of ` 11/kilo liter, `
12,100.

6. Pollution Control Board Certificate/Renewal

Pollution control certificate is required for operating the unit. The license fee to be paid for two years will
be ` 20,000/- for units establishing coast between 1 crore to 5 crore (including land value). Thus
`10,000/year are required for this purpose.

7. Annual maintenance

Annual maintenance includes maintenance of the building and equipment. The cost estimated is `
50,000/year

8. Miscellaneous expenditure

The miscellaneous cost is for meeting the unforeseen expenses during daily operations. The cost
estimated is `40,000/year

3.2.2 Income

The MC shall fix a service charge for using the facilities. The butcher charges have to be paid extra. The
suggested service charges excluding the butcher charges is ` 60/- for large animal and ` 20/- for small
animal. The income expected from this is ` 9, 80,000/year (14,000x60+7000x20).
3.3 CONCLUSION

The Central and State legislations like Prevention of Cruelty to Animals Rules 2001, the Municipality Act
1994, and Water (Prevention & Control of Pollution) Act 1974 etc., insists establishment of modern
slaughter houses and has to be monitored by the local bodies. However, this is not happening now and
most of the slaughter activities are carried out in residential areas. This is largely due to the absence of a
locally centralized slaughter house. This results in unhygienic slaughtering activity and unscientific
dumping of slaughter wastes in the drains and sewer.
The TMC has the responsibility of ensuring sanitary facilities for ensuring public health. Thus, they are
supposed to run the abattoir in a no-loss no-profit basis. The major benefit of the plant will be related to
the public health and environmental aspects, which cannot be counted on monitory basis.
The excess of income over expenditure as per the present economic analysis is ` 1, 24,900/year. This
shall be deposited in a corpus fund and can be used for establishing additional facilities in future. Thus,
project shall be operated in a self-sustainable manner.