Abattoir Design and Construction - PDF - Slaughterhouse - Animal Slaughter

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ABATTOIR DESIGN AND CONSTRUCTION
A modern abattoir should have essential components like lairage, ante mortem examination facility,
stunning section, humane slaughter facility, facility for flaying, dressing and washing of the carcasses,
postmortem inspection section, veterinary office and laboratory, facility for handling byproducts,
rendering and effluent treatment plant. The guiding principle for designing abattoir is to provide all
related services under hygienic conditions. The essential facilities required in any abattoir are as
follows:
1. Livestock receiving area: It is the area where animals are received. Receiving area must have
watering, feeding and animal inspection facilities. Animals are to be inspected by a Veterinarian.
Healthy animals are sent to lairage while sick and injured animals are to be sent to isolation pen.
2. Lairage: Place where animals are provided rest before slaughter. Rest is to be provided up to 24
hours to overcome the physiological stress involved in transportation of animals. Sheep have to
be kept off feed up to 12 hours before slaughter in lairage to reduce the gut contents thereby
reducing the chances of contamination during dressing of carcasses. Space requirement for
lairaging of sheep is 0.6 m2 per animal.
3. V race: It is the pathway that connects lairage with the slaughter hall. Length of the V race can
be up to 36 m. Pathway will be tapering with width of 50 cm and 80 cm in bottom and at the top
respectively.
4. Slaughter hall: Premises where stunning, bleeding and dressing of carcasses takes place in the
abattoir. Animal need to be stunned before slaughter for painless killing. To ensure proper and
safe stunning a restrainer has to be provided which will hold the animals firmly while stunning.
Stunning will be followed by bleeding which has to be done on a bleeding trough of 1.1 to 1.2 m
width for small ruminants. Dressing of the animals has to be done on rail for ensuring hygiene.
Height of the overhead rails has to be about 2.7 m at bleeding area and 2.3 m at dressing area.
5. Tripe and gut room: Space for cleaning of stomach and intestine. Proper water supply and
provision for disposal of gastro intestinal contents has to be provided at the tripe room.
6. Byproduct store room: Space for storing fat, skins, head and feet.
7. Offal room: Place for trimming and storing of liver, lungs, kidneys etc.
8. Isolation pen: Place for accommodating sick or suspect animals.
9. Chilling room: For chilling of carcasses after dressing. Temperature maintained in carcass store
room will be 70 C and that of offal will be at 30 C.
10. Cutting room: Room where carcasses are cut into cutup parts/ retail packs and packed as per
consumer requirement. Temperature maintained at cutting room will 100 C.
11. Freezer room: Storage of packaged meat at – 17 to – 200 C till dispatch.
12. Veterinary room: Section for Veterinarians who undertake ante and post mortem of animals.
13. Changing room: For changing dress of slaughterhouse personnel.
14. Effluent Treatment Plant: Facility for treating the effluent generated from an abattoir before
releasing to drainage or reuse or using for irrigation.
Abattoir Design Guidelines qobit@yahoo.com Page 1

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15. Emergency slaughter hall: This is the miniature abattoir for lairaging and harvesting of
diseased and suspect animals
16. Compound area: Whole slaughterhouse premises must be completely compounded along with
plantation across the boundaries.
17. Electrical & generator room: To ensure supply of adequate electricity in the plant.
18. Toilets – Adequate toilet facility is required to maintain hygiene (@ One/ 25 persons).
19. Office room
20. Security
21. Water storage sumps: Sumps for storing the required quantity of water for adequate and
timely supply of water.
22. Parking: For parking vehicles transporting animals, meat and the personnel.
In general the following basic guidelines should receive serious considerations.
1. A clear-cut separation between clean and unclean sections
2. There should be only forward flow of operation without any possibility of reversal
3. Building floor should be made upYou're Reading

of easily a Preview
cleanable and non slippery material.
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4. Walls should have white ceramic tilesyour documents
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sanitation and light reflection
5. Buildings should have efficient drainage and

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to Download
direction from edible product flow
6. Open windows should be screened OR
7. In modern abattoirs, overhead rail system ensures the basic requirements of hygienic conditions
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Model of slaughterhouse for small ruminants

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Design of loading facilities and holding pens
T. Grandin
Animal Science Department, Colorado State University, Fort Collins, CO 80523 (U.S.A.)
Abstract
Grandin, T., 1990. Design of loading facilities and holding pens. Appl. Anim. Behav. Sci., 28: 187-201.
Holding pens and loading facilities are used in abattoirs, saleyards, stockyards, and sorting facilities.
Long, narrow pens are recommended where animals enter through one end and leave through the
other. Constructing the pens on a 60-80° angle eliminates sharp 90° corners. Flooring in holding pens
should be non-slip. Indoor holding pens should have even, diffuse lighting that minimizes shadows.
Cattle, pigs and sheep have a tendency to move more easily from a dimly illuminated area to a more
brightly illuminated area. Facilities should be designed to minimize excessive noise.
In large facilities more than one unloading ramp may be required to facilitate prompt unloading.
During warm weather prompt unloading is essential because heat rapidly builds up in a stationary
vehicle. Ideally, holding pens should be built at truck height to eliminate ramps.
The maximum recommended angle for adjustable ramps for cattle, pigs, and sheep is 25° . Twenty
You're Reading a Preview
degrees is the maximum recommended angle for non-adjustable ramps. For pigs, 15° is
recommended. Ramps should haveUpload
a levelyour
dockdocuments to download.
at the top equal to one animal body length.
Stairsteps are recommended on concrete ramps. Recommended dimensions are a 30 cm minimum
Upload
tread width and a 10 cm rise for cattle, and a 25 to
cmDownload
tread width and 5 cm rise for slaughter weight
pigs. Both loading and unloading ramps should have solid fences. The crowd pen that leads to the
OR be placed on a ramp. Crowd pens must be level.
ramp should also have solid sides and it must never
Single file, curved ramps with solid fences are very efficient for loading cattle onto trucks. Ramps
used for unloading only should be 2.5 to 3-m wide to provide animals with a clear exit off the vehicle.
In Denmark and other Scandinavian countries trucks used for transporting pigs are equipped with a
hydraulic tailgate lift. Well designed holding pens and loading ramps can help reduce bruises and
stress.
Introduction
Holding pens and loading facilities are used in abattoirs, saleyards, stockyards, and sorting facilities.
Well designed facilities will help reduce bruises, stress, and mortality. Bruises and mortality cost the
livestock industry millions of dollars annually (Marshall, 1977; Livestock Conservation Institute,
1988a,b). Stress-related meat quality problems, such as dark cutting (DFD) and pale, soft exudative
(PSE) meat are also very costly (Canadian Meat Council, 1980). Another advantage of good facilities
is an improvement in animal welfare.
The basic principles of design are universal for all facilities but the purpose of the facility will affect
certain parts of its design. For example, American and Australian trucks hold more animals than
trucks in some European countries. This will affect the size of the holding pens. When a holding
facility is designed, space must be allocated for specialized functions such as weighing, sorting,
washing, or checking animal identification. To avoid serious design mistakes, the designer must fully
understand the specific handling requirements of the country or region where the facility will be
located.
Pen Layout

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Long, narrow pens are recommended in holding facilities where livestock are held for a relatively
short period of time (Kilgour, 197 1; Grandin, 1980a,b; R. Hoenderken, personal communication, 198
1 ). A major advantage of long, narrow pens is efficient animal movement. Animals enter through one
end and leave through the other. To eliminate 90" corners, the pens can be laid out on a 60-800
angle (Figs. I and 2). Each pen gate should be longer than the width of the alley, so that it opens on
an angle to eliminate the sharp corner (Fig. 1). Figure 2 is an indoor holding yard at a pig abattoir
which slaughters > 5000 pigs day. Long, narrow pens maximize lineal fence length in relation to floor
area. This may help reduce stress (Kilgour, 1978; Grandin, 1980a,b). Cattle and pigs prefer to lie
along the fenceline (Stricklin et al., 1979; Grandin, 1980b). Observations indicate that long, narrow
pens may help reduce fighting (Kilgour, 1976). Government regulations in some countries may
require walkways in between the pens for observation of animals prior to slaughter. The layout
remains the same except that a 1-m-wide walkway is placed between every other pen.

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OR

Fig. 1. Long, narrow holding pens, unloading ramps and curved race system for a cattle
abattoir.

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Fig. 2. Diagonal holding pens in a large pig abattoir.

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Group size
OR or stockyard is at least partially dictated by size
The size of the holding pens required for an abattoir
of the trucks. When small groups of animals are handled, block gates can be used in a long, narrow
pen to keep different groups separated. Minimum space requirements for holding fattened, feedlot
steers for < 24 h are 1.6 m' for hornless cattle and 1. 8 5 m' for horned cattle (Grandin, 1979;
Midwest Plan Service, 1980), and 0.5 M2 forYour
Start slaughter weight
30 Day FREE Trialpigs and lambs. During warm weather
pigs require more space. Wild, extensively raised cattle may require additional space. However,
providing too much space may increase stress because wild cattle tend to pace in a holding pen.
There must be adequate space for all animals to lie down.
Mixing
To reduce stress and preserve meat quality, strange animals should not be mixed shortly before
slaughter (Tennessen and Price, 1980; Grandin, 1983; Barton-Gade, 1985). Solid pen walls between
holding pens prevent fighting through the fences (Fig. 2). Solid fences in holding pens are especially
important if wildlife such as deer, elk, or buffalo are handled.
Pigs present some practical problems. In the U.S.A., pigs are transported in trucks with a capacity of
> 200 animals. However, they are fattened in much smaller groups. Observations at U.S. abattoirs;
indicate that mixing 200 pigs from three or four farms resulted in less fighting than mixing 6-40 pigs.
One advantage of the larger group is that an attacked pig has an opportunity to escape. Price and
Tennessen (1981) found a tendency towards more DFD carcasses and hence more stress when small
groups of 7 bulls were mixed, compared with larger groups of 21 bulls.
Pen and alley dimensions

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In countries with large trucks, larger pens and wider alleys will be required. Alley and pen widths are
also dictated by the number of animals per hour which must move through the facility (Tables I and
2). To avoid bunching and trampling, 25 m is the maximum recommended length of each holding
pen, unless block gates are installed to keep groups separated. Shorter pens are usually
recommended.
Table I: Pen and alley widths for pig and sheep holding facilities
Animals handled (h1) Pen width (m) Alley width (m)
< 4001 2 1.3
> 4002 3-4.2 2.5-3
1
Or truckloads of less than 80 animals.
2
Or truckloads of more than 150 animals.
Table II: Pen and alley widths for cattle-holding facilities 1

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Method of driving cattle to download.
Pen width (m) Alley width (m)
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On foot 3.5-4.2 3
OR
On horseback and on foot N/A 3.5

On horseback N/A
4.2
1
These recommendations apply to most
Start facilities
Your 30 Day FREE except
Trial a few specialized situations where
small numbers of cattle are handled.
2
The alley is too wide for a single person to block cattle turnbacks.
Specialized holding facilities
In Denmark, the design of the pig lairage at the abattoir is very specialized (Fig. 3). Pigs are held in
long, narrow pens equipped with manual push gates. A powered push gate moves pigs up the alley to
the stunner. This system was invented by T. Wichmann of the Danish Meat Research Institute. The
Danes have also developed automated block gates within the long, narrow pens to keep small groups
of 15 pigs in separate groups (Barton-Gade, 1989). When strange bulls are mixed, physical activity
during fighting increases DFD meat. The installation of either steel bars or an electric grid over the
holding pens prevented dark cutting in bulls (Kenny and Tarrant, 1987). These devices prevent
mounting. The electric grid should only be used with animals that have been fattened in pens
equipped with an electric grid. In Sweden and other countries where small numbers of bulls are
fattened, individual pens are recommended at the abattoir (Puolanne and Aalto, 1981). In some
European abattoirs, the holding area consists of a series of single-file races which lead to the stunner.
Bulls are unloaded directly into the races and are kept separated by guillotine gates.

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Fig. 3. Danish pig lairage with push gates and a power crowd gate.
Flooring You're Reading a Preview

Holding and loading facilities must Upload your documents
have non-slip flooringto(Stevens
download.and Lyons, 1977; Grandin, 1983).
For cattle, deep 2.5-cm "V" grooves in a 20 cm square or diamond pattern are recommended. The
deep groove pattern should not be used inUpload
living to Download
quarters for cattle. In pig holding facilities, the wet
concrete may be imprinted with a stamp made from expanded steel mesh with a 3.8-cm-long opening
(Grandin, 1982). OR
In abattoirs, concrete slats may be used in livestock holding pens, but the drive alleys should have a
solid concrete floor. Slats or gratings used in pig and sheep facilities should face in the proper
direction. Sheep move more easily when they walk across the slats instead of parallel with them
(Kilgour, 1971; Hutson, 1981 ). Figure Start
2 shows
Your the correct
30 Day FREE orientation
Trial of slats in holding pens. The
floor appears more solid when the animals walk across the slats. To facilitate animal movement, the
animals must not be able to see light or reflections off water under the slats.
Animals will balk at sudden changes in floor texture or color. Flooring surfaces should be uniform in
appearance and free from puddles (Lynch and Alexander, 1973). In facilities that are washed,
concrete curbs may be installed between the pens to prevent water in one pen from flowing into
another. Drains should be located outside the areas where animals walk. Livestock will balk at drains
or metal plates across an alley (Grandin, 1987). Flooring should not move or jiggle when animals walk
on it. Flooring that moves causes swine to balk (Kilgour, 1988).
Bruise Prevention
Edges with a small diameter such as steel angles and channels will cause severe bruises. Round pipe
posts are recommended and surfaces which come into contact with animals should be smooth and
rounded (Stevens and Lyons, 1977; Grandin, 1980c). Sharp corners should be padded with split tires
or conveyor belting.
All gates should be equipped with tie-backs to prevent them from swinging out into the alley.
Guillotine gates should be counter-weighted and padded on the bottom (Grandin, 1983).

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Lighting and Sound Levels
Indoor holding pens and loading facilities should have even, diffuse lighting that minimizes shadows
(Fig. 2). Cattle, pigs, and sheep have a tendency to move more easily from a dimly illuminated to a
more brightly illuminated area (Kilgour, 1971; van Putten and Elshof, 1978; Hitchcock and Hutson,
1979; Grandin, 1982). At night or in enclosed facilities, lamps can be used to attract animals into
trucks or races (Grandin, 1982). The lamps must illuminate the floor and must not shine into the eyes
of approaching animals. Loading ramps must never be pointed into the sun (Vowles, 198 5 ).
Livestock are more likely to balk if they are forced to move towards blinding sunlight. Pigs reared
indoors under artificial illumination preferred to walk up a ramp illuminated at 80 Ix (Phillips et al.,
1987). This was similar to the illumination of their living quarters. A ramp illuminated with less than 5
Ix was avoided. There was also a tendency to avoid an excessively bright ramp illuminated at 1200 Ix
(Phillips et al., 1987).
Livestock have sensitive hearing and they are stressed by excessive noise (Kilgour and de Langen,
1970; Kilgour, 1983). In steel facilities, gate strike posts should have rubber stops to reduce noise. Air
exhausts on pneumatically powered gates should be piped outside (Grandin, 1983). If hydraulics are
used to power gates, the motor and pump should be located away from the animals. Cattle held
overnight in a noisy yard close to the unloading ramp were more active and had greater bruising
compared with cattle held in a quiet pen (Eldridge, 1988).
Unloading and Loading Layout
In large stockyards, sale yards, or abattoirs more than one loading or unloading ramp is usually
Upload toDuring
required to facilitate prompt loading or unloading. Download
warm weather, prompt unloading is
essential because heat rapidly builds up in stationary vehicles.
OR
In some facilities, unloading pens (Fig. I ) will be required. These pens enable animals to be unloaded
promptly prior to sorting, weighing, or identification checking. After one or more procedures are
performed the animals move to a holding pen.
Loading dock height varies depending on the types of vehicles used. If vehicle heights vary by a few
Start ramps
centimeters, construction of nonadjustable Your 30is
Day FREE Trial
recommended, even with the lowest vehicles
used. This will enable the crossover bridge that is attached to the higher vehicles to be used more
effectively.
Width
Facilities used for unloading only should be 2.5-3 in wide to provide the animals with a clear exit to
the alley (Fig. I) (Grandin, 19 80d). The recommended width for facilities used to load livestock into a
truck varies depending on vehicle type. A vehicle with a tailgate that opens up to the full width of the
vehicle can be loaded with a ramp the same width as the vehicle. The large trucks used in North
America usually have a door which is just wide enough to admit cattle in single-file or pigs and sheep
double-file. A single-file loading ramp for cattle should be 76 cm wide. For pigs and sheep, a ramp 86
cm wide will enable 2 animals to walk up side by side. A partition down the middle of the ramp
improves efficiency because it prevents the pigs from turning around (Grandin, 1987) (Figs. 4 and 5).
The partition is made from "see through" wire mesh to promote following. It is a serious design
mistake to make a ramp or race 1 1/2 animal wide. This will result in jamming. Recommended widths
for single-file ramps used by slaughter weight pigs and sheep will vary from 3 5 to 43 cm depending
on animal size.
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Abattoir Design and Construction - PDF - Slaughterhouse - Animal Slaughter

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7/17/23, 5:24 PM Abattoir Design and Construction | PDF | Slaughterhouse | Animal Slaughter

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8. Isolation pen: Place for accommodating sick or suspect animals.

11. Freezer room: Storage of packaged meat at – 17 to – 200 C till dispatch.

13. Changing room: For changing dress of slaughterhouse personnel.

Abattoir Design Guidelines qobit@yahoo.com Page 1

18. Toilets – Adequate toilet facility is required to maintain hygiene (@ One/ 25 persons).

19. Office room

In general the following basic guidelines should receive serious considerations.

1. A clear-cut separation between clean and unclean sections

3. Building floor should be made upYou're Reading

5. Buildings should have efficient drainage and

6. Open windows should be screened OR

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Model of slaughterhouse for small ruminants

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Abattoir Design Guidelines qobit@yahoo.com Page 4

Fig. 2. Diagonal holding pens in a large pig abattoir.

Pen and alley dimensions

Abattoir Design Guidelines qobit@yahoo.com Page 5

Animals handled (h1) Pen width (m) Alley width (m)

< 4001 2 1.3

> 4002 3-4.2 2.5-3

Table II: Pen and alley widths for cattle-holding facilities 1

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Specialized holding facilities

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