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THE PROJECT

The proposal to develop a new, high quality slaughter facility in Sidoarjo is linked to:

 high-growth of the market for quality meat in Indonesia, and


 Indonesia’s National goals for food self-sufficiency.

This is an import replacement project, different to the existing Krian slaughterhouse which produces
hot meat sold in wet markets just hours after slaughter.

It is a new market that requires modern business and marketing expertise.

It is essentially a marketing project where production, product presentation, distribution and selling
to customers all require international standard best-practice approach.

Therefore the project must be developed using all modern production and marketing methods.

THE OPPORTUNITY

Indonesia’s economic growth provides more prosperity across its large population. The number of
households earning over US$15000 [IR 180,000,000] p.a. was 7 million in 2016 and this will further
increase to over 20 million households in before 2020.

Demand for quality beef products at dine-in restaurants and at supermarket, already high, will grow
more than three times current levels by 2020.

This quality meat is mostly beef imported from Australia. There is an opportunity to cater for this
growing market by producing prime quality beef for distribution through cold-chain distribution
(refrigerated slaughterhouse facilities and refrigerated transportation, refrigerated storage and retail
display}. It is also a responsibility to meet this demand from Indonesian industry [import
replacement] to comply with Indonesia’s self-sufficiency goals.

The modern process starts with ensuring the cow is not traumatised at the time of slaughter. Best
practice is to stun the cow with a powered bolt gun that knocks the cow unconscious but does not
penetrate or kill the animal. It is widely accepted as complying with Halal requirements. Once
unconscious the beast is laid from the restraining box into a place where cutting and bleeding is
done, again in a way acceptable to Halal requirements.

The cow is hoisted by its hind legs to attachments on a rail moving arrangement. In its ‘hanging’
position, the various steps of cleaning, evisceration /gutting, removal of hide, skin, hoof, abdomen
etc can occur. The carcass is then cut in half and moved on the hanging rail system to cold room
where it is chilled for 24 hours at 4 degrees. After 24 hours the half carcass is moved to clean, cool,
specially equipped boning room where expert butchering occurs. Various meat cuts are packaged
according to what the market wants. This packaged meat is distributed in either chilled or frozen
condition to its market customers in what is called the ‘cold food chain’.

A shorter ‘hot meat’ process can operate in this system, whereby the carcass can be taken to market
as ‘hot’ meat, without going to chilling room.
… refer figure 1. ...
Key controls in this process include the separation of ‘dirty areas’ and ‘clean areas’. In order to avoid
contamination of the meat in any way. Operators cannot move from dirty area to clean without
strict cleaning and sterilising provision, such as changing boots and other clothing / coats. Workers
wear different coloured boots and headwear and coats to identify the area where they can and
cannot be.

The building is sealed from external vermin and insects with the ‘clean’ areas more so.

Bi-product extraction, inspection, treatment and preparation is done progressively during the
process. [see list … ]

Maintaining hygiene, cleanliness and waste management is a constant priority.


Meat from different parts of the carcass are identified as having different taste and softness and
other characteristics.

… refer figure 3. Insert diagram …

Steps in the process include:

… Refer figure

List as per doc. Refer list with name and picture for each step

Equipment and facilities to enable the following operating procedures for slaughterhouse rail
dressing process

1. stockyard and transfer to slaughterhouse management.

2. Stunning.

3. Sticking.

4. Shackling.

5. Rodding.

6. Hoofs and Head treatmentHoofs and Horns removal

7. First leg

8. Change over and second leg

9. Flanking

10. Rump and bung tie

11. Hide removal

12. Brisket splitting

13. Evisceration.

14. Split carcass.

15. Correlation and inspection.


16. Pressure spray carcass cleaning

17. Forequarter hygiene carcass trim

18. Hind quarter hygiene carcass trim.

19. Scales.

20. Red offal treatment.

21. White offal treatment.

22. Condemned material treatment.

Areas associated with the slaughter floor include:

1. Services (water heater, air compressor, pumps, etc.).


2. Hide room.
3. Offal rooms (red, white and hide-on).
4. Staff entries (separate hide on and hide off).
5. Prayer room.
6. Condemned product room.
7. Retain area.
8. Wash area (for hooks, trolleys and other equipment).
9. Dry store.
10. Boning room.
11. Storage/accumulation area.
12. Despatch area and office.

Insert diagram 1. here.

Line activities

Insert diagram 2. here.

Floorplan

The following equipment is required to enable the slaughter process indicated in diagrams 1 and 2.

1. Holding yard to accommodate up to 150 cows


2. Race from holding yard to slaughter house, approx. 20 metres
3. Weighing
4. Stunning box
5. Safety restraining (for escaped beast)
6. Bleeding trough
7. Bloodletting trough
8. Bleeding elevation - Hoists and rail and hanging and conveying in bleeding area
9. Front feet and horn removal
a. Platform
b. Horn cutter
c. Hoof cutter
10. Rehang
11. Back feet removal
a. Platform
b. Cutter
12. Rehang
13. Prehide
a. Platform
b. Equipment
14. Dehide
a. Platform
b. Equipment, Puller, etc
15. Split breast
a. Platform
b. Equipment (Saw, Balancer, …
16. Evisceration
a. Platform
b. Tables
c. Chute
17. Carcass splitting - half.
a. Platform
b. Equipment (Saw, …
18. Carcass trimming
a. Platform
b. Equipment
19. Carcass spray cleaning
a. Platform
b. Equipment
c.
20. Rail elevated rail hang and conveyor structure for process line, approx. 30 meters
a. Components,
b. Shackles, hooks,
21. Chiller room Number 1, 9 x 12 x 4.4 metres
a.
22. Chiller room Number 2, 9 x 12 x 4.4 metres
a.
23. Rail structure to chiller rooms and to boning room?
24. Rail hanger structure in chilling rooms (2)
25. Quartering carcass (Hot carcass)
a.
26. Quartering carcass (Cold carcass)
a.
27. Boning room
a. Tables and benches
b. Conveyor
c. Knives and equipment, see list
d. Knife sharpener
e.
28. Packing room
a. Tables and benches
b. Sealer
c. Etc
29. Flash freezing
a.
30. Cold storage room
a.
31. Dispatch area
a.

Specifications.
The following details of equipment and outfitting are to be a guide to standards required
and therein, costs. Options consistent with these following examples can be considered.
cattle weighing system
Example, galvanized platform dimensions: 2400x1000mmcapacity: 1500kg

Stunning box

example. hot-dip galvanized compressed air 1 pneumatic entrance1 pneumatic side door for output1
control panel

safety barrier

Appropriate barrier to protect operators from danger from escaped cattle

bleeding elevator

used for raising cattle to bleeding rail hot-dip galvanized electric chain hoist lifting

height: 6m lifting capacity:

bloodletting trough

used for collection of blood for livestock bloodletting

stainless steel dimensions: 3000 x 1200 x 300mm with one outlet, DN100, used for drainage and
blood discharge with 1 nylon plug include:1 nylon plug

bleeding conveyor

used for livestock bloodletting on the chain hot-dip galvanized 60 x4.0 mm tube rail, hanging below
double U sections by hangers double U sections are connected by screw blots and plates tube rails
are connected with steel beams by hangers include: 5m tubular rail, 1 pneumatic releasing device, 1
pneumatic stopper, 10 shackle

shackle return system

to make bloodletting shackles automatically return to the operator’s place, for easily reuse

hot-dip galvanized 60 x4.0mm tube rail, hanging below steel frame by hangers

the descending machine is connected with steel beams by HALFEN channel


use guard rail, prevent shackle from sliding out of rail, include: 1 pneumatic shackle releasing
device, 1 descending machine 4m tubular rail

fixed platform for rehanging backfeet

stainless steel size: 1500x1200x2000mm

include: 2 square tube columns, 1 punching pallet ladder, 1 set of drain pan, 1 set of punching pallet
or engineering plastic mesh countertop, 1 set of guardrail, and with an entrance, high platform only,
1 apron washing device, 1 knife sterilizer

hoist for rehanging

hot-dip galvanized electric chain hoist lifting height: 3m, lifting capacity: 1000KG lifting speed:
6m/min, power: 380V 50HZ 1.5KW, include: 1 chain hoist, 1 hanging device, 1 supporting frame, 1
foot switch

dressing conveyor

used for livestock carcass processing on the chain hot-dip galvanized 60 x4.0mm tube rail, hanging
below double U sections by hangers, double U sections are connected by screw blots and plates,
tube rails are connected with steel beams by hangers, include:16m tubular rail, 2 pneumatic
spreading device, 4 pneumatic stopper

hydraulic lifting platform for dehiding

used for cattle prehiding and dehiding stainless steel and hot dip galvanized

dimensions: 2700 x 2400mm, roller diameter: 160mm, lifting height: 1600mmlifting, weight: 200kg,
include: 2 stainless steel pillar, 1 set of skin rolling unit, 1 hydraulic station, 1 set of chain, 1 set of
drain pan, 1 set of punching pallet or engineering plastic mesh countertop, 1 set of guardrail, 2
apron washing device, 2 knife sterilizer

pneumatic lift for take out white offals

stainless steel platform size: 1750 x 1200mm, double cylinder cylinder bore: 100mm, lifting height:
600mm, lifting weight: 150kg, weight: 250kg, include: 2 square tube columns, 1 ladder, 1 set of
guardrail, 1 apron washing device, 1 knife sterilizer, 1 drag chain, 1 offals receiving chute

pneumatic lift for splitting half

stainless steel platform size: 1750 x 1200mm, double cylinder cylinder bore: 100mm, lifting height:
1600mm, lifting weight: 150kg, weight: 200kg, include: 2 square tube columns, 1 set of guardrail, 1
apron washing device, 1 knife sterilizer, 1 drag chain

tubular rail scale x 2

used for carcass weighing, in order to calculate dressing percentage or dispatch, hot galvanized.
weighing length: 600mm maximum, weighing: 300kg weighing, resolving ability: 0-150kg:50g;
150-300kg:100g;300-500kg:200g, include: 1 set of sensor, 1 tubular rail and frame, 1 digital
display with a communication interface, 1 thermal printer
manual rail

hot galvanized 60 x4.0mm tube rail, hanging below double U sections by hangers; double U sections
are connected by screw blots and plates; tube rails are connected with steel beams by hangers.
include: 1 sets of hangers and rail beams, 1 sets of switches 1 LG, 1 sets of switches 1RG, 1 sets of
switches 2LG, 1 sets of switches 2RG, 1 sets of elbows

elevator for quartering carcass

for carcass quartering, hot-dip galvanized. descending height: 1000mm, conveyor speed: 10m/min,
single hinged chain nylon roller, ball bearing connection, vertical running, smoothly, 60 x4.5mm tube
rail, hanging below double U sections by hangers conveyors are connected with steel beams by
HALFEN channel, power: 380V 50HZ 1.1KW. include: 1 pneumatic elevator, 1 descender

rolling hook x 200 pc

aluminum alloy frame stainless steel hook,

loading capacity: 1250kg, weight: 2.3 kg, wheel duplex bearings, corrosion resistance, with two seals

meat vehicle

stainless steel size: 790 x 690 x 680mm flat-style standard cart capacity : 200L including 2 fixed
wheels and 2 activity wheels

x 6pc

manual sprayer

food-grade plastic material, 3m food-grade hose

hand washing basin with knife sterilizer

stainless steel square tubes as support equipped with splash plate, drain trap and lap top valve knife
sterilizer is equipped with manual valve, flow regulator, overflow and shelf, which can hold 2 knives
and 1 grinder

apron washing machine with knife sterilizer

stainless steel apron washer is equipped with oriented nozzle, splash plate, drain pan, foot valve and
disinfectant box. apron washer is equipped with a grid, knife sterilizer is equipped with manual
valve, flow regulator, overflow and shelf, which can hold 2 knives and 1 grinder

PART B
pneumatic stunner

used for cattle stunning before killing. Suitable for stunning of cattle, pneumatic drive, kindly stun
livestock, to meet animal welfare work safety, reduce operation risks of cattle kicking, high
efficiency, reduce the damage of bones. when tips stunning, the cattle get serious brain damage,
rather than breakdown brain stunning power: more than 300J, maximum livestock weight: 700kg,
stunning bolt length: 85mm, stunning bolt diameter: 16mm, weight: 12.6kg, air pressure: 13bar.
include: 1 balancer, 1 air compressor, 1 pack of compressed air pipes.
leg shear

used for big animal feet cutting suitable for cattle, backfeet cutting hydraulic drive, pneumatically
controlled, double handle, noiseless, self-locking, closing speed: under load 3S, operating pressure :
220bar. cutting width: 150mm, hydraulic shear weight: 25kg, hydraulic oil flow: 9L/min, aluminum
hydraulic pump station, hydraulic station capacity: 27L., hydraulic station weight: 130kg., include: 1
balancer, 1 hydraulic station, 1 set of connecting pipelines, 1 sterilizing device

reciprocating brisket saw

used for cattle carcass brisket bone cut suitable for cattle. brisket bone cut protecting round on the
blade top, to prevent from damaging offal damping balance block inserts, reducing vibration smooth
surface, the motor is completely sealed, convenient for cleaning, handle trigger is sealed to prevent
the entry of moisture and dirt, length: 711mm, saw blade length: 241mm, weight: 24kg, power:
1.4KW. include: 1 balancer, 1 pcs of spare saw blade, 1 sterilizing device

bandsaw splitting

used for cattle carcass half splitting suitable for cattle. half splitting advanced guidance system
makes the blade a longer life, blade thickness is moderate, in order to reduce the loss of meat the
seal of the gear mechanism provides a good operation and longer life, smooth surface, the motor is
completely sealed, convenient trigger is sealed to prevent the entry of moisture and dirt, length:
1295mm, blade length: 2845mm, weight: 56kg, power: 2.3KW. include: 1 balancer, 50 pcs of blades,
1 sterilizing device

circular breaking saw

used for cattle carcass cutting or quartering. compressed air drive, saw blade diameter: 200mm,
weight: 7.7kg. include: 1 balancer, 1 set of connecting pipelines, 1 spare blade

slat belt conveyor for boning and cutting

stainless steel food grade white slat belt. size: 5500x800mm. geared motor drive. include: 1 set of
drive device, 1 set of slat belt, 1 set of sprockets, 1 set of rollers

2 pc

worktable for deboning

stainless steel food grade nylon plate dimensions: 1200x1000x800mm, nylon plate thickness: 25mm

4 pc

worktable for meat cutting

stainless steel food grade nylon plate dimensions: 1350x650x800mm, dual-layer, nylon plate
thickness: 25mm., under layer suitable for 3 plastic case, plastic case dimensions:
610x420x155/180mm

4 pc

disc sorter
stainless steel, dimensions: 1500 x600mm, height suitable for cutting, conveyor power: 380V 50HZ
0.55KW. include: 1 control panel

worktable for packing

stainless steel food grade nylon plate dimensions: 2000x1000x800mm., dual-layer nylon plate
thickness: 25mm

1 pc

vacuum packing machine

used for vacuum packaging of cut meat stainless steel model: DZ-800/2S fully automatic

dimensions: 1830×910×1060mm, chamber dimensions: 920×780×220mm, capacity: 1-2 cycle /


minute, packaging size: less than 10kg per pack, sealing bar length: 800mm x4, sealing bar width: 8-
10mm, sealing bar interval: 650mm, power: 5KW., include: 1 control panel, 1 set of vacuum system

PART C
blood collecting system

for blood collection stainless steel Blood storage tank size: 1200 x2000mm

Blood storage tank capacity: 2T. include: 1 blood storage tank, 1 pneumatic diaphragm pumps, 1 set
of stainless steel pipelines

by-product worktable

stainless steel size: 1920x920x800mm., nylon board, thickness of 25mm, square tubes as frame.
include: 1 stainless steel frame, height adjustable

by-product water tank

stainless steel size: 1500x800x800mm, depth: 600mm

worktable for white offals

stainless steel size: 6000x800x(750+150)mm., support made of stainless steel square tubes, height
adjustable, 150mm flap located around the table

pounches washing machine

stainless steel single machine, dimensions: 1500x900x1100mm. round centrifugal structure, totally
sealed, diameter: 750mm., the giant infeed door easy to monitor the internal motor., speed:
280r/min, frequency adjustable processing cycle :10-15 minutes, processing capacity: 12-16 cattle
manifolds / hour; single machine weight: 400kg, power: 380V 50HZ 5.5KW

various carrying construction and suspension construction


Refer to diagram, floor layout. *** insert

hot galvanized, include: secondary steel beams, hanger screw bolts, nuts, platen
fasteners

electrical control system

GGD standard cabinets, sealed, waterproof (Schneider, Siemens or Delixi electrical components);
national standard wire and cable. include:1 set of cables and bridges

Sundry items, incidental, contingency

Indicate where subject to taxes, fees, Transport and handling charges.

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