processing meat

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MEAT PROCESSING PRACTICES AT Keels Food Product Limited Minuwangoda Road, Ekala , Ja-ela. By B.M.W.G.Jayawardhana, (02/AG/A/009) 2008 Department of Livestock Production Faculty of Agricultural Sciences Sabaragamuwa University of Sri Lanka. Belihuloya.

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Page 1: Processing Meat

MEAT PROCESSING PRACTICES

AT

Keels Food Product Limited

Minuwangoda Road,Ekala , Ja-ela.

By

B.M.W.G.Jayawardhana,

(02/AG/A/009)

2008

Department of Livestock ProductionFaculty of Agricultural Sciences

Sabaragamuwa University of Sri Lanka.Belihuloya.

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MEAT PROCESSING PRACTICES

AT

KEELS FOOD PRODUCT LIMITED

BY

B.M.W.G. Jayawardhana.(02/AG/A/009)

This report is submitted in partial fulfillment of the requirement of the degree of

B.Sc. (Agricultural Sciences)

(Specialized in Livestock Production)

Of

Faculty of Agricultural Sciences

Sabaragamuwa University of Sri Lanka

Belihuloya

Sri Lanka

2008

Approved by

Internal supervisor,

Dr. T.S.P.Jayaweera,

Senior Lecturer,

Department of Livestock Production,

Faculty of Agricultural Sciences,

Sabaragamuwa University of Sri Lanka

Belihuloya.

……………………………………..

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External supervisor,

Mr. Anton Kalubowila,

Purchasing Manager – Livestock,

Keels Food Products Limited,

Ekala, Ja- Ela.

……………………………………..

Dr. Anil Gunaratne,

Head of the Department,

Department of Livestock Production,

Faculty of Agricultural Sciences,

Sabaragamuwa University of Sri Lanka

Belihuloya.

………………………...................... Date: ………………….................

Synopsis

Keells Food Products Limited – Ekala, is the todays leader of the meat processing industry in

Sri Lanka which has 70% of market share. KFPL produces processed meat products as Keells

range products and battered and crumbed products as Krest range products. Sausages, meat balls,

ham, bacon, bomb products, fresh meat cuts etc. are some Keells range products, and Chinese

rolls, drumsticks, nuggets, fish burger, fish finger etc are some of the Krest range products. I

had a great opportunity to do my in-plant training in those factories and I gained ample

knowledge about processing and quality control practices of processed meat products.

The factory has a receiving bay in which all raw meat are received and dry ingredients are

bought through dry stores and other ingredients are sent to freezes or chiller. They also receive

live pigs and slaughter them in the slaughter house in the factory premises. After slaughtering

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pigs and other received carcasses are sent to de- boning section for de- bone according to the

production requirement. From that variety of products are made and stored in freezers until sent

to ‘Finley’ cold stores.

In krest factory, battered and crumbed meat products are produced and marketed as Krest range

products. Further more the factory has its own waste water and water treatment plant and waste

disposal system which does not release hazards to the environment

Apart from that quality control department of KFPL is doing a great job to assure the safety of

customers via maintaining the quality of the food. They perform microbiological, chemical

testing according to SLS methods and sensory evaluations to ensure product safety.

I got familiarized with all the production procedures are well as quality assurance in KFPL.

Apart from that I carried out many case studies and most of those were based on swab sample

testing method.

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Acknowledgement

I would like to express my deepest gratitude to my internal supervisor Dr. T.S.P. Jayaweera

(Senior lecturer, Department of Livestock Production, Faculty of Agricultural sciences,

Sabaragamuwa University of Sri Lanka) for giving his assistance to undertake this study and his

valuable guidance in carrying out this training successfully.

At the same time , I wish to acknowledge my gratitude to the external

supervisor Mr. Anton Kalubowila (Manager – Livestock Purchasing, KFPL) for his valuable

guidance, constructive criticism and invaluable assistance given for the successful completion of

this program.

Secondly I would like to thank Dr. Jagath Munasinghe (Coordinator- industrial training program,

Department of Livestock Production, Faculty of Agricultural Sciences, Sabaragamuwa

University of Sri Lanka) , Dr. D.M.A. Gunaratne , Head of the department of Livestock

Production and all the academic non academic staff of the Faculty of Agricultural Sciences,

Sabaragamuwa University of Sri Lanka for their guidance and help extended me in numerous

ways.

I offer my special thanks to Mr. Lasath Ratnayake (Head-Qulity Assurance of the KFPL) and all

the executives, supervisors and workers of the KFPL for their valuable contribution and

necessary advices in completing my training period.

Finally I would like to extend my sincere thanks to parent, my colleagues for their kind co-

operation to make this study progressively.

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Table of content

Content Page number

Synopsis ………………………………………………………………………iAcknowledgement …………………………………………………………… iiTable of content …............................................................................................iiiList of figures …………………………………………………………………ivList of tables …………………………………………………………………..v

Chapter 11.1Introduction …………………………………………………………………1.2 History of the company ……………………………………………………

1.3 Organization structure of the Keells Food Products Limited ……………..

1.4 Policies of the company ……………………………………………………1.5 Management Hierarchy of the company …………………………………..1.6 Objectives ………………………………………………………………….

1.7 Nature of the training ……………………………………………………….1.8 Distribution and marketing of Keells products …………………………….

Chapter 2

Receiving bay, Slaughter house and de-boning section of KFPL

2.1 Receiving bay …………………………………………………………………

2.1.1 Purchasing of live animals …………………………………………….

2.1.2 Purchasing of raw meat and fish ………………………………………

2.2 General procedure while receiving live animals and raw meat………………….

2.2.1 Receiving of live animals ……………………………………………… 2.2.2 Receiving of pork carcasses (leg and loin) and beef carcasses (forequarter and

hindquarter) and mutton …………………………………..

2.2.3 Receiving of beef …………………………………………………

2.2.4 Receiving of chicken ………………………………………………….. 2.2.5 Receiving of fish ………………………………………………………. 2.2.6 Receiving of non meat ingredients ……………………………………….2.3 Ingredients used in processing of meat products …………………………………… 2.3.1 Non meat Ingredients ……………………………………………….. 2.4.2 Special steps that are strictly controlled in slaughter house ……………..

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2.4 Slaughter house operations …………………………………………………………

2.4.1 Slaughtering of animals in KFPL ……………………………………..2.5 De-boning of carcasses ……………………………………………………………

Chapter 3

Processing section of Keells factory

3.1 Meat processing equipments and utensils ………………………………………..

3.2 Meat processing methods ………………………………………………………….

3.3 Different meat products ……………………………………………………………..

3.4 Processing of Krest products ……………………………………………………..

3.4.1 Production of formed products ……………………………………….

Chapter 4

Packing Section

4.1 Concept – (FIFO) …………………………………………………………………

4.2 Good manufacturing practices at KFPL …………………………………………..

4.3 Equipments used in packing section ………………………………………………

4.4 Packing materials ………………………………………………………………….

4.5 Processes involve in packing………………………………………………………

4.6 Color code system for finished product bundles………………………………….

Chapter 5

Handling and storage of raw materials and finished products at KFPL

5.1 Concept: First In First Out (FIFO)

5.2 Handling and storage of raw materials

5.3 Handling and storage of half processed products

5.4 Handling and storage of finished products

5.5 Steps should be followed when products are stored in plate freezer

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Chapter 6

Quality Assurance Department

6.1 The routine schedule of quality assurance department

6.2 Media preparation

6.2.1 Potato Dextrose agar (PDA) media

6.2.3 Baired Parker media

6.2.2 Mac Conkey Broth

6.2.3 Baired Parker media

6.2.4 Peptone Broth

6.2.5 Sellanite Cystene broth

6.3 Microbiological Tests

6.4 Chemical Analysis

6.5 Sensory Evaluation

Chapter 10

Discussion

10.1 Strengths

10.2 Weaknesses

10.3 Recommendations

List of figures

Figures Page numbers

Figure 1: Contribution of different sectors to John Keells Holdings group………….

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Figure 2: Contribution of different sectors to Food and Beverage sector of JKH……

Figure 3: Management Hierarchy of John Keels Holdings Group …………………..

Figure 4: Operational involvement of different units if KFPL ………………………

Figure 5: Role of nitrite, ascorbate and heat in cured meat pigment formation ……

Figure 6: Ingredients used in KFPL for the production of processed meat products..

Figure 7: Zones of hygiene in pigs slaughtering and processing …………………..

Figure 8: Pork primal cuts ……………………………………………………………

Figure 9: Different types of casings ………………………………………………….

Figure10: Different meat product at KFPL …………………………………………

Figure 11: Flow of production of formed products …………………………………

Figure 12: Flow of production of formed products …………………………………

Figure 13: Waste water treatment system at KFPL …………………………………

Figure 14: Potable water treatment system at KFPL …………………………………

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List of tables

Table Page number

Table 1: Color code system for finished product bundles …………………..

Table 2 : Different types of chillers and freezers in the factory ……………..

Table 3: Microbial counts of samples with brine A (Purac) sodium lactate…

Table 4. : Microbial counts of samples with brine B sodium lactate …………

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List of abbreviation

AOAC -

FIFO - First In First Out

HACCP - Hazard Analysis Critical Control Point

IPA - Iso Propyl Alcohol

ISO -

KFPL - Keells Food Products Limited

LAB - Lactic Acid Bacteria

MDM - Mechanically De-boned Meat

MSM - Mechanically Separated meat

PDA - Potato Dextrose Agar

SLS - Sri Lanka Standards

SLSI - Sri Lanka Standards Institute

TPC - Total Plate Count

TVP - Texturized Vegetable Protein

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Chapter 1

1.1 Introduction

John Keells Holdings PLC (JKH) specializes in the sectors of Food & Beverage, Transport,

Leisure, Information Technology, BPO, Financial Services, Property Development, Plantation

and Investor Services. JKH preserves the identity of each sector group, yet successfully bring

them together as John Keells Holdings PLC.

The Food & Beverage Sector Group is home to a portfolio of leading brands in the

Beverage, Frozen Confectionary, and Processed Meats categories which include "Elephant"

carbonated soft drinks, "Elephant House" Ice Creams, and the "Keells" and "Krest" ranges of

Processed Meats. All brands are market leaders in their respective categories and are supported

by a well-established distribution channel of almost 80,000 Outlets Island wide.

Keells Food Products PLC is presently Sri Lanka’s market leader in the processed meat

industry and enjoys a market share of approximately 70%. A subsidiary company of John Keells

Holdings, KFP PLC started its operations in the year 1983, and today takes the pride being solely

responsible in developing the Sri Lankan Processed Meats industry to its current heights.

KFP PLC have kept abreast of the industry through strategic investments in state-of-the-art food

processing technology, quality control systems, an aggressive companywide R&D orientation

and ground breaking marketing leadership in the food industry of Sri Lanka.

‘Keells’ world class Sausages, Meat Balls, Hams, Bacons, Cold meats and ‘Krest’ battered and

crumbed delicacies combine gourmet taste, nutrition and offer superior quality. The range offers

convenience to meet today’s demanding lifestyles of consumers all over the world.

KFP PLC, the first meat further processing company with SLS product certification, ISO

9001:2000 and HACCP certification, today it serves local markets, super markets, hospitality

industries as well as certain markets in India, United Arab Emirates & Maldives

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1.3 Organization structure of the Keells Food Products Limited

Strategic reinvention and diversification for over 130 years has enabled John Keells to become

Sri Lanka's largest business group and a leading investor in the country's economy. They

specialize in the sectors of Food & Beverage, Transport, Leisure, Information Technology, BPO,

Financial Services, Property Development, Plantation and Investor Services and successfully

bring them together as John Keells Holdings PLC. Among all the sectors of JKH, Keells Food

products PLC contribute 8% to the total by producing wide range of products under the popular

brand names of Keells, Krest and Elephant House.

Figure 1: Contribution of different sectors to John Keells Holdings group.

Food and Beverage 8%

Plantation 19%

Transport and Infrastructure 17%

John Keells HoldingsFinancial service 9%

Information Technology 2%

Trade and Export 3%

Leisure 27%

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Figure 2: Contribution of different sectors to Food and Beverage sector of JKH.

1.4 Policies of the company

Mission of the company

“To be the largest provider of value added meat, fish and vegetable products in Sri Lanka while

establishing regional brand presence and catering to international markets with Asian

communities, environmental friendly technology.’

Vision of the company

“Our passion is to deliver pleasure and nutrition throughout peoples lives, through exciting and

superior products, whenever and wherever they choose to eat and drink”

Food safety policy

Food and Beverage Sector (8%)

Keells Food Products PLC

Elephant House ice

cream

Elephant carbonated soft

drinks

Krest battered and crumbed products

Keells processed meat

products

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“Keells food is committed to continually improve its processes to align itself changing consumer

perceptions. Through our competent staff, we offer safe, nutritious, trendy and convenient meat,

fish and vegetable pasted products consistently meeting on exceeding the consumer demand

1.5 Management Hierarchy of the company

John Keells Holding Group

Assistant Vice President (Head of operation)

Chief Executive Officer

Production Executives

Stores Executives

Quality Assurance Executives

Sales Manager

Brand Manager

Human Resource Manager

Quality Assurance Manager

Livestock Purchasing Manager

Factory Manager

Marketing Manager

Financial Manager

Maintenance Manager

AccountantsAssistant Production Managers

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Figure 3: Management Hierarchy of John Keels Holdings Group

1.6 Objectives

Specific Objectives

To be familiarized with the safe and hygienic production procedures from raw materials

to finished products at Keells Food Products PLC.

To be familiarized with the quality assurance practices and laboratory testing those are

applied for raw and finished products.

General Objectives

To familiarized with the general working procedure and basic manufacturing practices

and to obtain practical experiences and knowledge on quality assurance, research and

development and other functional and operational aspects of the meat processing plant.

To develop personal skills such as problem solving ability, interpersonal skills,

leadership, ability to work as a team to achieve targets, that are demanded by the current

organization atmosphere.

To identify the strengths and limitations the plant as well as to point suggestions for the

improvement of the factory.

1.7 Nature of the training

During my training period I gathered knowledge on all the production procedures including

receiving, processing, packing and distribution, quality assurance procedures, laboratory testing,

water and waste water treatment, incineration practices and waste disposal procedures of the

factory.

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1.8 Distribution and marketing of Keells products

Keells and Krest companies produce wide range of processed meat and battered and crumbed

products respectively. Raw materials are received from local as well as international suppliers

and then those are sending to processing section after quality inspection. Finished products are

sent to Finely cold storage after giving assurance for quality. From Finely cold stores, products

are distributed to local markets, hotels and super markets as well as international markets.

Product complaints are come back to the factory in an opposite way to product flow. Customer

complaint sheets are distributed to shop keepers and they collect complaint. Monthly evaluations

and remedial actions are under taken by the department of quality assurance.

Receiving

Quality inspection

Customers

Processing

Quality assurance department

Distribution /Market returns

Quality inspection

Final product

Finely cold stores

Customer complaints

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Figure 4. Operational involvement of different units if KFPLChapter 2

Receiving bay, Slaughter house and de-boning section of KFPL

2.1 Receiving bay

Raw meats are received to the receiving bay. Meat and related products are stored in storage

freezer or cold stores at (-18 to -30) 0C. Meat and non meat ingredients are stored and dispatched

using first-in-first-out system to the production unit when it is necessary. Purchasing of live

animals (pigs) are undertaken by the inspectors in the receiving bay. Receiving bay is one of the

critical point that leads contamination. If the initial contamination is high, keeping quality of raw

meat as well as the end product is very less. Therefore quality inspection is critically done for

raw materials in order to achieve high quality end products.

2.1.1 Purchasing of live animals

KFPL purchases live pigs from local farmers. The company provides technical knowledge and

financial assistance to the farmers, and purchase their product at a reasonable price. Pork

carcasses (after slaughtering live animals) are graded according to weight and fat basis and paid

accordingly. Registered farmers directly supply the live pigs to the company through the

approval of veterinary surgeons. To receive best quality meat farmers should satisfy company

requirements as follows;

Adequate water should be provided to animal prior to transportation.

Animals should transport in a manner that reduce the stress

During loading and unloading animal should be handled carefully.

Well ventilated, comfortable vehicle should be used to transport animals.

Proper spacing and well bedded floor should be provided during transportation.

Both unnecessary delay and high speed should be avoided during transportation.

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2.1.2 Purchasing of raw meat and fish

Raw meat and fish are purchased from local and international farms. KFPL purchase pork, beef,

chicken, lamb and mutton in raw form to produce various processed meat products. Major

suppliers of raw meat are Maxies Company (pvt.) Ltd. , Pussellawa farms, Chutiduwa farms,

Nelna Farm etc.. Some frozen raw meat, MSM and other some materials are imported from

foreign countries, only after the approval of quarantine center. All carcasses are visually

inspected and samples obtained are subjected to chemical and microbiological testing by the

quality assurance department at the receiving point to ensure that they meet the required

company standards. During transportation following conditions should be satisfied;

Vehicle should have a freeze or at least chill conditions.

All raw meat should be packed in baskets and covered well.

Raw meat should supply to receiving bay as soon as possible.

Raw meat should be free from foreign materials, bad odor and discolorations.

2.2 General procedure while receiving live animals and raw meat

2.2.1 Receiving of live animals

Ante mortem inspection

Weighing and tattooing of pigs

Grading according to sex and age

Adequate water and feed is given if animals are kept more than 24 hours

Cool water is sprayed to reduce the stress.

2.2.2 Receiving of pork carcasses (leg and loin) and beef carcasses (forequarter and

hindquarter) and mutton

KFPL has its own slaughter house in the factory premises but total requirement for the

production cannot be fulfilled by themselves. Because they slaughter only 255 pigs per week.

Therefore they purchase pork leg & loins and legs from outside farms. Following procedure is

followed when carcasses are received.

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Unloading of leg & loins and hang on trolleys.

Inspection for bad odors, foreign matters, wounds, blood patches and discolorations.

Removing of foreign materials from the carcasses.

Weighing of carcasses

Spraying of disinfectant solutions on carcasses

Washing of carcasses after 15 minutes.

Spraying of lactic acid solution on carcasses

Collecting samples for microbial analysis.

Storing carcasses in the slaughter chill room until they will be taken to the de- boning

section.

2.2.3 Receiving of beef

Unloading of beef cuts and Inspection for discolorations and bad odors

Removing of unwanted fat, foreign materials and bones in beef only.

Spraying of disinfectant solutions on carcasses

Putting in to water tub and wash with water.

Sort out meat cuts for different products.

E.g. Top side, Silver side, Knuckle, Strip loin, Fillet, Rump

Weighing separately.

Collecting samples for microbial analysis.

Storing in chill room.

2.2.4 Receiving of chicken

Unloading of chicken meat (boneless meat, loose meat, MSM, breast meat)

Sorting out different types of chicken meat.

Weighing separately

Collecting samples for microbial analysis.

Storing in the main freezer.

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2.2.5 Receiving of fish

Unloading of fish to the receiving table

Inspection for bad odors, foreign matters and discolorations.

Trimming of unwanted skin parts, discolored parts and bones.

Dipping of fish in disinfectant solution and mixing with ice.

Collecting samples for microbial analysis.

Packing of fish in polythene bags.

Storing in freezer

2.2.6 Receiving of non meat ingredients

Non meat raw materials (ingredients, packing materials, casings and other) are inspected for

quality, quantity, date of expiry, grade, origin and other required information. Then the samples

are drawn according to the sampling plan for further testing.

E.g.

Bread crumbs - Tested for particle size, moisture, yeas and mold count

Packing materials - Measured the width, length and thickness and compared

with the specifications

Spices - Analyze for moisture, ash content and sensory attributes

2.3 Ingredients used in processing of meat products

2.3.1 Non meat Ingredients

2.3.1.1 Salt (Sodium Chloride)

Principle function of salt is to, solubilize and extract the myofibrilla protein needed to form a

bind during cooking. By dehydrating and altering osmotic pressure, salt inhibits bacterial growth

and subsequent spoilage. Other than that it maintains taste of the final product

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2.3.1.2 Nitrite salt (NaNO2)

However salt is used along with curing salts (NaNO3, NaNO2) which stabilize the cured color

and flavor, inhibit the growth of Clostridium botulinum and retard development of rancidity. In

order to fix the color of the meat, the nitrite must convert in to nitric oxide which actually

combines with myoglobin to form a pink- red nitrosylmyoglobin or pigment of cured meat.

Conversion of nitrite in to nitric oxide can be accelerated by adding reductants like ascorbic acid.

Myoglobin

Nitrite

Met myoglobin Ascorbate

Nitric oxide

Nitrosyl metmyoglobin

Or SH - group

Nitrosilmyoglobin

Heat

Nitrosilmyochrome

Figure 5 . Role of nitrite, ascorbate and heat in cured meat pigment formation.

Approximately 10 to 30% of the added nitrite remains intact as residual nitrite, 45% is consumed

for curing color and nitrite formation, while the reminder is involved in other actions. According

to SLSI guild lines residual amount of the finished product should not exceed 125 ppm. However

usage of nitrite has been questioned, as it reacts with secondary and tertiary amines in meat and

produce carcinogenic nitrosoamines.

2.3.1.3 Binders

Binders or extenders are referred to as fillers, emulsifiers or stabilizers. Those are added to,

improve, flavor, cooking yield, slicing characters, protein content, emulsion stability fat binding

and water binding and reduce the formulation cost. Binders are portentous substances which

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contribute to structural, emulsifying, binding and gelling qualities as well as color and flavor of a

product. Fillers are carbohydrate products able to adsorb extensive quantities of water

E.g.: Modified corn starch, Milk powder, isolated soy protein, Rusk powder

2.3.1.4. Antioxidants

Foods, containing fats and oils, are prone to oxidative deterioration as a consequence of contact

with atmospheric oxygen during processing and storage. When oxidation occurs in food, it

causes a development of an unpleasant smell, taste and loss of nutritive value. The most effective

way to delay the onset of oxidative rancidity and to obtain the desired shelf life is addition of

minute quantities of antioxidants. BHA, BHT E300 and E301 are the antioxidants used in KFPL.

2.3.1.5 Texturized Vegetable Protein

Meat and marine products are the most desirable and prestigious source of high quality animal

protein for man. But its limited availability and high costs reduces its consumption Therefore

food industry has made a meat substitute from vegetable sources fortified with vitamins, amino

acids, etc. TVP does not alter the texture, palatability and nutritional value of meat products.

Rate of substitution varies from product to product.

2.3.1.6 Spices

E.g.: Black pepper, white pepper, chille, cinnamon, cardamom, cumin, clove, coriander, nutmeg,

maze, ginger, curry powder, herbs etc.

Most of the spices add to the flavor to the product while certain spices act as antioxidants

retarding the rate of oxidative changes in processed meat products. (Onion, rosemary, sage,

thyme, ginger, black pepper, garlic, clove etc.) Cinnamon, onion, garlic and a number of other

spices are able inhibit proliferation of distinctive micro organisms.

2.3.1.7 Sweeteners (Sucrose, Dextrose, Sugar syrup etc.)

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Sugar is added to meat as an adjunct to counteract the salty taste to give flavor and to serve as a

substrate tfor bacterial acid production. Browning compounds which produce due to melting of

sugar with amino acid add color and flavor to the product.

2.3.1.8 Ascorbis acid (Sodium ascorbate / Erytrobate)

Reductants react with nitrite to give nitric oxide thus fastening the development of pink red color

in cured meat products. Ascorbete apperently rapidly reduce metmyoglobin to myoglobin and

secondly reacts wih nitrite to produce nitric oxide more efficiently.

2.3.1.9 Phosphates

Phosphate salts elevate the pH of meat, thus improving it’s water binding capasity. It also acts as

a buffer and raaises the ionic strengh of he slutions while retard the devekopment of oxidative

ransidity n meat products.

E.g.: Terasodium pyrophosphate, Sodium hexametaphosphate ect..

2.3.1.10 Flavor enhacers

Flovor enhancers are used to enhance the meat flovor of the processed products.

E.g.: IMP, GMP, MSG

2.3.2Meat Ingredients

KFPL uses different types of meat and meat cuts as ingredients during process flow.. Following

figure illustrate all types of meat ingredients used for processing of Keells foods.

2.3.2.1 MSM/ MDM

Mechanically separated meat or mechanically deboned meat, are used as an ingredient in

processed meat products. Those are ground, frozen, compact meat ingredients and can be

produce from Beef, Pork, Poultry and Mutton

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Chicken Turkey Cuts Leg & loin 1. Whole carcass 1.Sappars

2. Leg & loin 2.Coppara

1. Boneless 1.Silver side 3. Shoulder 3.Prawn

2. Loose meat 2. Top side 4.Cuttle fish

3. Fillet 3. Knuckle

4. Brest meat 4. Fillet

5. Liver 5. Eye of round

6. Gizzard 6. Strip loin

7. Skin 7. Rump

Figure 6. : Ingredients used in KFPL for the production of processed meat products

2.4Slaughter house operations

2.4.1 Slaughtering of animals in KFPL

After purchasing pigs, they are kept in well maintained pens. Adequate water and feed are given

if they are kept more than one day. Cool water sprayer reduces the stress of them due to

traveling. Stressed animals give low quality carcasses. In KFPL only pigs are slaughtered.

However maximum time of keeping pigs in pens is two days. Pigs are come to the stunning area

in a queue, one by one. That also reduces the stress of them because they cannot see the process

inside.

2.4.1.1 Stunning (Making animal unconscious)

Meat Ingredients

Poultry Mutton Beef Lamb Pork Fish

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Before stunning pigs are cleaned well with water. Then animal is made unconscious by using

240V DC current for about 15 seconds. For this purpose, a pair of stunning tons is used. In

KFPL, head to head stunning is done. That is the most effective way of stunning.

2.4.1.2 Sticking (Removing blood from the animal)

Blood should be removed within 15 seconds after stunning. Sticking knife is sterilized by using

100 0C boiling water.Pig is hanged by its’ hind leg and carotid artery is damaged by using

sticking knife. Bleeding is done for 3 to 4 minutes.

2.4.1.3 De-hairng (Scalding), Scraping and Singing

Animal is kept in de-hairing machine for 3 minutes at 65 – 75 0C water are spred and rubber

fingers are rotating then heirs are removed. Then remain hair on its’ body are scraped by using a

shapend knife. But some hair may remain on the skin.Therefore the balance hair which is on the

body is removed by a flame. This also help to sterilize the carcasses.

2.4.1.4 Eviseration

Evisceration is the removal of viscera (internal organs, especially those in the abdominal cavity).

The abdomen is opened from the top to bottom where the internal organs are loosened and

removed from the body. The abdominal organs are inspected and the stomach and intestine are

emptied of manure. Digestive track is removed without any contamination with the carcasses. If

carcass is contaminated with the faces, the carcasses are washed and cleaned immediately. A

clean bung end holder is used to prevent the coming of faeces from the anus. Removed digestive

track is then put in to relevant baskets and small intestine is separated to use as casing in

preparation for lingus. Other than that following internal parts (Red offal) are used as by

products.

Lungs – not use for processed meat products

Heart - Use in making processed meat products

Liver – Use in make red head and cheese with blood

Tongue – Use to make processed meat products

Kidney - Use to make processed meat products

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2.4.1.5 Scoring

The central bone is marked using a small cut from tail to head. Then a deep cut is made to some

extent from both sides of the central back bone. This facilitates the removal of back bone during

de- boning.

2.4.1.6 Splitting

Carcasses are separated in to two halves through the back bone.

2.4.1.7Jowl separation

Jowl is separated from the head of the animal. This facilitates the handling of carcasses when

those are hanged.

2.4.1.8 Final Washing, Lactic acid treatment and weighing of the carcasses

Whole carcass is then washed with pressurized water flow. Next 2% lactic acid solution is

sprayed on to the carcass to reduce the initial microbial count of the carcass and finally weight

and grade of the carcass are recorded before it is sent to the chilling room.

2.4.1.9 Chilling

Clean carcasses are then conveyed to a cold storage area for rapid chilling. Carcasses are chilled

in chill room until those are taken in to de- boning section. Since new carcasses are come to chill

room following a slaughtering of new animal, carcasses are not kept in chill room more than 3

days.

2.4.2 Special steps that are strictly controlled in slaughter house

2.4.2.1 Ante-mortem inspection

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Animals are inspected for following aspects before slaughtering. Skin damages, wounds, leg

damages, age, body conformation, physiological status, health, cleanliness, nutritional status,

respiration, behavior, gait, posture and discharges.

2.4.2.2. Post- mortem inspection

After slaughtering of animals, internal organs are inspected to check whether they have disease

conditions or not. In addition to that, degree of bleeding and color of animal are checked. Fat

thickness and body weight give a clear idea of the age of the animal. Followings are some

disease conditions of animals.

E.g. : Lungs – If attached to ribs, Pneumonia

Liver - White /milk spots, Worm infection

Kidney –If water bubbles present, Kidney disease

Fat content – Measure at 5th rib,

Fat thickness: (5-20) mm – Grade A , (20-30) mm- Grade B

More than 30 mm – Grade

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2.4.3 The zones of hygiene in pig Slaughtering and processing

Unclean side clean side

Dispatch

Storage

Packaging

Processing

De-boning

ChillingReceiving

Cleaning

Stunning

Sticking

Scalding

Scraping

Singing

Evisceration

Post mortem inspection

Splitting

Final washing

Lactic acid treatment

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Figure 7. : Zones of hygiene in pigs slaughtering and processing

2.5 De-boning of carcasses

Beef and pork carcasses are de-boned at the de-boning section of KFPL. Pork carcasses are come

to the de-boning section from the chill room after slaughtering. Whole carcass is then divided in

to three main parts as shoulder, middle and leg. From each part different products are prepared.

For instance shoulder is used for the production of shoulder ham, green gammon etc., middle

part is used for the production of back bacon and streaky bacon, fillets etc., From the leg, pork

cuts (Knuckle, silver side, top side, Eye of round), various products of ham such as special

cooked ham, cottage ham, honey roast ham, palmer ham, millennium ham, smoked leg of ham

are prepared.

Figure 8 : Pork primal cuts

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Chapter 3

Processing section of Keells factory

3.1 Meat processing equipments and utensils

Meat processing equipment and utensils used in industry must have some special characteristics

such as they should be made of appropriate materials to avoid corrosion and should have rugged

construction to minimize maintenance, satisfactorily designed to limit the handling of meat and

to facilitate thorough cleaning after using and capacity to meet any expected production

requirement. All these requirements should be provided with necessary safeguard to ensure that

they are not harmful to the labors.

Jig-saw

Electrically operated device, consists of a rotating blade which saw off the pork carcass across

the hard bone fragments located in the legs and shoulders.

Band saw

Band saw is used to trim off the frozen carcass or meat chunks in to small pieces/ chops of meat.

Band saws use thin, flexible, continuous steel strips with cutting teeth on one edge. The blade

runs on two pulleys, driver and idler and through a work table where material is manually fed.

De- render

This machine is to skin off the pork primal cuts with very small fat thickness, which is difficult

to remove out with the knife.

Gilatin.

This is used to cut frozen MSM and cheese

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Multi needle injecting machine

This machine is used to inject brine to bacon, ham and English gammon. A pump in the machine

sucks brine in the brine holding tank through a series of filters and takes it to the injecting

needles via a regulating valve. Brine which comes first through the injecting needle, is injected

to meat by needles which move up and down and penetrated to the muscle component in exact

amounts. Brine which is not injected, is flows back in to the brine tank. Conveyor belt facilitates

forward movement of meat cubes since belt moves forward when needles are in a higher

position from meat cube.

Tumbler

Tumbler rotates around its horizontal axis. It contains identically spaced rods inside the drum

adjacent to its periphery and parallel to its rotation. Rods contain teeth which produces mass of

small cuts on the surface of the meat. Tumbling and formation of small cuts increases the

exposure of myosin protein at the surface and thereby penetration of brine in to the meat cubes.

Mincer

This machine is used to grind or mince ingredients. Loose meat and de-boned meat are grind into

very small particles which are then used for the production of sausages, meat balls etc.

Ball chopper

Bowl choppers are essentially composed of a horizontally revolving metal bowl equipped with a

set of curved very sharp knives, mounted on a horizontal axle rotating at high speed. The high

speed blades cut the meat with less friction and heat production than a conventional meat

grinder. The chopper can emulsify meat by continuing to chop until the product reaches batter –

like consistency. Temperature control is important during emulsifying. The batter must warm

enough to allow microscopic fat particles to be encapsulated by the meat proteins.

Vacuum filler machine

This machine is basically equipped with a feeding hopper, vacuum chamber, filling device and

twisting device. When the meat mixture is sent through the vacuum chamber, air and excess

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moisture removes out. Then the pressurized meat mixture goes through the pressure tube to the

filling tube, by means of a pump wheel and a pinion. According to the diameter of the sausage,

the filling tube can be replaced. There is a pressure sensor, which is requested to be fed with the

constant filling pressure. Twisting g occurs according to the filling weight, speed and pressure,

which are manipulated by a computerized programme.

Cooking / Smoking chamber

The chambers are used for thermal processing such as cooking, smoking, baking and drying of

sausages, meat balls, ham, bacon and bomb products. Smoke is produced by using hardwood saw

dust and bacon is a smoked product. The smoke gives desirable flavor and color to the product.

Temperature of the chamber can be altered according to the product but most commonly used

temperature range is 65 to 72 0C. Sausage, meat ball and bacon are cooked products. These

products are cooked until its’ core temperature reaches to 72 0C.

Peeler

The peeler machine peels the non edible casing of the cooked chicken sausages. Cooked

sausages are entered to the machine from one end and it pass through a chamber with steam and

then through the blade, which peels the casing and peeled sausages are then drop on to a

conveyer travel to the packing section.

Slicer machine

This is used to slice the final products such as ham, bacon, chicken roll etc. Product is mounted

vertically on a spiked platform which slowly revolves. A sharpened rotating disk blade is then

cuts the product in to required size. Cut pieces are then send to packing table via a conveyor.

Multivac packing machine

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Machine has multiple functions such as forming, vacuuming and sealing of the retail packages.

Manually filled packs are vacuum packed by using this machine. There are adjustable blocks to

maintain the package sizes in the forming machine.

Metal detector

Each and every product, after packing, is sent through the metal detector. If the quantity of

metals exceeds the standard limit , it gives a signal and blocks the passage of packs. Then the

sample with high amount of metal can be identified and suitable action can be taken. Accuracy

of the detector is checked by passing a metal sample which is 2.5 mm in thickness through the

detector twice a day.

3.2 Meat processing methods

Fermentation

The main desirable effect of starter micro organisms on flavor and taste of fermented meats are

formation of lactic acid, trans formation of compounds from abiotic breakdown of lipids,

degradation of peptides and amino acids by meat proteases

Curing

Curing adds various flavors and taste to foods and also it is a preservation method especially of

meat or fish, by the addition of a combination of salt, sugar and either nitrate or nitrite. Curing

with salt and sugar is called as salt curing. Curing in water solution or brine is called wet curing

or pickling or brining.

Smoking

Smoking has been used as a preservation method since ancient time. Smoke preserves food via,

protecting from oxidation, developing aroma, flavor and developing new compounds. In addition

it produces color and form protective skin on emulsion type sausages.

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3.3 Different meat products

Fresh meat items

Local meat and some imported raw meat cuts are directly packed after deboning, are called as

fresh meat cuts.

E.g. : Curry pork, Lamb chops, Local mutton cubes, Mutton and Pork chops

Sausages

Sausages are a unique type of comminuted meat product that are usually spiced or seasoned to

obtain various flavor intensities and profiles. According to the classification, sausages can be

categorized as fresh, cured, cooked and fermented sausages. Cooked items are divided in to two,

as skin on and skin less. Sausages with edible casings are not peeled during processing and

packed with the casing itself but inedible casings are peeled off before packing of sausages

Figure 9. Different types of casings

Meat balls

Casings

Edible

Natural

Inedible Viscofan, Nojax

Artificial

Sheep and pig casings

Devro

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Meat balls are another type of comminuted, cooked meat product, the production is similar to the

sausage production except usage of casings.

Cured and smoked products

All range of hams, bacons, smoked products and roasted products are included to this group.

Those are Chicken tondorey, smoke chicken breast, spicy chicken breast, smokes beef etc.

Roasted products are roasted pork, roasted turkey etc.

Bomb product

The production procedure is similar to the production of sausages but the mixture is filled in to

large casings and prepared as bombs. After cooking casing is peeled off and bomb is sliced and

packed.

Bacon

Properly trimmed pork loins and bellies are cured in pickle solutions and processed with or

without smoking. The major types of products are back bacon, streaky bacon beef bacon and

bacon ends. Back bacon is prepared from pork loins, streaky bacon from pork bellies, beef bacon

from beef sir loin and bacon ends are produces from end cut of bacon during slicing.

Ham

There are different types of ham varieties such as, special cooked ham, chicken ham, beef ham,

honey roast ham etc. Most important steps of manufacturing of ham are pickle curing and

tumbling to get the desired texture. Typical ham is cured with a mixture of Salt, sugar, nitrite,

ascorbic acid and phosphates.

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Bacon Skinless Ham Raw cuts Cooked

Skin on Smoked products Cut Products

Roasted Products

Figure10. : Different meat product at KFPL

3.4 Processing of Krest products

3.4.1 Production of formed products

There are number of formed products such as fish cake, fish finger, nuggets, burger etc.

Production procedure for all products is similar except the shape of the products. For instance

burgers are round in shape, fingers are cylindrical, nuggets are irregular in shape etc. To change

the shape of the product different forming plates are fixed to the machine with relevant shape.

Cured and smoked meat

Bomb Items Meat ballsSausage range Products

Fresh meat Items

Meat Products

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Figure 11. : Flow of production of formed products

3.4.2 Production of Chinese rolls

Preparation of meat mixture

Final packing

Pre cooling Store in blast freezer

Crumbling Battering

Forming of productsInsert the mixture to the machine

Frying

Packing

Store in transit freezer

Preparation of filling RollingFormation of pan cake

Crumbling

Final packing

Store in a blast freezer

BatteringFrying

Packing

Store in transit freezer

Pre -cooling

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Figure 12. : Flow of production of formed products

Chapter 4

Packing Section

4.1 Concept – (FIFO)

KFPL follows first In First Out concept (FIFO). Products that comes first, pack first and release

to the market firstly.

4.2 Good manufacturing practices at KFPL

Caps, marks, gloves should be worn correctly. For instance ears should be covered by cap.

Nose e and mouth should be covered by marks.

Boots should be worn and cleaned with a sanitizing agent

Hands should be washed before enter to the packing section, after coughing, sneezing

and after going to toilet.

Hands should be washed with soap and dried using paper towels.

No jewelry policy.

Food which is on the floor should not be used.

Clean baskets and tubs should be used.

Baskets should not be allowed to touch the floor.

Used caps, masks, gloves muse put in to dustbins without putting everywhere.

The surroundings should be cleaned well.

.Peeler, Slicer, slicer table. Packing table should be cleaned using iso propyl alcohol.

Be silent in the section.

4.3 Equipments used in packing section

Sealer

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Sealer is used to prepare the seal when producing polythene bags.

Vacuum sealer

Packed products can be vacuum pack and seal by vacuum sealer. Gas in the pack is sucked by

the machine and creates a vacuum condition while sealing.

Thermo sealer

This is an automated machine which is used to pack the products at high speed. There are two

types of seals, top reel and bottom reel. Bottom reel passes through the forming mold and it

forms as polythene containers. Then products are packed in to containers manually. After that it

passes through the sealing mold and it is sealed with the top reel while creating vacuum

condition in the pack.

4.4 Packing materials

Bags -a. Printed retail pack

b. Unprinted bundle bags

Polyethylene reels – top reels and bottom reels

Card board boxes - a. printed boxes

b. Unprinted boxes

Labels

4.5 Processes involve in packing.

Vacuum packing

Raw meat products and processed meat products are prone to spoilage specially due to aerobic

micro organisms. Vacuum packs are used to remove aerobic conditions in packs and it creates an

anaerobic condition which elongates the shelf life of raw and processed meat products.

Non Vacuum packing

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Products like roasted duck, roasted lamb etc. don’t prefer vacuum condition. Therefore those

products are wrapped in flexible films and packed in cardboard boxes where there are holes to

facilitate air circulation.

Information on the package

Information which is important to customer should be included on the main panel and other

panel of the package according to the SLS standards. For instance common name of the product,

brand name, ingredients, price, date of expiry, date of manufacture, net weight, batch number,

storage instructions, instructions to preparation, nutritional claims etc.

4.6 Color code system for finished product bundles

A color code system is used to identify the products, which is produced in relevant month. A

color tapes, which are specified for a relevant month, are bind around the product bundles. Then

products can be easily identified.

Table 1: Color code system for finished product bundles

Month Color

January Orange

February Green

March Red

April Blue

May White

June Black

July Light green

August Pink

September Yellow

October Light blue

November Beige

December Transparent

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Chapter 10

Discussion

Keells Food Products PLC is today’s market leader of meat processing industry which processes

a range of innovative meat products contributing to 70% of market share. During the period of

my in- plant training I was able to gather experiences on all the functional and operational

aspects of the organization as well as to recognize the strengths and weaknesses of the factory.

10.1 Strengths

KFPL has its own well equipped production facilities to efficient production and ensure

product safety.

Present Sri Lanka’s market leader in the processed meat industry and it owns a market share

of approximately 70%.

Keells world class Sausages, Meat Balls, Hams, Bacons, Cold meats and Krest battered and

crumbed delicacies combine gourmet taste, nutrition and offer superior quality.

The range offers convenience to meet today’s demanding lifestyles of consumers all over the

world.

Products are made at a factory accredited with ISO 9001: 2000 for Quality Management and

ISO 22000:2005 for Food Safety Management

The manufacturing process which is semi automated takes place in a sterile environment.

Hygiene and sanitation is well maintained in packing sections of the Keels and Krest factory.

Company supplies its products to international markets such as India, United Arab Emirates

& Maldives according to their requirements.

KFPL has well equipped laboratory which make sure that the products conform to pre

determined and regulatory standards. All procedures are sensory evaluated, chemically and

microbiologically assessed to ensure that consistent levels of quality parameters are

determined.

Company has requisite blast freezing, chilling and other storage facilities which ensure

products, maintained at the desired freshness till reach to consumers.

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KFPL handles customer complaints and take remedial actions to correct it.

No jewelry policy and no food policy while working.

10.2 Weaknesses

Wastage is high during production process in the keels plant. Reasons are careless of the

workers, wreaked machineries and malfunctioning machines.

Not required space in the processing area of the keels plant to the workers to do their job

well. Then wastage is high, Efficiency of production process goes down.

Flore is not good enough for food handling factories. (Slippery flore) ,Sharp edges, broken

edges, difficult to properly clean.

Even there is a queue to enter the animal to stunning area more than one animal is entered to

that section. Animals are struggled and lead to skin damages, leg damages as well as animals

get stressed. Finally it produces low quality meat with low pH value. ( Final pH is less than

5.5)

In some occasions kept stunning tons to every where without considering head to head

stunning. It also produces low quality meat with less pH because animal get stressed.

Cross contaminations are possible for raw materials and finished products.

Fryers in Krest factory emits large amount of heat. Even there is a heat removing system, hot

condition is present in the factory. Due to that some workers complain that it is difficult to

wear masks for long time.

Even though company follows GMP , microbial contaminations are possible for finished

products.

Bio gas is produced by the anaerobic digester of waste water treatment plant. But it is

released the environment without getting any use.

10.3 Recommendations

At one time one animal should be taken in to stunning area to minimize stress.

Stunning tons should be kept behind the eye and below the ear correctly for 10 to

15 seconds.

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Workers should be advocated and educated regarding safe processing practices.

Responsible people should monitor whether the workers follow all the safety measures.

Workers who work in separate areas not be allowed to enter to other areas in which cross

contaminations are possible. For instance workers in slaughter house should not be allowed

to enter packing area.

All workers in processing and packing areas should wear caps, masks, gloves and boots.

All who enter to processing section must go through foot dips.

Workers should change gloves immediately, when necessary.

Swab sampling tests should be done frequently to check the cleanliness and hygienic

condition of workers and factory environment.

Fryers in Krest factory should be isolated in an insulated room in the factory and rest of the

factory can be air conditioned.

Bio gas can be used as an alternative for fuel requirement of the factory which is a cost

effective way.

Implementation and maintenance of quality management systems (total quality management,

environmental management, food safety management – HACCP) is essential to improve the

quality of the products as well as the credibility of the company.