Bulawayo Abattoir, Zimbabwe

Project
Apart from servicing the local Zimbabwean market, the New Bulawayo Abattoir will facilitate the availability of raw materials for the canning branch of the Cold Storage Commission (CSC), as the abattoir is EEC approved. The construction of this abattoir is intended to lead to an increase in exports of canned meats to countries other than the EEC.

The abattoir produces primal cuts, whole sale cuts, Trupac beef, tallow for the bakery industry and white offal for the pet food industry. Waste products from the abattoir are turned into stock feed.

Client: Cold Storage Commission (CSC), Zimbabwe

The project is funded by Commonwealth Development Corporation and European Investment Bank

The standard of the projects meets with the EEC regulations.

Awards
The Zimbabwe Institute of Engineers’ Achievement Award for 1991 was made to the Cold Storage Commission for their New Bulawayo Abattoir. The award was made with the objective of providing public recognition of noteworthy engineering achievement with the aim of

1. Challenging and encouraging engineers to strive for professional excellence

2. Drawing public attention to the contribution of the engineering profession to the
quality of life

Production and Capacity
Production and Capacities
Slaughtering
The abattoir has been designed for a daily slaughter of 600 heads of cattle (average live weight 450 kg) with allowance for an increase to 800 heads in the future.

The following procedures take place on the dressing floor

  • Horn removal
  • Head removal
  • Skinning
  • Evisceration
  • Carcass splitting

Boning and packaging facility
The capacity of the boning facility where hind quarter and forequarter beef is de-boned into either primal cuts or wholesale beef is 450 heads of cattle per day.

The capacity of the Trupac facility where low-grade beef is cut up and pre-packed is 400 quarters per day.

Offal packaging
Immediately beneath the dressing floor, the area is divided into areas for red and white offal treatment and packaging for automatic carton freezing.

Cold Room Complex
Beef quarters descend from the dressing floor into the cold room complex for overnight chilling to 7°C in one of the five hot beef chillers.

Thereafter the carcasses are either held in one of 3 holding chillers, one of 2 local sales chillers, on of 4 carcass freezers or taken to a quartering station prior to boning and dispatch.
The complex has the following refrigeration and cold storage capacities:

  • Quick chill 640 carcasses per day
  • De-bone 240 carcase equivalents per day
  • Freeze 150 carcasses per day
  • Tru Store production 100 carcasses per day
  • Chill Hold 1000 carcasses
  • Freezer Stacking Clean Products 375 tonnes
  • Rough Product 250 tonnes
  • Semi-automatic Carton Tunnel Freezers 4 tunnel freezers, one or rough offal (1600 cartons), one for clean offal (1600 cartons) and two for beef from boning room (1900 cartons each)

Rendering Plant
Rendering takes place using materials from the two-storey dressing floor/by-products collection building and the boning room. Tallow, meat and bone meal and blood are produced. Waste heat is recovered from the rendering plant to generate hot water for use throughout the abattoir.

The capacity of the rendering plant covers all waste and by-products from the abattoir.

Hides preparation
Hides are conveyed directly from the de-hiding operation at the dressing floor to the hide department.

Hides are trimmed, mechanically de-fleshed and salted.

Storage is provided for 6,000 hides.

Responsibilities
INTERCOOL was responsible for all equipment and materials imported into Zimbabwe for this project, viz. the refrigeration plant, the pre-fabricated panels for the cold rooms, the principal process equipment and the rendering plant.

Furthermore INTERCOOL was responsible for the design, supply, installation and commissioning of:
  • Processing equipment throughout the abattoir, boning, packaging
  • By-product treatment equipment
  • Rendering plant equipment
  • Services installations
  • Refrigeration plant and pipe work
  • Under-floor heating cables
  • Under-floor insulation
  • Pre-fabricated panel walls, ceilings and cold room doors
  • Complete electrical installations related to the refrigeration plant
INTERCOOL FOOD TECHNOLOGY LTD.