Masvingo Refurbished Abattoir, Zimbabve

Project
The Masvingo Refurbished Abattoir is part of the capital development programme of the Cold Storage Commission (CSC). When elaborating the programme, the CSC decided to refurbish its existing cattle slaughterhouse at Masvingo by adding a number of new facilities while re-using certain existing facilities that were commissioned in 1978. Among other things, a new dressing floor for cattle and a separate sheep line were added.

Cattle and sheep slaughtered at the Masvingo Refurbished Abattoir are intended for the local market and are sold as chilled or frozen meat by the CSC

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.

Production and Capacity
Products from the abattoir include:

Beef (frozen or chilled)

  • Sides
  • Quarters
  • Boned meat
  • Tru-pack cuts

Sheep (chilled)

  • Whole carcasses

Beef and Sheep

  • Rough and clean offal
  • Pet food material
  • Sterilized tallow
  • Meat and bone meal
  • Blood meal
  • Hides and pelts

Slaughtering and de-boning facilities

The daily slaughtering capacity of the refurbished plant on the basis of 8 hour working day is 400 cattle per day and 200 sheep per day to be processed at the conclusion of the beef kill.

The de-boning capacity is 100 carcasses per working day.

Average live weight is presumed to be 410 kg for cattle and 25 kg for sheep.

Procedures on the dressing floor

Cattle
Horn removal, Head masking and head removal, De-hiding, Evisceration, Carcass splitting, Veterinarian inspection, Trimming, Classification

Sheep
Horn removal, Head masking and head removal, De-skinning, Evisceration, Veterinarian inspection, Classification

Offal Packaging
Immediately beneath the dressing floor, the area is divided up into areas for red and for white offal treatment and packaging for freezing in cartons

Cold Room Complex

Cattle
Hot side of beef descend from the dressing floor into the cold room complex for overnight chilling to 7°C in one of five hot beef chillers with a total capacity of 500 carcasses per day.

Thereafter, the carcasses are either held in one of the following:

  • Four 100 head capacity holding chillers where the temperature of the carcass sides is further reduced to 2°C over a 24 hour cycle.
  • Two 75 head capacity local sales chillers at 2°C
  • Two 100 head capacity, carcass freezers operating with an air temperature of -26°C, during 40 hour freezing time achieving a temperature of -18°C of the sides.
  • Or taken to a quartering station prior to boning or direct to dispatch.

Sheep
Sheep carcasses are conveyed to the cold room complex for overnight chilling to 7°C before being kept in one of the holding chillers for further reduction of the temperature to 2°C

Offal
After having been cartonized or packed in trays, all offal are taken to one of four blast freezers, two for rough offal and one for clean offal.

Rendering Plant
Rendering takes place utilizing waste from the two-storey dressing floor/by-product collecting building and the boning room. Tallow, meat and bone meal and blood meal 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 to the hide department.

The department has been designed to trim, mechanically de-flesh and salt 400 hides per day (possible extension to 600 hides per day). Storage is provided for 8000 processed beef hides and 1000 sheep pelts.

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
  • Equipment for tallow extraction, refining and clarifying
  • 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.