NutriRoost Poultry Processing & Rendering

Presentation to KINFRA dated 11th July 2019

NutriRoost Proposal - Introduction
• NutriRoost Ventures Pvt. Ltd. proposes to set up a state of the art, fully automated poultry processing facility at the KNFRA Mega Food
Park, Palakkad and a cold chain distribution network across Kerala.
• This venture is being promoted and backed by the Industry leaders from the Hospitality and the F&B Industry of Kerala along with a
group of professionally qualified technocrats with varied industry experience.
• This venture looks to integrate the farmer/grower with the end user (hotels and restaurants) through the farm to fork concept,
ensuring an assured return to the farmer with price and quality assurance for the end customer (F&B Industry in Kerala – HORECA
Segment Hotels, Restaurants & Catering).
• This venture would be extremely environment friendly with almost 100% recycling of waste through rendering and in the process
creating substantial volumes of high-protein animal feed supplements, which can be used in various types of animal and pet foods.
• This venture aims to bring safe food with fully assured traceability norms with modern HACCP, GMP practices to the consumer,
through the adoption of modern farming practices at the farm level and international standard practices at the processing and cold
chain using Information Technology as a backbone.
• This venture looks to add value to the project and the society through the adoption of latest waste management systems and is
looking at this part of the business as a major profit centre (instead of this being an unavoidable cost centre) which can add substantial
revenue to the project and ensure almost negligible environment impact.
• This would be the first poultry venture in India which is being majorly promoted by the end user group (Hotel and the F&B Industry)
with a team of highly qualified and experienced professionals with assured returns to the grower and farmers in the “Farm to Fork”
model.
NutriRoost Proposed Poultry Processing & Waste Management plant – Level 1 Chart
Poultry Processing Waste Water Management (ETP)
WASTE WATER
Treated Water
UF Treatment
Blood Collection Chute
Activated Carbon Filter
Live Bird Receiving

Disinfection
Scalding Pressure Sand Filtration
Stunning

Aeration Treatment Two Stage Sludge

Segregation
DAF Treatment
Plucking
Fine Screen
Coarse Screen
Evisceration & Giblet Processing Processed Water

Poultry Waste Management (Rendering)

Chilling Process
-4
Degree Oil
Extractor
Portioning
Vaccum Cooker Vaccum
Processed Bird Dispatch

Pump Pump
Vaccum Pump
Chilled Garbage Room
Storing
Chemical Vaccum
Collection Vaccum Vaccum Cooler &
Wash Pump
Protein Pump Pump Dryer
Transport Powder

POULTRY WASTE
 NutriRoost Proposed Poultry Processing – Level 2 Chart Process Index
COMPRESSOR SHED Unit A - Scalding & Plucking

A01 Slaughtering Overhead

Conveyor.
A04 A02 Transmission & Tensioner.
A11 A03 Stunner.
SW 1
A02 A04 Blood Collection chute.
A05 Scalder
A03 A06 -1 Plucker.
A05 COLD ROOMS A06- 2 Plucker
A07 Head Puller
SCALDING & PLUCKING A08 Shackle Unloader
A09 Rehanging Table.
A10 Vertical Shackle Washer
A11 Control Panel
B07
A06 -1 A06 -2
A08 A07
LIVE BIRD RECEIVING

SW 2
A01

LOADING BAY
A09 MANUAL EVISCERATION &GIBLET PROCESSING
A10
B02 B03
B01
SW 3
B04 Unit B - Manual Evisceration
GRADING , PORTIONING & PACKING
B06 C02 B01 E V Overhead Conveyor
C01 B02 Transmission & Tensioner.
B03 Giblet Through.
SW 4 B04 Outside Washer.
B05 Feet Cutter
B05 B06 Shackle Unloader
B07 Control Panel

C05
C03 C04
CHILLING ROOM
Unit C - Chilling

C01 Spin Chiller

C02 Water Dripping Table.
Solid Waste Sources
C03 Flake Ice Machine.
SW 1 Slaughtering Blood
C04 Compressor Frame.
SW 2 Plucked Feather
C05 Control Panel
SW 3 Internal Parts
SW 4 Bird Feet
NutriRoost Poultry Processing -Advanced Technology

SR No Highlights

1 Fully Automated Processing line through shackle conveyor belt for E2E process.

2 Automated concealed blood collection system.

3 New generation scalder for soft scalding at 56 Degree Celsius.

4 Two numbers of feather plucker in comparison to standard one plucker used normally.

5 Special feather collection system with feather press and vacuum pump to move the feather to rendering area.

6 Fully automated offal handling system – with offal pumps – offal collection tanks – offal chill rooms – feather
press – blood collection system etc – First time in India.

7 First time in India chilled garbage room maintained at -4 Celsius temperature.

8 Very low usage of water – under 4 litres per bird – compared to about 15 litres in similar plants in India.

9 Processing plant is climate controlled with negative pressure to prevent Air outflow, also this system ensure
fly and rodent control.
 NutriRoost Waste Management (Rendering) – Level 2 Chart
Cooling

Collector
Vaccum Pump Tower

Dust
Condenser
Chilled Garbage
room (-4)

Vaccum Pump
Vaccum Pump Cooker Silo

Oil Extractor
Cooler & Dryer

Chemical Washing
Chemical Washing
LPG / Diesel
Boiler

Heated Oil

Silo
Tank

Oil
Extractor

Oil
Pump

Grinder

Oil Tank Oil Tank

Automatic
Packing
 30 Ton of slaughter waste capacity per day and our poultry Bio FILTER
processing output will be only 10 Ton . Means there is
potential to manage external poultry waste up to additional Oil
Pump
20 MT
NutriRoost Waste Management (Rendering) - Advanced Technology

SR No Highlights
1 Fully Automated Offal Handling System – with Offal Pumps and Silos.
2 Climate Controlled Offal Holding Room (-4’ Degree Celsius) First Time in India
3 Special Equipments like Feather pump, Feather press etc.
4 Separate Cooking and Cooling cum Meal Drying System – Fully Automated with Silos and Bins First Time in
India
5 After this process the Meal is automatically grinded into fines and then packed into bags - in an auto bagging
system. 6
6 Fully Automated Odour Management System with Vaccum Pump Unit
7 Physical Treatment - Air Cooled Condenser and Cooling Tower
8 Chemical Treatment – Two stage Air Washer cum Scrubbers
9 Final Biological Treatment – Bio Filter with activated carbon and enzyme treatment.

• Such an advanced rendering cum odour management program related to a poultry processing will be first time in
India. (Can be referred as a model project)
NutriRoost Effluent Treatment Plant– Level 2 Chart
PROCESSED COARSE
FINE SCREEN 1 FINE SCREEN 2
WATER SCREEN

COLLECTION ANAEROBIC
TANK REACTOR

DAF
TREATMENT
ETP Capacity -50,000 – 100000 LTR /Day

SLUDGE ANNOXIC TANK

SEGREGATION 1 (MBBR)

SLUDGE
HOLDING TANK AERATION
TREATMENT
(MBBR)
SLUDGE
SEGREGATION 2
DRYING
BED/BIOGAS
SECONDARY
PLANT
CLARIFIER TANK

BIO MANUER PRESSURE

FILTER FEED
SAND DISINFECTION
TANK
FILTERATION

ACTIVATED
TREATMENT
WATER REUSED UF TREATMENT CARBON
WATER
FILTERATION
NutriRoost Plant Sanitation & Public Health Management -Advanced Technology
In a poultry processing plant Hygiene is of utmost importance as it directly impacts not only the product safety but
also Public Health. So following protocol will be followed in our proposed plant.

SR No Highlights
1 The Unit would be designed as per HACCP & GMP Protocols maintaining the highest QC standards and Food
Safety (FSSAI) norms.
2 Public Health Concerns can be broadly addressed through efficient management of Solid wastes through
Rendering, Water Waste through ETP and odour through – the odour management systems as part of the
Rendering process
3 Cleaning and sanitation of the plant is also of vital importance to prevent and fly or rodent issues. We plan
to use a combination of High Pressure Cleaning, with Special Powder Foam Application on all surfaces
including walls, floors, Plant & machinery etc, again followed with High Pressure washing, finally followed
with disinfectant wash (CLO2) or Hydrogen Peroxide and Fumigation of the plant and premises on a
continuous and ongoing basis.
4 Special measure would also be considered for continuous sanitation of persons and vehicles entering and
leaving the facility.
5 Highest levels of Sanitation protocols as per EU and USFDA Standards would be followed to prevent any
issues concerning Plant Hygiene and Public Health.
NutriRoost Proposal - Socio Economic Benefits of the Project

•Direct & Indirect Employment Generation in the State

This project would generate direct employment to about 100 people and indirect employment to about 1000 more people
through various contract farms spread across Palakkad, Malappuram and Trichur Districts.
•Direct Benefits to the Rural Economy through Contract farming
There would be hundreds of small contract broiler farms growing birds for the company as part of the contract farming model.
This would generate regular and substantial income to hundreds of rural households throughout the year.
Additionally these farms would get very good quality organic manure from the poultry the farming operation, which they can
use for their own agricultural activities or can be used in other agricultural operations in these villages, which directly lead to
substantial increase in the production of rural crops like Paddy, Coconut, Plantains and Rubber.
•Safe and Hygienic Poultry value chain in Kerala
Through this project the end consumers would have regular access to reasonably priced and safe poultry products with all
certifications. The tractability protocols as per the new FSSAI Food Safety norms will be fully complied with and proper
documentation would be maintained from farm to fork. The customer would be fully assured of the safety and quality of the
product in every batch, with detailed farm level records of each batch, medication history etc.
•Environment Management through Slaughter Waste Rendering
Kerala generates about 250 Mt of slaughter waste per day, 90% of which is unprocessed and thrown away. This has led to an
explosion of stray dogs (primarily on a diet of slaughter waste & raw meat) and the increase in the aggressiveness of the dogs,
due to the regular consumption of raw meat, blood and slaughter waste. This unit can handle slaughter waste from the
processing of 50,000 birds every day (using the latest technology and global best practices), which is more than 10% of the
total slaughter waste currently being generated in Kerala.
NutriRoost Proposal - Conclusion

Proposal
Based on the above study and plans ‘NutriRoost Ventures Pvt Ltd’ proposes
to set up a Poultry processing plant spread across 3 acres of land inside the
KINFRA Mega Food Park, Palakkad with support from KINFRA.