412

Foreword

The PAES 412:2002 standard was initiated by the Agricultural Machinery Testing and Evaluation Center (AMTEC), with the purpose of standardizing the construction and operation of poultry dressing plants in the Philippines. It is funded by the Bureau of Agricultural Research (BAR) under a project aimed at enhancing the implementation of the Agricultural and Fisheries Modernization Act (AFMA). The standard adheres to PNS 01-4:1998, which reflects international best practices as set forth by ISO/IEC Directives Part 3:1997. The standard specifies general requirements for the construction and operation of poultry dressing plants, ensuring that they meet safety, health, and sanitation standards essential for the poultry industry. It is important to note that the document utilizes specific terminology: "Shall" indicates mandatory requirements that must be followed, while "Should" suggests practices that are recommended but not obligatory.

References

The standard references various authoritative materials and frameworks, including:

  • AO No. 07 Series of 2001: Code of Practice for Birds Dressing.

  • Environmental Sanitation Rules and Regulations established by the Department of Health.

  • Establishment Design and Construction Guidebook provided by the Virginia Department of Agriculture.

  • Meat Manual of Procedures from the Canadian Food Inspection Agency.

  • Birds Industry Processing Standard from the Birds Industry Standards Council.

Scope

This standard specifies the general, structural, and functional requirements necessary for poultry dressing plants to operate effectively and safely.

Reference Normative Documents

The following normative documents serve as references for the guidelines set out in PAES 412:2002:

  • Meat Hygiene protocols from the National Meat Inspection Commission.

  • National Structural Code of Building regulations.

  • Philippine Electrical Code 2000.

  • National Plumbing Code of the Philippines.

  • PAES 414-1:2002, detailing Waste Management Structures for Agricultural Liquid Waste.

  • PAES 414-2:2002, addressing Waste Management Structures for Agricultural Solid Waste including composting practices.

Definitions

  • Carcass: The body of dressed birds post-processing.

  • Dressing: A comprehensive process that includes bleeding, defeathering, and evisceration while removing inedible parts to prepare the bird for consumption.

  • Offal: By-products and organs derived from the bird, excluding the meat.

  • Evisceration: The surgical removal of internal organs from both abdominal and thoracic cavities of the bird.

  • Shackling: The process of restraining birds prior to the slaughtering step (slitting).

  • Trench drain: A specialized trough designed for collecting waste and directing it toward a drain opening for disposal.

Location

4.1 Compliance: The chosen location must comply with both the National Meat Inspection Commission’s regulations and relevant environmental requirements.4.2 Water Supply: A continuous and well-drained water supply is essential for maintaining hygiene and operational efficiency.4.3 Electricity: Ensure the availability of adequate electric sources to support the facility's operational needs.4.4 Site Size: The site must provide sufficient space for the construction of buildings, parking areas, access points, and waste management systems.4.5 Accessibility: The site should be accessible year-round to facilitate operational activities and regulatory inspections.

Structural Requirements

5.1 Floors: Floors must be elevated to facilitate effective drainage. They should be made of concrete, properly reinforced, and feature moisture-proof surfaces (such as tiles or rubberized paints). The minimum slope should be between 2% - 4% toward drains, and wall intersections should be rounded with a radius of 50 mm - 60 mm.5.2 Walls: Constructed from concrete and painted with non-toxic oil or plastic paint. Areas above the floor should be tiled or finished with impervious materials, and wall tops must be sloped at 45 degrees to prevent debris accumulation.5.3 Roof: The roof structure may be made from timber or steel and should be treated with anti-rust paint. Durable roofing materials such as G.I. sheets are recommended. Skylights are suggested for natural lighting, and properly screened vents are essential for ventilation.5.4 Ceilings: The minimum ceiling height should be 2.4 m, and the design must prevent the accumulation of dirt and debris.5.5 Windows: Windows should be fitted with 16-mesh screens, with ledges sloped to prevent debris buildup.5.6 Doors:

  • External Doors: These should be fitted with screens or air curtains and have a minimum width of 1.8 m.

  • Internal Doors: Must be snug fitting, self-closing, have a glass panel at eye level, and a minimum width of 1.5 m.5.7 Columns: Constructed from durable, non-porous materials.5.8 Structural Design: Must conform to the National Structural Code of Building for any structural designs not explicitly mentioned within the standards.

Functional Requirements

6.1 Holding Area: Designated area for live birds, requiring proper ventilation to ensure animal welfare.6.2 Slitting Area: This area must be designed to minimize stress on the birds during slaughter while incorporating provisions for blood containment.6.3 Scalding and Defeathering: Facilities should be equipped with a vented scalding tank strategically located near defeathering machines for operational efficiency.6.4 Evisceration Area: Arranged for efficient and sanitary operations, including designated tables for the processing of edible offals.6.5 Refrigeration: Refrigeration systems are necessary if carcasses are not processed within six hours, with storage temperatures maintained below 4°C. Environmentally friendly refrigerants must be utilized.6.6 Dry Storage: Storage areas must be protected from vermin to maintain hygiene.6.7 Holding Area for Dressed Birds: This area is intended primarily for the loading and storage of crates containing dressed birds and must be secured against vermin.6.8 Equipment and Facilities: Equipment should be made from materials impervious to liquids, with stainless steel as the preferred option. There must be adequate waterproof containers for waste materials produced during operations. Tables should be designed to a height of 0.8 m, avoiding the accumulation of dirt.6.8.4 Lighting Requirements: Adequate artificial lighting must be provided in areas where natural light is insufficient; specific lighting intensity standards should be established for different operational areas.6.8.6 Electrical Installation: Must comply fully with the Philippine Electrical Code.6.8.7 Water Supply and Plumbing: A clean and ample water supply must be ensured, combined with an effective drainage system for sanitary practices.6.9 Ventilation: Facilities should include screens to protect against dust and insects, and mechanical ventilation systems must ensure a continuous flow of fresh air.

Waste Disposal

Operators should refer to PAES 414-1:2002 and PAES 414-2:2002 for comprehensive waste management practices applicable to poultry dressing plants.

Annexes

  • Annex A: Sample Layout of Small-scale Dressing Plant Design includes a live bird holding area, chilling tank (optional), stunning, slitting & bleeding areas, drainage rack, eviscerating table, scalding tank, plucker, cutting table, and holding areas for dressed birds.

  • Annex B: Detailed lighting requirements for different bulb types and intensities per square meter are specified, focusing on adequate illumination for all operational spaces.

Note: All relevant pictures and diagrams should be included to enhance understanding of the layout and operational requirements of the poultry dressing plant.