1. Management of the slaughter procedure
(1) Before unloading the live pigs entering the holding pen, the certificate of conformity issued by the original animal epidemic prevention supervision agency will be checked, the vehicle should be inspected.
(2) After unloading, the quarantine personnel must observe the health status of the live pigs one by one, divide and number them according to the results of the inspection. Drive the qualified and healthy pigs into the pen to rest; suspicious sick pigs driven into the isolation pen and continued to observe; sick and disabled pigs are sent to the emergency slaughterhouse.
(3) For the detected suspicious sick pigs, after drinking water and adequate rest, they can be driven into the slaughtering holding pen if they return to normal; If the symptoms cannot be relieved, they will be sent to the emergency slaughterhouse.
(4) Pigs to be slaughtered should stop eating and rest for 12-24 hours before slaughtering, so as to eliminate fatigue during transportation and restore normal physiological state.
(5) Before the pigs enter the slaughterhouse, they should first take a shower to wash off the dirt and microorganisms on the pig's body, and at the same time, a shower is also convenient to deal with stunning.
(6) After the shower, the pigs are driven into the slaughterhouse through the pig driveway, the pig driveway is generally designed as triangle type, and the pig driveway can be used for 2-4 pigs to move forward side by side, and gradually only one pig can move forward, and the pig can not turn around and go back, at this time, the width of the pig driveway is designed to be 380-400mm.
2. Stunning
(1) Stunning is an important operation in the process of pig slaughtering, the purpose of using instantaneous stunning is to make the pig temporarily unconscious and in a coma, so as to assassinate and bleed, ensure the safety of the operator, reduce labor intensity, improve labor production efficiency, keep the surrounding environment of the slaughterhouse quiet, and also improve the quality of meat.
(2) manual pig stunning devices are currently commonly used for stunning in small slaughterhouses. Before the use of this equipment, the operator must wear insulated long rubber shoes and rubber gloves to avoid electric shock. Two electrodes of the manual stunning device will be immersed into salty water with a concentration of 5% to improve the conductivity, stunning electric voltage: 70-90V, stunning time: 1-3s.
(3) Three-point automatic electric stun machine, which is also called pig stunning machine is the most advanced electric stunning equipment at present. The live pig enters the conveying device through motor driven conveying belt, supports the pig's abdomen and four hooves suspended in the air for 1-2 minutes to eliminate the tension of the pig, and instantly stunning of the brain and heart when the pig is stable. Stun time: 1-3s, stun voltage: 150-300V, stun current: 1-3 amps, stun frequency: 800 Hz. This stun method has no blood spots, no fractures, delays the decline of PH, greatly improves the quality of pork, and also improves animal welfare.
3. killing and bloodletting
(1) Horizontal bloodletting: The stunned hairy pig slides into the horizontal bloodletting plate conveyor through the chute for killing and bleeding with a knife, and through 1-2 minutes of blood draining, 90% of the pig's blood flows into the blood collection tank, which is conducive to the collection and utilization of blood, and also improves the slaughter ability. It is also the most perfect combination with the three-point electric stun machine.
(2) Inverted bloodletting: The stunned hairy pig hind leg is shackled with chain, and the pig is lifted into the track of the hairy pig's bloodletting automatic conveyor line by the pig hoisting machine or the lifting structure of the pig bloodletting line, and then killed and bleeding with a knife.
(3) The track designed height of the automatic pig bleeding conveyor line is not less than 3400mm from the 0 level of the workshop, and the main completed processes on the automatic conveyor line for pig bleeding are: hanging, killing, draining, cleaning of pig carcasses, head cutting, etc., and the blood draining time is generally designed to be 5min.
4. Scalding and hair removal
(1) pig scalding tank: The bleeding pig is unloaded into the receiving table of the tank through pig unloader, and the pig body is slowly slid into the tank for scalding, and the water temperature of the blanching pond is generally controlled between 58-62 °C, Scalding time: 4-6min. A "skylight" is designed directly above the pig blanching pool to discharge water vapor.
(2) continuous pig scalding tank: the blood-drained pig body is automatically transported into the continuous pig scalding tank by the pig bleeding automatic conveyor line through the descending curved rail, and immersed for 4-6 minutes. The scalded pig is automatically transported out by the automatic conveyor line through the hoisting curved rail, and the insulation effect of this continuous pig scalding tank is good.
(3) Horizontal hair removal: This method of hair removal mainly uses 100 type pig hair removal machine, 200 type mechanical (hydraulic) pig hair removal machine, 300 type mechanical (hydraulic) pig hair removal machine, using a rake to move out the pig and automatically enter the pig hair removal machine. Through the rolling of the dehairing drum and the scraping of the soft hair remover, pig hair will be removed, and then release the hair removal pig into the scraping conveyor or clean water pool to remove the remained hair.
(4) Spiral continuous hog dehairer machine: This type of hog hair removal is used in conjunction with continuous pig scalding tank, and the scalded hogs will drop in the dehairer machine automatically via the pig unloader, and the hair removal pig is driven out from the other end of the dehairer machine and enters the scraping conveyor for scraping.
5. Mechanical skin removing
(1) After the pig head is cut off on the automatic bloodletting conveyor line, pig is unloaded onto the pre-peeling conveyor, and operations such as removing the front hooves, removing the hind hooves and pre-skinning are carried out on the pre-peeling conveyor.
(2) Transport the pre-peeled pig to the skinning station, use the skinning device of the skinning machine to clamp the pig skin. After the roller rotation of the mechanical skinning machine, the whole pig skin will be peeled off the pig body, and the peeled pig skin is automatically transported outside or transported to the leather temporary storage room by the skinning cart.
6. Carcass processing
(1) Carcass processing line: carcass trimming, rectal sealing, genital removal, chest cutting, white visceral removal, trichinella inspection, pre-picking red offal, red offal removal, splitting, inspection, fat removing, etc., are all completed on the automatic carcass processing conveyor line. The designed height of the carcass processing line is not less than 2400mm from the workshop floor. It will be changed if the pig body is too big or too heavy.
(2) The hair removal pigs or skin removed carcass will be lifted to the carcass automatic conveyor line by the carcass elevator, and the hair removal pigs need to be singed and whipped; Skinned pigs need to be trimmed.
(3) After opening the pig's brisket, remove the white internal organs, the removed white viscera are placed in the tray of quarantine conveyor for inspection.
(4) Take out the red internal organs, namely the heart, liver and lungs. Hang the red internal organs on the hook of the red internal organs synchronous quarantine conveyor for inspection.
(5) Use a belt splitting saw or splitting robot to divide the pig into two halves along the spine. (6) The trotters and tails are transported to the processing room by trolley.
(7) Remove the pig kidneys and remove the fat, and the removed kidneys and fat are transported to the processing room by a trolley.
(8) Trim the pig carcass, and after trimming, enter the electronic scale to weigh the carcass. Grading and stamping are carried out according to the results of weighing.
7. Synchronous health inspection
(1) Pig carcasses, white viscera and red offal are transported to the inspection area for sampling and inspection through the quarantine conveyor.
(2) The unqualified suspicious carcass will be pushed onto the track through the switches, conduct a re-inspection, to determine if the carcass is okay or not. Confirmed condemned carcass will enter the sick body track line, unload the sick carcass and put it in the closed car and pull out the slaughtering workshop for processing.
(3) The white internal organs that fail the inspection are taken out of the tray of the quarantine conveyor and put into the closed car and pulled out of the slaughtering workshop for processing.
(4) The red internal organs that fail the inspection are removed from the hook of the quarantine conveyor and put into the closed car and pulled out of the slaughtering workshop for processing.
(5) The hook of the red visceral synchronous quarantine conveyor and the tray of the white visceral quarantine conveyor are automatically cleaned and disinfected by cold-hot-cold water in order.
8. By-product processing
(1) Qualified white viscera enter the white visceral processing room through the white viscera chute, remove the stomach content in the tripe and intestine into the air delivery tank, fill it with compressed air and transport the stomach content through the air pipeline to about 50 meters outside the slaughtering workshop. Pig tripe will be washed with a washing machine after scalding. Pack the cleaned intestines and tripe into the refrigerator or preservation warehouse.
(2) Qualified red offal enters the red offal processing room through the red viscera chute, cut and clean the heart, liver and lungs, and pack them into the refrigerator or preservation warehouse.
9. Chilling or aging
(1) The trimmed carcasses are put into the chilling room for "acid removal", which is an important part of the pork cold segmentation process.
(2) In order to shorten the chilling time of carcasses, the carcasses will enter a fast cooling process before entering the chilling room, the temperature of the fast cooling room is designed to be -20 °C, and the quick cooling time is designed to be 90 minutes.
(3) The temperature for chilling room: 0-4°C, and the chilling time does not exceed 16 hours.
(4) The design of the chilling room track is not less than 2400mm from the floor height. In the aging room, the track spacing is 800mm, and the carcasses of 3 pigs can be hung per meter.
10. Meat cuts and packing
(1) The carcasses after chilling are removed from the track through the meat unloader, and each half of carcass is divided into 3-4 segments with a segmented saw, which is automatically transmitted to the station by the conveyor, and then divided into various parts of meat by the dividing personnel.
(2) After sorting, the divided meat is vacuum packed, put it into the freezer tray and push it to the freezer (-30°C) with a cold meat rack to freeze or put into the finished product cooling room (0-4°C) to keep it fresh.
(3) Pack the frozen product into boxes and store them in the refrigerator (-18°C).
(4) Temperature control in the meat cutting room: 10-12 °C, temperature control between packaging: below 10 °C.
