As Built Guide. Processing OPEN-AIR MOBILE POULTRY PROCESSING UNIT

Transcription

1 As Built Guide to the Lampson Brook Farms Community Mobile Poultry Processing Unit (Open-Air MPPU) Based at NESFI s Lampson Brook Farms Belchertown, MA Processing OPEN-AIR MOBILE POULTRY PROCESSING UNIT A Local Infrastructure for Good Food & Green Energy Project New England Small Farm Institute at Lampson Brook Farms 275 Jackson Street, P.O. Box 937, Belchertown, MA

2 Foreword Why an MPPU? Consumer interest in fresh, local, naturally produced and humanely treated meat and poultry is growing. Here in the Pioneer Valley of Massachusetts, our farmers were among the first to express interest in this market over a decade ago. Their interest was triggered by availability of a new technology mobile poultry processing units that can travel from farm to farm, enabling farmers to slaughter their own birds, under their own control, on their own farms. Under USDA and state regulations, small-scale growers, producing fewer than 20,000 birds each year, can take advantage of this option. The Lampson Brook Community MPPU offers affordable* access to, and mentoring in shared use of this processing equipment to local farmers who want to produce, process and direct market fresh poultry but cannot, on their own, bridge the gap between field and market without access to this technology. Why is Shared-Use Local Food System Infrastructure Important? The not-so-recent national and more recent global trends toward industrial agriculture have fostered the disappearance of local food system infrastructure including local mills and slaughterhouses and the skilled workforce we need to operate them. Along with these services, availability of locally produced meat and poultry has dwindled or disappeared. But things are rapidly changing. Demand for locally produced and processed products is growing. Here in the Pioneer Valley, we have the farmers, the acreage, and the customers we need to create a more sustainable, local food system. Our new challenge is to provide the critical field- 2

3 to-market missing link local food processing and handling infrastructure. The Lampson Brook Community MPPU is an important example of this sorely needed infrastructure. It joins a growing number of local food system development projects that, taken together, can help the Pioneer Valley community meet challenging local food system goals. Thank You to USDA Rural Development RBEG, the Massachusetts Society for Promoting Agriculture, and New Entry Sustainable Farming Project (via MDAR/MAIC and NESARE grant sub-contracts) for funding support that has enabled MPPU design, fabrication and pilot testing, regulatory research and compliance, and producer training needed to launch mobile poultry processing as a viable option for Massachusetts small-scale and start-up poultry producer-processors. *Unit cost: $26,258 plus supplies As-Built Guide to the Lampson Brook Community MPPU Contents: Foreword Page 1 Introduction: Brief History & Current Status Page 3 MPPU Basics: Equipment List & Floor Plan Page 4 MPPU Trailer & Decking Page 5 Processing Equipment: Killing Cone Cabinet Page 6 Poultryman Scalder Page 7 3

4 Poultryman Plucker Page 9 Pre chill Tank Page 10 Eviscerating Tables Page 10 Overhead Trigger Nozzle System Page 10 Pedal-operated Hand Sinks Page 12 Chill Tanks Page 13 Hot Water Heater Page 14 Propane Tank Rack & Changeover Valve Page 15 Unit Accessories & Processing Supplies: Electric Stun Knife Page 16 Pintle Hook Page 16 Work Area Barrier Page 16 Waste Chutes Page 17 Water Meter & Backflow Preventer Page 17 Access Steps & Crate Rack Page 18 Shade & Rain Shelter Page 18 Other Accessories & Supplies Page 19 MPPU As Built Budget Summary Page 20 4

5 This Guide has been prepared in partial fulfillment of New England Small Farm Institute s contractual obligations under USDA Rural Development Rural Business Enterprise Grant Program project, Extending & Enhancing Mobile, On-Farm Processing Options for Massachusetts Small-scale Producers. Prepared by Judith Gillan, November 2011 Guide to the Lampson Brook Community MPPU Introduction While the niche market for locally grown pastured poultry continues to grow, convenient and affordable processing remains a serious challenge for small-scale poultry producers, preventing many from accessing this important market niche. Throughout the US, farmers and service providers have turned to mobile poultry processing units ( MPPUs ) to enable smaller producers to process their own products on their own farms, allowing them to take advantage of this valueadded on-farm enterprise. However, regulations vary widely from state to state, and Massachusetts s requirements are among the most stringent. Through a collaborative effort, MA producers, agency personnel and processing professionals have worked with New England Small Farm Institute (NESFI) and New Entry Sustainable Farming Project (NESFP) to develop training opportunities and MPPU technology and management protocols that pass regulatory muster and enable MA producers to participate in this market opportunity. BRIEF HISTORY: Interest in developing mobile on-farm processing options for Massachusetts small scale poultry producers emerged as early as December 1999 when a group of growers met in Belchertown to explore the possibility. This grassroots gathering was followed by informational meetings with state and federal regulators and confirmation that, as a first step, MA Department of Public Health (DPH) approval of unit design and management protocol (including licensure) would be required. Over time, additional requirements emerged from other regulatory agencies: MA Department of Environmental Protection (DEP) established protocols for unit siting, rinse water discharge and solid waste management/ composting; MA Department of Agricultural Resources (DAR) assumed responsibility for flock 5

6 health inspection and bio-security oversight. With funding from USDA s Rural Development Rural Business Enterprise Grant (RBEG) program and the Massachusetts Society for Promoting Agriculture, a prototype MPPU was custom fabricated according to an agency-approved plan, modified, and field tested in the fall of Unit fabrication 1 and subsequent modifications were contracted to Bob Gray and Arnie Voehringer through White Oak Farm Shop, Belchertown, MA. Operated state-wide as a DPH pilot project for three ( ) production seasons, the Lampson Brook MPPU began profitable operation 2 as a regional feefor-service enterprise in CURRENT STATUS: The Lampson Brook MPPU is now available for on-farm use by trained 3 and licensed Pioneer Valley producer-processors. Outreach to local producers is scheduled to begin early in each calendar year. Mentoring through the licensure process, individual training in Unit operation, and the services of a certified crew leader are available for a fee for first-time users. Prior to initial use, approval by the local Board of Health is necessary and each farm site is inspected by a state agency representative. Custom slaughter of birds raised solely for home use is being explored and will be widely advertised if/when this service is approved. MPPU Basics The Lampson Brook Community MPPU is designed to support safe and affordable on-farm poultry processing when operated by licensed, trained users according to the Lampson Brook MPPU Food & Farm Safety Management Guide. (See Fabricated under contract to White Oak Farm Shop, Belchertown, MA, the 24 Open-Air Unit is fitted with on-board systems for 1 Contact NESFI for information about building or contracting for fabrication of a similar Open-Air MPPU Lampson Brook MPPU Management & Financial Report is available at life/mppu. 3 An MPPU Training CD (contact NESFP) and Self-Directed Learner s Guide to Operating the Lampson Brook Open-Air MPPU (contact NESFI) will be available for the 2012 season. 6

7 delivering potable water, 110V electric power and propane, all supplied by the farm. Equipment includes: 1.Stainless steel killing cone cabinet with optional turkey cone 2.Stainless steel rotary scalder with hot water generator 3.Stainless steel rotary plucker with external waste chute 4.Stainless steel pre-chill tank 5.2 Stainless steel eviscerating tables with overhead trigger nozzles & external waste chutes 6.2 Stainless steel pedal-operated hand sinks 7.4 Double-wall, covered chill tanks on casters 8.Hot water heater 9.Propane tank rack 10.Unit accessories & processing supplies FLOOR PLAN: Designed to support a smooth transition from slaughter, through scalding, plucking, pre-chilling and evisceration to chilling and packaging, the Unit is separated by a removable barrier into two activity areas. Each area is accessed by removable steps. 7

8 MPPU TRAILER For this first-in-the-state Unit, fabricators selected a new 24 dualaxle CAM Superline utility trailer equipped with pintle-eye coupler and electric brakes. With a GVW of 11,960 pounds, most farm trucks can serve as Unit transport vehicle. The state-approved floor plan includes independent access to two separate work areas. Retractable stabilizer legs support front and rear Unit corners. Standard wood decking has been replaced with Veranda ArmorGuard composite lumber (12 16 $35), a sanitation-promoting modification required 8

9 by DPH. Floor boards are spaced to allow pre- and post-operation rinse water to drain directly to the ground. Cost: Trailer - $5,600 Composite Decking - $420 4 Stabilizer Legs - $120 PROCESSING EQUIPMENT Cornerstone Farm Ventures, Norwich, NY, provided assistance in selecting the processing equipment purchased for the Unit. Sized to 9

10 accommodate the Unit s 300 birds/day processing limit as well as likely on-farm water pressure and electric power constraints, careful matching of kill cabinet, scalder and plucker capacity insures smooth progression of birds through the line. All equipment was purchased through Cornerstone and delivered directly to NESFI s Belchertown site, where potential users convened to confirm appropriate placement on the trailer for efficiency and ease of use. 1. Killing Cone Cabinet Designed to accommodate up to 6 birds, the stainless steel cabinet features a catch basin for blood which exits into a 5 gallon bucket through a single drain. A single stainless turkey cone can be provided with the unit and can be attached to the cabinet on the outside. 10

11 Optional equipment includes a Knase electric stun knife. (Note central discharge chute and removable crate rack positioned to left.) Cost: $1, Poultryman 60,000 BTU Rotary Scalder Stainless steel, gas- fired scalder includes automatic temperature control and timer. Requires 110 Volt service, minimum 30 psi water pressure and connection to 20 pound propane tank. Rotating wire rack lifts birds in and out of water. Scalds at 147 degrees F. Sized to accommodate 4 birds. Cost: $2,495 11

12 Poultryman Rotary Scalder with Thermostat Control 12

13 Scalder: Rotating Wire Rack Scalder: Propane Burner, above, is controlled by thermostat 13

14 3. Poultryman Plucker The stainless steel 27 Poultryman Plucker comes equipped with a ¾ HP electric motor, water spray, and ¾ hose. Operation requires 110 Volt service and minimum water pressure of 30 psi. The 27 drum accommodates up to 4 birds. The Lampson Brook plucker has been customized with an exterior chute for off-unit feather and water discharge into a tub. Cost: $1,795 Plucker drum interior, with 3 ¼ rubber fingers 14

15 Custom feather discharge chute (Hose connection to the left; scalder discharge to the right) 4. Pre-chill Tank Fabricated from a used dairy milk tank, this stainless steel holding tank is located on the clean side of the Unit, adjacent to the evisceration tables (to right). Filled with ice water slurry, it receives birds directly from the plucker where they are held until removed for processing by the evisceration team. (The Unit s insulated hot water heater is positioned in space directly below.) Cost: Custom fabrication 5. Two 6 Stainless Eviscerating Tables with Custom Overhead Trigger Nozzle Flush Valve System & External Waste Chutes The Unit s 4 trigger nozzle wands are equipped with removable lung removers. Cost: 2 Tables $910 4 Trigger Nozzle Wands with Lung Removers - $250 Overhead Rack & Hose Custom fabrication 15

16 Evisceration Tables (Barrier separating slaughter and processing areas is visible to left.) 16

17 Evisceration Tables with Custom Fabricated Overhead Trigger Nozzle System (Plucker & Pre-chill Tank in foreground; Cargo Trunks stored directly below.) 17

18 6. Two Pedal-operated Stainless Hand Sinks with Soap Dispensers 18

19 Hand Sink to the left is accessible only to processing team members working on the slaughter or dirty side of the Unit. Sink to the right is accessible to folks working on the clean side: members of the evisceration / chilling / packaging team. Pedal (or hands-off ) operation and constant availability of both hand sanitizing soap and hot and cold water ensures compliance with safe food handling operating protocols. Discharge from the sinks may be directed to moveable tanks or onto the ground. Cost: $595 19

20 7. Four Double-wall Chill Tanks on Casters, with Sliding Covers Four chill tanks travel with the Unit. Depending on number of birds to be processed, all may not be needed; on-board or on-the-ground placement is permitted. Tanks are fitted with a bottom drain spigot, 20

21 with optional hose connection. Chill water (ice water slurry) may be broadly dispersed as irrigation water on a growing field or piped directly to a compost pile of sufficient size to absorb the water. Impact on surface and ground water is a primary management concern. Cost: $1,846 21

22 8. Hot Water Heater The Unit is equipped with a Suburban Manufacturing Co. gas-fired 10- gallon hot water heater (Model SW10P), with standard pilot / match lite ignition and 10.2 gallon/hour recovery. Installed directly under the Unit s pre-chill tank, it is served by the Unit s water and propane 22

23 delivery systems and is directly connected to the Unit s two hand-wash sinks. (Note pre-chill tank discharge chute to left.) Cost: $450 (includes flush-mounted external door) 23

24 9. Propane Tank Rack & Changeover Valve Standard RV equipment, the tank rack and changeover valve accommodate two 20 lb. propane tanks, which must be provided by the user. Tanks must be removed prior to over-the-road transport. Cost: $78 24

25 10. Unit Accessories & Processing Supplies Electric Stun Knife Knase Midwest Processing Systems SKVS200 Electric Stunner Unit. The stun knife requires a 110 outlet and is available for rent for an additional fee. Cost: $2,150 Receiver Mount 5-Ton Pintle Hook Rigid-type pintle hook with integral receiver bar links trailer securely to towing vehicle with a 5/8 locking pin. Designed for over-the-road towing, caution is required for off-road towing such as, for example, across a farm field. Cost: $85 25

26 Work Area Barrier A standard 4 livestock gate separates slaughter and evisceration work areas. The gate can be removed for pre-op and post-op sanitation of the Unit floor. Cost: $40 Removable Waste Chutes Solid waste, blood and processing wastewater discharged from the killing cabinet, scalder, plucker, chill tank and evisceration tables exit the Unit through 26

27 custom fabricated waste chutes into portable tubs or watering tanks for transport to adjacent compost windrow. Disposal alternatives include use of an on-board trash pump with waste hose extending directly to compost pile. Cost: Custom fabrication Water Meter & Backflow Preventer Valve An in-line water meter allows producers to document daily water use, in compliance with DEP requirement that the maximum amount of water generated at any given small farm shall not exceed 400 gallons on any day. Potential for backflow contamination of farm s potable water supply is eliminated by a double check backflow preventer at interface of Unit s water delivery system with the farm s potable water source. Cost: $369 Removable Steps & Crate Rack Custom fabricated steps (below) allow access to and from slaughter and processing 27

28 areas. Crate rack places (right) birds conveniently near killing cones. All are removed and stored onboard during Unit transport. Cost: Custom fabrication Optional Shade & Rain Shelter Custom fabricated framework supports tarps (provided with Unit) over each work area, providing option for protection from sun and inclement weather. Weather permitting, most operators prefer to work in the open air. Cost: Custom fabrication 28

29 10. Unit Accessories & Processing Supplies (continued) Folding Work Table: $38 Propane-fired Turkey Cooker (30 gal. back-up hot water source): $70 Propane Torch: $45 Flotec ½ HP submersible sump pump (electric): $130 Cargo Box 1: Information Pack: operating information for propane hookup, plucker, scalder, turkey fryer, propane torch, hot water heater, sump pump, stunning knife & trailer hitch. Copies of trailer registration, MPPU Daily Use Log, Farm & Food Safety Guide, sanitation 29

30 guidelines & MSDS sheets for Clorox, Simple Green and PVC pipe. Tool Box: flashlight, screwdriver, hammer, pliers, wrench, Stanley multitool, Stanley cutting tool, 25 measuring tape, WD-40, scissors, duct tape, insulation tape, electrical tape, sink stoppers, spare plucker fingers, potable water hose menders/washers, pump-to-drain connectors, drain hose-to-hose connectors, drain hose clamps, evisceration table drain clamp, propane lighter wand, 50 rope, black marker & note pad/pen. Emergency Processing Supplies Box: First Aid Kit, paper towels, Clorox, measuring cup & spoons, chlorine test strips, Simple Green concentrate, timer, aprons, latex gloves, no-stick cooking spray [for scalder], digital thermometers, zip ties, food grade plastic bags, hand sanitizer, hand soap & trash bags. Also: 4 lung scraper wands, 4 tarp tie-downs, Fix-a-Flat tire inflator, hand wash soap, 2 hand pump spray bottles, 2 wash-down pails w/ scrub brushes, 5 gallon pail for kill cone drain, 100 heavy duty electric cord, 2 25 ½ food grade hoses with hose nozzles. Cargo Box 2: Turkey cooker, 2 25 potable water hoses, sump pump, /8 food grade hoses, ¼ drain hoses with connectors (for pump to compost) & trailer hitch Also on Board: Turkey cone, floor mats, floor scrub wand, 3 40 gal. stock tanks, chill tanks, folding work table, tarps. 30

31 As-Built Budget Summary: Lampson Brook Open- Air MPPU Utility trailer, composite decking & stabilizer legs: $6,140 Killing cabinet & turkey cone: $1,045 Poultryman rotary scalder: $2,495 Poultryman plucker: $1,795 2 eviscerating tables: $910 4 trigger nozzle flush valves with lung scrapers: $250 2 pedal-operated hand sinks: $595 4 double-wall chill tanks with covers: $1, gallon hot water heater: $450 Propane tank rack & changeover valve: $78 Double check backflow preventer: $119 Water meter: $250 Pintle hook: $85 Work area barrier: $40 Food grade hose (4 50 ; 2 25 ): $160 Custom fabrication & construction services & supplies: $10,000 Sub-total: $26,258 Knase electric stunner unit: $2,150 31

32 Work table: $38 Sump pump & hose: $250 Turkey cooker: $70 Propane torch: $78 2 cargo boxes: $90 2 tarps: $70 Miscellaneous supplies: $280 Total cost: $29,284 The Lampson Brook Open-Air Community MPPU is a Local Infrastructure for Good Food & Green Energy Project of New England Small Farm Institute, Inc. 32