VALUE ADDITION IN POULTRY: PRESENT STATUS & SCOPE IN INDIA
Compiled, & shared by-DR. RAJESH KUMAR SINGH, (LIVESTOCK & POULTRY CONSULTANT), JAMSHEDPUR Post no 1328 Dt 22/07//2019
JHARKHAND,INDIA 9431309542, rajeshsinghvet@gmail.com
Value addition. in poultry plays in important
role in increasing the profits. The value
addition may be through nutritional
manipulations, processing and transgenesis.
Omega-3 enriched eggs and meats are
available in the market for premium price
developed by nutritional approaches .
Feeding the chicks with rich sources of
omega-3 fatty acids will aid in increasing
the levels of omega-3 fatty acids in eggs
and meat of the birds. Experiments on
fortification of Zinc and Vitamin B12 in
chicken egg and meat through dietary
manipulation for enhanced value addition
and shelf life are going on and need
commercialization. The second one is
through biotechnological approaches,
where in the gene (inter species) responsible
for specific trait can be made through
transgenesis. However, this approach is still
in primitive stage where in research is being
carried out. The commonly utilized method
for value addition is processing of the
poultry products. By value addition low
valued meats and by products can processed
in to a highly nutritious finished products
adding to the returns.
Poultry industry in India is a mega billion industry
having third position in egg production and fifth position in
broilers in the world. The total egg production accounts to
100 billion and broilers 3.8 billion. The average cumulative
growth rate in layer and broiler is 8% and 12 % respectively.
Even though production is in accelerated trend still
processing and marketing strategies are not in a well
defined manner which leads to overall moderate
profitability and less export promotion. This sector is
responsible for 0.45% of India’s Gross Domestic Product
(GDP) and 10% of livestock GDP. Poultry production in
India contributes to 5% of meat and 2.5 % egg of total
global output. Even though production is in faster rate, the
per capita consumption of egg and poultry meat is 62 eggs
and 3.4 Kg of meat. In India the consumption pattern varies
between urban and rural areas. In urban areas one third of
the population consumes two third of the poultry products
due to increased farm size, increased income and better
knowledge on health and nutritional benefits of poultry
meat. But in rural areas due to decreased knowledge on
nutritional benefits of poultry meat and poor families their
consumption is lower than urban people (Hai et al. 2008)
Irrespective of massive breakthrough in production front,
the processing sector is still in infantile stage and marketing
sector is mostly in disorganized way (Singh 2012)Currently
only 20 % of the chicken and 6% of the eggs are processed.
Among the dressed chickens, 70 % are sold as dressed or
chilled or frozen whole carcass, limiting remaining 30% to
cut up parts and further processed products. On the other
hand, in the industrialized countries, whole broiler sales recorded at 15%, cuts and boneless breast fillets 35%
further processed products 50%. Likewise 30% of the eggs produced are processed as pasteurized chilled-frozen liquid egg, dehydrated and ready to eat egg products. Right now, only dozen modern mechanized processing plants with capacity of 2000-4000 chicken per hour and three export oriented egg processing plants process the 4.5 million eggs per day (Singh 2012).
Major constraints in our country for lack of processing is
less preference for frozen chicken by the consumer,
insufficient cold chain infrastructure facilities, lack of well
organized marketing system, less domestic demand for
value-added egg products, non-availability of adequate
technology, fluctuating export trade, high import duty and
strict sanitary and phytosanitory norms by importing
countries. However, India with so many limitations now
emerged as a leading exporter of shell eggs, frozen and
dehydrated egg products and frozen broilers accounting to
Rs.458 crores during 2011-12. Indian poultry Industrial
growth is accelerated by gains in real per capita income and
changes in poultry prices.
2. Commercial Poultry Meat Products
Chicken meat products prepared from ground meat are emulsion based technologies which have the advantages of improved palatability, nutritive value and lesser production cost. Application of processing technology depends on global competitiveness, energy conservation and socio-
economic benefits.
2.1. Emulsion Products
Emulsion products like chicken meat blocks, nuggets, slices and patties utilizes tough meat, trimmings and edible by-products. The common steps of processing include comminuting/mincing to reduce meat and fat particle size (grinding, mincing, chopping or flaking), mixing with ingredients, making into specific shape, thermal processing and finally packaging.
Chicken nuggets are produced by making the meat batter into blocks and cutting the steam cooked and chilled meats into nuggets of different slices. Burgers/patties which contain 70% meat are prepared by mincing the meat, blending with ingredients, forming batter into patties which are cooked at 180°C (Anjaneyalu et al. 2012).
2.2. Processing of Sausages
Sausages are made by cutting meat and fat into fine
pieces mixed with spices and stuffed into animal intestines
and cooked in hot water. Emulsion based sausages are
made by grinding, chopping, stuffing, linking, cooking,
peeling, slicing and packaging. They are categorized by United States Department of Agriculture (USDA) meat inspection system as fresh, uncooked smoked, cooked, smoked, dry and semidry sausages and luncheon meat, loaves and jellied products (Anjaneyalu et al. 2012).
2.3. Restructured/Low Fat Chicken Products
These are meat products having high protein and low fat made by restructuring dark and white meat from heavy broilers. Excessive fat is trimmed off and other connective tissues are chunked out and formed. Blade tenderization, flaking and bay tumbling are modern methods available to produce tender products. Prepared meats can be used as steaks, cutlets, chops and roasts or they can be freezing stored (Anjaneyalu et al. 2012).
2.4. Cured and Smoked Products
Curing process involves addition of curing agents like
salt, sugar, sodium nitrite, sodium ascorbate and sodium
polyphosphate to the primal chicken cuts for enhancement
of colour, flavour and preservation. Chicken is injected
with pickle and dipped in it for faster curing giving a juicy
texture. Smoking involves heating, drying, smoking,
steaming/ cooking showering, chilling and packaging
which give a distinctive flavour. Cured and smoked chicken
on the whole has a niche market (Anjaneyalu et al. 2012).
. Enrobed/ Coated Products
Enrobing involves applying an edible coating to the products forimproving their texture, flavour, nutritive value, juiciness and tenderness. They act as sealing agents to prevent excess oil absorption. Chicken parts can be enrobed using whole egg liquid (viscous liquid and good batter), curd, flours, corn flakes and bread crumbs which give crispy taste (Anjaneyalu et al. 2012).
2.6. Retort Pouched Products
Thermal processing of meat destroys microorganisms and enzymes responsible for food spoilage. Thermal processing in metal cans or retort pouches increases shelf life of products and decreases 50% processing time. Some products include traditional Indian curries, soups, Keemas etc. Retort packaged products could be stored for a period of 6 to 12 months (Anjaneyalu et al. 2012).
2.7. Heritage Products
Heritage chicken products include traditional fast foods such as meat balls, kebabs, tikka, chicken tandoori, haleem, curries, enrobed and battered products and pickles which are prepared from chicken breast, thigh, drumstick and gizzard muscles. Pickles preserved with vinegar are stable up to 3 months (Anjaneyalu et al. 2012).
. Value Addition to Edible by Products
Edible poultry by products like dressed whole chicken
carcass and giblets such as liver, heart, gizzard and neck have good marketing values which are sold as package stuffed into cavity of carcass. Minced skin, gizzard and heart are used in emulsion of chicken products. Ova collected during dressing of layer chickens are used in sausage formulations, patties and kebabs. Chicken soup is another nutritious food that is categorized as low fat food (Anjaneyalu et al. 2012).
3. Commercial Egg Products
Egg products at USDA may be classified under following ways
(a) Refrigerated (as liquid) e.g. Whole eggs, whites or
yolks, sugared egg yolks, salted egg yolk, scrambled
egg mix, extended shelf life whole eggs
(b) Frozen: e.g. Whole egg, white or yolk, scrambled egg
mix, salted whole egg, sugared egg yolk and whole
egg mix
(c) Dried: e.g. White egg or yolk solids, dried egg, whole
egg
(d) Specialty products: e.g. dried hard cooked, peeled egg,
whole hard cooked peeled egg, egg yolk, long egg
quiche mix, and ultra-pasteurized liquid egg products.
Certain commercialized egg product preparations are as
follows
1. Pickled eggs: A simple, cost-effective and efficient
technology developed for ready to eat pickling of quail eggs/ chicken eggs for storage and marketing at ambient temperature.
2. Salted chicken eggs: Preparation of salted chicken
eggs technology is so simple to be used by unskilled people.
3. Albumen rings: Albumen rings are egg snack food,
prepared by cooking blended egg albumen in ring moulds and battering and breading the coagulated albumen prior to deep fat frying.
4. Egg roll: It is a nutritious, tasty and convenience egg
product suitable for meals or as snack foods.
5. Egg crepe: Egg crepe is a thin, fat, circular product
and may be filled with meat or vegetables and rolled or folded.
4.Advantage of Poultry Products
Marketing
Encouraging the poultry product marketing ensures
steady flow of products to the consumer in an effective
manner, thereby increasing the economic activity. It further
maintains the steady price distribution for the sale of
product in much profitable manner due to high returns. It
also gives way to employment generation and income
generation activity. Marketing of the poultry product can
also enhance the nutritional security of the different target
groups. Marketing of the poultry products make the poultry
products available at the right time, right place in right
quantity and at right price. However in India major problem
in marketing is the lack of efficient and organized market network.
4.1. Production Cost
In general the average variable cost of production is
lowest in the south followed by west, east and north. The
feed consumption rate (FCR) based market is generally
higher in the north because of higher market weight, higher
mortality rate due to extremes of hot and cold temperature.
Projected global egg and meat production during 2020 are
77 million tons and 123 million tons to cater to the demands of 8 million of the human population.
4.2. Channels of marketing
Currently more than 75% of the poultry products are
reaching the consumers through various channels of
distribution leading the consumers to pay more and
producers to get fewer margins. Besides, major share of the
profit at present goes to the middlemen. At present poultry
products are marketed in the following four marketing
networks.
1. Producer-Consumer
2. Producer- Wholesaler- Retailer- Consumer
3. Producer- Collector- Assembly merchant- Consumer
4. Producer- Retailer
Channel 2 may account to marketing of major portion of
eggs to the consumers. Channel 4 is responsible for getting
12-15% of the total profit to the retailers. However in
channel 2 a middleman gets 22% of the profit. National
Egg Coordination Committee owned by private sector
organization and National Agricultural Cooperative
Marketing Federation governed by Government of India to
some extent streamline the marketing of major poultry
products.
Major Meat consumption pattern in India are towards
fish, mutton, bovine and goat meat as given in the figure 1
below:
4.3. Prospects of Poultry Marketing
Considering the fast growth of the poultry industry in the past further growth and marketing of the poultry industry are limited due to the following factors
• Demand for poultry meat is highly price sensitive among low and middle income groups
Major limitation is logistics and distribution network within India mostly due to limited demands for frozen products, high cost of transport infrastructure unreliable cold chain facilities and the quality of the products produced.
• Vertical integration encourages higher production,
better marketing efficiency with reduced consumer
prices
• In India marketing efficiency is important than the
production efficiency
• Competitive feed price results in competitive meat and
egg production
• Seasonal variation due to religious practices
4.6. Prospects of Future Poultry Products Marketing
4.6.1. Strength: Technology Identified
4.6.1.1. Chicken Meat
Countinuous research and development efforts lead to
generation of cost-effective and efficient technologies for
the processing and preservation of egg and poultry meat,
tenderization of spent hen meat, deduction of meat
adulteration, development of value added poultry products,
packaging systems, optimum storage conditions, utilization
of poultry by-products etc. Besides, thorough inbuilt
measures are established to detect hazardous residues like
pesticides, antibiotics, antibacterial, heavy metals,
mycotoxins and biopathogens.
Currently some of the processing techniques include hot/cold deboning, thermal hydrolysis, enzymatic and blade tenderization of tough meat, massaging and tumbling for increasing myofibrillar proteins solubility and meat particle binding, flaking and dicing for restructured products, chopping and emulsification for comminuted products, marinating/ battering and breading for enrobed products, canning, curing and smoking and hurdle technology for shelf-stable poultry products.
Some of the value added poultry products include
chicken essence, chicken whey soup mixes, tandoori,
barbecues, canned/retort processed chicken products in
flexible pouches, cured and smoked chicken, chicken meat
and skin snacks, gizzard snacks, cooked chicken stock,
enrobed thighs, drumsticks and wings, marinated chicken
breast fillets, chicken spread, shelf- stable spiced chicken
bits, wafers, freeze- dried chicken pulav, retort- processed
curried chicken, and intermediate moisture chicken meat
etc. Other restructured products like chicken sausages,
patties/ burgers, nuggets, rolls, loaves, balls, cutlets, steaks,
kebabs, croquettes and chunkalona are other quality
products developed from low value spent hen or culled
breeder meat, skin, gizzard, heart, ova yolk and adipose fat.
4.6.1.2. Egg
Almost two-thirds of the global egg production has
occurred in developing regions of Asia. Egg processing is
mainly dominated by industrialized countries where 35% of
table eggs are converted into processed products. Table
eggs and liquid egg products are traded within European
and Asian countries. Dehydrated egg products are better
traded in large amounts because of its long shelf- life and
low transport cost.
India has also ventured in this on a modest scale. India’s
combined egg processing plants capacity is at 12000 metric
tons per year. Major areas of research in egg processing in
India is on design and fabrication of a low cost, batch -type
immersion egg washing machine and development of egg
washing powder. Recent advancements in egg processing
technology include improved egg spray washers and egg coating oil for preservation which maintains the quality of eggs up to 4 weeks at ambient temperature (26°C). Further processes have been developed to control gelatin in frozen yolk/whole egg liquid by 0.02% pepsin, 0.5% trypsin, 5 to 10% common salt or cane sugar or 5% glycerol in the egg magma prior to freezing.
Manufacturing technologies for a number of value-
added products live as whole egg powder, yolk granules, albumen flakes, albumen rings waffles, canned curried eggs, scrambled egg, omelet premixes, egg patties, egg- chicken meat patties, egg pizzas, egg roll, sponge and pancakes, albumen yolk cubes, mayonnaise, egg- enriched biscuits, breads and egg milk beverages have been adopted.
Ultra-pasteurization-cum-aseptic packaging techniques are also available to extend the refrigerated shelf-life of liquid egg up to 4 and 24 weeks at 10°C and 4°C respectively for marketing in non-frozen form. Presently another advanced method of vacuum evaporation of liquid whole egg followed by quick freezing to produce frozen egg pellets has also been developed.
Poultry slaughter waste, hatchery waste and egg shell
waste are being generated to the tune of three lakh tons, 0.6
lakh tons and 0.34 lakh tons respectively in India.
Conventional methods are being employed to convert the
egg shell into egg shell meal by centrifugation to recover
residual albumin subsequently with autoclaving, oven
drying and grinding into coarse or fine powder. Extrusion
technology has also been attempted to utilize the poultry
by-products into extruded pet food. Unorganized disposal
of poultry offal could be easily transported using 2% formic
acid or 4 % acetic acid for the period of 10 days at 26± 2°C.
Projected global egg production and meat production
during 2020 are 77 million tons and 123 million.
4.6.2. Weakness
4.6.2.1. Need for Emerging Technologies to Encourage
Marketing
Marketing of any products depend upon its shelf life ,
maintenance of nutrient content, easy transport, eco-
friendly packing material, easy availability, aesthetic
acceptance of the consumers. Accordingly there is a
necessity to concentrate on the research and development
wing to come out with newer technologies on the following
lines.
Design of mini poultry processing units
Shelf-life extension of poultry products by application of hurdle technology and biotechnology means
Developing newer techniques for tenderization of
meats
Efficient processing techniques for extraction of lysozyme, avidin, lecithin and other biomolecules from eggs
Ultra-pasteurization cum aseptic packaging technology for liquid egg
Uniform processing technology for traditional poultry products
Improved packaging techniques like vacuum, MAB, CAP, retort and aseptic
Development of quick and sensitive methods for detection of pathogens and hazardous feed residues Application of bio- processing techniques for efficient disposal of poultry products
User-friendly transport system as per the food engineering norms
4.6.2.2. Opportunities
Rapid urbanization, industrialization, rising disposable
income, changing food habits towards processed products
and higher middle income group are major positive factors
to boost up processed food markets. Strict adaptation of
GMP and HACCP system can give major possible export of
frozen broilers in the European Union, Japan and Russia as
per Rabo bank report 2008. Major limitation factor for
export of poultry products is attributed to non-compliance
of quality norms prescribed by the codex alimentarius.
Following are the major elements need to be given due
attention to encourage the export of poultry products
Application of modern processing techniques Provision of logistic support
Production of quality products fit for export Policy changes in the government level
Developing the appropriate packaging technology
Effective R & D work to increase the shelf life of the
products
Harmonization of quality control norms Single window approach for export
Creation of database
Well trained techno graphs and skilled human resources
NABL accredited laboratories for certification of food products
Cost effective mini poultry processing units
4.6.3. Threats
4.6.3.1. Marketing System
At present poultry marketing is dictated by the private
traders and commission agents present in various cities and
towns. Most of the trading activity of the poultry meat and
egg is in the disadvantageous position to the farmers giving
lesser margins of profit than the traders’ profit margin.
Right now, organized marketing network need to encourage
positive trend for uniform profits to all the players in the
poultry industry.
Indian Poultry Industry is one of the fast growing markets in poultry production accounting to 3.8 billion
broiler and 100 billion egg production. Although poultry industry shows enormous growth, the poultry processing
sector is still underdeveloped due to less demand for the ready to eat and cook products and less acceptability of
processed poultry products. At present marketing of poultry
products has many hurdles such as, unstable market,
increased taxes on processed foods, competitive feed costs,
high transportation charges, lack of cold chain facilities and
non-compliance of food safety norms. However continuous
research and development leads to the development of low
cost and efficient poultry processing technologies and well
established quality control norms. Poultry marketing
system in India dominated by private traders and
commission agents needs to be transformed into an
organized system for uniform sharing of profits by all
players in the industry.
