ABATTOIR

Our state of the art abattoir is situated on the outskirts of Pakistan’s largest city of Karachi. It is strategically situated with access to international trade routes via the country’s largest airport and sea port. The abattoir, which is one of the most modern of its kind in Pakistan, is certified to export to some of the largest regional markets around the globe and qualifies as a high throughput facility with a daily slaughtering capacity of 800 cattle and 1000 mutton.

Procurement

We select some of the finest free-range, grass-fed animals from the Punjab and interior Sindh. The animals are young, roam freely on the farms and no hormones or antibiotics are used in their feed. This ensures that there is no chemical contamination of the meat. Good, healthy animals are procured to provide high quality meat to our customers.

Processing and Production

Free range, healthy cattle are brought in from interior Pakistan and then kept in our facility before slaughtering and then processed in a state-of-the-art HACCP certified abattoir.

They animals are kept in a lairage that is covered, providing protection against adverse weather conditions. It is constructed with impervious material so as to facilitate easy and thorough cleaning with a safe foothold for the animals. Facilities have also been provided for the ante-mortem inspection to take place and detention facilities of animals that require further inspection and evaluation.

Handled carefully, the meat is moved to the chillers and refrigeration section for storage before shipping out to the retail outlets. Meat for export is packed accordingly and made ready for overseas shipment by air.

Al Shaheer’s state-of-the-art, fully automated slaughtering plant was imported from the Nippon meat industry from Australia. Foreign technicians and experts were involved in setting up of the plant and in the training of the staff. The plant has been developed keeping in view the international standards of food safety and hygiene. The entire construction and design has been made to prevent contamination and bacteria from affecting the meat. All floors, walls, coverings, doors, windows, ceilings /overhead fixture and stairs, in the production area, are constructed of material that is durable easy to clean and suitable for the arduous nature of the slaughter house. The plant has a capacity to process 80 tons of beef and mutton on a daily basis.

Packaging

Beef carcasses meant for exports are cut into four quarters, comprising two legs and two shoulders and properly wrapped in cotton cloth with expiry date tags attached, before being exported to the client’s location. In case of boneless meat, the meat is packaged in different sized packages (by weight) as per customer requirements and specifications, put in boxes with expiry date tags attached and then delivered to the client.

Testing & Compliance

Appropriate proactive measures are taken to prevent contamination of the meat. The plant comprises of a laboratory where our microbiologists perform and evaluate tests for potential microbiological and bacterial growth that may harm the meat. All SOPs related to food safety, hygiene and meat quality are implemented at the fullest. This is our deepest concern as a food manufacturer.

Storage of meat is also one of our main concerns due to the perishable nature of our product. To increase the meat’s shelf life and to retard microbial growth, we have installed chillers, freezers and cold storage rooms. The meat is never frozen; it is kept fresh by chilling retaining the natural taste, flavor and tenderness. The total chilling capacity at the plant is around 80 tons.

Distribution & Shipment

Al-Shaheer’s facilities are located near Karachi, which provides easy access to the biggest seaports and airport of the country for easy export of our meat overseas. The ready access saves time, which helps retain the freshness of the product. The company has a fleet of specially designed refrigerated trucks to move the slaughtered meat to the retail outlets or to the ports for export. The temperature of these trucks is maintained and they are cleaned prior to each shipment to avoid any bacterial growth or cross contamination.

Given the lower cost of transportation, Pakistani meat is one of the most cost-effective options for Saudi Arabia and the Middle East. Initially all meat was exported by air freight but by November 2010, Al Shaheer will be able to supply deboned and/or vacuum packed chilled meat by sea to its international clients.