AACo Meat Processing Plant, Darwin, Australia

Australian Agricultural Company (AACo) started construction of a state-of-the-art meat processing plant in Livingstone Valley, Darwin, Australia, in late 2012

The facility will produce beef products, hides and other products for the US, European and Asian markets.

"The plant will have the capacity to handle 179,000 cattle a year."

The plant will have the capacity to handle 179,000 cattle a year, which is expandable to 225,000 with additional investment. AACo is expected to invest approximately $85m (including land cost) in the project. The plant's commissioning is expected to take place in the second half of 2014. The Northern Territory government approved the project in April 2012.

Thinc and construction company Sunbuild, both based in Darwin, were contracted in November 2012 for providing project management for the construction.

Benefits of the AACo meat processing plant project

The new plant is expected to process stock from the northern part of Queensland, South Australia, Western Australia, and the Northern Territory. It will support the meat processing industry in this region, where there is a lack of processing facilities.

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Cattle in the region are currently transported more than 3,000km to various processing plants across Australia. The transportation of live cattle over such long distances affects their welfare and also contributes to carbon emissions.

The construction of the new plant will ensure the welfare of the cattle. Since the cattle will be processed locally, it will reduce transportation costs and carbon emissions caused by transportation. The plant will ensure efficient use of resources and ethical treatment of animals.

The project is expected to generate new jobs in the meat processing industry in the region. It will generate 230 jobs during construction and another 270 once it becomes operational.

In addition, it is expected to create $126m in economic benefits for the region.

Site details of AACo meat processing plant

The site of the plant is a hay and cattle farm spread over 600ha. AACo acquired the site in May 2012 at a cost of $13.27m.

"The plant will produce 28 million kilos of saleable beef in different grades."

The processing plant will occupy about 4ha of the site. Waste recycling infrastructure will be built on another 14ha of land. The remaining area of the site will be used for irrigated feed crops with limited cattle grazing.

The site is logistically well-connected with the Port of Darwin, which is located nearby. A railway line runs along the property and the site is also located close to the Stuart Highway. The site is well-connected to transport products quickly, which will reduce the environmental impact of the plant.

Design of the meat processing plant

The plant will include a main processing unit, boning unit, freezing and chilling systems, and a rendering plant for processing by-products. It will also include a hide processing unit, holding yards, workshops, refrigeration, offices, and a wastewater treatment plant.

Construction of the facility consists of two phases.

The project also includes a community centre, which will provide day care, health care and training facilities.

Cattle processing capacity

The plant will be Halal-certified. The cattle will be held in yards located next to the plant. They will be electrically stunned in adherence with animal welfare standards.

"The plant will incorporate several energy-saving features."

Hot-boning will be used for processing the cattle. The plant will bone and process the carcass immediately after slaughter. It will have the capacity to process 1,000 heads a day.

To ensure hygienic meat production, the boning processing room will be maintained at a temperature of 80°C. Refrigeration units will provide chilled storage at 20°C and frozen storage at 180°C.

Beef products produced by AACo

The plant will produce 28 million kilos of saleable beef in different grades, as well as 36 million kilos of by-products.

Sustainability

The plant will incorporate several energy-saving features, including the use of gas for thermal heating. Ventilation throughout the building will be computer-controlled to ensure efficiency.

The wastewater treatment plant at the facility will use a dissolved air flotation system to remove nutrients from the wastewater using a chemical process, before sterilising it using an ultraviolet system.