JULY 2016

www.WATTAgNet.com

2016 Nutrition & Feed Survey:

Formulating poultry feed

for antibiotic-free production

PLUS
2015 Italian poultry production
up 3.6 percent, growing
How to control Campylobacter
in broiler production
How to reduce cleaning costs
in poultry meat processing
Digital version at www.poultryinternational-digital.com
VOLUME 55 NUMBER 7

JULY 2016
COVER STORY
8 2016 Nutrition & Feed Survey:
Formulating poultry feed for
antibiotic-free production

FEATURES
16 SPACE to celebrate 30th anniversary
in 2016

18 2015 Italian poultry production

up 3.6 percent, growing

22 Top 5 broiler producers dominate

US production

26 Broiler super pre-starter formulation

secrets revealed

30 How to control Campylobacter in

broiler production
Cover image by: Nirutdt | Dreamstime.com

34 5 tips for rasing healthy antibiotic-free

poultry
DEPARTMENTS
38 How to reduce cleaning costs in 4 Editors Comment
poultry meat processing 6 News
42 Products
43 Marketplace
44 Advertisers Index

July 2016 www.WATTAgNet.com

4 PoultryInternational

EDITORS COMMENT BY MARK CLEMENTS

CORPORATE HEADQUARTERS
303 North Main Street, Suite 500,

Survey reveals mixed but

Rockford, Illinois 61101-1018 USA
Tel: +1 815 966 5400; Fax: +1 815 968 0941
Publisher, International: Greg Watt

optimistic outlook gwatt@wattglobal.com

Publisher, N. America: Steve Akins
sakins@wattglobal.com

This edition of Poultry International brings you the VP/Director of Content and
Innovation: Bruce Plantz
results of our annual Nutrition & Feed survey. bplantz@wattglobal.com
Director of Global Digital &
North American Agribusiness Sales
Jeff Miller; jmiller@wattglobal.com

EDITORIAL OFFICE
The good news is that, despite some difficulties in the
Editor: Mark Clements
sector, most respondents were positive about profitability mclements@wattglobal.com
Tel: +44 7866 475 388
over the year ahead. However, the survey has revealed re- Content Director - Agri business:
Terrence OKeefe
gional variation once again. tokeefe@wattglobal.com
Mixed grain quality, high input costs and exchange rate Nutrition Editor: Ioannis Mavromichalis
imavromichalis@wattglobal.com
volatility have all been causing problems for some, while
COPY DESK TEAM
concerns about antibiotic resistance are now becoming an Digital Content Director: Tara Loszach
ever-more universal concern. SEO Editor/Senior Editor:
Kathleen McLaughlin
Pressure from retailers and consumers is increasingly coming to bear on the Senior Editors:
agricultural industry. Some have been subject to this pressure for quite a while Alyssa Conway, Lisa Kirschner
Staff Reporter: Roy Graber
now and are advanced along the path in using alternatives, while the change Agriculture Reporter: Austin Alonzo
is causing pain for others. The survey highlights fears over loss of production Associate Editors:
Andrea Gantz, Ann Reus
gains and the cost of alternative feed ingredients.
ART/PRODUCTION TEAM
Senior Art Director: Tess Stukenberg
Successful change Production Manager: Jim Riedl
jriedl@wattglobal.com
But as this issue shows, the change can be made. We offer five tips for rais-
Advertising Production Coordinator:
ing healthy antibiotic-free poultry. This issue also includes a positive market re- Connie Miller

port from Italy, where antibiotics as growth promoters in animal feed have been SALES TEAM
Northern Europe, Asia, Africa
banned for more than a decade, as they are in other European member states. Frans Willem van Beemen
In terms of markets, we take an up-close view of which companies dominate fvanbeemen@wattglobal.com
Tel: +31 344 653 442; Fax:+31 344 653 261
U.S. poultry production and reveal how many people are employed by just the Southern Europe, Latin America
top five players. Tineke van Spanje
tvanspanje@wattglobal.com
Tel: +31 495 526 155; Fax: +31 495 525 126
Southeast Asia
Dingding Li, dingdingli@vip.163.com;
Follow Mark Clements in his blog Tel: +86 137 640 39062
www.WATTAgNet.com/MarkClements.html USA/Canada
Pam Ballard, pballard@wattglobal.com
Tel: +1 815 966 5576; Fax: +1 815 968 0941
Mary Harris, mharris@wattglobal.com
Tel: +1 815 980 5938; Fax: +1 847 908 7551
Classified
Craig Greuel, cgreuel@wattglobal.com
Community Tel: +1 815 966 5591

https://www.facebook.com/WATTAgNet www.youtube.com/WATTPoultryTV For article reprints and reprint quotes

contact: FosteReprints
https://twitter.com/WATTAgNet www.linkedin.com/groups/WATT-AgNet-4855866 +1 866 879 9144 www.fosterprinting.com
6 PoultryInternational

Get up-to-the-minute news from around the world on WATTAgnet

at www.wattagnet.com/topics/459

MHP plans for poultry plant in Netherlands stirs worry

Ukrainian poultry company, Myronivsky Hliboproduct (MHP), is set to open a processing plant
in the Netherlands. The new processing plant will be in Veenendaal, near to Utrecht.
www.WATTAgNet.com/articles/27246

Russia confident China will accept Russian poultry

Russia is optimistic that China will open its market to Russian poultry exports within the next
several months. Russian Agriculture Minister Alexander Tkachevsaid Chinese officials decided
to allow imports of pork from regions in Russia that had not been affected by African swine
fever (ASF), and that he believed the poultry market, which had been restricted because of
avian influenza concerns, would also be opened.
www.WATTAgNet.com/articles/27240

Zoetis gains USDA contract to produce avian flu vaccine

TheU.S. Department of Agriculture (USDA) has awardedZoetisits latest contract for vaccines
that could be used against avian influenza.
www.WATTAgNet.com/articles/27234

Complete Poultry Rendering Solutions

Haarslev Industries
Market leader in design, manufacture, Bogensevej 85
DK-5471 Sonderso
consultancy and installation of equipment for pro-
Denmark
cessing of animal by-products. Tel. (+45) 63 83 11 00
Email: info@haarslev.com
Web: www.haarslev.com

www.WATTAgNet.com July 2016

 www.bigdutchman.de

Relax: the group laying nest for broiler breeders

Easier for you,

easier for the birds.
For modern and successful broiler breeder management, Big Dutchman offers tailor-made concepts, the
required expertise and the necessary equipment. Our tried and tested Relax group laying nest with a
divided roof and a nest locking mechanism is just one example.
| High nest acceptance due to optimum entrance height
| Rapid and easy monitoring of the nest and the egg belt with the help of the divided and very light nest roof
| Optimum hygiene and cleaning owing to the clever, wood-free nest design
| Reduced egg contact thanks to an egg belt with triangular holes
| Highest egg quality as a result of short rolling-off distances and gentle transport of the eggs
8 PoultryInternational

2016 Nutrition & Feed Survey:

Formulating poultry feed for
antibiotic-free production
Annual survey reveals AGP alternatives, feed additive usage trends

JACKIE ROEMBKE

Compared with 2015, respondents to WATT Global
Medias annual Nutrition & Feed Survey had a fairly
positive 2016 outlook, with 67 percent citing improving
profitability or at least maintaining last years business.
However, 40 percent of respondents have seen inclem-
ent conditionssuch as exchange rate fluctuations,
variable grain quality, and high ingredient and addi-
tive costscontinue to chip away at their profitability,
mainly in Latin America, Asia and Africa.
Antimicrobial resistance, its potential ties to animal
2015 Nutrition & Feed Survey:
www.WATTAgNet.com/
articles/22354
agriculture and the push to eliminate its use for growth
promotion are the primary focus of animal producers.
Given the threat of the widespread human health
crisis posed by antimicrobial resistance, the use of anti-
microbials in animal protein production is increasingly

Profitability outlook, 2011-16 Percentage of antibiotic-free animal feed production

Source: WATT Global Media Source: WATT Global Media

50 100 percent of production

45 20% is antibiotic free
Response percent (%)

40 17% Between 50 percent and

35 99 percent of production
is antibiotic free
30
25
Between 25 percent and
19% 49 percent of production
20 is antibiotic free
15 26% Less than 25 percent of
10 production is antibiotic free
18%
5 None of production is
0 antibiotic free
2011 2012 2013 2014 2015 2016

Improving profitability Negative or deteriorating profitability

No change in profitability
due to economic conditions Even though one-fifth of respondents are not producing
antibiotic-free products, an impressive 43 percent report
Most respondents felt positive about profitability or at least that that upwards of 50 percent of their feed production is
it wasnt falling off. However, for a second year in a row, Latin now antibiotic free.
America had a more negative outlook due to its continuing
struggles with exchange rate volatility.

www.WATTAgNet.com July 2016

 PoultryInternational 9

As a result of increased Reaction to consumer pressure to reduce/eliminate AGPs in 2016

consumer and retail pressure Source: WATT Global Media

to reduce or eliminate the 40

use of AGPs in poultry 35

products, 35 percent of 30

Response percent (%)

respondees cite that the 25
topic will be the focus of 20
upcoming strategic meetings. 15
An additional 27 percent are
10
testing AGP alternatives on
5
their flocks.
0
Immediate action taken to Flock testing Hiring a The focus of upcoming Nothing at all
reduce/eliminate AGPs nutrition consultant strategic meetings

Primary AGP-elimination challenges Is your company actively exploring,

Source: WATT Global Media testing or using feed additives as
Overcoming the production antibiotic alternatives/replacements?
losses related to going AGP free 123 Source: WATT Global Media

Significant capital investments

to improve animal welfare 103
Yes
Difficulty implementing
changes at the farm level
95 65%
Learning curve for No
35%
nutritionists 70
Feed additive costs 96
Inconsistent research,
unknown results 89

0 20 40 60 80 100 120 140

Number of respondents
Sixty-five percent of survey respondees
The majority of respondents cited the loss of production gains as are investigating AGP alternatives.
their greatest obstacle in phasing out AGPs. In addition, the cost
of refurbishing existing operations to promote animal health and
welfare came in second.

Additives used to replace AGPs

Source: WATT Global Media
Sixty-one percent of
70 respondents use organic
60 acids to replace AGPs in
animal feed formulations.
Response percent (%)

50
Enzymes and probiotics tie
40
for a close second. Perhaps
30
unsurprisingly, phytogenic
20 feed additives, such as
10 essential oils, prove an area
yet to be explored.
0
Organic acids Phytogenics/ Enzymes Probiotics Prebiotics Other
essential oils

July 2016 www.WATTAgNet.com

10 PoultryInternational

2016 NUTRITION & FEED SURVEY

under public and government scrutiny. In the United States,
the National Research Council cites that animal agriculture
consumes an estimated 80 percent of all antibiotics.
As the consumer rightfully becomes more concerned,
major retailers and companies are taking a proactive
stance. In less than 12 months, many major U.S. meat
producers such as Tyson and Perdue, restaurant chains
including McDonalds and Subway, and retail chains such
as Costco have vowed to eliminate the use of human anti-
biotics by the end of 2017. Such professions will no doubt
set the course for a sea of change in public expectation.
Meanwhile, the world agriculture industry is coming to
terms with the fact that its time to reexamine long-standing
practices before they become mandated by regionaleven-
tually, perhaps internationalregulators.
The necessary production, management and for-
mulation shifts required to even begin to address the
overuse and elimination of antimicrobials from produc-
tion weighed heavily on respondents. Fifty-eight percent
consider the elimination of antibiotics in feed due to con-
sumer pressure and/or government regulation as a critical
obstacle to overcome in 2016.
World feed industry inches toward AGP
elimination
Antibiotic-free production refers to the elimination of
medically important antimicrobials for growth promotion
(AGPs) and the judicious use of antibiotics for the treat-
ment of sick animals. Of those surveyed, 17 percent were
able to report 100 percent antibiotic-free production, and
an additional 26 percent noted that 50 percent or more of
their companys production is antibiotic free.
Given the current climate, it will be interesting to com-
pare the 2016 responses to 2017s results.
Poultry meat producers are especially feeling the pres-
sure to go antibiotic free.

g radi n g pac ki n g p r o c e s s i n g

Omnia PX: The new standard in egg grading

ENGLAND, UK | We choose the Omnia PX for

many reasons including greater egg handling
ability, a machine wash down program with
Cleaning In Place and Cleaning Out Place features,
meeting ours and our customers expectations.
Next to a great machine we also enjoy excellent
after sales & service support.

Mr. Matthew Bird

Director Bird Bros Eggs, England, UK
www.moba.net/PX700
www.moba.net/PX700

www.WATTAgNet.com July 2016

Cost per kg meat? Check!
Feed needs support to live up to the demand of modern
animal production. CreAMINO boosts natural creatine
synthesis, reduces the need for arginine, and saves energy.
To get performance up and costs down.

Simply Efficient

animal-nutrition@evonik.com
www.creamino.com
12 PoultryInternational

2016 NUTRITION & FEED SURVEY

Effectiveness of traditional AGP alternatives Though some of these com-

Source: WATT Global Media panies may be in the early stages
50 Effective
of AGP-free feeding, all report
45 Uneffective significant challenges in making
40 Dont know the transition.
Response percent (%)

35
Respondents were asked
30
to identify their two greatest
25
20 challenges in erasing antibiotic
15 growth promoters from their op-
10 erations. It comes as little surprise
5 that the production losses are the
0
Organic acids Phytogenics/essential oils Enzymes Probiotics Prebiotics hardest to overcome. From a flock
management perspective, large
Mirroring the findings from the additive replacement chart, respondents find capital investments that would be
probiotics, organic acids and enzymes to be the best AGP alternatives. Many are required to improve the hygiene
unsure of the efficacy of phytogenics. and handling of animals pose a
significant barrier to antibiotic
How would you characterize the inclusion of the following items? elimination (37 percent), as well
Source: WATT Global Media as difficulty to enforce cultural
Increased Decreased Stayed the same Not used and operational changes at the
farm level (34 percent).
Mycotoxin binder/inhibitor
On the feed side, the ability to
Essential oils
justify the cost of new feed additives
Yeast cell wall products
as antibiotic replacements presents a
Prebiotics
significant hurdle for nutritionist and
Probiotic organisms
formulators (35 percent).
Therapeutic antibiotics For those who have made the
Subtherapeutic antibiotics leap, the big question is: How are
Anticoccidial drugs you doing it and what feed ad-
ditives are you using to replace
0 20 40 60 80 100 120
Response percentage AGPs?
While the inclusion of some feed additives remained static, most report
decreases in the amount of therapeutic and subtherapeutic antibiotics The efficacy of AGP
if they even use them at all. alternatives
Sixty-five percent of survey
In 2016, 24 percent of survey respon- will be the focus of upcoming strategic participants report that their company is
dents report that their company has taken meetings. Others have taken steps to test actively testing or using feed additives
immediate action to reduce or eliminate the waters before implementing AGP-free as antibiotic alternatives.
the use of AGPs in their poultry opera- feeding by hiring a nutrition consultant (18 Of these companies, 60 percent of
tions. Nearly 35 percent cite that the move- percent) and testing the new formulations/ respondents report that the use and ap-
ment toward antibiotic-free production additives on their flocks (27 percent). plication of a feed additiveor a com-

www.WATTAgNet.com July 2016

14 PoultryInternational

2016 NUTRITION & FEED SURVEY

bination of feed additivesdiffers
within their company. The application
of these AGP replacement additives
vary rather evenly by the flock type,
the poultry complex, the individual
grower or farms and by the time of
the year the feed is fed.
If more than one feed additive
is used as an AGP replacement, 35
percent use multiple additives in
combination to achieve the desired
effect, and 32 percent utilize differ-
ent combinations in different rations.
Survey respondents used organic
acids (61 percent) as their primary
AGP replacement additive, while
enzymes and probiotics tied for sec-
ond at 59 percent. Unsurprisingly,
it seems that phytogenic feed addi-

Better digestion for

tives lag behind (34 percent) in their
popularity despitethe relative ben-

better feed efficiency

T
EN
M
AN
AGE
M efits reported by those using them
in their AGP-free formulations.
Add the power of A unique blend of herbs, essential oils and functional avors In terms of their efficacy as
Phytogenics to Proven in science and practice antibiotic replacements, prebiotics
your diet: Tailored to the animals needs
seem to be the most reliable (45 per-
cent), though these are likely used
in combination with other additives.
Enzymes (40 percent) and organic
acids (41 percent) also fared well.
The jury is still out, however, on the
efficacy of phytogenics.

Animal feed additive usage

Beyond the AGP replacement
dialogue, the popularity of some
staple feed additives endures.
When looking at the inclusion
characterizations of eight types
of feed additives, antibiotics
for both therapeutic and
subtherapeutic applications saw a
drop. Concurrently, probiotic and
prebiotic usage is on the rise.

Jackie Roembke is editor of

digestarom.biomin.net Feed Management and Feed
International. Contact Roembke
Naturally ahead
at jroembke@wattglobal.com.

www.WATTAgNet.com July 2016

 ILATION PR
ENT O
V

D
UC BEST FANS. PERIOD.
ITY

TS
QUAL

E R I C A N MADE
AM OWNED
AMERICfoAr Nmore
rs.
85 yea
than

REASON #2
BLADES
Coolair manufactures two types
of quality blades. Our premium
product, Coolair cast aluminum
airfoil blades, are poured here
in our own foundry. Our high-
strength die-formed steel blades
are an economical choice.
Epoxy-coated for corrosion
protection, these steel blades
are replaceable. All of our
blades are manufactured in our
factory in Jacksonville, Florida.
Large photo: cast aluminum airfoil blades.
Inset photo: steel blades

P.O. Box 2300 | Jacksonville, FL | 32203-2300

v: 904/389-3646 | f: 904/387-3449 | agfans@coolair.com | coolair.com

Value that Stands the Test of Time

16 PoultryInternational

SPACE to celebrate
30th anniversary in 2016
This years expo will look back at changes, ahead to the future

Research and Development Village

The Research and Development Village at SPACE,
spearheaded by the Brittany Chambers of Agriculture,
has been a vector of proactive discussions for livestock
farmers about the challenges of the future.
This year, the village will address the major future
challenges related to climate change. Its central concern,

When and where Producing for the future, will address changes related
to the climate, energy management and land use. The
Exhibition Centre of Rennes Airport
goal is to showcase practices for each sector that can
La Haie Gautrais
have a positive impact on the productivity and profitabil-
35170 Bruz
ity of farms. Solutions and ideas will be presented in four
September 13-15: 9 a.m. to 6 p.m.
main areas: saving energy, producing energy, reducing
September 16: 9 a.m. to 5 p.m.
greenhouse gas emissions and storing carbon.
www.space.fr

SPACE will celebrate its 30th edition from
September 13-16, 2016, in Rennes, France.
The livestock sector is going through difficult and
uncertain times. Farmers and their partners are dealing
with profound changes. In this volatile environment,
SPACE promotes innovation by showcasing the techni-
cal and technological solutions that farmers and all live-
stock sectors need to compete and improve their work-
ing conditions. SPACE is also a source of new prospects,
new ideas and new directions to help build the future
and improve the visibility and confidence of an industry
that plays a vital role in feeding humanity.
This years expo will look back at the changes that
have occurred in the livestock sector over the past 30
years, using various materials and media. In 1987,
SPACE had 260 exhibitors from 18 countries, and
32,000 visitors. In 2015, SPACE had 1,446 exhibitors
from 492 countries, and 106,226 visitors. Exhibitors
present this year who were also present in 1987 will re-
ceive a special distinction.

exhibitors a place to promote new prod- The InnovSpace label is a marketing

InnovSpace
InnovSpace allows exhibitors to pro-
mote new products and services.
Billed as a place for companies to
launch new products, InnovSpace offers
ucts and vie for the InnovSpace award.
InnovSpace prize winners are featured
in the French and international press.
There have been 1,073 prizes awarded
in 20 years.
and promotional tool for companies at
SPACE. This distinction attracts customers
and prospects looking for new products,
where exhibitors can showcase their abil-
ity to innovate.

www.WATTAgNet.com July 2016

 Plasson's Advanced Drinking
& Feeding Systems

Solutions for all Types of Birds

FEEDING DRINKING

No Grill for Visible Feed and Optimum Performance

Easy Access and Best Results
Designed for Better Animal Highest Flow Rate, Quality
Welfare and Reliability
Plassons High Quality Designed Versions for Broilers,
Feeders Made to Last Turkey, Layers and Breeders
11902 4.15

Maagan Michael, D.N. Menashe, 3780500, Israel

Tel: +972-73-2413001, Fax: +972-73-2333711
Feeding Drinking Climate Housing info@plassonlivestock.com | www.plassonlivestock.com
 18 PoultryInternational

2015 Italian poultry production

Snowboy234 | Dreamstime.com up 3.6 percent, growing
Despite falling broiler prices and flat output for other species,
the Italian poultry industry grew in 2015 and has made a good start in 2016.
MARK CLEMENTS

Italian poultry meat and egg production recorded a posi- Italian poultry meat market
tive 2015 and expansion is expected to continue into 2016, 2014-15 (000 tons)
reversing last years poor performance.
Growth was driven by broiler production, while output
from other poultry species was either stagnant or contracted.
Production 3.6
Italian industry association Unaitalia reports that total poul-
1,261.20 2014
try meat production in the country rose by 3.6 percent over 2015 1,307
2014 to stand at 1.31 million tons. By value, Italys poultry

Leading Italian poultry companies 2014 2.9 Imports

94.5 2014
Head slaughtered
Company Location (million) 2015 97.2

AIA Verona 350

Gruppo Veronese Verona 350
Amadori Cesena 250
For more information, go to:
Exports
170 2014
3.2
www.WATTAgNet.com/worldtoppoultry.html 2015 175.5

production is estimated to have been worth EUR5.56 billion

3.9
(US$6.38 billion).
There was also positive news for the Italian egg indus- Per capital
try. 2015 saw Italys egg producers largely recovered from consumption (kg)
switching out of conventional cages and production levels
returning almost to those before the switch.
19.45 2014
2015 20.21

Chicken meat outpaces other species

Higher chicken meat output was the driver for the overall Source: Unaitalia

Poultry meat production was 3.6 percent higher in 2015, and poultry meat consumption on the
home market and exports were also up. Imports of poultry meat, however, were also higher.

www.WATTAgNet.com July 2016

 COUNT ON COBB
Consistent Genetic Progress

Pedigree FCR Improvements

Cobb selection programs for over 30 years have emphasized feed
efficiency and meat conversion as high priorities in the development of the Cobb500.
Cobb combines both attributes in the worlds most successful broiler, the Cobb500.

cobb-vantress.com
LEARN MORE
20 PoultryInternational

2015 ITALIAN POULTRY PRODUCTION particularly keeping in mind that total food consumption in
Italy is stagnant, allows us to be optimistic.
Italian egg market
When we look in detail, despite the poor performance
2014-15 (million pieces)
of turkey and other species, the strong performance of
chicken has pulled the sector higher.
Production 2.2
12,534 2014 Italys poultry meat consumption
Consumption of poultry meat in Italy rose by 3.9 percent
2015 12,816
last year. For 2013, per capita chicken meat consumption in
Italy stood at 14.63 kg, while the average Italian ate 4.29 kg
of turkey. This figure stood at 20.21 kg for all poultry meat.
-3 Imports Unaitalia reports that 99 percent of the white meat con-
1,398 2014 sumed in the country is produced on the home market.
Italy is now 102.9 percent self-sufficient in chicken meat
2015 1,355
and 119.9 percent self-sufficient in turkey meat. Without ex-
pansion into foreign markets or a significant increase in per
capita consumption, there may be little room for production
Exports
704 2014
4.3 to grow further without more downward pressure on prices.

Falling broiler prices

2015 734
Despite the increase in production and consumption, not
all was positive for Italys poultry industry last year. The
decline in broiler prices that occurred throughout 2014 con-

1.4 Per capital

tinued into 2015. By year end, broiler prices were 7 percent
lower than in 2014.
consumption (kg) Nevertheless, the sector remained profitable due to the
downward trend in feed prices that started in the second
218 2014
half of 2013 and has continued into 2016.
2015 221

Source: Unaitalia
The difficulties experienced by Italys egg producers moving
away from traditional cages are not over. Production and
consumption of eggs are rising, while imports continue to fall.
rise in poultry production last year. Increasing by 4.8 per-
cent, total chicken production reached 915,000 tons.
Turkey meat production also expanded slightly, rising
by 0.8 percent to 313,000 tons, while meat production from
other poultry species was either flat or contracted.
Aldo Muraro, Unaitalia president said: The signs of re-
covery for poultry meat witnessed over the past 12 months,
Egg production
Italys egg production also expanded in 2015. Unaitalia
notes that table egg production was 2.2 percent higher at
12.8 billion.
Nevertheless, the country continues to import eggs.
However, the need for egg imports is decreasing. Egg im-
ports stood at 694 million last year, a 3 percent decrease on
2014 and a 47 percent decrease on 2013.
Muraro notes that Italys egg producers have been
through a transitional period due to implementing European
welfare legislation, abandoning conventional cages and
adopting either enriched cages or free-range production sys-
tems. This resulted in production temporarily contracting.
However, the sector is now working efficiently.

www.WATTAgNet.com July 2016

22 PoultryInternational

Top 5 broiler producers

dominate US production
The countrys top five largest broiler companies account for more
than half of national production.
AUSTIN ALONZO

To access the World

In the United States, the top five largest Top Poultry Companies
poultry companies produce the majority of database in full, go
the countrys broilers. to: www.WATTAgNet.
Five broiler companiesTyson Foods Inc., com/directories/80.
Pilgrims Pride Corp., Sanderson Farms Inc., html
Perdue Farms Inc. and Koch Foods Inc.pro-
duced about 60 percent of the U.S. ready-to-
cook (RTC) chicken last year, according to WATT Global The National Chicken Council, a Washington-based
Medias Top Poultry Companies database. Between them, association representing the broiler industry, estimates
they produced about 493.21 million pounds weekly. that the industry employs about 280,800 U.S. workers.
Three companiesTyson, Pilgrims Pride and
Sandersonproduce approximately half of the nations
chicken. 1 Tyson Foods
Tyson Foods Inc. is the largest chicken company in
the United States and one of the largest
food companies in the world.
Top 5 US broiler producers 2015 by weekly The Springdale, Arkansas-based
ready-to-cook chicken production multinational company had one of its
RTC per 2015 best years ever in 2015. It reported
week revenue
Rank Company (lbs million) ($ billion) Company profile $40.6 billion in salesa record for the
1 Tyson Foods Inc. 175.6 11.4 http://goo.gl/uNHXwB companyduring the year. According
to WATTs data, the companys rev-
2 Pilgrims Pride Corp. 141.67 7.1 http://goo.gl/lHG7gY
enue grew to $11.4 billion from $11.1
3 Sanderson Farms Inc. 66.2 2.8 http://goo.gl/B68qP1
billion the previous year.
4 Perdue Foods 61.74 3.9 http://goo.gl/Kybk2o
Tysons weekly production
5 Koch Foods Inc. 48 3 http://goo.gl/elHdV3
of ready-to-cook (RTC) chicken
Source: WATT Global Media
dropped slightly, however, to 175.6
To view a full list of the Top 34 broiler producers in the U.S. to and million pounds from 176.31 million
learn more about their production, visit: http://goo.gl/0TtwUh pounds the previous year.
The top five broiler producers in the U.S. account for more than half of the The company, which purchased
countrys broiler production, and earned a collective $28.1 billion in revenue Hillshire Brands and Boscos Pizza Co.
last year. in 2014, is broadening its food produc-

www.WATTAgNet.com July 2016

24 PoultryInternational

TOP 5 BROILER PRODUCERS DOMINATE US PRODUCTION strategy focused on efficiently raising broilers
and keeping costs competitive. In 2015, the com-
Top US ready-to-cook chicken producers 2016 pany launched a pair of operations in Texas and
started construction on a new broiler complex in
(% of total volume) North Carolina. The Laurel, Mississippi poultry
Koch Foods companys annual revenue increased to $2.8 bil-

6.4 Others
lion in 2015 from $2.7 billion the previous year.
The companys weekly RTC chicken production
34.6 grew to 66.2 million pounds in 2015 from 58.8
Perdue Foods million pounds in 2014.

8.2 The company, led by CEO Frank Sanderson

Jr., employed 12,283 in 2015, an increase from
Tyson Foods 11,624 in 2014.

23.3
Sanderson Farms Pilgrims Pride 4 Perdue Foods
Perdue Farms Inc., which is increasing its
8.7 18.8 antibiotic-free broiler production, is also diversi-
fying into turkey production and energy projects.
Source: Watt Global Media In 2015, the company acquired Natural Food
Holdings, which included pork, beef, lamb, cage-
Five companies operating in the U.S. account for more than half of free egg, and smoked and cured meat products.
the ready-to-cook chicken produced in the country each year. In 2015, the companys weekly chicken pro-
duction increased to 61.74 million pounds from
tion portfolio and reducing its focus on chicken, pork and 56.49 million pounds in 2014. The companys revenue grew
beef production. The company, led by CEO Donnie Smith, to $3.9 billion in 2015 from $3.8 billion in 2014, according
employed 124,000 in 2015, according to WATTs data. to WATTs data.
The Salisbury, Maryland companys employment fell to

2 Pilgrim's Pride
Pilgrims Pride Corp., owned by Brazilian meat giant
JBS S.A., grew in 2015 with the acquisition of Tyson de
18,588 in 2015 from 19,878 in 2014. The company is led by
CEO James Perdue.

Mxico, Tysons Mexican operations, in an acquisition that

was valued at $400 million.
The Greely, Colorado, chicken company reported $7.1
billion in 2015 sales to WATT. In 2014, the company re-
ported $7.6 billion in annual revenue.
Pilgrims weekly RTC chicken production increased
in 2015, to 141.67 million pounds from 138.36 million
pounds in 2014. The company, led by CEO Bill Lovette,
employed 39,200 in 2015, according to WATTs data, an
increase from 35,000 in 2014.
5 Koch Foods
Koch Foods Inc. neither gained nor lost ground in
2015. The Chicago-based chicken processing company
invested in improvement and expansion of facilities in Ohio
and Mississippi during the year.
Weekly chicken production, revenue and employment
at the company, led by Joseph Grendys, were flat from
2014 to 2015. Weekly RTC chicken production was 48
million pounds, annual revenue was $3 billion and em-
ployment was 12,500, according to WATTs data.

3 Sanderson Farms
Sanderson Farms Inc. is focusing on a build-and-grow
Austin Alonzo is a reporter at WATT Global Media.
Contact Alonzo at aalonzo@wattglobal.com.

www.WATTAgNet.com July 2016

 International
Poultry Forum China

2016Environmental Friendliness
and Sustainability Strategy
22-23 July 2016
Shanghai Marriott Hotel Hongqiao
Shanghai, China

Join notable industry leaders from around the world as they

gather to share expertise and insights on sustainable poultry
farming practices, food safety and animal welfare at this
premier two-day educational and networking forum.

PRESENTATION THEMES:
Environmental Friendliness and
Sustainable Development
Food Safety and Animal Welfare

For more information:

Online: www.ch-agri.com
Email: dingdingli@vip.163.com
Tel: +86 137.64039062

Organized by:

Supported by:
China Animal Agricultural
Association, China Broiler
Alliance, Shanghai Poultry
Industry Association
26 PoultryInternational

Broiler super pre-starter

formulation secrets revealed
Formulating a commercial super pre-starter does not have to be a
secret; here we talk about it with real commercial experiences.
IOANNIS MAVROMICHALIS

We have already discussed the

Examples of conventional and super reasons and benefits from using a
pre-starter broiler feed formulas super pre-starter broiler formula
Super, no during the first seven days post-
Ingredient Conventional Super antibiotics
hatch. We have also deliberated
Wheat and/or corn 50-60 50-60 55-65 about ingredients that make such
Soybean meal, 47 % 30-35 20-25 15-20 formulas so special , giving them
Animal plasma - 1-3 2-4 that extra boost young chicks
Soy protein concentrate - 5-10 5-10 require early in life. But, placing
Soy oil + + + all these together remains top-
Feed-grade amino acids + + + secret among nutritionists, most
Dicalcium phosphate + + + likely because this technology is
Calcium carbonate + + + so brand new. It does not have to
be so, and here we will talk about
Mineral and vitamin premix + + +
these formulas, giving a real-life
Sodium chloride + + +
example.
Phytase + + +
Choline chloride + + +
Real-case formulas
Xylanase and/or beta-glucanse - Maybe Yes The formulas presented in
Antibiotics + + No Table 1 are generic ones based on
Anti-coccidial + + + real-case scenarios from custom-
Organic acids + Maybe Yes ers raising broilers on large scale
Phytogenics + Maybe Yes in Europe and elsewhere. The
Functional fibers + Maybe Yes conventional formula, a typical
Nutrient specifications pre-starter fed for seven days
Metabolizable energy, kcal /kg 3000 3000 3000 post-hatch, is indeed a heavily

Crude protein, % 23-25 23-25 22-24

Table 1 shows two actual
Crude fiber, % 2-3 2-3 2.5-3.0
formulas used under European
Lysine, % 1.4-1.5 1.4-1.5 1.4-1.5
commercial conditions to
Methionine, % 0.6-0.7 0.6-0.7 0.6-0.7
test the efficacy of a super
Calcium, % 0.8-1.00 0.8-1.00 0.8-1.00 pre-starter broiler feed over a
Non-phytic phosphorus, % 0.4-0.5 0.4-0.5 0.4-0.5 conventional one.

www.WATTAgNet.com July 2016

28 PoultryInternational
BROILER SUPER PRE-STARTER FORMULATION SECRETS REVEALED
fortified diet. It is not as high on en-
ergy as some nutritionists might sug-
gest, but it is sufficient in amino acids
and all other vital nutrients.
In this particular formulation, we
have used a typical antibiotic plus
anticoccidial approach, and, as such,
it is not ready for a program devoid of
these compounds. The new formula,
the super pre-starter, is formulated to
similar nutrient levels with the only
difference being the use of highly
digestible protein sources (animal
plasma and soy protein concentrate).
Animal plasma promotes gut health
and feed intake, whereas soy protein
concentrate is a dense source of
highly digestible amino acids. Other
specialty ingredients may be added,
but there is a cost limit. The last diet
is one that uses no in-feed growth-
promoting additives. Instead, it de-
pends on enzymes, organic acids and
phytogenic compounds to replace
antibiotics; but still a coccidial prepa-
ration is used. These formulas are
generic examples, as each specific
farm will require customization to
Super pre-starter versus conventional broiler feed formula result
Final weight, g
FCR
Cost ()/kg weight
Mortality, %
Kg per sq.m
Profit per chick placed
Table 2 shows the results from feeding a super pre-starter broiler formula versus a conventional one for the
first seven days post-hatch in a European commercial facility.
suit genetics, health status, facilities,
ingredients and targets. They are pre-
sented for discussion purposes only.
Field performance that pays
for the extra cost
When such formulas are used
under commercial conditions, results
can be satisfactory to exceptional
in any case, more than enough to pay
for the extra cost. I will bring to your
attention results obtained by a com-
mercial integrator in Europe. There, a
customized form of the conventional
and super pre-starter diets presented
in Table 1 were fed followed with
typical starter and grower diets until
slaughter. As can be seen in Table
2, after two batches of broilers were
tested, the conventional diet did a
very good job. The performance is
comparable to many modern farms
using similar genetics and nutrition
programs. But, as expected, the super
pre-starter gave birds an early ad-
vantage that lasted until market age.
Broilers fed the super pre-starter for
the first seven days post-hatch were
Batch 1
Conventional Super
2,168 2,243
1.65 1.59
0.54 0.52
4.24 2.94
43.03 44.88
0.01 0.09
(on average, for two batches):
60 grams heavier at market age
More efficient in converting feed to
meat by eight points
Less costly to feed despite the extra
cost of the super pre-starter
More efficient in using available
surface
More profitable by 7 euro cents
per bird
It might look surprising that such
small changes in feed formulation
for such a small period of time can
have such an impact throughout the
commercial life of a broiler, but those
who deal with young animal nutrition
can attest to this phenomenon: an in-
vestment in early nutrition pays good
dividends in the end. This is true not
only for broilers, but also for piglets
and calves.
Further improvements to
formulas
Ideally, the super pre-starter
formula would contain even less
soybean meal and more purified pro-
teins, such as soy protein concentrate
Batch 2
Conventional Super
2,243 2,289
1.6 1.51
0.52 0.5
4.11 3.39
46.01 45.87
0.12 0.18
www.WATTAgNet.com July 2016
 PoultryInternational 29

or wheat gluten. The exact amount expensive super pre-starter might Ioannis Mavromichalis,
for wheat gluten can range from 2 be sufficient for only four days post- Ph.D., is nutrition editor for
percent (Europe and the U.S., where hatch, but we have lots of research WATTAgNet and Editor-in-Chief
it is more expensive) up to 10 percent ahead of us. In any case, this is an of Pig International. Contact
(Asia, where it is relatively inexpen- exciting new frontier for nutritionists Mavromichalis at imavromichalis@
sive). This is an area where each for- who specialize in early nutrition. wattglobal.com.
mulator will have to find the balance
between cost and benefit. Perhaps
fishmeal could further improve this
formula, but this remains to be seen.
An investment in early nutrition Three Ways to Save
pays good dividends at the end. With Chore-Times ENDURA Fan
Also, I would have liked to see to-
tal crude protein reduced to avoid the
problems of excess dietary protein
that "robs" broilers of performance
potential , but this is my personal
preference. This recommendation is
even more pertinent when traditional
growth promoters (antibiotics) and
anticoccidials are excluded. In such
case, it is almost imperative to keep
crude protein as low as possible and
organic matter digestibility as high
as possible to avoid overloading the
Patented with Additional Patents Pending
hindgut with nutrients that can be
used by pathogens. STOP before buying your next fan and
check out the top-performing ENDURA Fan!
Pushing to the extreme
Naturally, when a little bit of good
is desirable, a lot more cannot harm, Save energy with top efficiency.
right? Perhaps adding such specialty Save money with long-lasting
ingredients in grower and finisher durability.
broiler diets can confer even further Save performance by maintaining
improvements in performance and airflow to the end of the flock.
profitability. This is not an unreason-
able assumption by those who first www.choretime.com
encounter the benefits of early nutri-
HYFLO Shutter Doors minimize
tion. Experiences from other species obstructions to maintain airflow
have shown that the return on invest- to the end of the flock when it is
needed most. A DIVISION OF CTB, INC.
ment diminishes very rapidly, and, as A BERKSHIRE HATHAWAY COMPANY

such, it is best to place the "weight"

Find your nearest independent distributor at www.choretime.com/contacts
early on. An even more fortified and

July 2016 www.WATTAgNet.com

30 PoultryInternational

How to control
Campylobacter in
broiler production
Combining strategies may be the best approach to
minimizing Campylobacter levels in broiler flocks.
ANDREW ROBERTSON

Campylobacter is the most
frequent cause for food-related
gastroenteritis in western Europe.
There are an estimated 9 million cases of campylobacteriosis in the EU alone each year,
costing EUR2.4 billion (US$2.72 million). There is still no definitive solution to control
Campylobacter in poultry flocks. However, there are several strategies that can be followed to
reduce its incidence, thus improving food safety and enhancing farm profits.
Broiler producers need to apply a series of measures to reduce Campylobacter contamina-
tion levels using a mixed approach, starting with improved biosecurity, changes to management
practices, feed or water intervention with additives, and intervention measures during slaughter.

Campylobacter control strategies

Management stategies Success and implementation status
Claims to reduces rate of carcass contamination by
Extreme temperature intervention
up to 90%. Does not eliminate risk to humans.
Chlorine wash Not permitted in the EU due to concerns over carcinogenic residues
May reduce rate of carcass contamination by 50-70 percent,
Stringent biosecurity
although difficult to attain under commercial conditions.
Single out-loading of flocks can reduce contamination by 80 percent.
Stop thinning
Puts pressure on production, introduces short-term challenges.
Dramatic reduction in contamination levels.
Slaughter at 28 days
Impractical due to market requirements.
Nutritional strategies
Some effect in scientific trials showing reductions of
Bacteriocins
contamination in the caeca. More work required.
In vivo use tends to be therapeutic. Considered for in-slaughterhouse
Bacteriophages
treatment of carcasses, but problems may occur in registration.
Mixture of acids needed. The pH of drinking water has to be lowered
Organic acids
to between 4.0 and 4.5 for optimum results. Varied results to date.
Phytogenic feed additives In vitro trials not replicated in vivo. More work required.
Trials show significant reduction of Campylobacter colonization.
Probiotics
Perhaps the most promising for commercial purposes.

Adopting a mixed approach may help to bring Campylobacter levels down to acceptable levels.

www.WATTAgNet.com July 2016

 PoultryInternational 31

Safety Memo
Biosecurity
Biosecurity has already been improved in many
countries above the standard controls, with marked in- To: All Decision Makers
creases in barrier biosecurity into each poultry house. From: Diamond V
This means each poultry house worker has footwear Date: ASAP
which can only be used in the house, and there is a Re: NOVEL TECHNOLOGY
physical barrier at the entrance where boots have to be
changed before entering the house.
Responsibility lies within each link
Thinning of the food supply chain, from farm
Stopping thinning has been shown to reduce the in- to fork, to produce a safe, sustainable,
cidences of Campylobacter contamination in broilers in abundant food supply.
markets such as Scandinavia, where farms are restricted
Insist on Diamond V Technology today
in size and down time.
for unmatched benefits and natural
solutions for food animal production.

USDA finalizes Salmonella,

Campylobacter reduction measures EVERY BIRD. EVERY DAY. TM

www.WATTAgNet.com/articles/25822

However, in the larger poultry markets, where per

capita consumption of poultry meat is greater, the diffi-
culties in increasing the housing requirement to comply
with EU or local regulations would mean that this could
only be brought in gradually, and the cost of chicken to
the retailer would have to increase.

Slaughterhouse interventions
In-slaughterhouse interventions include high chlorine
washes (not permitted in the EU) or extreme tempera- Strengthen Your Chain.
ture treatments: either rapid surface chilling or steam
along with ultrasound. Both of these treatments can
reduce the level of contamination on the carcass by be-
tween 1 and 2 log10.
However, the levels of saleable chicken will greatly
depend on the level of contamination entering the
slaughterhouse.
In addition to management strategies, there is also
the option to use feed additives or water treatments,
which can further reduce the level of Campylobacter
contamination. ,
For more information, call 800-373-7234
or visit www.diamondv.com
July 2016 www.WATTAgNet.com
32 PoultryInternational

HOW TO CONTROL CAMPYLOBACTER IN BROILER PRODUCTION

Bacteriophages Multi-approach, multi-benefit

In vivo use tends to be therapeutic. Bacteriophages have
been considered for in slaughterhouse treatment of carcass-
es. However, problems may arise in registration.
Organic acids
A mixture of acids is needed to control campylobacter,
and the pH of drinking water must be lowered to between
4.0 and 4.5 for optimum results. To date, results using or-
ganic acids have been varied.
Probiotics
Several trials using probiotics to control Campylobacter
colonization have been carried out and have shown signifi-
cant reductions in bacterial colonization. Use of probiot-
ics may be the most promising approach for controlling
Campylobacter through nutritional interventions.
Each of the interventions listed above will help to reduce
overall contamination. Combined, they may possibly give
the required reduction of Campylobacter contamination in
finished broiler meat.
Campylobacteriosis in humans usually results in severe
abdominal pains and diarrhea, which can lead to hospitaliza-
tion. But it can lead to death or serious complications, such
as Guillain-Barre syndrome, reactive arthritis, bacteremia,
inflammatory bowel disease and irritable bowel syndrome.
Campylobacter spp are not necessarily commensal bacte-
ria but have the potential to cause disease in poultry, diarrhea
and reductions in feed efficiency. Controlling the situation on
farm benefits poultry producers, and not just meeting con-
tamination levels for poultry leaving the processing plant.
Andrew Robertson, is a poultry technical manager
with Biomin GmbH.

LESS FEED, MORE MEAT.

Feed cost represents over 70% of live production cost of a

broiler, the highest levels in history. Hubbard offers the best
products to save feed costs on breeder and broiler level.
The Feedsaver concept of the JV and F15 breeders
saves about 15% of feed to produce a broiler day-old-chick
compared to conventional breeders.
All Hubbard broilers have an excellent FCR compared to
other breeds.

Just use less kg of feed to produce 1 kg of live broiler, 1 kg of

carcass or 1 kg of total meat !

www.WATTAgNet.com July 2016

34 PoultryInternational
5 tips for raising healthy
antibiotic-free poultry
The difculties of antibiotic-free poultry production can be overcome
by following carefully considered strategies.
OLE LUND
Demand for antibiotic-free (ABF) poultry is growing
fast, and what was once considered a passing trend has
become a well-established, health-conscious require-
ment for consumers worldwide.
However, ABF production presents challenges for
meat producers, who are taking distinct approaches to
its development with different results.
While some producers still have difculties in con-
trolling health challenges, others have had success due
to improvements in housing and changes in feeding,
management and health programs. The various ap-
proaches to ABF production can be grouped as:
Investor coalition: End irresponsible
antibiotic use
www.WATTAgNet.com/articles/26548
1 Manage nutrient intake
A common misconception in ABF production is
to focus only on controlling intestinal diseases. These
are the main health issues when any ABF program is
implemented, but the reality is that they are the conse-
quences, not the causes, of the real problem.
Excess nutrients, especially protein and fat, may not
be well digested and absorbed by the bird. Undigested
feed increases microbial proliferation in the ceca, lead-
ing to potential infections. Appropriate digestibility is
key to broilers overall health and can help control mi-
crobes and resultant diseases.
Factors such as a balanced diet and sufcient water
consumption are essential to improve digestibility. A
pH between 5 and 7 and water temperature between
16C and 25C are ideal conditions.
To further strengthen the effect of endogenous
enzymes, additives such as phytases and xylanases
can be added to feed. Moreover, to guarantee acidic
crop, organic acids are a good option.
Feed management plays an essential role too.
Grain damage and conditions that could in-
crease mold and insect spoilage must be min-
imized and, at the same time, fat storage
conditions should be frequently revised.
www.WATTAgNet.com July 2016
 PoultryInternational 35

2 Modulate microflora
The gut flora plays an impor-
tant role in supporting the immune
are the foundations of effective
ABF poultry production. Optimum
temperature, air velocity and rela-
Stress due to heat, cold, very
dry or very humid air could affect
feed intake and intestinal motility,
system. In addition to a balanced
diet and good housing conditions,
feed additives and minerals can
Approaches to antibiotic-free production
help maintain a healthy microflora. Standard ABF Organic USDA-AMS
programs production Never Ever 3
Enzymes are an alternative
to eliminate the antinutritional
Chemical antibacterials x x
effects of water-soluble polysac- Chemical anticoccidials x
charides, while organic acids cause Ionophore coccidiostats x
the inhibition of bacterial growth.
Essential oils can support gut
Antibiotics x x x
microflora balance and stimulate Animal by-products n/s n/s x
digestive enzyme production. Synthetic growth-
promoting compounds n/s n/s x
Only appropriate testing and
use can guarantee success. One n/s - not stated.
solution working in one flock may
not work in the next as the environ- The various antibiotic-free production systems all come with their own
ment may have changed. challenges ranging from higher costs to lower productivity, but there are
ways these challenges can be addressed.

3 Improve house
environment,
biosecurity
tive humidity according to the age,
phase of production and size of the
causing reduced digestibility.
Lighting programs may also
Proper environmental conditions birds should be considered. affect feed intake, motility and

s-Hertogenbosch, The Netherlands, +31 (0)73-656 91 94

ventilation
www.tpi-polytechniek.com components
July 2016 www.WATTAgNet.com
36 PoultryInternational
5 TIPS FOR RAISING HEALTHY ANTIBIOTIC-FREE POULTRY
digestion. Light intensities lower than
10 lux and 4 to 6 hours of total dark-
ness per day improve feed conversion
ratios, indicating slower feed intake
and better digestibility.
Good house ventilation is key
for ABF programs to maintain litter
moisture below 30 percent and to
minimize condensation and caking.
Flock management is also impor-
tant to allow the flock more space
during the brooding period. This
helps avoid excessive stress.
4 Maintain flock health
Preventing coccidiosis and ne-
crotic enteritis are normally the main
concerns during ABF production.
In cases where no anticoccidial
medications are allowed, coccidiosis
vaccines and litter management are
the principle controls. Cocci vac-
cination for broilers has been applied
in traditional poultry production
systems and new ABF programs for
years in many countries.
Furthermore, the appropriate
feeding regime and use of feed addi-
tives, such as the eubiotics category,
may help maintain healthy microflora
adding to flock health.
Control of other intestinal para-
sites, worms and poultry diseases
that affect intestines and immunity is
also necessary.
Practices including bioexclusion,
limiting visitors, vehicles and equip-
ment that visit other poultry farms,
biocontainment, isolating the houses,
and controlling insects, rodents and
entry of wild birds and animals can
help prevent new infections.
5 Improve breeder health
Broiler breeder nutrition is fun-
damental for adequate development
of their progeny.
Embryo development is totally de-
pendent upon egg nutrients deposited
by the hen, and specic nutrients
such as vitamin D, trace minerals,
carotenoids and fatty acidsare key
in immunity and gut development.
Hens also affect embryo nutrition
and development via eggshell proper-
ties, including porosity and thick-
ness, which determine conductance.
Eggshell conductance dictates the ca-
DayolD chick
vehicles
with the EcoTransport technology
www.veit.cz
pacity of eggs to exchange gases and
water vapor, affecting embryo yolk
and general nutrient utilization.
These physical factors, especially
the capacity to obtain sufcient oxy-
gen, limit the type of metabolism,
rates of tissue development and em-
bryo growth.
This is more important during the
last three or four days prior to hatch,
when development of many tissues,
including the gastrointestinal tract,
bones and muscles, is fastest.
Breeders can transfer intestinal
microbes and immunity to their prog-
eny, so companies practicing ABF
production should ensure adequate
intestinal health in breeders and ef-
fective vaccination programs.
Holistic approach
There are numerous concepts
around the ways ABF systems in
poultry meat production can be im-
plemented to improve productivity.
As ABF programs for poultry
production become more common,
and to make these programs suc-
cessful, a holistic approach along the
whole production system is needed.
Not only are feed, feed additives or
enteric pathogen control important,
but also are housing management,
water quality and biosecurity at
breeder and grow-out levels .
Ole Lund Svendsen is marketing
manager at DSM Nutritional
Products.
www.WATTAgNet.com July 2016
38 PoultryInternational
How to reduce cleaning costs in
poultry meat processing
Adopting a new way of cleaning the chicken processing plant can
save time and money, while raising productivity
EDUARDO CERVANTES LPEZ
Cleaning and disinfecting the poultry processing
plant is a daily necessity, but it comes with a cost.
These costs not only comprise investment in, and re-
placement of, equipment but also time and impact on
workers.
Several operations need to be completed as part of
the plant sanitation program, including the removal of
any solid materials, washing and brushing with deter-
gent, rinsing and disinfection. The equipment normally
used to perform these tasks is heavy, subject to wear
Car wash cleaning operations usually have
a compact structure, and this can be easily
adapted and installed in the poultry processing
plant.
Key checks to optimize poultry processing
www.WATTAgNet.com/articles/13287
and tear, and has an impact on workers.
There are, however, examples from other sectors
where cleaning is conducted more efficiently. Take for
example, how a car wash operates. The structure com-
monly used in car washes could be applied to the pro-
cessing plant, bringing with it several benefits.
Alternative cleaning design
Typically, a processing plant depends on heavy-du-
ty wall-mounted hoses that need to be reeled out across
the floor and reeled back once cleaning is complete.
These cumbersome hoses can make cleaning the
overhead conveyor difficult and extremely tiring, and
then there is the constant wear and tear as hoses are
reeled out, moved around the plant and put away at the
end of the cleaning shift. In addition, hose guns can
become damaged if they are dropped onto the floor.
Car washes, however, have overcome many of these
problems and can serve as a model for the poultry pro-
cessing plant. Typically, they are compact, efficiently
laid out and have a hose support structure that stops
hoses from ever hitting the ground, as well as revolv-
ing supports that allow hoses to be moved 360 degrees
safely, comfortably and quickly. Car wash hoses are
light, made of durable materials and use ergonomically
www.WATTAgNet.com July 2016
 PoultryInternational 39

designed guns.
Additionally, each car wash operation has its own
set time for completion.

Application in the processing plant

The principles employed in car washes can be
adapted and adopted in the poultry processing plant by
following these steps:
In each section of the poultry processing plant,
install a high-level H-beam between two parallel
walls
Install a trolley with a rotating support on the
H-beam, similar to those used on bridge cranes.
The support will hold the hose, similar to those used
in pressure washers. In contrast to the heavier hoses
often used in processing plants, these hoses are very
light. Their support has a retracting mechanism,
ensuring that the hose never comes into contact with
the processing plant floor, minimizing damage.
The hoses will end with guns similar to those used
Hoses that can be moved 360 degrees make
accessing equipment easier, more comfortable
and safer.
on pressure washers. This type of gun tends to be
very light, and their design allows for easy access
to any part of the equipment or processing plant
section without ever having to get too close.
One of the two suspended hoses supplies water,
which can be either at room temperature or hot,
while the other hose will be fitted with a special-

A ROBOT WITH A KNIFE

Innovative fixed-weight batching

A perfect integration of:

- RoboBatcher Flex, most advanced fillet batching solution
- I-Cut 122, high-speed portion cutter to fixed weight
Selective cutting according to order requirements
High product utilization with fillets and offcuts as high
value products
Reducing give-away to an absolute minimum

Contact us to find out more: +31 485 586 111

Info.poultry@marel.com | marel.com/robotwithknife

July 2016 www.WATTAgNet.com

40 PoultryInternational
HOW TO REDUCE CLEANING COSTS IN POULTRY MEAT PROCESSING
ized brush to automatically deliver detergent.
On each of the parallel walls, there will be a storage
unit to hold the guns when not in use.
Once the necessary times have been established to
complete the various cleaning tasks, a timer can be set,
ensuring that the cleaning operations are completed
within the time deemed necessary.
Car wash system in practice
Once chicken processing has finished, cleaning staff
should collect all solid materials that may be present on the
equipment, walls and channels, or on the floor.
When this has been completed, one worker starts to
wash each piece of equipment, while a second worker will
brush down the equipment with detergent.
Once these tasks have been completed, the first worker
will then rinse down the machinery and other equipment.
Lastly, the second staff member applies disinfectant.
This two-person sanitation team then moves to the next
section of the processing plant to clean that. The number of
work groups will be proportional to the size of the process-
ing plant and to the amount of equipment that needs to be
cleaned in the various sections.
Moving away from commonly used, independent hoses
to a system based on how car washes operate can reduce the
time needed to clean the plant, and can also cut down on
the amount of water and detergent needed.
In addition to this, the cost of replacing hoses and hose
guns is lower because neither are ever subjected to friction
or knocks against the processing plant floor.
Eduardo Cervantes Lpez is an international consultant
based in Colombia. He can be contacted at icproave@
hotmail.com or via www.icproave.com.
www.WATTAgNet.com July 2016
42 PoultryInternational
Products
MAREL V-PUMP FOR RevoPortionerproduces up to
REVOPORTIONER 5,000 kg of high-quality meat
The Marel V-Pump for the convenience products per hour
inal !
The Orig
Drinking-Systems
With a LUBING Drinking-
System you are always on the
safe side.
Completely equipped with
innovative technical details
LUBINGs Drinking-systems
assure a reliable water supply
for cages as well as for floor
management.
Top-Climate-Systems
The LUBING Top-Climate-
System is a highly effective
cooling system for poultry
houses.
Special high-pressure nozzles
(70 bar/1000 psi) spray a fine
fog of evaporated water into
the house.
Humidity rises, the tempera-
ture falls. The floor stays dry.
The animals feel better.
LUBING LUBING
Global Solutions Maschinenfabrik GmbH & Co. KG
49406 Barnstorf (Germany)
Drinking-Systems Tel.: +49 (0) 54 42 - 98 79-0
Conveyor-Systems Fax: +49 (0) 54 42 - 98 79-33
Climate-Systems www. lubing.com info@lubing.com
To search a full list of
products, go to
www.WATTAgNet.com.
in one system. Two alternat-
ing belt-wide pistons deliver a
uniform pressure to the forming
unit, moving the meat mass over
a small distance with a mini-
mum of pressure, thus retaining
the original meat structure and
texture as much as possible. The
V-Pump is durable and easy to
operate; there are few moving
elements, leading to low mainte-
nance costs. The V-Pump works
only with theRevoPortioner 700.
www.marel.com
TNI PACKAGING CHICKEN
TUCKER POULTRY
TRUSSING LOOP
TheTNI Packaging Chicken
Tucker is apre-tiedpoultry
trussing loop for themeat,
poultry and food industries.
TheChicken Tuckermeets all
food grade requirements by the
USDA, FDA and CFIA.
www.tnipackaging.com
www.WATTAgNet.com July 2016
 PoultryInternational 43

To To
place
place
a Marketplace
a Marketplace
adad
contact:
contact:
MM
Craig
Craig
Greuel
Greuel
cgreuel@wattnet.net
cgreuel@wattglobal.com
Tel: +1
Tel:
815+1966
815 5591
966 5591 arketplace
arketplace

ServiceS
Kunafin the Insectary..........www.kunafin.com.........830-757-1181 Custom
Committed to Integrated Pest Management REPRINts
Custom reprint products of articles and features

FLY PROBLEMS?
from Poultry International create powerful marketing
tools that serve as instantly

Got Manure: We have the cure!

credible endorsements.

Biological Fly Management Program RePRInts aRe Ideal foR:

Entomologist/Consultation Available n New Product Announcements

kunafin
n Sales Aid For Your Field Force
Printed and
n PR Materials & Media Kits
The Insectary
electronic custom
n Direct Mail Enclosures
Worldwide
reprints are
n Customer & Prospect Presentations
Phone: 1-800-832-1113
available.
n Trade Shows/Promotional Events
Made in U.S.A. Fax: 1-830-757-1468 n Conferences & Speaking Engagements
www.kunafin.com
Give yourself a competitive advantage with reprints. Call us today!
use this logo on white or lighter
backgrounds

The Poultry International rate is: $210 per inch per insertion (1-time rate), $200
For additional information, please contact Foster Printing
per inch per insertion (6-time rate), or $170 per inch per insertion (12-time
Service, the official reprint provider for Poultry International.
rate). The production charge is included except for ads with excessive make-up
demands. Logos are acceptable. Make your classified stand out- add color for an
Call 866.879.9144 or
use this logo on black or darker

additional $40 per color per insertion. backgrounds. The Printing

rhondab@fosterprinting.com
Service is in white.

C: 56
M: 0
Y: 100
K: 27
PMS 370 C
44 PoultryInternational

ADVERTISERS INDEX Sales Team

Company Page
Frans Willem van Beemen
5th Mediterranean Poultry Summit ............................................................. 33 Tel: +31 344 653 442
American Coolair Corp ........................................................................... 15 Fax: +31 344 653 261
Big Dutchman Intl GmbH............................................................................ 7 fvanbeemen@wattglobal.com
Biomin Holding GmbH ............................................................................ 14
Chore-Time ............................................................................................. 29 Tineke van Spanje
Cobb-Vantress Inc ................................................................................... 19
Tel: +31 495 526 155
Diamond V ............................................................................................. 31
Fax: +31 495 525 126
DPI Global ............................................................................................. 40
tvanspanje@wattglobal.com
Duram Industries A C Ltd .......................................................................... 41
Elanco Spain SLU ................................................................................... 2-3
Evonik Nutrition & Care GmbH................................................................. 11 Dingding Li
Fiera Di Forli .......................................................................................... 13 Tel: +86 137 640 39062
Giordano Poultry-Plast SpA ......................................................................C2 Fax: +86 21 541 33676
Haarslev Industries A/S ............................................................................. 6 dingdingli@vip.163.com
Hubbard S A S ....................................................................................... 32
Jefo Nutrition Inc ..................................................................................... 21 Pam Ballard
Liptosa ................................................................................................... 13 Tel: +1 815 966 5576
Lubing Maschinenfabrik GmbH................................................................. 42 Fax: +1 815 968 0941
Marel Stork Poultry Processing BV ............................................................. 39 pballard@wattglobal.com
Merial Inc Intl ...................................................................................23, C4
Moba BV ............................................................................................... 10 Mary Harris
Novus International Inc ............................................................................ 27 Tel: +1 815 980 5938
Plasson Ltd ............................................................................................. 17
Fax: +1 847 908 7551
Specht Ten Elsen GmbH ...........................................................................C3
mharris@wattglobal.com
TPI-Polytechniek BV .................................................................................. 35
VEIT Electronics s r o ............................................................................... 36
Walinga Inc ........................................................................................... 44 Craig Greuel
Wuhan Sunhy Biology Co Ltd ..................................................................... 5 Tel: +1 815 966 5591
cgreuel@wattglobal.com

Jeff Miller
Tel: +1 815 966 5582
Fax: +1 815 968 0941
jmiller@wattglobal.com

Subscriptions: www.WATTAgNet.com or contact

customer service at +1.800.869.6882 or +1.763.
746.2792. Business and occupation information must
accompany each subscription order.

Brought to you by POSTMASTER: Send address changes to POULTRY

INTERNATIONAL, PO Box 47706, Plymouth, MN
55447.
Copyright 2016 WATT Global Media All rights

Special Anniversary
reserved.
ELECTRONIC SERVICE REQUESTED
Vol 55, Issue 7, POULTRY INTERNATIONAL (ISSN
0032-5767) is published monthly by WATT Global

Edition of
Media, 303 North Main Street, Suite 500; Rockford,
Illinois, 61101 USA. All rights reserved. Reproduction
in whole or in part without written permission from the
publisher is strictly prohibited. Poultry International
and its logos are registered trademarks of WATT

available now
Global Media. Postage paid at Rockford, IL, USA and
additional mailing offices. Canada Post International
Publication Mail Product 1686224.

The Summer 2014 issue of SideRoads celebrates Walingas 60th Anniversary,

featuring a special section sharing the companys rich history and
commentary on the past and future of the global feed industry.

Read this special digital issue today at www.SideRoads.net!

www.WATTAgNet.com July 2016
 ORIG
INAL

Envir
onm
anima entally an
l frien d
dly

Egg collection
Aviary breeding system
Egg production

Varia system
Cage-floor
Rearing

Group housing

Egg belt

Feeding system

Manure drying system

ORIGINAL

GmbH & Co.KG

Dassendaler Weg 13 D-47665 Sonsbeck (Germany)
Tel.: +49 (0) 28 38 912-0 Fax: +49 (0) 28 38 27 91 POULTRY EQUIPMENT
info@specht-tenelsen.de www.specht-tenelsen.de Poultry Equipment Equipement Avicole