Alabama Poultry Magazine July/August 2022 by Alabama Poultry & Egg Association

A L A B A M A P O U LT R Y | july - august 2022

OFFICERS STANLEY USERY, President, Athens * RYAN TURNER, Vice President, Guntersville * STEVE SMITH, Treasurer, Hanceville * CHARLIE PEACOCK, Secretary, Tuscaloosa* CASEY JONES, Immediate Past President, Hoover* DIRECTORS Johnny Adcock, Woodland Lou Ayers, Jasper Marc de Beer, Huntsville Randall Ennis, Tanner Shane Guy, Guntersville Tim Holmes, Decatur Harold Hunt, Gadsden Clint Lauderdale, Hanceville* David Lesnansky, Cullman Frank Loftis, Cullman Neil Martin, Dothan David Massey, Enterprise Richard McElrath, Albertville Kevin Parnell, Boaz Mitchell Pate, Mobile Keith Rhodarmer, Collinsville Cliff Rule, Guntersville Kenneth Sanders, Brundidge Jason Shell, Boaz Jason Spann, Hanceville Michael Starling, Secretary, Shorterville* Doug Thiessen, Montgomery Rod Thomas, Montgomery David Thompson, Anniston Larry Upchurch, Lineville Josh Whitley, Snead Brad Williams, Jack Jamie Young, Russellville *Executive Committee Members ADVISORS Vernon Abney, Auburn Dr. Jeremiah Davis, Auburn University Dr. Bill Dozier, Auburn University Jerad Dyess, Montgomery Dr. Tony Frazier, Montgomery APEA STAFF Chief Executive Officer Johnny Adams Associate Director Ray Hilburn Communications Director/Editor Caleb Hicks Administrative Director Jennifer Shell Alabama Poultry Magazine (USPS 23800; ISSN 2767519X) is published bimonthly by the Alabama Poultry and Egg Association at 465 Bainbridge St., Montgomery, Ala. 36104. Phone (334) 265-2732 | FAX (334) 265-0008. Periodicals postage paid at Montgomery, Alabama. POSTMASTER: Send address changes to Alabama Poultry Magazine, P.O. Box 240, Montgomery, AL 36101 Editorial matter from sources outside APEA is sometimes presented for the information and interest of our members. Such material may or may not coincide with official APEA policy. Publication does not necessarily imply endorsement by APEA.

alabamapoultry.org

It’s officially summer here in Alabama, and I’m sure none of us were ready for the brutal heat. On the bright side, though, with hot weather, the chances of an avian influenza outbreak continue to trend downward. We still haven’t seen a positive case in commercial poultry here in Alabama, and I hope and pray we don’t. We’ve been busy with several key events the last few months. Both our annual spring golf and bass tournaments were highly successful. We look forward to these events each year, and we appreciate everyone who supported them. Speaking of events, we held the Evening of Fun concert June 11 in Birmingham. I’m proud to say we had close to 1,000 attendees. This year, we featured Tyler Farr as the entertainment, and he certainly was a crowd-pleaser. We are already beginning to plan and prepare for the 2023 Evening of Fun, so stay tuned early next year for those announcements. We also just wrapped up our annual meeting, which drew nearly 400 folks to Sandestin. I’d like to personally thank each of our sponsors for helping us put this meeting on. During the meeting, we recognized and thanked outgoing APEA President Casey Jones for all the hard work and time he’s given to this organization in the past year. Stanley Usery has now assumed the role as president, and we look forward to another prosperous year with him at the helm. We also congratulated our 2022 Alabama Poultry Farm Family of the Year, Ken and Amanda Hightower. I’d especially like to thank them for their service to the poultry industry and for being good stewards. I hope each of you has a great summer.

Johnny

In This Issue 6 9

2022 Evening of Fun Concert Faith, Family Foundation for Farm Of Distinction

Cogongrass Campaign 13 New Addresses Threat To Alabama Named 2022 16 Hightowers Alabama Poultry Farm Family

24 Made From (semi) Scratch 27 Practical Applications

On The Cover Ken and Amanda Hightower were named the 2022 Alabama Poultry Farm Family of the Year and were recognized in June.

Photo by Caleb Hicks

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A L A B A M A P O U LT R Y | july - august 2022

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1st place team: Austin Outlaw, Cypress Hathorn, Mark Gaines and Drew Wood

2nd place team: Russ Harper, Ryan Marlow, Sam Golden, Brett Pepper (not pictured)

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Closest to the Pin winners: Richard Dyer, Myron Morrow, Dale Benefield and Mike Bobo

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A L A B A M A P O U LT R Y | july - august 2022

Faith, Family

FOUNDATION FOR FARM OF DISTINCTION

“WHEN I WANT TO ACHIEVE SOMETHING, I’M GOING TO DO MY VERY BEST TO ACHIEVE IT. I HAVEN’T ALWAYS BEEN SUCCESSFUL. LIFE’S A STRUGGLE SOMETIMES. BUT I DON’T SEE THAT AS A FAILURE. ONCE YOU GIVE IT ALL YOU’VE GOT, THEN THAT’S A SUCCESS.”

Mark Byrd

aith and family are the foundation on which Mark and Sandy Byrd built the business recognized April 7 as Alabama’s 2022 Farm of Distinction. “I don’t know how anybody could farm without having God on their side, without trusting Him,” said Mark, who accepted the award during the Alabama Farm-City Awards Program and Luncheon in Birmingham. “We’ve overcome so much. When you go through challenges, you have to stay focused july - august 2022 | A L A B A M A P O U LT R Y

Mark and Sandy Byrd of Morgan County won Alabama’s 2022 Farm of Distinction contest. The Byrds, seated, are pictured with TriGreen’s Jay Hamlett and Lynne Morton; SunSouth’s Lester Killebrew; Alfa Insurance and Alabama Farmers Federation President Jimmy Parnell; and Alabama Farmers Cooperative’s Jade Randolph.

and trust the Lord to see you through those times.” For Byrd Family Farms in Danville, tough times have included storms, droughts and a tragic fire that destroyed one of its chicken houses. Despite those challenges, the Byrds have grown from 100 acres and four poultry houses in 1993 to a diversified farm with fields spanning 40 miles in two counties. “We’ve totally upgraded all the older chicken houses,” Mark said. “We’ve added shops and storage barns for our equipment in addition to more chicken houses. “We went from about 40 acres of corn, soybeans and wheat the first year to nearly 2,000 acres now. We’ve got a grain handling system where we can store right at 100,000 bushels of grain, which really helps during harvest.” As Farm of Distinction winners, the Byrds received a John Deere Gator from SunSouth and TriGreen dealers;

A L A B A M A P O U LT R Y | july - august 2022

a $1,000 gift certificate from Alabama Farmers Cooperative , or AFC; and a farm sign from Alfa Insurance. They also will receive $2,500 as Alabama’s representative in the Swisher/Sunbelt Expo Southeastern Farmer of the Year contest Oct. 18-20 in Moultrie, Georgia. The Byrds farm with their sons, Perry and Rodney. Both are mechanically minded and have contributed to the farm’s success by refurbishing old equipment, making repairs and manufacturing solutions for daily tasks. Over the years, the Byrds’ operation has included a wheat straw business, custom hay baling and a trucking company. The five-year plan includes building a store along busy Alabama Highway 157 where they can sell farm products and Alabama-grown goods. Mark said he’s driven by the same determination that led him to buy a used tractor and hay baler at age 14 and plant his first 15-acre crop at 18.

“I don’t like somebody to tell me, ‘no,’” he said. “When I want to achieve something, I’m going to do my very best to achieve it. I haven’t always been successful. Life’s a struggle sometimes. But I don’t see that as a failure. Once you give it all you’ve got, then that’s a success.” Known throughout the Southeast as bass singer for the Living Faith gospel quartet, Mark also serves as Morgan County Farmers Federation president and represents District 2 on the Alabama Farmers Federation state board. The Byrds attend Temple Baptist Church. Stanley Walters of Perry County was runner-up in the Farm of Distinction contest. He received a Traeger grill and supplies valued at $1,000 from First South Farm Credit and a $500 gift certificate from AFC. Article contributed by the Alabama Farmers Federation.

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A L A B A M A P O U LT R Y | july - august 2022

NEW COGONGRASS CAMPAIGN ADDRESSES THREAT TO ALABAMA

he Alabama Department of Agriculture and Industries, or ADAI, has initiated a new social media campaign to raise awareness of the dangers cogongrass poses to the state. With agriculture and natural ecosystems at risk, ADAI is calling on Alabamians to recognize this threat and share the information. Cogongrass has now infested more than 75% of Alabama’s counties. This federally regulated noxious weed was

introduced in the U.S. in 1911 as packing material in the port of Mobile. In the decades since, it has greatly expanded and become more dangerous. Cogongrass chokes out forests and hunting lands, threatening habitats. It inhibits the growth of other plants and ruins pasturelands, as livestock have trouble eating or digesting it. The weed is also highly flammable and increases the risk of devastating wildfires. Considering how widespread cogongrass is, the cost to eradicate it is high, exceeding $300 per acre, or $60 million in taxpayer dollars. The annual loss of forest productivity alone is $50 per infested acre, or $7.5 million. Cogongrass is difficult to control due to the ease of which it spreads along rights of way. Some varieties are also sold at nurseries and used by landscapers, increasing the spread. Cogongrass contaminates machinery, clothing, soil and vehicles that come into contact with the weed. Because of this, if found, no attempt to remove it should be made. Rather, it should be reported immediately. Visit www.alcogongrass.com to learn how to spot cogongrass and report it when it blooms again in the spring. To report cogongrass, call (334) 240-7225, or use the SEEDN (Southeast Early Detection Network) app, downloadable for Apple® and Android® devices at www.alcogongrass.com.

july - august 2022 | A L A B A M A P O U LT R Y

NEW STUDY HIGHLIGHTS BENEFITS OF PARTNERSHIP BETWEEN CONTRACT FARMERS AND CHICKEN COMPANIES The National Chicken Council released a study in mid-March that presents the results of a recent broiler industry survey designed to capture key live chicken production statistics. In addition, the study summarizes several key trends in broiler production efficiency, returns and loan quality data. “Raising chickens under contract is one of the best and most reliable sources of cash flow that helps keep families on the farm,” said agriculture economist and the study’s author, Thomas Elam, president of FarmEcon LLC. “The business partnerships between chicken farmers and chicken companies are mutually beneficial, viable and profitable. The real winner is the American consumer, though, who benefits from the healthiest and most affordable protein in the meat case.” The study represents the most recent publicly available government data and a new survey from companies responsible for 83% of total chicken production in the United States. A summary of the findings include: • According to the most recent USDA data available, the $68,455 median income for chicken farmers was significantly higher than both all farm households and all U.S. households. Sixty percent of chicken farmers earned household incomes that exceeded the U.S.-wide median. • The top 20% of contract chicken farmers earn on average $142,000, significantly higher than the top 20% of all farm households ($118,000) and all U.S. households ($101,000), according to the same data. • In terms of broiler farm loan performance, data show significantly lower charge off and deficiency percentages for chicken farmers compared to all agricultural loans. • Responding companies reported significant waiting lists for those who would like to enter live chicken

A L A B A M A P O U LT R Y | july - august 2022

production or expand existing operations. There were 1,672 applications from potential producers and 335 expansion requests from existing farmers. These applications indicate a steady interest in entering contract chicken production. • In 2021, only 6% of respondent’s farmers left their company, including retirements. Of those, only 0.7% of farmers left due to contract termination. • The health and well-being of the chickens has greatly benefited from the contract farming structure. In 2021, the average on-farm livability of a flock of U.S. broiler chickens was almost 95%. In 1925, it was only 82%. Farmers who furnish live chicken housing have captured this benefit of better chicken performance. The performance-based contract structure of modern poultry production was instinctively designed to put the well-being of the birds as the top priority, as incentives are given to farmers who raise the healthiest birds, take risks and work hard. It incentivizes farmers to do their best, to compete, just like every other business in America or any other free market.

“On any given day, swings in the cost of feed inputs for livestock — things like soybeans and corn — could financially challenge a farmer,” Gary Anderson, a retired U.S. Army helicopter pilot and chicken farmer in Alabama, said in a recent column. “Changes in the end prices of chicken could, too. As a chicken farmer, I don’t worry about that. Processors take these market risks for me — providing the feed and a baseline price for chicken — letting me focus on raising the flocks in the best way possible.” “What this data further show is that the chicken industry should be looked at as a model, and not a target of unwanted and unnecessary regulations that are being discussed in the Biden administration,” added NCC President Mike Brown. “The latest Consumer Price Index released last week marked the biggest inflationary gain since 1981. "At a time when input costs are through the roof, is now really the time to be discussing regulatory burdens that would increase costs for producers and add more costs to already soaring grocery bills for Americans?” Article contributed by National Chicken Council

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2022 ALABAMA POULTRY FARM FAMILY The Hightowers 16

A L A B A M A P O U LT R Y | july - august 2022

en Hightower got into the poultry business in 2004, fully intent on getting out of the poultry business one day. What he’d do was, build four pullet houses behind his home in Calhoun County’s Rabbittown community, and he and wife Amanda would run those on top of their fulltime jobs, his as a route salesman with Petrey Wholesale and hers as a White Plains Middle School library assistant. Eventually, he would sell. Eighteen years and another dozen pullet houses later, he’s still at it, only he’s been farming full time for 15 years, and when a prospective buyer made an offer on the operation two years ago, Ken said no. Why? “I like working for myself too much,” he said. “That’s the biggest reason. “Plus, I like how chickens don’t talk back. A lot of times, I’ll go several days in a row where Amanda’s the only one I talk to, and I’m fine with that.” In 2006, the couple left their day jobs so Amanda could devote more time to their four chicken houses and Ken could join Amanda’s dad, Woody Cheatwood, in working his 2,000-acre cotton and soybean farm just down the road from Rabbittown. Shortly thereafter, the Hightowers built their second fourhouse pullet farm. Things changed a decade later, when Cheatwood decided to retire not only from row-cropping but from poultry farming as well. He leased the cropland and sold Ken his eight poultry houses. “I figured, I’ve already got eight houses; I might as well add eight more,” Ken said. Ken is basically a one-man show, and he likes it that way. “[Son] Eli worked with me when he was in high school and college, and Amanda’s dad is usually available to help when needed, but I would hate to know these days that I had to look for and find three or four people who I knew I could trust and depend on to do their work,” he said. The 16 Hightower houses are located on four different farms within a fivemile radius of Rabbittown. Growers

The Hightower's son, Eli, left, used to help Ken on the farm and is now a coach at Ranburne High School while daughter, Kendall and husband, Riley Murphy, live in Birmingham with their baby boy, Marshall.

for Koch Foods, Ashland, they produce 320,000 replacement pullets and 48,000 males a year. In June, the Alabama Poultry and Egg Association recognized the couple as its 2022 Alabama Poultry Farm Family of the Year winners. “Ken takes a lot of pride in his work,” Amanda said. “He doesn’t do anything halfway. He’s meticulous in everything.” In nominating the Hightowers for the award, company service technician Michelle Davidson agreed with Amanda, making special note of Ken’s “meticulous nature and attention to detail.” “Ken and Amanda maintain their 16 houses in an unbelievable balance of strict routine of feeding, collecting mortality and maintenance,” Davidson said. “Ken has the best livability of our pullet producers, and once they reach the breeder hen farm, his birds perform very well in egg production and hatch.” Sometimes, Ken gets so wrapped up in the day-to-day operations, he loses sight of the reality that he is helping feed the world. “We were at an Auburn football game a few years ago, and I started talking with a guy who asked what I did,” Ken said. “He actually got emotional when I told him. He said, ‘I want you to know how much appreciate what you do. I mean, I really, really do.’

“Granted, he’d had a few, but it was a good reminder.” The Hightowers married in 1991 and have two children. Kendall lives in Birmingham with husband Riley Murphy, a real estate attorney, and baby boy Marshall, and Eli is a coach and teacher at Ranburne High School in Cleburrne County. Ken and Amanda are active members of Rabbittown Baptist Church. This year, generous donations each from award sponsors Alabama Ag Credit, Alabama Farm Credit and First South Farm Credit upped the first-place prize package to include a $10,000 poultry house washer, $2,500 in cash, and hotel accommodations for the Evening of Fun in Birmingham in June and the APEA annual meeting in Destin in July. The gifts also expanded the awards to include second- and thirdplace prizes valued at $2,600 total. Second-place winners were Tyson Foods, Eufuala, pullet growers Bob and Emily Cox, and third-place winners were Michael and Cassie Williams, who raise breeders for Ingram Farms in Cullman.

july - august 2022 | A L A B A M A P O U LT R Y

Peco collected more than 18,000 canned good for local food organizations.

PECO FOODS SHARES 2021 COMMUNITY IMPACT, CONTINUES PRIORITIZING COMMUNITY STEWARDSHIP P

eco Foods, one of the nation's top poultry producers continues to positively impact the communities where team members live and work. With 11 locations across Alabama, Arkansas and Mississippi, Peco intentionally sources community engagement opportunities throughout the year, living out its commitment of doing the right thing to provide a positive work environment for all team members. Peco engrains itself within its communities through regular engagement opportunities, including food drives, toy donations, volunteerism, local sponsorships, scholarships, nonprofit partnerships and environmental stewardship. “At Peco, we take pride in becoming active members of the communities where we live, work and conduct business,” Mark Hickman, Peco Foods president and CEO, said. “This commitment has held true since our founding in Gordo, Alabama, 85 years ago, where we relied on community support to successfully start this company and remain one of the country's largest poultry employers today. Our success wouldn’t be possible without the support of each of the communities that we’ve grown to be a part of.” In 2021 alone, Peco’s footprint collectively made an impressive impact, including: • Logging 300-plus volunteer hours for local philanthropies and initiatives, including highway cleanups, educational support, food kitchen volunteering, holiday gift packaging and more.

A L A B A M A P O U LT R Y | july - august 2022

• • • •

Collecting more than 18,000 canned goods for food banks across multiple states. Donating more than $4,500 in toys to organizations and municipalities impacting children. Contributing 350 backpacks to local schools. Supporting hyper-local initiatives team members are passionate about, including groundskeeping at cemeteries where loved ones were buried, planting trees for Earth Day and honoring military veterans with hot meals and gift cards.

“We are proud to see the passion and generosity that our teammates have for their communities,” said Hickman. “Doing the right thing is part of our DNA, and we look forward to continuing to make a positive impact in our communities.” Maintaining a community focus is a common thread throughout the organization that helps team members feel proud of where they work. “We should be good stewards in the community and give back what this great company has blessed us with,” said Stacy Fisher, a Peco team member in the company’s Pocahontas, Arkansas, facility. “Peco has grown to over 6,300 team members spread across three states, and, despite our size, we strive to create a familial work environment,” said Verna Matthews, Peco Foods HR manager. “Being a family-owned business, we are committed to building strong and respectful relationships with our team members and rooting our decisions in honesty and integrity.” Not only does Peco support its communities, but it maintains a strong internal focus on its people by offering scholarships, bonuses and monetary gifts to team members and provides COVID-19 support that meets or exceeds industry standards. Peco values the talent of each individual and is committed to providing a positive working experience through In 2021 Peco donated more than $4,500 in toys to organizations that impact children. respectful, open two-way communication. “We believe that hiring the best people and providing them with the training, tools and opportunities needed for success will promote their development and growth,” Hickman said. “This commitment includes our team member scholarship programs and financial support for education.”

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It’s grilling season, so fire up the grill for some delicious chicken dishes. Easy Grilled Chicken Thighs are a flavorful and economical way to serve chicken this summer alongside your favorite Southern sides like pasta salad, sliced tomatoes and fried okra. Or, make your own Shortcut Grilled Chicken Pizza that tastes like it was made at a brick-oven pizzeria. Your friends won’t believe it when you tell them it starts with naan bread. (Find directions on how to make it with store-bought pizza dough at GritsAndGouda.com.) It’s also peak harvest time for vegetable gardens and many farm crops. Although I have a garden, my squash wasn’t ready to pick yet when I developed this recipe for Easy Yellow Squash Casserole. Luckily, I met some Sweet Grown Alabama farmers recently at a dinner honoring farmers. Mr. White from Ole’ House Farms in Loxley, Alabama, fixed me up with enough summer squash to photograph it just in time Kathleen Phillips is a to share with you. Southern shortcut recipe Before we can turn around twice, it will be time for developer and cookbook the kids to head back to school. If their lunchbox has author who uses her a cold pack inside, send them off with one of these talents to make life Best Simple Egg Salad Sandwiches. It also makes easier in the kitchen. Find more of her recipes for a satisfying after school snack scooped up with at GritsandGouda.com. crackers.

A L A B A M A P O U LT R Y | july - august 2022

THE BEST SIMPLE EGG SALAD Prep time: 5 minutess Yield: 1 2/3 cups (4 to 6 servings) • • • •

1/3 cup mayonnaise 1 1/2 teaspoons yellow mustard 1/2 teaspoon salt 6 large hard-cooked eggs, peeled

Combine mayonnaise, mustard and salt in a medium-size bowl. To save washing another bowl, mash the eggs with a potato masher in the same bowl. If you prefer larger pieces of egg, chop eggs on a cutting board. Stir eggs into mayonnaise mixture. Serve between slices of bread or with crackers.

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EASY GRILLED CHICKEN THIGHS Prep time: 5 minutes Marinade time: 30 minutes Grill time: 12 minutes Yield: 4 servings • 4 boneless, skinless chicken thighs • 3/4 cup bottled chicken marinade or teriyaki sauce, such as Lawry’s sesame ginger Place the chicken thighs in a large plastic zip-top bag or in a shallow casserole. Add marinade or teriyaki sauce to the chicken and squeeze the bag to coat the chicken. Seal the bag and refrigerate at least 30 minutes, or up to 24 hours for maximum flavor. Prepare a gas or charcoal grill according to manufacturer’s directions to achieve medium heat,* about 375-400 degrees. Remove the chicken from the zip-top bag; discard the marinade in the bag. Coat the grill grates with oil and immediately place the chicken on the grill. Close the lid and cook for 7 minutes. Turn chicken over with tongs and grill 5 more minutes, or until chicken registers 170 degrees (dark meat) with an instant read thermometer. Remove chicken onto a plate and let rest 5 minutes before serving. NOTE: Medium heat is the trick to not burning chicken that has been marinated.

EASY YELLOW SQUASH CASSEROLE Prep time: 10 minutes, Cook time: 35 minutes, Yield: 6 servings • 1 pound yellow squash, sliced (about 4 cups) • 1 cup sliced onion • 2 medium or large eggs • 1/2 cup whole or 2% milk • 1/2 cup shredded Cheddar cheese • 1/2 teaspoon salt • 1 cup fresh breadcrumbs or 2/3 cup dried breadcrumbs • 2 tablespoons melted butter Preheat oven to 350 degrees. Cook the squash and onion in a small amount of water for 5 minutes, or just until slightly softened. Drain well in a colander and pat dry when cooled to the touch. Meanwhile, whisk the eggs in a medium bowl. Gradually stir in the milk, then cheese and salt. Stir in 2 tablespoons of the breadcrumbs. (This helps slightly thicken the “sauce” mixture.) Add the squash and onion to the egg mixture. Pour the squash mixture into an 8x8-inch or 1 ½-quart casserole dish that has been sprayed with cooking spray. Add butter to the remaining breadcrumbs and gently combine. Sprinkle breadcrumb mixture on top of casserole. Bake for 30 minutes, or until the top is crispy and bubbly around the edges. NOTE: This small-batch recipe is perfect for a family meal and easily doubles for a potluck.

GRILLED CHICKEN PIZZA Prep time: 10 minutes Grill time: 4 minutes Yield: 4 servings • 4 naan breads* • Vegetable oil for the grill grates • 3 tablespoons Thai peanut sauce, teriyaki sauce or spicy barbecue sauce • 3/4 cup thinly sliced grilled chicken • 1/2 cup thinly sliced red or green bell pepper • 1/3 cup matchstick carrots, optional • 1 cup finely shredded mozzarella cheese • 1 tablespoon chopped peanuts, optional • 2 tablespoons sliced green onions • 1 tablespoon cilantro leaves, optional Prepare a gas or charcoal grill according to manufacturer’s directions to achieve medium-high heat, 450-500 degrees. Using a silicone grill brush, brush oil onto the grill grates. Place the naan breads on the grill. Close the grill lid and grill for just 1 to 2 minutes, or until grill marks start to show on the bottom or the bread is toasted on the bottom. Using tongs, remove the bread and place on a platter or baking sheet, grilled side up. Spread peanut sauce evenly over each naan bread, then layer, in order, the chicken, bell pepper, carrot, and cheese. Slide the pizzas back onto the grill with a long-handled spatula or tongs, untoasted side down. Close the lid and grill for 2 minutes. The bottom side will get toasted, and the cheese will melt. Slide the pizzas back onto the platter to serve. Sprinkle with peanuts, green onion and cilantro. Notes: This pizza recipe features Thai flavors. For a Spinach Alfredo Pizza, simply use bottled alfredo sauce, sauteed fresh spinach, chicken and cheese. For directions to make this recipe with store-bought pizza dough, visit GritsAndGouda.com.

july - august 2022 | A L A B A M A P O U LT R Y

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PRACTICAL APPLICATIONS

POULTRY FARM WATER SUPPLY TROUBLESHOOTING Jess Campbell, Jeremiah Davis, Kelly Griggs, Carson Edge and Cody Smith National Poultry Technology Center – July/August 2022 We get a lot of inquiries about troubleshooting farm performance issues and where to start looking for problems during hot weather. One of the first things that should be inspected when a farm is not performing is to verify that the farm has a sufficient supply of water for the maximum demand of peak flow for birds, evaporative pads and other needs. Let’s get started by answering the question of how much water demand in gallons per minute (gpm) a modern broiler house requires. We need to know some information about the farm before this demand can be estimated. Let’s go over a few questions and simple examples. 1. How many birds are placed in the house? 2. How much total tunnel air capacity in cubic feet per minute (cfm) is installed in the house? 3. What other water demands exist on the house? Simplified Example 1: (for estimation purposes only) 40x500 broiler house with 20,000 birds using 250,000 cfm of fan power and wash down faucet in front. 2 gpm for birds + 10 gpm for pads + 3 gpm for wash down (other) = 15 gpm total per house Simplified Example 2: (for estimation purposes only) 66x600 broiler house with 40,000 birds using 450,000 cfm of fan power and wash down faucet in front. 4 gpm for birds + 18 gpm for pads + 3 gpm for wash down (other) = 25 gpm total per house

Figure 1: Water Component Troubleshooting Demonstration: We recently built a poultry farm hands-on project specifically designed for training purposes in our NPTC building. During our seminars, producers and service technicians get firsthand experience estimating bird water demands, testing water supply capacity and troubleshooting water supply restrictions.

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Figure 2: Example Bucket Test: We conducted a water flow bucket test on a farm and discovered the existing dirty filter (left) only produced 1.7 gpm, and after a new filter (right) was installed, the test measured over 13 gpm. Dirty filters can be very restrictive to water flow if allowed to go unchecked.

Estimating Water for the Birds There are a couple of ways to estimate bird water consumption: Method 1: Take the total 24-hour metered reading from the water meter or meters. For example, 2,400 gallons per day (gpd) in a 24-hour period. Next, we need to know how many hours the lights were off when birds were resting and should not be drinking. Let us use 4 hours of dark for this example, which means lights were on for 20 hours. So, 2,400 gpd / 20 hours = 120 average gallons per hour (gph) when lights were on. To get the number of gpm, then divide 120 gph / 60 minutes = 2 gpm. This 2 gpm is the average estimated water flow when the lights are on, and birds are drinking. Method 2: The rule of thumb of 0.1 gpm (0.08 gpm for smaller birds) of water flow for every 1,000 birds is a good starting point for estimating large bird water use. (See the University of Georgia Poultry Housing Tips, Broiler Farm Water Usage and Pipe Sizing Rules of Thumb, Volume 19, Number 6, 2007 by Mike Czarick for rules of thumb.) For example, if there are 20,000 birds housed, divide it by 1,000 then multiply by 0.1 gpm (20 x 0.1 gpm) to estimate about 2 gpm needed for birds. The estimated 2 gpm is the average flow rate for a day at market age. If the water supply system is only supplying the 2-gpm average, the system is not adequate during peak consumption periods. For example, if the supply only provides 2 gpm and the birds need 3 gpm of flow when the lights come on in the early morning and daybreak stimulates activity, performance could be negatively affected. We recommend supplying about 1.5 to 2 times the average water flow to the drinker system to cover these peak

A L A B A M A P O U LT R Y | july - august 2022

periods. For example, multiply the 2-gpm average by 2 = 4 gpm of estimated continuous flow to the drinkers at all times. Maintaining this goal of 4 gpm of water flow should manage the peak demands for the birds, with some room for error. Speaking of error, we have discovered multiple farms that are managed very well but still are not performing and competing like they should be. If this situation sounds familiar, then it is time to perform a water flow test in those houses. Step 1: Perform a flow test using a 5-gallon bucket, a ¾” minimum jumper hose, and a timer. If you have not done this before it might be useful to ready our Auburn University NPTC newsletter, ANR-2827 NPTC Tools of the Trade — Measuring Water Flow Rate for more details. Step 2: The water needs to be running in all houses to perform this test. It is best and easiest to conduct this test when the farm is already under full water demand with large birds, full tunnel and maximum pad operation. Example: a 95-degree -day with 50% relative humidity and 55-day-old birds or whatever the final days of market age growth would be. Step 3: With the rest of the farm under maximum demand, evaluate each house on the farm and compare the flow rates to those estimated in this newsletter. This is usually done with a ¾” minimum ball valve directly from the water panel after the filter, regulator, and meter if possible. If there is only a water hose faucet, the test will be helpful but will restrict the water flow during the test. Check out NPTC newsletter ANR-2721 Do Your Valves and Hose Bibs restrict water capacity? to determine if you have restrictive faucets. If the house passes the test with 6 gpm and doing so through a restrictive faucet, the supply will be adequate. If the estimate is 2 gpm and you only

get 2 gpm, then we recommend changing the filters upstream if possible and planning an inspection after the flock is sold. If the house water flow is less than needed during the test, serious inspection of each component upstream should be prioritized. We do not recommend doing any plumbing work during the flock unless it is absolutely required. We recommend installing PVC unions on both sides of any component during this process. Unions allow you to routinely check regulators, medicators and filters for signs of corrosion or debris restrictions.

Estimating Water for the Pads Six-inch evaporative cooling pads can consume significant water on a hot dry day. For much of the broiler belt, we can assume these systems will consume about 4 gpm for every 100,000 cfm of fan power on a house. The plumbing systems are typically designed to supply 5 gpm of water flow for every 100,000 cfm of tunnel fan power to manage peak demands. Our examples at the beginning of the article used 10 gpm for a 40-foot house and 18 gpm for 66-foot-wide house. Again, these are peak demand estimates only. The same testing procedures can be conducted at each water supply point at each cooling system. It is important to supply the designed water capacity to each cooling system unit, so it does not take water flow from the birds during peak cooling demand periods. If a house fails the test at the pads but passes the test in the control room, the producer may have a restriction somewhere between the control room and evaporative system water supply point. If the house failed the test in the control room, then there should be more focus on the supply system to the house or the farm. More information can be found on estimating evaporative cooling water system demands by reading: Evaporative Cooling Pad System Water Usage, Volume 29 Number 1, Czarick & Fairchild, 2017. How Much Water Does Your Evaporative Cooling System Need by Mississippi State, Linhoss, et al., Publication 3329, 2020. Figure 3: Example Water GPM for Birds, Pads, and Total Flow: This graph illustrates the water flow (gpm) of a 66x600 broiler house on a hot day. There were 44,000 birds placed in the house. Lights come on at 2 a.m., birds begin to drink, and the bird peak water meter flow occurs at 8 a.m. Using the rule of thumb of 0.1 gpm for every 1,000 birds, the estimated peak for birds is 4.4 gpm, but it reached 5.7 gpm. The birds reached the estimated 4.4 gpm threshold at 6 a.m. and the bird flow rate remained above this until 9:20 a.m. In short, the bird rate exceeded the

Figure 3: Example Water GPM for Birds, Pads and Total Flow

estimated average rate for three hours. If this house were only able to provide the estimated 4.4 gpm or less, the flock would not be getting adequate supply during this period and for the duration of the grow out. Notice the pads reached 13.1 gpm on this day at 8:10 a.m. bringing the maximum measured house total to 18.1 gpm. Also, it is helpful to know that this house consumed 4,076 gallons of water for the birds and 6,352 for the evaporative pads, for a total of 10,428 gallons in one day. It is important to remember this was not the hottest or driest day of the year, and the flock was not maximum age or size. Bottom line: The producer loss of income can be significant if major water supply restrictions exist on a farm. An estimated 3% reduction in livability and 0.5 lb. reduction in average sale weight on four 40x500 houses is $3,603.60 ($900.90/house) and $7,207.20 ($1,801.80/house) on four 66x600 foot houses. A few hours of troubleshooting and money invested in new plumbing parts offer the opportunity for a very quick payback if you identify and correct a problem in the plumbing system. If you are not comfortable doing plumbing repair or maintenance, now might be a suitable time to contact your local plumber for professional help. Notice: Estimating water demand needs for a single house varies based on and not limited to the number, type and size of birds housed, total tunnel exhaust fan air capacity, evaporative cooling system size and media type, geographic location, feed formulation, drinker type and management and producer management differences. This article is for estimation and troubleshooting purposes only. For more information, visit poultryhouse.com, download our Poultry Toolkit smartphone app or contact Jess Campbell at jesscamp@aces.edu or (334) 332-6830.

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