Alabama Poultry, May/June 2009

May/June 2009 – VOL. 4 NO. 3

The Graces of Jasper

AP&EA P.O. Box 240 Montgomery, AL 36101 Address Service Requested

Board of Directors Officers Ken Taylor, President, Anniston* Fred Cespedes, Vice President, Hanceville* Wendell Shelton, Treasurer, Boaz* John Pittard, Secretary, Guntersville* Jack Sherwood, Immediate Past President, Troy* Directors Johnny Adcock, Woodland* Ronnie Adrian, Collinsville George Attwood, Anniston Roger Chappell, Cullman Billy Conquest, Cullman Melissa Durbin, Birmingham Randall Ennis, Huntsville Tim Esslinger, Eufaula Dale Gambrill, Snead Billy Gilley, Cullman Harold Hunt, Gadsden Spence Jarnagin, Huntsville* Ted Lankford, Athens Heath Loyd, Decatur David Massey, Montgomery Dennis Maze, Horton Joe McGlamery, Enterprise Todd McMahen, Dothan John Roberts, Cullman Kenneth Sanders, Brundidge Roddy Sanders, Gordo Taylor Steele, Albertville Phyllis Thomas, Russellville David Thompson, Ashland Stanley Usery, Athens Ricky Walker, Snead

GOLD

AlaTrade Foods, LLC Aviagen, Inc. Cobb-Vantress, Inc. Evonik-Degussa Hill Parts

Hubbard LLC Intervet /Schering Plough K Supply Company, Inc. Marel Food Systems Sand Mountain Electric Cooperative

Advisors Dr. Don Conner, Auburn University James Donald, Auburn University Dr. Joe Hess, Auburn University Mickey Humphries, Montgomery Dr. Tony Frazier, Montgomery Perry Oakes, Auburn

*Executive Committee Members

AP&EA STAFF Advanced Poultry Equipment & Supplies, Inc.

Franklin Industries, Inc.

SILVER

Alpharma Biomune Company Elanco Animal Health

Ivesco, LLC M and M Poultry Supply/MEMCO Pfizer Animal Health

Federal Land Bank Assn. of N.A

The Vincit Company

EXECUTIVE CORPORATE SPONSORS

Federal Land Bank Assn. of S.A.

Walco International Inc.

Purchasers of 20 or more tickets.

American Proteins, Inc., Hanceville, AL

Haarslev Inc., Kansas City MO

D & F Equipment Sales, Inc., Crossville, AL

International Paper, Bay Minette, AL

First South Farm Credit, NA, Cullman, AL

Tyson Foods, Inc., Snead, AL

GSM Steel & Mechanical Contractors., Guntersville, AL

Wayne Farms LLC, Troy, AL

Johnny Adams – Executive Director Wanda H. Linker – Administrative Director Huck Carroll – Communications Director/Editor Jennifer Shell – Support Director

Alabama Poultry is published by the Alabama Poultry & Egg Association 465 South Bainbridge Street Montgomery, AL 36104 Phone: 334-265-2732 Fax: 334-265-0008 Send editorial and advertising correspondence to: Alabama Poultry Editor P.O. Box 240 Montgomery, AL 36101 Advertising rates and closing dates available upon request.

Editorial matter from sources outside AP&EA is sometimes presented for the information and interest of our members. Such material may or may not coincide with official AP&EA policy. Publication does not necessarily imply endorsement by AP&EA.

w w w. a l a b a m a p o u l t r y. o r g

Director’s MESSAGE

Many thanks to all who bought tickets and attended this year’s “Evening of Fun” festivities. The crowd really got its money’s worth. Diamond Rio’s reputation for putting on a terrific show is still intact. Of course, the FFA’s Sylvania Quartet almost stole the show.

As you may know, the proceeds from the “Evening of Fun” fund AP&EA operations throughout the year. This involves funding educational seminars and office expenses, as well as legislative efforts and all of our communications, including this magazine. We are grateful for your continuing support, and for the support of our generous sponsors. We are here to serve your needs.

We also want to thank Ken Taylor for his outstanding work as Association president. Ken has brought a unique perspective into the office, having been associated with every aspect of the poultry industry. His leadership and encouragement have meant a great deal to this organization.

Several months ago, AP&EA joined with other animal agriculture groups and related groups to form a coalition called the Alabama Coalition for Farm Animal Care and Well-being. This was in response to potential threats to the Alabama animal agriculture industry from the animal rights movement. This is a most timely move, as you will see.

In the last issue of our magazine, we ran an article titled “Have You Seen This Man” about a young man who is an undercover activist for radical animal rights groups. His aim is to video tape so-called “mistreatment” of animals on farms or processing plants and expose that “mistreatment.”

He is, in many cases, the instigator of much of the abuse he tapes.

In our article, we encouraged everyone in the industry to be watchful.

That watchfulness has paid off. Several weeks ago we received a call from a processing plant in north Alabama to inform us that a man answering the description of the man in the article had applied for a job. Alert employees in the personnel office recognized him and had security escort him from the premises.

It is encouraging to know that the security in our poultry plants is better than in many of the federal office buildings in Washington, D.C.

FEATURING

Governmental Affairs Association News Fishing Tournament Golf Tournament Evening of Fun 2009 Farm Family Recipes 4-H Chickenque Membership News Practical Applications

Alabama Poultry Magazine

THIS MONTH

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May/June 2009

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G over nment al Affairs

A Tale of Two Letters – One Published in the Washington Post A Deadly Ingredient in a Chicken Dinner

By Douglas Gansler Friday, June 26, 2009

Most people don’t know that the chicken they eat is laced with arsenic.

The ice water or coffee they enjoy with their chicken may also be infused with arsenic. If they live on or near a farm, the air they breathe may be infected with arsenic dust as well.

Why do our chicken, our water and our air contain arsenic? Because in the United States, most major poultry producers add an arsenic compound known as roxarsone to their chicken feed. Inorganic arsenic is a Class A carcinogen that has been linked to heart disease, diabetes and declines in brain function.

Recent scientific findings show that most Americans are routinely exposed to between three and 11 times the Environmental Protection Agency’s recommended safety limit.

The poultry industry has been using the feed additive roxarsone — purportedly to fight parasites and increase growth in chickens — since the Food and Drug Administration approved it in 1944. Turns out that the arsenic additive promotes the growth of blood vessels in chicken, which makes the meat appear pinker and more attractive in its plastic wrap at the grocery store, but does little

else. The arsenic additive does the same in human cells, fueling a growth process known as angiogenesis, a critical first step in many human diseases such as cancer.

The arsenic additive also presents health risks to farmers who work with the chemical or fertilizers. Chicken growers have reported illness from contact with roxarsone while preparing feed.

Because most smaller growers rely on contracts with larger chicken producers that mandate the use of arsenic in chicken feed, the smaller growers are often unable to avoid the health risks associated with roxarsone.

In 1999, recognizing that any level of inorganic arsenic in human food and water is unacceptable, the European Union outlawed its use in chicken feed.

Reportedly, several American chicken producers, including Tyson Foods and Perdue Farms, have acted responsibly by discontinuing the use of roxarsone in their animals. Other growers have turned to “organically fed” chicken operations.

Nevertheless, as recently as 2006, 70 percent of the more than nine billion broiler chickens produced annually in the United States were fed roxarsone.

Chicken consumption in the United States has increased dramatically in the past 40 years. In addition to the arsenic Americans consume at the dinner table,

American broiler chickens generate billions of pounds of animal waste each year — more than 1.2 billion pounds annually in Maryland alone — causing significant runoff of arsenic into soils and surrounding waterways. The dangerous levels of arsenic in chicken manure ultimately contaminate crops, lakes, rivers and fertilized lawns, and it may even reach drinking water. Meanwhile, the poultry industry labors under the legal fiction that although it owns the chicken feed and the chickens that eat the feed, it has no responsibility for the chicken manure.

The federal Food and Drug Administration should ban arsenic from chicken feed. Working through the environmental committee of the National Association of Attorneys General, Maryland has enlisted more than 30 states to join in this effort.

The poultry industry’s continued use of arsenic creates unnecessary and avoidable risks to our health and environment.

The FDA has delayed banning this poison from our diet for far too long. If offered a side order of arsenic with my chicken, I’d say no. Wouldn’t you?

The writer is attorney general of Maryland. He serves on the executive board of the National Association of Attorneys General and is co-chair of the association’s environmental committee.

The National C hicke n Council’s Re sponse Maryland Attorney General “Provably Wrong” About Safety of Chicken, NCC Says

The attorney general of Maryland, Douglas Gansler (D), has written an opinion article in The Washington Post stating that chicken is “laced with arsenic.” Mr. Gansler is wrong: absolutely, provably wrong.

If Mr. Gansler were actually to read up on this subject, rather than take his lead from various activists, he would study the findings of the U.S. Food & Drug Administration, which is the federal agency charged with monitoring

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May/June 2009

the presence of arsenic and other substances in certain foods.

Arsenic is a naturally occurring element that is widely found. As the World Health Organization puts it: “Arsenic is ubiquitous, found in air, water, fuels, and marine life. The daily human intake of arsenic contained in food is in the range 0.5–1 milligrams.” Because trace amounts of arsenic occur widely, the FDA sets a tolerance level in foods.

For chicken, that level is 0.5 parts per million.

“The truth is that the U.S. Food and Drug Administration (FDA) samples chicken among many other food for

Alabama Poultry Magazine

residues of arsenic and many other chemical compounds. The sampling for 2007 showed exactly zero violations among the chickens sampled. Zero,” NCC President George Watts wrote in a letter published in today’s Washington Post.

FDA also reports findings that do not violate the tolerance level. Some of the samples of chicken livers had findings of arsenic above the level of detection but below the tolerance level. This is because elements such as arsenic tend to “bioaccumulate” in the liver. You would have to eat an enormous amount

Continued on pg. 30

A ssoci at i on News

Cullman County Holds Annual M eeting Cullman County Poultry & Egg Association held its annual meeting on Saturday, May 2, 2009, at the Cullman Civic Center. The crowd of more than 350 enjoyed a delicious barbecued chicken dinner, followed by remarks from the keynote speaker, Commissioner of Agriculture and Industries Ron Sparks. Sparks talked about his administration’s record of accomplishments and expansion of overseas poultry markets. Sparks, has also announced his candidacy for governor.

Outgoing President Paul Holmes announced next year’s slate of officers: President Nancy Garrison, Vice President Chad Federer and Secretary Treasurer Robert Crumley.

Next on the program was the introduction of the 2009 inductee into the Cullman County Poultry Hall of Fame, George Scott. George, who will soon be 78, has been growing chickens since 1959, with only a brief retirement in 1977. He partners with his daughter, Patti, and her husband, Rex Motes. They grow for Ingram Farms.

The Cullman association has always been known for its good works in the community. This year was no exception, with checks going to Project Lifesaver, Cullman Autism Society, Hospice, Good Samaritans and Cullman County Victims Services.

The evening finished with the always exciting drawing for door prizes furnished by local merchants and the big drawing for a John Deere Gator.

This year’s winner was Rodger Brown of West Point.

Congratulations to the CCP&EA on another outstanding job!

(Above) George and Bessie Scott along with Paul Holmes.

(Below) Receiving checks are, left to right, Carol Kugler, Victims Services; Wanda and Jordan Davis, Autism Society; and Jerry Jacobs, Good Samaritans.

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May/June 2009

Alabama Poultry Magazine

Greg Graham Vice-President 2201G Gault Avenue North Fort Payne, AL 35967 877-245-4271

A ssoci at i on News

3rd Place

2nd Place

1st Place

Ricky Knott and his “leviathan.” There is a rumor that when Ricky released the fish, the fish looked up at Ricky and said, “I’ll see you next year!”

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May/June 2009

May 16, 2009 – 5:30 am – Lake Guntersville The quiet serenity of Lake Guntersville was broken at 5:30 am on Saturday, May 16, 2009, as 44 high-powered bass boats roared off into the dawn to various parts of the beautiful lake in the AP&EA Bass Tournament.

About 11:15 the boats began to trickle in, bringing their “live wells” to the scale for weigh-in. There were some good weights recorded and some big fish in the five to six pound range measured.

The Knott-Willoughby boat was one of the last to come in to weigh their catch. When they put their catch on the scales, there were gasps of amazement. Their total of 28.2 pounds was more than 10 pounds heavier that their closest competitor. Ricky Knott’s 8.68 pound monster bass was a full two pounds bigger than its closest rival.

The tournament winners are: First Place – Ricky Knott and Johnny Willoughby; Second Place – Tim Gore and Jeff Sims and Third Place – Jamie Ford and Chad Morris. Ricky Knott walked off with the prize for the “Largest Fish.”

Many thanks to our volunteers and to Fred Cespedes of American Proteins for supplying lunches for all.

This year’s 44 boats is a significant increase from last year. Much of this increase can be attributed to the Allied Committee’s decision to up the prize money from $500 to $1,000 and open participation to the public. Heading up the Bass Tournament Committee, James Sanford of American Proteins did and outstanding job, as did the volunteers who helped at the event.

Alabama Poultry Magazine

Closest to the pins Casey Jones John Pittard Jim Hipple Chris Carter

The first Friday in June felt more like late March, as the poultry pros teed it up for the EOF Poultry Classic at Bent Brook Golf Club on the outskirts of Birmingham. The number of participants was down and the clouds were low, but the competition was still hot.

With the cooler than expected temperatures, players and observers, as well, were ready for the gourmet hamburger lunch in the clubhouse. As the players ate, their scores were tabulated.

First through third place teams received Edwin Watts gift certificates and closest to the pin winners received cash prizes. A set of Cobra golf clubs, donated by Southwestern Sales, was presented as a door prize to Fred Cespedes of American Proteins.

The tournament was the kick-off event in the AP&EA “Evening of Fun” weekend and was graciously sponsored by AP&EA’s VIP Sponsors and individual hole sponsors.

HOLE SPONSORS AlaTrade Foods, LLC American Proteins, Inc. D & F Equipment Sales, Inc. First South Farm Credit NA GSM Steel & Mechanical Contractors H. J. Baker & Bro., Inc. Reeves Supply Co., Inc. Sports Transportation LLC

3rd Place Team Norman Bond Cory Early Clint Lauderdale Ted Lankford

2nd Place Team Randall Smith Dale Gambrill Chris Carter Jimmy Pankey 1st Place Team Jeff Sims Suzanne Young David Edmonson Perry Norris

See and download photos of the golf tournament at www.alabamapoultry.org

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May/June 2009

Alabama Poultry Magazine

With anticipations running high for another blockbuster “Evening of Fun,” more than 50 growers assembled in the Sheraton ballroom for the “work before play” part of the evening. It was time to elect directors to serve John ny A d c o ck on the AP&EA board for the coming year, to present the 2009 “Farm Family of the Year,” and to view a presentation, “Energy Efficiency in Poultry Housing and Your Future,” by Jess Campbell of the National Poultry Technology Center and a CAFO Update by James McAfee of the Alabama Department of Environmental Management.

Johnny Adcock, chairman of the AP&EA Grower Committee, served as the master of ceremonies, and welcomed everyone. He thanked those in attendance for their commitment to the industry and to the Association.

The first order of business was to elect directors who will serve on the AP&EA board for the next two years representing the growers. The bylaws specify that there will be six directors representing the growers on the board.

Ken Taylor, Association president, will continue next year as immediate mpbell Je s s C a past president; Billy Gilley from Holly Pond and Stan Usery from Athens each have another year left on their two-year terms. Three additional directors needed to be elected.

Ken Taylor presented the nominating committee report, saying, “The Nominating Committee recommends that Johnny Adcock from Woodland, Dennis Maze from Horton and Kenneth Sanders from Brundidge be elected to serve two-year terms as AP&EA directors.” The floor was opened for additional nominations, but none were forthcoming. Adcock then declared the nominations be closed. On a hand vote, the nominees were elected without dissent.

The next order of business was the introduction of the Alabama Poultry & Egg Association Farm Family of the Year: Dorman and Susan Grace of Ken Taylo r Jasper. Dorman Grace is a third generation poultry farmer with six houses and grows for Pilgrim’s Pride. The Graces were nominated by their field rep Lyle Garrison. The Graces have two sons, Cade, 21, and Jud, 17. You can read more about them beginning on page 14.

Jess Campbell began his portion of the program covering such topics as House Tightness, Solid Walling, and Insulation; Utilizing Stir Fans; Energy Efficient Lighting; and Energy Efficient Ventilation Fans. Each topic was aimed at saving the grower money and making his houses more efficient.

James McAfee finished the program with a CAFO Update, then a drawing was held for cash door prizes.

With the “business” done, a picnic supper was served for all in atamily G ra c e F e h t d n lor a tendance. With the fun part of the evening just across the street, everyKe n Tay one was anxious to get started on the “Evening of Fun.”

Alabama Poultry Magazine

May/June 2009

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By the time the Birmingham-Jefferson Convention Center doors opened, the crew waiting outside was ready for some tunes and some fun.

They would not be disappointed.

As the crowd was filing in, they were entertained by the a cappella sounds of the FFA State Champion Sylvania Quartet. This dynamic foursome offered the audience a lively and melodic taste of what was to come later, singing songs like the old Gospel favorite “I’ll Fly Away” and “Swing Low Sweet Chariot.” They are outstanding young musicians, with a stage presence that is thoroughly captivating.

Alabama Poultry & Egg Association Executive Director Johnny Adams welcomed everyone and introduced Association Treasurer Wendell Shelton, who delivered the invocation. Then the Sylvania Quartet returned to sing the National Anthem.

AP&EA President Ken Taylor introduced the Executive Committee. Next, Executive Director Johnny Adams introduced the special dignitaries in the audience including Supreme Court Justice Greg Shaw and his wife, State Auditor Sam Shaw; Susan Parker of the Public Service Commission; Judge Jim Main of the Court of Criminal Appeals; Judge Terri Willigham Thomas and Judge Tommy Bryant of the Court of Civil Appeals: Deputy Commissioner Glen Zorn of the Department of

Agriculture and Industries; Alabama State Senators Priscilla Dunn of Bessemer and Kim Benefield of Woodland; and Alabama House of Representative members James Fields, Jr. of Hanceville, Earl Hilliard, Jr. of Birmingham, Richard Lindsey of Centre, Artis McCampbell of Demopolis, and Mary Sue McClurkin of Indian Springs.

The most anticipated introduction was for the AP&EA 2009 Farm Family of the Year: Dorman and Susan Grace with their son Jud of Jasper.

Just before the entertainment began, a drawing was held to give away two big screen tvs. Unfortunately there had been a snafu with the tickets.

Ticket takers had not given the stubs back to the attendees, so when the numbers were drawn on stage, no one in the audience had stubs to compare with the numbers. Fortunately, everyone kept a good sense of humor and the concert went on.

Diamond Rio came onto the stage like a group of old friends you haven’t seen for a while coming into your living room, relaxed, easy, reassuring, maybe even comfortable, but still exciting.

Diamond Rio is a well-established band, and clearly comfortable in their own shoes. Their music is personal with songs like “I Believe” and ”One More Day,” or hard-driving like “Unbelievable.” The concert featured many of the songs that have made them famous over the years, plus a tribute to Marty Robbins, with a medley of his songs.

There were several memorable bluegrasss banjo solos by J.D. Crowe and some great mandolin work by Gene Johnson.

It was a great concert by old friends. It got your blood pumping, it made you laugh, it put a lump in your throat and maybe even a tear or two in your eyes. Hey, it’s Diamond Rio, they’re old friends!

You can see and download all of the photos from the concert and dance at our website www.alabamapoultry.org

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Alabama Poultry Magazine

Alabama Poultry Magazine

May/June 2009

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Once the concert was over, folks made their way over to the Sheraton ballroom for some old-fashioned boogie. The Tip Tops were ready to oblige with a highenergy sound that was pure ‘60s “Motown.” There was some Four Tops, some Otis Redding, with the Temptations and Marvin Gaye thrown into the mix.

Then there were “The Toppettes,” who brought in the feminine side with some Aretha, some Supremes, with some Gladys Knight and some Pointer Sisters for

(Left) Michael Barksdale and his Pilgrim’s Pride rep, Cheryl Lovell

TV Winne rs Ge t The i r Pri ze s

(Below) Jimmy Payne and his grandson

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May/June 2009

good measure. Put them all together and you have dynamite on the dance floor.

Speaking of the dance floor – there were some interesting moves out there. Fred Astair would lift more than an eyebrow at some of those steps.

It was late in the evening before the poultry partiers headed for bed, but everyone acknowledged – a good time had been had by all!

They didn’t get to take them home with them that night – but hey, their cars were probably packed too full anyway. They did, however, get them hand delivered.

Congratulations to Michael Barksdale of Boaz, a grower for Pilgrim’s Pride and to Jimmy Payne of Moundville who grows for Peco Foods.

Those 42-inch TVs should make for a good many evenings of fun themselves!

Alabama Poultry Magazine

When Dorman and Susan were married, Dorman was so selfconscious, when the minister told him he could kiss his bride, he couldn’t do it, not in front of his parents.

Dorman Susan

Dorman Grace does things by the book, and by all accounts, he has been very successful at it, starting at an early age. The primary book that he goes by can be seen in the family photo on the cover of this magazine, it’s his Bible, and he says, “It is the only true book you can believe in.” A second book is “I Dare You!” by William Danforth, the founder of Ralston Purina. Written in 1931, it presents the timeless challenge, especially to young people – the dare: to be one’s best, to live a four-fold life, and to serve others. Dorman received the book in the sixth grade as a reward for winning a countywide 4-H essay contest on farm safety. Throughout the years, after having loaned it to so many, who needed its inspirational message, it finally disappeared. Susan, his wife of 27 years, graciously replaced it with a newer copy.

Not only has the reading of books been important to him, so too has keeping books been an essential part of his life. As a youngster, he began keeping an Alabama 4-H Club Member’s Project Record Book.

He This book is a record of nine years in the life of Dorman Grace. It details not only his 4-H activity, but also gives great insight into his character.

Cade

Jud

was 18, and a freshman at Walker College, when he completed it.

Beginning in 1965 and going year-by-year, it details his activities on the family farm in the Boldo community, just outside of Jasper in Walker County. That first year, at the age of nine, according to the book, he assisted his family, now in its second generation of poultry production with four broiler houses, in growing out 136,000 chickens. In so doing, he also helped wash 550 water jugs for baby chicks 16 times and helped fill 400 feeders daily for baby chicks. He helped scatter shavings and clean out chicken houses four times that year and still had time to participate and win his first county chickenque. As the years went by, Dorman increased in knowledge, skill and a haul of medals and awards, not to mention press clippings.

High achievement was only natural for the youngest of the three sons of Dorthan and Evelyn Grace, both of whom were actively involved in educational and civic affairs, as well as running a farm where they raised cattle, hogs, cotton, hay and had four chicken houses. Though they had little formal education, they supported and encouraged their sons.

Dorman’s older brothers, Jerry and Galen, had excelled in 4-H participation, winning awards and serving in high offices. For Dorman, eight years younger than Galen and nine years younger than Jerry, expectations were high.

Those expectations were not unrealistic. By the time he graduated from Walker County High School in

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May/June 2009

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The Grace family: left to right, Dorthan, Galen, Evelyn, Dorman and Jerry, meet with their Gold Kist field rep.

1974, he had already achieved an impressive list of accomplishments. He had held every office in his 4-H Club and won numerous prizes for livestock showing and for exhibitions at the Northwest Alabama Fair. In July of 1974, he was chosen to attend the 15th World Poultry Congress in New Orleans. Here, he was asked to give the invocation at the dinner sponsored by Colonel Harlan Sanders of Kentucky Fried Chicken.

Dorman also got to spend some time with Colonel Sanders. It was quite an honor for a young man.

In August, he turned in his 4-H record book in competition with other Alabama 4-H regional poultry winners. The notebook won him the top prize and made him eligible for a trip to the National 4-H Congress in Chicago, where he also delivered the invocation at the national poultry awards banquet.

The greatest thrill came, however, when he was selected as a national scholarship winner for his poultry projects and leadership activities. Kentucky Fried Chicken furnished the $700 scholarship.

In September of 1974, Dorman entered Walker College in Jasper with his sights set on studying to get into veterinary school. Two years later he entered Auburn University’s department of poultry science. Some time during the two years at Walker College, he had given up on the idea of a career in veterinary medicine and decided to return to the farm as a poultry farmer.

The summer of 1977, between his junior and senior year at Auburn, he had been working as an intern for Ralston Purina in Trussville as a breeder supervisor, spending lots of time on the road visiting farms. He re-

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alized that he really didn’t want to work for anyone else. He wanted to be back on the farm.

During his Thanksgiving break, he told his father that he wanted to come back to the farm and raise poultry. His father wisely counseled him to think about it until Christmas. Dorman agreed. Dorman’s father contacted Gold Kist about building the new houses, and permission was given to build four.

When Christmas came, Dorman’s resolve had only strengthened, so he and his father went to the bank with a plan to build four 40’ x 400’ broiler houses. These were to be Dorman’s houses, even though his father signed the paperwork for the loan with Dorman. The banker impressed upon Dorman the risk that his father was taking on, and the responsibility that he had to follow through with his intentions. There was never any hesitation on Dorman’s part.

The paperwork was signed in February of 1978 for a $132,000 loan, and ground was broken. The first shipment of chicks was scheduled for July, but there was something else going on in Dorman’s life.

It started one afternoon at the agricultural fraternity, Alpha Gamma Rho, fraternity house. A crowd of girls came over for a social. One of the girls, a petite blonde freshman from Brundidge, Susan Davis, caught Dorman’s eye. Things must have gotten serious pretty soon because, when that first shipment of chicks ar-

Dorman won the statewide 4-H Chickenque, sponsored by AP&EA in 1972.

Alabama Poultry Magazine

rived at 2 o’clock on the morning July 12, 1978, Susan was doing something that most college freshman girls wouldn’t be caught dead doing. She was with Dorman, on the farm, putting out chicks.

The four houses were the first clear span houses in the area, and, of course, they attracted a lot of attention. Several weeks after finishing at Auburn in August of 1978, Dorman sold his first birds, 3.5 pounders with a growout time of eight weeks and three days. His career seemed to be off and running.

Then came the Russian invasion of Afghanistan and with it, the Carter Administration’s boycott of the Olympics and embargo of grain shipments to the Soviet Union. With grain shipments shut off, the Russians retaliated by cancelling all contracts to import poultry.

Gold Kist, with major contracts, and chickens ready to ship was caught in an economic vise. The market was suddenly flooded with chicken.

With the price of chicken at an all time low, Dorman and other farmers were hit with skyrocketing interest rates. He had not realized it at the time, but his note at the bank had a fluctuating interest rate. It suddenly became a struggle just to pay the interest on the note. He had to live at home with his parents, even sharing a pickup truck with his father, until the economy improved.

In April of 1982, just after Susan graduated from the University of Alabama School of Nursing in Birmingham, they were married at her home church in Brundidge. In 1988, their first son, Cade, was born. That year, Dorman also built two more chicken houses.

In 1990, just before their second son Judson, called Jud, was born, the Graces were named Alabama Poultry Farm Family of the Year.

Today, the Graces still operate their six broiler houses. Those houses have undergone extensive renovation, including tunnel ventilation conversion and computerization. They grow a 7.5 to 8 pound bird for Pilgrim’s Pride, in just under nine weeks. Dorman credits advances in feed technology, genetics, house design and growing methods for such a dramatic increase in the size of finished chickens.

Cade is a junior at Auburn University studying horticulture. This summer, he is studying in England. Jud has just graduated from high school and plans to attend Walker College this fall, but his real desire is to come back to the farm.

Dorman sees a number of challenges facing Alabama farmers in the coming years. Chief among those

concerns is the growing number of environmental regulations and the cost of complying with those regulations. Other issues such as energy costs, water issues and urban creep concern him.

These issues, and others have influenced him to toss his hat-in-the-ring as a Republican candidate for Ron Sparks’ soon to be vacant spot as commissioner of agriculture and industries. Dorman believes that it is time for a real farmer to be in that position.

Dorman and Susan are very active in their church, First Baptist Church of Jasper. Dorman has taught a boys Sunday School class for a number of years. They are also active in community activities.

The Alabama Poultry & Egg Association is proud to name Dorman and Susan Grace, along with their sons, our 2009 Poultry Farm Family of the Year.

A Partial List of Dorman’s Achievements

2007-2009 Serve on the board of the Alabama Agribusiness Council. Elected second vice president in 2009.

2003-2009 Appointed by Gov. Riley to Department of Agriculture and Industries board.

2003-2009 Appointed by Gov. Riley to the Alabama Surface Mining Commission. This commission regulates the coal mining industry in Alabama.

Serves as chairman.

1996-2008 Walker County Economic and Industrial Authority.

Served as chairman from 2005-2007.

1992-2004 Alabama Poultry & Egg Association board of directors.

2004 President of the Walker County Cattleman’s Association 2004-2009 Chairman, Walker County Soil and Water Conservation District Board. Served on this board since 1983 2003-2008 First South Farm Credit Association North Alabama Regional Board.

1996-1997 President, Alabama Poultry & Egg Association.

Family farming is important to Dorman Grace. He wants to be able to pass it on to his son Jud.

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May/June 2009

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Re c i p e s

Apple-Glazed Chicken Drumsticks

Chicken Part: Drumstick | Preparation Method: Broil, Grill Ingredients

Barbecue Plank Roasted Pesto-Stuffed Chicken Breasts Chicken Part: Breast | Preparation Method: Grill, Marinade Ingredients

6 chicken breast halves, bone-in and skin on 8 cups water 1 1/2 cups salt, divided 1 1/2 cups sugar, divided 2 tsps salt 1 tsp black pepper Basil Pesto Stuffing (see recipe), or prepared pesto sauce of choice 2 packaged cedar planks (Western Red Cedar)

4 chicken drumsticks, skin-on or skinless Marinade: 1/4 cup apple butter 1/4 cup molasses 1/2 teaspoon ground ginger 1/2 teaspoon salt

1/4 teaspoon freshly ground black pepper 2 apples, cored and sliced

Instructions

From the Blue Ribbon Cooking School in Seattle, Washington

Instructions

In medium bowl, stir together all ingredients for the marinade. Add the drumsticks and toss to coat. Cover and refrigerate for 15 minutes. Preheat the broiler. Line a broiler pan with aluminum foil and then set the drumsticks in it. Broil for 20-30 minutes, turning the drumsticks occasionally and brushing them with marinade. Can also be cooked on the grill.

Serve with apple slices.

Makes 4 servings

Pre-soak cedar planks according to package directions. Usually, this will involve soaking boards for a minimum of 2 hours in a bucket or sink of water.

In each of two gallon-sized zipper lock bags, pour 4 cups of water. Dissolve 3/4 cup salt and 3/4 cup sugar in each bag of water. Add 3 chicken breasts to each bag and seal, pressing out as much air as possible. Refrigerate chicken about 1 1/2 hours.

Prepare gas or charcoal grill.

Remove chicken from brine marinade, rinse well and pat dry with paper towels. Loosen skin of the chicken.

Place 2 tablespoons of basil pesto under the skin of each breast. Spread pesto around under the skin. Season skin side of chicken with salt and pepper.

Place each chicken breast, skin-side-up, on a pre-soaked piece of cedar. Lay cedar planks on grill rack and close lid. Cook 30-35 minutes until chicken reaches an internal temperature of 145-150 F. To grill without planks:

Prepare gas or charcoal grill. Place chicken, skin-side-up, on grill over medium heat. Cover grill and let cook 30-35 minutes until chicken reaches an internal temperature of 145-150 F. Basil Pesto Stuffing:

In bowl of food processor, place 1/2 cup fresh basil leaves, 3 tablespoons parsley, 1 clove garlic, 1/3 cup grated Parmesan cheese, 2 tablespoons butter, 1/4 cup pine nuts, 1 teaspoon salt and 1/2 teaspoon white pepper. Puree pesto ingredients. With processor running, slowly pour 1/4 cup olive oil into mixture. Blend until pureed. Refrigerate until needed. Pesto will thicken when chilled.

Serves 6

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May/June 2009

Alabama Poultry Magazine

AP&EA Sponsors 4-H Chickenque Championship MONTEVALLO – June 19, 2009 – Under the trees on the University of Montevallo’s historic quadrangle, 4-H Chickenque champs from all over Alabama came together for a smoky, sweaty showdown to decide who was the top-griller.

When the smoke had cleared and the judges had licked the sauce from their fingers, the decision was rendered. The winner in Senior Level 2 was Lauren Cooper. Lauren is a senior at St. Jude High School in Montgomery. Lauren lives in Tuskegee. Her parents are 4-H alumni and her brother is a former Chickenque winner.

Winner in the Senior Level 1 was Grace Drouet. Grace will be a junior at West Point High School in Cullman. Her sister, Victoria, an AP&EA scholarship winner, is a recent Auburn poultry science graduate.

Congratulations to both Lauren and Grace for their hard work. Congratulations also to Alabama 4-H on a centennial of service to the youth of Alabama. Grace Drouet Thanks 4-H for letting us be a part of your great work.

Alabama Poultry Magazine

Lauren Cooper

May/June 2009

19

Membe rshi p News

Alltech Holds 25th International Symposium

“Focus on Food Safety” he disLEXINGTON, KY – Alltech, a nity: Are we ready to formulate cussed Alltech’s anti-infective glyglobal leader in animal health and for maximum health? – Dr. th can, BioMos®, that prevents nutrition celebrated its 25 InternaBrooke Humphrey, California tional Animal Health and Nutrition infections in a natural way that doesPolytechnic State University – Symposium on May 18-20. The n’t produce antibiotic resistance.

Traditionally, nutritionists fortheme for this year’s symposium So far, we haven’t heard much mulate diets to fulfill requirewas “Sustainability.” from Alltech in Alabama. However, ments for maximum growth That theme was summed up by with their leadership team and sciperformance. Dr. Humphrey Alltec president, Dr. Pearce Lyons entific commitment to the poultry suggested that a greater underas, “Development that meets the industry – coupled with their forstanding between nutrition and needs of the present without comward thinking, it shouldn’t be long immunity will help to enhance promising the ability of future genbefore they have a major impact on animal production efficiencies. erations ability to meet their own the industry.

Trace minerals improvements needs.”

Consider attending their sympoin egg quality – Dr. Sheila E. The second day of the symposium next year. It is an event that is Scheideler, University of Nesium was dedicated to species spewell worth the time and effort. braska – Dr. Scheideler highcific topics. Poultry industry topics lighted that while included: many of our curPathogen Control: Present rent mineral incluand Future – Dr. Dennis sion levels are Wages, North Carolina State based on the NaUniversity – Dr. Wages questional Research tioned pathogen control and the Council (NRC) use (and abuse) of antimicrobial recommendations feed additives. documented in Focus on food safety: ReducCraftmaster 1994, these levels ing salmonella using novel inare based on refeed anti-infective agents – Dr. search conducted Colm Moran, Alltech, Ireland over 30 years ago.

– The traditional method of salAs management, monella control through the use genetics and nutriof antimicrobials is becoming tion have changed more difficult due to the rapid dramatically in appearance of resistance and this time, she regulatory control in some parts questioned of the world. Dr. Moran recomwhether current mended three key strategies to mineral inclusions control Salmonella: infection are still correct. control, good hygiene and nuSeveral of the tritional support. topics covered AllNutrition to optimize immutech products. In Dr. Moran’s presentation

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May/June 2009

Alabama Poultry Magazine

Hubbard and I. P. Tsusho Sign Agreement for Distributio n of H u b b a r d F l e x i n Ja p a n

JAPAN - Hubbard is very pleased to announce that they have signed an agreement with I.P. Tsusho Co., Ltd. in Japan, covering an exclusive sales representation and a Grand Parent agreement for the Hubbard Flex in Japan.

David Fyfe, Hubbard business director Asia, comments: “the I.P. Tsusho company has been closely involved in the development of the Hubbard Flex in Japan. We are very confident that I.P. Tsusho will be able to develop the sales of the Hubbard Flex in the Japanese market, so

that Hubbard will very soon become one of the major suppliers of conventional broiler breeding stock in Japan.”

“We have completed a full set of field evaluations on breeder, commercial broiler and processing level.

These extensive field trials have proven that the Hubbard Flex is very competitive and suits the specific needs of the Japanese market very well. Therefore, we have decided to bring the sales and distribution in Japan to the next level through an exclusive representation

Mashiro Takeuchi, CEO and president of I. P. Tsusho Company of Japan shakes hands in agreement with David Fyfe, Hubbard business director Asia.

of the Hubbard Flex for Japan”, added Mr. Masahiro Takeuchi, CEO and president of I.P. Tsusho Co., Ltd.

Alabama Poultry Magazine

May/June 2009

21

Me mber shi p News

New Avatec® Plus 3-Nitro® combination-use approval Now brings turkey growers the only ionophore-based coccidiosis control with the performance of 3-Nitro BRIDGEWATER, N.J. – Turkey growers can now capitalize on feeding an ionophore in combination with 3-Nitro,® thanks to a new feed additive combination-use approval to medicate feed containing both Avatec® and 3-Nitro.

In late May, the U.S. Food and Drug Administration approved Alpharma Animal Health’s application to combine the two products for turkeys. The approval permits use of Avatec at 68 to 113 grams of lasalocid per ton of feed in combination with 3-Nitro at 22.7 to 45.4 grams of roxarsone per ton of feed. The combination is approved by FDA to prevent coccidiosis caused by the protozoa Eimeria meleagrimitis, E. gallopavonis, and E. adenoeides, and for increased rate of weight gain, improved feed efficiency and improved pigmentation in growing turkeys.

Despite over 50 years of research and product development, coccidiosis remains a common health and economic challenge for turkey growers. Coccidiosis is recognized as the most costly parasitic disease in poultry production, costing the global industry about $800 million annually – with more than half that in the U.S. poultry industry alone.

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May/June 2009

Pra ct i cal Applications

By Jess Campbell, Jim Donald, Gene Simpson, and Ken Macklin, Auburn University National Poultry Technology Center

“Growers have asked us repeatedly for a combination like this,” according to Alpharma senior technical service manager for poultry, Dr. Steven Clark, “one that would allow them to use 3-Nitro for optimal gut health without having to sacrifice the effectiveness of Avatec. This new combination will allow them to take advantage of the full health and performance benefits achieved by using these two products together.

“This is a unique combination approval for turkeys; the only approved program that combines 3Nitro with an ionophore,” Dr. Clark says. “For turkey growers who depend on 3-Nitro during the starter and grower to take advantage of its performance-promoting benefits, the main drawback has been the absence of any FDA-approved combination with an ionophore for coccidiosis control. Now they can have both.”

As the only ionophore approved to be fed in combination with 3Nitro, Avatec is one of the most efficacious anticoccidials on the market, providing year-round (non-seasonal)

Alabama Poultry Magazine

coccidiosis protection even under conditions of excessive heat and humidity. Avatec allows growers to control coccidiosis without depressing feed and water intake which can negatively impact feed conversion and weight gain. Avatec has a broad dose range and is demonstrated to have a high margin of safety.

The approval also increases flexibility for incorporating 3-Nitro into shuttle and rotational programs with chemical anticoccidials. This new tool brings the grower the ability to design programs that offer greater coverage where coccidiosis exposure is high.

About Alpharma Alpharma Inc. is a global animal health company with a leadership position in the registration, manufacture and marketing of a broad range of pharmaceutical and nutritional products for food-producing animals. Alpharma is presently active in more than 60 countries. For more information please visit www.Alpharma.com.

Temperatures in the Alabama are bumping 100°F and it seems that the rain showers we are getting are only enough to increase the relative humidity and too brief to cool things down very much. Hot weather and high relative humidity mean that we need to get the maximum out of our poultry houses to ensure good bird cooling. Many poultry growers and managers have been calling or emailing the National Poultry Technology Center with questions related to maintaining maximum efficiency and cooling in hot weather operation. Following are our top recommendations for avoiding hot weather problems, based on the most common questions we receive.

Keep Up Regular Fan Maintenance

full of suboptimal performing fans could drop the inhouse full tunnel wind speed by as much as 100 feet per minute, which is about the airflow equivalent of turning two tunnel fans off in full tunnel mode. This would cause end-to-end house temperatures to go up, and also could decrease bird wind chill by more than 5 degrees F, depending on bird age. To make sure your fans deliver the airflow needed, inspect all fan belts, pulleys, and tensioners at least once per flock to ensure that the belts are held tightly to the fan motor pulleys, belts and pulleys are not worn, and tensioner pressure has not been compromised during operation. Fan motors, housing, blades, shutters, wire guards, and cones must all be cleaned between every flock. Fan bearings should be greased a minimum of two times a year, or per manufacturer recommendations.

Keep Cooling Pads Clean

The tunnel fans are the heart of the tunnel ventilation system. Their job is to remove house heat and develop sufficient wind speed to remove sensible heat from the body of the bird. The first step in making sure you are getting maximum performance from a tunnel house is to be sure all tunnel fans are tuned up and running as efficiently as possible. Performing a thorough inspection of every tunnel fan and then correcting deficiencies is important to good operation of the fan and the house. Dirty tunnel fans or shutters, coupled with worn or slipping belts or fan pulleys, can easily cause a 20 percent or more drop in a fan’s performance. A house

Wetted evaporative cooling pads catch insects, feathers, and other debris as air enters the cooling system. This trash can build up quickly during continuous use of the cooling system, restricting air flow through the pad just as though the inlet were blocked. Clogged pads place undue work load on the tunnel fans and cause them to operate at higher than normal static pressures.

Pads should be inspected and kept clean during hot weather and periods of continuous system use. If the inhouse static pressure has increased 0.01 inches or more in full tunnel ventilation mode with all fans operating, this points to a restriction in the ventilation system, and dirty pads could be the culprit. The inside, outside, and

Loose or cracked belts, as shown in photo at left, and worn belts or motor pulleys, as shown in photo at right, will all cause lowered fan rpm and reduced house air flow. You don’t want low fan rpm, or loss of a fan from a broken belt, in the middle of a hot day. If belts or pulleys are worn, retensioning will NOT restore fan rpm.

Insects, dust, dirt, and dander can quickly clog evaporative cooling pads during summer months. Keeping the pads clean greatly improves airflow and bird cooling

Alabama Poultry Magazine

May/June 2009

23

Sumps of cooling systems need to be dumped between flocks and at least once a week or the equivalent in bleed off during hot weather growouts to maintain water quality.

Recirculating dirty water shortens pad life and causes filters and header holes to plug up.

flutes of the pad are all important to the ventilation system and must be kept free from debris buildup.

When it is time to service the cooling system use only pad manufacturer approved cleaners and algicides in the system and on pads. Dry streaks on pads usually mean distribution header holes are clogged and must be unstopped. Filters, strainers, and pump screens must be kept clean and checked on a weekly basis to make sure there are no additional restrictions placed against the cooling system pumps. Every square foot of pad should be wetted in full cooling mode to ensure that all air entering the house enters through wetted pad and not dry pad. It is also very important to maintain a fresh, clean water source during periods of high use.

In high-ceiling houses, air deflector baffles placed lower than about 9 feet above the floor will restrict airflow too much, lowering wind-chill cooling and increasing fan static pressure.

your numbers are more than 5-8 percent short you could have restricted air flow because you don’t have enough pad area installed. After the air passes through the cooling pad we need to get it into the house with as little restriction as possible. Keep in mind that anything that increases the speed of the air entering the house, or makes it change direction, will increase static pressure on the fans. Every time we squeeze the air stream with a restriction we are adding more workload to the tunnel fans at the far end of the house.

In high ceiling houses that use deflector baffles to

increase air speed and make air flow more uniform from side-to-side, we often see baffles improperly installed, typically too close to the ground. In houses with low clearance deflector baffles (7.5 feet) we have seen increases in air speed and reduction in fan end static pressures by raising the deflector heights to between 9 and 10 feet from the floor. Keep in mind that to accurately measure the static pressures that fans are operating against in high ceiling houses with deflector baffles, we need to make the measurement with a magnahelic approximately 50 feet from the fan end.

Dirty evaporative cooling pads, as discussed above, can also be considered an air inlet restriction. The take home point here is that what looks like a fan problem might be a problem at the other end of the house.

Assure Adequate and Clean Water Supply

We have had multiple calls about water pressure and pipe sizing on farms since the outside ambient temperature has broken the 90s and stayed there. Much like electrical problems, insufficient plumbing problems don’t show up until the system is operating at maximum capacity. This is often on some of the hottest days of the year and during the last week of the flock, just before birds are sold. Unless blockages, leaks or pump issues can be found to account for the problems, the most likely cause is either too small pipe sizing or inadequate water supply. In this case, not much can be accom-

Monitor and Maintain Electrical Systems

Avoid Restricting Air Flow

We often blame lack of wind speed or high static pressure in a tunnel ventilated house on the tunnel fans.

The fact is, a lot of times it is the characteristics of the house, the inlet, or the equipment in the house that is the root of the problem. First, be sure you have enough cooling pad to do the job. A good rule of thumb is you need about one square foot of operating six inch paper pad for each 350 CFM of air installed on a house at a 0.10 static pressure. A house with eight fans that each move 26,250 CFM at 0.10 static pressure needs about 600 square foot of six inch pad (210,000/350 = 600).

That works out to a 60 ft x 5 ft system on both sides of the house, or 75 square feet of pad per fan.

There is a small leeway in that calculation, but if

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May/June 2009

plished until all of the houses on the farm are vacated.

Plumbing systems for poultry houses should be designed to meet or exceed water demands on the whole farm on the hottest day of the year with market age birds. One way to see if the plumbing system is sufficient for maximum demand water use is to empty all water storage tanks on the farm and fill them all up at the same time to simulate a maximum demand scenario. If control room pressure drops much below 40 psi during this test, the water source (well or municipal) or supply plumbing lines could be insufficient to carry the maximum water demand of the farm.

The designed maximum flow rate, in gallons per minute, varies based on the number and size of birds in each house and the amount and type of evaporative cooling system installed, the amount of tunnel fan installed capacity on the house, and the assumed maximum outside temperature and relative humidity. Since this design maximum demand is highly variable, the plumbing system should be custom designed for each farm. It is best to compare the measured water flow on the farm, in gpm, to the integrator’s maximum demand requirement per house. It is important to be able to supply all evaporative cooling systems, as well as bird drinker systems and high pressure fogging systems at the same time. It is a good idea to test for plumbing problems prior to hot weather flocks so that if a problem is seen, a solution can be determined and the problem fixed without birds in the house. Maintaining a reliable back up supply source of water that is tied into the primary system is imperative for every poultry house during hot weather.

Tunnel curtains that bunch up and fail to drop below the bottom of the tunnel inlet opening will seriously interfere with airflow in the house. In this house, the top flap for the tunnel curtain is hanging down and obstructing the top of the inlet, so it is also restricting air flow (and raising static pressure).

Alabama Poultry Magazine

Water pressure at the control room needs to be about 40 psi under maximum demand flow. If the water system cannot maintain good pressure under maximum demand, there is a problem to be found and fixed.

Catastrophic bird losses will occur in less than 30 minutes in modern houses if we lose power in hot weather. Birds don’t like heat and neither do electrical components. Panel boards, motors and wiring all heat up and are much more susceptible to failure in summer when it is hot and we are running at maximum capacity.

Utility power is also subject to failure in hot weather.

We cannot say enough about regular testing and servicing of the standby generator, transfer switch, and the alarm systems that are installed on most modern poultry farms. This equipment is often overlooked, abused, and taken for granted, but it is your life line.

However, your standby generator is worthless if you lose a main house breaker. That’s why it’s important to monitor all electrical equipment on a regular basis. Over time, electrical connections can increase in resistance,

Alabama Poultry Magazine

May/June 2009

25

By Gene Simpson, Jim Donald, Jess Campbell, Ken Macklin, and Neil Burrow* An overheated breaker like the one shown in the infrared photo above is big trouble about to happen.

causing them to heat up. An infrared temperature gun is a relatively inexpensive and quick way to spot overheating breakers or other gear. (See “Tools of the Trade” at www.poultryhouse.com.) If breakers are hot or are tripping often, we need a qualified electrician to tell us why they are hot and how to fix the problem.

If you are experiencing problems with fan motors in hot weather you might want to get a qualified electrician to take voltage and amperage readings on your tunnel fans while they are operating. A voltage reading taken when the fan is not running is not an indicator of the voltage that is present at the fan motor when it is running. The voltage test must be done under operational load. Too low voltage under load will cause a fan motor to draw higher amperage, which can cause motors to trip out, burn up, or fail prematurely. Too small a wire size for the length of the wiring run, which results in a large voltage drop in the wire itself, is a common cause of such problems. We see this most often in houses that have breaker panels installed at one end of the house and the fan motors installed at the other end of the house, so the circuit may be 500 or more feet long. You can have adequate voltage at the breaker box but by the time the electrical current reaches the fan motor there is sufficient voltage drop so that the fan motor is operating at low voltage. The proper cure for this problem is increasing the wire size to the motors, thus reducing the voltage drop.

The Bottom Line

When we spend our money for high quality fans and evaporative cooling systems to achieve good performance, we have to install them correctly and perform the

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May/June 2009

Pointing a fan at the breaker box is at best a mere band-aid until the electrician arrives. An infrared temperature gun is a relatively inexpensive and quick way to spot overheating equipment.

necessary maintenance to keep them operating at their optimum levels. Of course, catastrophic losses from a total failure in a poultry house can be many thousands of dollars, and must be prevented at all costs. But even seemingly minor deficiencies or inefficient equipment performance can also add up. For a four-house farm with 80,000 birds, a 0.1 pound per bird loss in catch weight amounts to a $400 or more loss to the grower, ignoring settlement position. On that same farm, having to run two additional fans for the last three weeks of a hot weather flock to overcome deficiencies will total $450 or more per flock at prevailing electric rates. Also, running houses at higher static pressures may create other problems down the road, such as decreased fan motor life, electrical overloads, and undue stress on ceilings.

There is a definite payback for attending to the details outlined in this article.

For information on related hot weather topics and more detailed information on the topics listed in this article, visit www.poultryhouse.com and look for the following newsletters: #41 – May 2006 - Keys to Top Evaporative Cooling Performance #37 – October 2005 - Preventing Common Electrical Problems #30 – July 2004 - Fan Belts, Pulleys, Shutters, Cool Pads – And Profits #7 – September 2000 - Key Water Factors for Broiler Production

Alabama Poultry Magazine

While broiler house lighting typically only accounts for 15 to 25 percent of a broiler grower’s total annual electric bill, depending on house type and location, it is still a significant cost. Recent developments in light bulb technology now make it possible to replace standard or longer-life incandescent bulbs with new energy efficient bulbs which are more cost-effective. High pressure sodium vapor lights have a very high initial cost and do not provide good light uniformity. Light Emitting Diode (LED) bulbs typically produce a cone-shaped, non-uniform light pattern, are very expensive, and also may require some detailed electrical work to be undertaken, but they may become more affordable over time. At the present time, Cold Cathode (CC) and Compact Fluorescent (CFL) bulbs seem to offer broiler growers the best opportunity to achieve energy-efficient, uniform lighting in a cost-effective manner. Widespread replacement of incandescent bulbs with CC/CFL bulb combinations is occurring across the Broiler Belt. When done correctly, a CC/CFL combination can result in reducing a broiler grower’s lighting cost by as much as 85 percent. This article focus on CC/CFL lighting technology and how growers can easily realize these savings.

The National Poultry Technology Center (NPTC)

began a project in April 2008 to demonstrate the cost reduction of CC/CFL bulb combinations in commercial broiler houses. Alabama Power Company installed high level circuit monitoring and data recording equipment on an older typical solid wall 40’ x 500’ tunnel ventilated commercial broiler house on a multi-house farm in north Alabama. During the first flock, conventional incandescent lights were used with dimmers on circuits located above the feed lines, and on non-dimming circuits down the house center. During the brood period, all brood end lights were operated at full intensity. Following brood, feed line and center lights in the off end were turned on and the flock was turned out to whole house. After birds settled in to whole house and migration fences were installed, all center line lights were turned off and front and rear feed line circuits were dimmed to very low intensity. This lighting program was specified by the integrator and was maintained for the rest of the growout.

Before the second flock was placed, all incandescent bulbs on dimmer circuits were replaced with 8 watt CC bulbs, and all center line lights (non-dimmer circuit) were replaced with 42 watt CFL bulbs. The 8W CC bulbs emitted the equivalent light of a 45W to 55W incandescent bulb, and the 42W CFL bulbs emitted the equivalent light of a 150W incandescent bulb. During brooding, the primary goal was to provide as much light

Cold cathode (CC) and compact fluorescent (CFL) light bulbs use dramatically less power than incandescent lighting. Poultry growers across the Broiler Belt are replacing their incandescent bulbs with CC/CFL bulb combinations, saving as much as 85 percent on lighting costs. Photo shows two clear-globed CC bulbs at left and a frosted globe CC on the right; third from left is a CFL bulb. * Neil Burrow is an energy consulting specialist with Service Concepts in Indianapolis, Ind.

Alabama Poultry Magazine

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27

as possible using 8W CC bulbs on the dimmer circuits, and then adding enough 42W CFL bulbs in the center to maintain the 3 foot candle (fc) minimum reading required by the integrator. The identical lighting program used in the first flock was used in the second, third, fourth, and fifth flocks. No change in flock performance was noticed when comparing this house with like houses on the same farm. For this typical North Alabama broiler house, approximately 50 CC and 14 CFL replacement bulbs were used at a total cost of approximately $450.

Usage readings from the monitoring equipment and actual electric bills were used to calculate all costs. Electrical cost was assumed to be 11.5 cents per kWh.

Major Findings of the Study

• CCs work very well with modern dimmers. Older dimmers may need one 75-100W incandescent bulb in the CC circuits to avoid erratic dimming.

• CFLs do not dim very well (even those claiming to be dimmable CFLs); and when used on dimmer circuits CFL bulb life appears to be shortened dramatically.

• CC and CFL bulbs both produce very uniform light, with no trace of any shadowing effect.

• CC/CFL combinations can meet most company lighting program requirements (3 to 5 foot candles for the brood period; varies by company).

• Lower power draw of CC/CFL lighting allows lighting cost saving of up to 85 percent, with payback of investment as short as two flocks.

• 10-20 times longer life of CC and CFL bulbs over incandescents (typically only 800-1,200 hours) more than compensate for higher cost.

Energy Efficient Light Bulb Facts: • Cold Cathode (CC) – Bulb is an 8W (45-55 W incandescent equivalent) – 15-18 percent of incandescent

power draw, with a typical life of 22,000-25,000 hours.

• Available light color spectrum (in degrees Kelvin) = 2,200-2,300 K; 2,700-2,850 K (preferred); & 4,0004,100 K. • Clear bulb CC globes are preferable to frosted bulb globes. Price: $7.00-$7.50.

• Compact Fluorescent (CFL) – use only about 18-28 percent of incandescent power draw and have a typical life of 12,000-18,000 hours. Bulb sizes vary by brand, but most common CFL bulbs are: 23-28W (100W incandescent equiv) – 23-28 percent incandescent power, 2,700 K & 4,100 K, Price: $4.00$4.50.

40-42W (150W incandescent equiv) – 27-28 percent incandescent power, 2,850 K & 4,100 K. Price: $7.00$8.00.

55-65W (300W incandescent equiv) – 18-22 percent incandescent power, 2,700 K & 4,100 K, Price: $17.00-$20.00.

In discussions with many different broiler companies and with thousands of these bulb combinations in use in the field, the common observation is that CC and CFL bulbs in the 2,700 to 2,900 K spectrum range are most conducive to optimal broiler performance in a commercial setting. In most commercial houses, water consumption was slightly improved for flocks provided light within this color spectrum range relative to those in either the lower or higher spectrum ranges. Increased water consumption generally implies increased feed consumption. Other color spectrum ranges may be better suited to pullets and hens.

The table on page 29 provides a summary of electricity usage and cost by circuit type (fans or lights). Percentages do not add to 100 percent since other circuits (pumps, feeder motors, control room equipment, etc.) account for the remaining percentage of electrical usage.

On page 30, the charts, showing the electrical usage breakdown are presented.

Twin Socket Adapters (Y-Splitters)

If light meter readings are just below acceptable levels, the use of a twin socket adapter or “Y- splitter” to accommodate two bulbs, as shown in photo at right, may achieve the desired target. Y-splitters can be used with CC bulbs on dimmable circuits and with CFL bulbs on standard circuits without any problems. For example, a Y-splitter with two 150W equivalent CFL bulbs rather than one 300W equivalent bulb would be less ex-

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May/June 2009

Alabama Poultry Magazine

pensive initially. Also, if slightly more light over the feed lines is desirable, the use of a Y-splitter and two 8W CC bulbs would be sufficient. Y-splitters will not work if bulbs are required to be in glass globe enclosures commonly called “jelly jar fixtures.”

Additional Wiring Needs

We have encountered a few older open ceiling houses which may require additional receptacles or circuitry in order to provide any level of reasonable lighting at all, regardless of bulb type. The cost of additional wiring in these houses would still be only $500 to $1,500 (plus bulb cost), so rapid payback can still be realized.

Bulb Disposal Issues

Cold cathode and compact fluorescent bulbs contain mercury, which is a toxic element. CC bulbs contain only about 10 percent as much mercury per bulb as CFLs. At present, there are no national laws specific to CC or CFL bulb disposal, but local or state laws may apply. In the event of bulb breakage, the affected area should be thoroughly cleaned. Spent and broken bulbs should be double bagged and taken to a recycling center which accepts items of this type.

The Bottom Line We in the National Poultry Technology Center are committed to helping growers reduce costs wherever possible, without sacrificing bird performance. In our study, we have seen no difference in bird performance, but growers are saving $200 to $250 per house per flock on their electricity cost and a typical bulb replacement effort only costs $400 to $500 per house. Thus, full payback on bulb replacement is realized in about two flocks; for every flock thereafter, the grower keeps his $200 to $250 in savings in his wallet.

Additionally, bulb life of CCs & CFLs is much longer than incandescent; typically 20-25 times longer for CCs and 15-18 times longer for CFLs. Longer life of CCs and CFLs more than compensates for their higher cost and also reduces labor time in replacing burned-out bulbs.

We have encountered so many different light circuit arrangements (circuit layout, receptacle spacing, bulb wattage, etc.) on farms across the Broiler Belt, it is impossible to use a “cookie-cutter” approach, but most local complexes only have several such arrangements to consider, so on a local complex level it is fairly simple to develop workable lighting scenarios for the four or five arrangements they encounter. Again, the overall goal is to use cold cathode bulbs down the dimmer circuits, and supplement them with compact fluorescent bulbs down the center.

Electrical Usage And Economics Summary Table – Incandescent vs. CC/CFL Combination For five flocks in a typical 40’ x 500’ solid wall, tunnel ventilated broiler house, north Alabama, 2008-2009 Total

Fan

Light

Light

Light Cost

Flock

Bulb

Total

Fan

Light

Electric

Electric

Electric

Electric

Reduction

No.

Type

KWH

KWH

KWH

Cost

Cost

Cost

Savings

Percentage

1

Incandescent

8,688

5,409

2,329

$999

$622

$268

-Base-

-Base-

(62 %)

(27 %)

291

$756

$700

$33

$235

87.7 %

(93 %)

(4 %)

429

$424

$247

$49

$219

81.7 %

(58 %)

(12 %)

523

$365

$158

$60

$208

77.6 %

(43 %)

(17 %)

311

$461

$404

$36

$232

86.6 %

percent of total electric usage and cost: 2

CC/CFL

6,572

6,091

percent of total electric usage and cost: 3

CC/CFL

3,688

2,144

percent of total electric usage and cost: 4

CC/CFL

3,172

1,371

percent of total electric usage and cost: 5

CC/CFL

4,006

3,512

% of total electric usage and cost: (88 %)

(8 %)

Average per flock savings was $223.50 per house, compared to the initial base flock.The total cost of CC & CFL bulbs was approximately $450 per house. Full payback of the initial investment occurred within approximately two flocks. Expect to have much longer bulb life with cold cathode and compact flourescent bulbs.

Alabama Poultry Magazine

May/June 2009

29

A Tal e of Two L et te rs Continued from pg. 4

Comparison of day by day electric usage for flocks grown with incandescent vs CC/CFL lighting shows that the dramatically lower power draw by cold cathode/compact fluorescent lighting means that in a CC/CFL-equipped house lighting power draw (blue lines) is almost negligible, and almost all house electric power consumption is accounted for by fans (green lines). Fan power draw in the two charts differs somewhat because of slightly different conditions during the two growouts.

King Realty

With the ever increasing demand for poultry farms and land (with or without a house), we are extremely short of farms to cover the demand.

Here are a few of our phone calls and emails.

• Buyer from Sarasota, FL is looking for a 4 to 6 house broiler farm with a home and acreage.

• Buyer from Nashville is looking for a breeder farm.

• Buyer from Tifton, GA is looking for large tracts of pasture and timberland. * Buyer from Tallahassee, FL is looking for a large poultry farm.

If you are interested in selling your farm give us a call.

United Country King Realty 334-566-8053 www.troy-al-real-estate.com

30

May/June 2009

Alabama Poultry Magazine

of chopped liver before you would come close to having a problem, even on a theoretical basis.

As for chicken meat, which is what people normally eat, the agency found no samples with any arsenic at all. This shows that any arsenic present was so insignificant that it was below the level of laboratory detection.

It also shows that chicken is not “laced” with arsenic, whatever Mr. Gansler might think.

Animal health products that include arsenic as one of their chemical building blocks are used in some chicken flocks by some poultry companies. These products are effective in preventing coccidiosis in chickens, which is an infection by microscopic parasites. The use of these products is regulated by FDA. These products are used to keep the chickens healthy, and a withdrawal period is observed to ensure that these products are not present when the chickens are processed for food. The fact that zero violations were found is proof that the prescribed withdrawal period is observed.

Mr. Gansler claims to have signed up a number of the other state attorneys general in his quest to ban the use of safe, effective products in poultry production.

His colleagues might want to look at the facts and take their cue from the experts rather than from an uninformed politician.

The National Chicken Council represents integrated chicken producer-processors, the companies that produce and process chickens. Member companies of NCC account for approximately 95 percent of the chicken sold in the United States.

ADVERTISING INDEX AirTight pg 21 American Proteins pg. 31 Auvil Insurance pg. 22 Craftmaster pg. 20 Federal Land Bank pg. 5 First Financial Bank pg. 6 First South Farm Credit pg. 7 King Realty pg. 30 Poultry Supply pg. 32 Ross/Aviagen pg. 9