34 minute read
USA Tyson complex in Humboldt Tennessee chooses SmartPro™
from Pas Reform Times
Tyson complex in Humboldt Tennessee operating with SmartPro™
US-based Tyson chose Pas Reform North America to equip its new, greenfield hatchery complex in Humboldt, Tennessee. Pas Reform North America supplied incubation equipment, hatchery automation and climate control. The SmartCenterPro™ information system provides complete monitoring and control of all these systems.
The hatchery automation consists of farm-to-setter-trolley transfer system, two fully automated transfer candling lines with heartbeat candling and in-ovo vaccination, stackers, de-stackers, SmartCount™ chick counter and separator. To complete the project, a 5-year Smartcare™ preventive maintenance program has been agreed.
Steve Warren, President of Pas Reform North America, comments: “Since the inception of this project, Pas Reform North America have been in frequent contact with Tyson staff, visiting their hatchery operations with our incubation and technical specialists and communicating with them on a regular basis via alternative means. This has been a great way to gain in-depth knowledge of their operations and to help maximize performance. It has enabled us to get to know the Tyson team, and, of course, they have also gotten comfortable with us, our equipment, and company philosophy.” Barry Vincent, Director of Breeder & Hatchery Operations at Tyson Foods, says: “Working together with Pas Reform we have been pleased with the expertise they bring to the table with their Total Hatchery Solutions Concept. They manage their projects professionally and in an integrated way, and we think this is an approach that works well for today’s modern hatcheries. The SmartCare™ preventative maintenance program ensures we have joint responsibility for preventive maintenance – as well as proactive hatchery management, which is a great step forward for us. So far, we are very pleased with this new way of working.”
“The hatchery has been operational since end 2020 and the results have been excellent,” says Brandon Womble, Hatchery Manager for the new Humboldt Tennessee project. “We have seen outstanding hatch results and first-week mortality numbers, improved feed conversion, and excellent uniformity to the plant.”
Walt Wages joins the Pas Reform North America sales team
Walt Wages, who joined Pas Reform North America earlier this year in the incubation support team, has been newly appointed as a sales manager. Walt, from Snead, Alabama, had previously gained seven years poultry industry experience with Koch Foods.
Starting with three years as a supervisor on the processing side at Koch Food’s Debone department, Walt then shifted to live production – as assistant hatchery manager at the company’s newly renovated hatchery operation in Crossville, Alabama. He was instrumental in the start-up of Crossville, which went 100% single stage on their newly expanded wing. It was there that Walt gained extensive experience with the Pas Reform North America team and products. immediate impact, and with his first-class client-side operational knowledge and understanding he will prove to be a valuable addition to the sales management team.”
A 360° approach to service & supportA 360° approach to service & support
Pas Reform Hatchery Technologies Pas Reform Hatchery Technologies
Tyson’s customised SmartCare™ package delivers an assurance of efficient, uninterrupted performance at every level of hatchery operations
Scott Conley, technical sales director, Pas Reform North America
Ameta launches new Bulgarian hatchery facility
Ameta is one of Bulgaria’s largest food companies and a leader in poultry meat production. Part of the German PHW Group, the company supplies a comprehensive range of primarily fresh chicken-meat products, together with some frozen, for both the domestic market and for export throughout the European Union.
Ameta is in a process of integrating new facilities in the northeast part of Bulgaria – to provide the business with further expansion opportunities for the coming years. Construction of its greenfield ‘White Pines’ hatchery, near Razgrad, started in 2018 and it was commissioned at the end of 2019.
The facility is fitted with a range of Royal Pas Reform’s integrated hatchery systems and equipment, including SmartSetPro™ setters, with a capacity of 124.416 eggs each, and SmartHatchPro™ hatchers, with a capacity of 20.736 eggs each. Also installed is an egg setting line, chickcounting and boxing systems, inline washing machines and a vacuum waste system. Royal Pas Reform also designed and engineered the plant’s HVAC system.
This is Ameta’s second hatchery project with Royal Pas Reform. The first, a 3-stage expansion in Kamchia Shumen, was started in 2007 and completed in 2012.
“The hatchery has delivered great results from the start,” says Tsvetomir Genchev – Investment Project Manager. “Like Ameta, Royal Pas Reform’s quality is the result of its attention to detail.”
“In Ameta, we control all the different levels, with the primary goal of delivering the best product to match our customers’ requirements. We do not make compromises at any stage of the production process and we take pride in on-time execution of orders and delivery.”
Ameta is one of the largest fully-integrated poultry processing and distribution companies in south-eastern Europe. It operates a processing plant, feed-mill, hatchery and breeder and broiler farms. Significant part of its production is exported to Greece, Romania, Italy, Macedonia, the UK and Cyprus. Ameta also supplies the major retailers in Bulgaria, restaurants and meat processors.
“We are delighted to be working with Ameta again,” says Niels Stam, Sales Director at Royal Pas Reform. “They are a progressive and quality led business and our integrated hatchery solution has provided them with optimized production efficiency that delivers the highest number of best quality chicks.”
Uruguay’s La Cabaña Avícola chooses Royal Pas Reform
La Cabaña Avicola, a family company based in the municipality of San Bautista, near Montevideo in Uruguay, has been a pioneer in introducing, promoting and democratizing the consumption of chicken meat in what is predominantly “cattle” country, with a high red-meat consumption profile.
La Cabaña chose Royal Pas Reform’s SmartPro™ technologies for its first-ever owned hatchery. While the company already has a full production chain in place, the decision to invest in a new hatchery was to be sure of having top quality, day-old chicks for its broiler farms.
The hatchery is equipped with SmartPro™ technology and Royal Pas Reform’s customized climate control system. The hatchery will initially produce one-million chicks per year, rising to two million in phase two of the project.
Gabriela Baldi, Managing Director of La Cabaña, says: “This is a very important step for our company and will sustain our aiming of producing top-quality chicken meat for Uruguayan consumers. We have chosen Royal Pas Reform because of both its high-quality equipment and service support, which is considered to be the best amongst its industry competitors.
“We at Royal Pas Reform are very happy with this project,” says Gonzalo Begino, agent for Argentina and Uruguay, “The installation went smoothly, despite the pandemic restrictions at the time. We now are pleased to say ‘welcome to the family’ to La Cabaña!”
Steve Warren, President, Pas Reform North America
Efficient data management in the hatchery
By Lotte Hebbink, Incubation Specialist, Royal Pas Reform
Optimising hatchery performance requires good data management. Data can be stored in various ways, ranging from simple Excel sheets to sophisticated data management software. It is also not uncommon for a large part of the hatchery’s data to still only be on paper. That’s a pity, because this data is much more valuable for data analysis when it is digitally stored in the right way.
Basic data entries
Here we look at the most basic hatchery data collection. We assume that in each hatchery for each batch of eggs the following is known:
– Flock number, farm, house number, flock age, breed – Egg production date – Arrival date in hatchery – Setting and hatch date – Number of eggs set – Number of clears detected during candling – Number of saleable chicks (and ideally also number of culled chicks)
These data can be used to calculate hatch results such as hatchability of eggs set and hatch of transfer. The data is often recorded on separate pages for each hatch day. This might be a great way to report daily production, but it does not allow for deeper analysis such as identification of the best breeder farms, effect of flock age and egg storage time on hatchability, hatchery performance compared to the previous year, comparison of incubation programs, and so on. One has to flip through endless pages and it is difficult to obtain a good overview of historical data.
Set date Hatch date #Eggs Setter Flock ID Breed Flock age Lay date #Clears #Saleable chicks #Culls
21-2-2019 14-3-2019 57600 2 56 A 45 16-2-2019 5184 49795 150
21-2-2019 14-3-2019 57600 2 41 A 47 13-2-2019 5670 48730 250
25-2-2019 18-3-2019 57600 3 23 B 35 20-2-2019 4608 51402 100
25-2-2019 18-3-2019 57600 3 14 B 36 20-2-2019 4896 51650 95
Table 1. Example of a format for basic hatchery data entries
Hatch date Flock ID Placement farm House #Chicks placed #7d Mortality
14-3-2019 56 Farm B 1 20000 200
14-3-2019 56 Farm B 2 15000 75
14-3-2019 56 Farm F 1 14000 140
14-3-2019 41 Farm Y 1 35000 196
14-3-2019 41 Farm Y 2 14000 490
18-3-2019 23 Farm A 1 25000 375
18-3-2019 23 Farm A 3 24500 221
18-3-2019 14 Farm D 2 33000 297
18-3-2019 14 Farm D 3 20500 205
Table 2. Example of an additional data table Design data sheets
Hatchery data sheets that are generated on a daily and/or weekly basis usually have a dual purpose: they serve as data entry tables and as reports. In addition, data from different hatchery production processes and calculations are put together on one page to obtain a summarising table. Although this may seem efficient, it actually makes data management unnecessarily complex. When preparing these data for analysis you will encounter problems such as multiple data repetitions with differences in detail level, copy/paste errors and non-uniform data entries.
It is more convenient to separate basic data entry tables from daily or weekly summary reports. An example of a basic data entry table can be found in Table 1. As you can see, amounts (#) are used instead of calculations (%). A separate report should contain calculations, e.g. hatch of eggs set, days of egg storage, % first week mortality, and these can be generated daily or on request. Ideally, for quick analysis using a program such as Excel, data entries like those in Table 1 should be made in one large continuous file instead of a new file for each hatching day.
Paul Smits appointed as new CEO of Royal Pas Reform
At the start of 2021 Royal Pas Reform welcomed Paul Smits as the company’s new CEO – bringing more than 25-years of poultry sector experience to the role. Vice President and Managing Director of the Instruments and Controls Group (ICG) of CTB – which includes the Dutch livestock-farming technology business, Fancom BV. development-led, strategy for innovation – supporting our customers with a complete, sustainable and integrated product and service package.”
Smits sees important similarities between the focus of his new role and that at Fancom – which involved developing automated total process solutions for the
Link files together
Very often data is scattered over several files, as it is here in Tables 1 and 2. If you take a closer look at these tables, you will see that the detail level is different. Keep the data in separate files but use a common column to link the two tables together. In this example you can link them with the ‘Hatch date’ and ‘Flock ID’ columns.
Advice
– Make the names of the data fields consistent when using different files with overlapping data. – Do not combine basic data entries and daily production reports in one table. – Use amounts and dates when entering data; don’t enter calculations directly. – For simple analysis you can use Excel Pivot Tables or
Graphs.
Masagana Farm expands with Royal Pas Reform
Egg production enterprise Masagana Farm, based in Bulacan in the Philippines, has extended its collaboration with Royal Pas Reform to meet growing consumer demand for table eggs in the Bulacan and Manila areas.
Based on Royal Pas Reform’s integrated hatchery solutions, the family run hatchery started operations in 2020. This was the first phase of Masagana’s strategic development to provide its own supply of layer hens for the company’s highly successful fresh-egg sales operation.
That first phase included 6x SmartSetPro™-2 setters – including Adaptive Metabolic Feedback (AMF™) and Energy Saving Module (ESM™) – and 2x SmartHatchPro™ hatchers. In the second phase, 6 further setters and 2 hatchers have been added, which brings the hatchery’s total capacity to 7.8 million day-old chicks per annum.
Willy Uy, Masagana Farm’s owner, comments: “From the first phase we saw Royal Pas Reform as a knowledgeable partner. They put in the time and the effort to make sure any project they are involved in is a success. We consistently have outstanding service from Royal Pas Reform and excellent performance from their equipment.”
Because of the Coronavirus restrictions that were in place during this development, Royal Pas Reform was not able to send a supervisor from The Netherlands to the Philippines. However, FSI (Filtration Solutions Inc.), Royal Pas Reform’s representative in the Philippines, was able to play a central role in the success of the installation.
“We are very grateful to our partners at FSI for their excellent support in ensuring the smooth and efficient delivery of the project under such challenging circumstances”, says Bas Kanters, Royal Pas Reform’s Sales Director in Asia. “This latest phase – in Masagana’s 30th anniversary year – marks another milestone in the company’s growth journey and we are very pleased to be a part of it.”
SmartPro™ technologies chosen for two hatchery expansions in Korea
South Korea-based hatcheries Allpines and BH have both chosen Royal Pas Reform SmartPro™ solutions for their latest expansion projects.
Allpines, which was established 40 years ago, has installed 6x SmartSetPro™ setters, 6x SmartHatchPro™ hatchers, and an automated chick counter. According to Allpines’ president, Mr. J.K. Lee, the company chose Royal Pas Reform because chick quality was most important to get a chick supply contract with a big broiler integrator. He had learned that other hatcheries in the area that have Royal Pas Reform solutions, including DY Farms and SungJin, had good hatching results and he was convinced that Royal Pas Reform incubators will give him the required performance.
Fast-growing BH has operated with Royal Pas Reform incubation systems for almost 20 years. Its latest expansion includes 12x SmartSetPro™ setters, 12 SmartHatchPro™ hatchers and an automated chick counter.
livestock and poultry farming sectors that deliver better performance and higher returns for customers.
“This is very much in line with Royal Pas Reform’s position as the world’s only single-source supplier of fully integrated hatchery solutions,” he explains. “With incubators, hatchery automation and climate control systems connected by SmartCenterPro™ – which provides unrivalled access to data at every level of hatchery operations – Royal Pas Reform supports large-scale facilities with fully integrated and connected incubation processcontrol to profit from the highest number of best-quality chicks. “I am very much enjoying working with Royal Pas Reform – helping to drive this dynamic, hard-working company to further extend its strong global presence.” Michaël Kampschöer, sales director Asia, Royal Pas Reform
Innovative partnership produces practical and smart solutions for Schotman
Schotman hatchery and poultry farms has been breeding chicks in Lichtenvoorde, The Netherlands, since 1950. Innovation is at the heart of its business philosophy and Royal Pas Reform has been a long-term partner in this venture.
Having its own rearing, breeding and broiler farms in the Netherlands and Germany gives the family-owned company flexibility. Schotman works with Royal Pas Reform incubators and the options offered to customers all over Europe include hatching eggs, incubated eggs, regular or slow-growing broilers, and in-ovo vaccination – with or without early feeding.
“We love innovating and taking opportunities”, says Erik Wolterinck, one of the company’s owners. ”We give customers what they ask for. From a standard chick and whether to choose an IB spray or not, the product range has expanded to many varieties. The broiler farmer chooses what suits him and his business and we provide it.” Brothers Erik and Rob Wolterinck are the third generation of the Schotman family to be breeding chicks. Along with ten relatives, they run agricultural businesses whose main activity is poultry. Over the years the company has grown significantly and today it has a staff of 80. Internationalization has long been a focus for the business and most of Broederij Schotman’s turnover is now generated abroad. Schotman and Royal Pas Reform are ideal partners to develop and test innovations. “Innovating together takes you further,” says Rob Wolterinck. We enjoy being among the leaders in the field.”
One of those innovations is SmartStart™ early feeding. With feed, water, and light in the hatchers this is a flexible, practical, and simple system that has been co-developed and tested by Schotman. All the hatchers have been adapted so that SmartStart™ can be used flexibly. “Intelligent lighting is a new feature in the hatcher,” Rob Wolterinck says. “After hatching, the light intensity is gradually increased. With the special feed unit, it takes two minutes to fill the dolley with hatcher baskets with liquid feed – all under perfectly hygienic conditions.”
Schotman now has many customers who order SmartStart™ chicks on repeat. “This means that they are satisfied,” says Rob Wolterinck. “Our tests show that losses in the first week have fallen by 30%. The chicks are really calm and have a good start.”
Better results for Dutch hatchery businesses
Get in touch
Our highly skilled and dedicated service team is available 24/7, to provide first line support.
+31 (0) 314 659 100 service@pasreform.com
Royal Pas Reform’s SmartStart™ solution delivers better results for Dutch hatchery businesses
Three of The Netherlands’ leading hatcheries have adopted Royal Pas Reform’s SmartStart™ post-hatch feeding solution, which is proven to result in a significantly lower 7-day chick mortality. Elshuis, Munsterhuis and Schotman are all hatching chicks from the SmartStart™ system on a regular basis and have reported seeing the businesses benefit.
SmartStart™ is a flexible post-hatch feeding solution that gives newly hatched chicks the earliest possible access to feed, water and light. SmartStart™ promotes the development of robust, day-old chicks and helps to reduce the need for antibiotics. SmartStart™ comprises two key elements that can be applied individually, or together: precision feeding and intelligent lighting. In 2019, Royal Pas Reform, in collaboration with a European integration, designed and carried out a large field study to test the effect of SmartStart™ on first-week mortality in the farm in a commercial setting. Day-old chicks from SmartStart™ and regular hatchers were housed separately in the farm to monitor results. A total of almost two-million birds were placed during this trial – which was largely carried out during 2019, but which continues to provide new information on a daily basis.
For each trial, the eggs were divided equally over the test and control hatchers, taking into consideration the breeder flock, flock age and egg storage time. The chicks were unloaded from both hatching systems at the same time. The time of chick pulling, processing and transporting them to the farm were also kept equal for both systems. The field trial results showed that the first-week mortality was significantly lower for the SmartStart™ chicks, which was validated by a reputable Dutch university. “The SmartStart™ system offers a perfect start for newborn chicks,” says Erik Wolterinck of Schotman hatchery and poultry farms. “It is good for the wellbeing of the new-born chicks – as stress can be harmful to their health. Our customers see real differences when the chicks arrive on the farm. They are much more relaxed.”
Erwin Prinzen, product & sales director, Royal Pas Reform
Kasturi Poultry Farms India (KPF) has chosen Royal Pas Reform to build its new, single-stage integrated hatchery in Dharapuram, Tamil Nadu. The facility, which is expected to be fully operational at the end of 2021, will have a capacity of one-million day-old broilers per week.
The state-of-the-art installation will also feature a fully integrated climate control system and complete hatchery automation – making it one of the most modern facilities in Southern India. KPF’s ambition is to play a major role in the future growth of Tamil Nadu’s poultry industry. Based in Coimbatore, Tamil Nadu, KPF is an associate company of Venkateshwara Hatcheries Group (Venky’s) and was founded in 2010.
Its plans are taking shape today, and the company has recently made significant investments to expand both its integration facilities – to supply hatching eggs and day-old chicks throughout India and by developing its poultry feed business at KPF’s plant in Dharapuram.
Pradeep Kumar, Director of Kasturi Poultry Farms says: “I have been working with Pas Reform incubation equipment for more than 20 years and we have developed a strong relationship over this time. When we came to make our investment in these state-of-the-art facilities, it was a logical step for us to go for a single-stage hatchery with the world’s leading single-stage incubation and integrated incubation project specialist. Choosing Royal Pas Reform was the logical choice for us.”
Bouke Hamminga, Royal Pas Reform Director International Sales & Business Development comments: “We are delighted that such an important company as Kasturi Poultry Farms has chosen to work with us. I am sure that, as an integrated hatchery solutions supplier, we can prove to be a leading partner with KPF across the entire Indian subcontinent.”
Royal Pas Reform opens its new Polish headquarters in Kościerzyna of up to 20 staff will be based there.
Located in Kościerzyna, near the northern port city of Gdansk, the launch of the new premises has been driven by Pas Reform’s expanded product and support offerings. It strengthens the company’s already strong presence in Poland – where Royal Pas Reform incubators
Royal Pas Reform is pleased to announce the grand opening of its new business headquarters in Poland. The 800-square-meter facility includes offices for the sales and customer support teams, a warehouse, service and spare parts department and an HVAC production area. A team at present produce 600 million day-old chicks per year – while also providing important operational and resource efficiencies.
“The decision to open this office was a logical next step in our business growth strategy,” says Jarek Piankowski, Market Director Poland. “The new location and enhanced operational efficiencies will help us continue to grow and develop to keep pace with our customers’ needs.
“Pas Reform Polska will serve as a service hub for the entire Polish market and allow us to provide superior service along the way: with spares on stock and direct technical support – building on 25 years’ experience of servicing complete hatchery installations.”
Pas Reform Polska can be contacted by email at jarmaxled@icloud.com, or on mobile at +48 603 957 229.
Wasikowski family leads Poland’s ZWD Czarne hatchery into the future
The thriving family hatchery business ZWD Czarne was founded more than 50 years ago by Jan Wasikowski in Czarne, Poland. Today, the second generation of Wasikowskis are managing the company – proud successors of Jan, who are continuing a thirty-year partnership with Royal Pas Reform.
Marek Lewandowski and his wife Wiesllawa Lewandowski, who is founder Jan’s daughter, (pictured, centre) are building on a strong heritage and using their great drive and energy to lead the company into the future ¬ based on Smart™, future-focused technology from Royal Pas Reform.
Jan Wasikowski started his business in 1967 and ZWD Czarne quickly became known as ‘Jan Wasikowski’s Hatchery’. He adopted Pas Reform incubation systems more than 30 years ago. In 2006, in a bid to increase production inline with growing opportunities in their domestic market, the hatchery took the decision to transfer its operations to single-stage, closed-door, Smart™ technologies.
Over the years, the hatchery has grown organically, with the addition of several smaller extensions. In addition to investment in new setters and hatchers, the company also embraced hatchery automation systems. In 2014, ZWD Czarne installed the intelligent SmartCount™ counting and dosing system, and Pas Reform’s climate control equipment. By early 2019, the setting capacity had increased to 56 million day-old chicks per year.
ZWD Czarne’s partially integrated operations also include parent-stock farms, to produce Ross and Cobb day-old broiler chicks for sale into the domestic poultry meat production market. “Today, our hatchery is fully programmable – to optimize production across a variety of breed and age-related incubation programs,” Marek Lewandowski explains.
Throughout this time, Wasikowski’s Hatchery has received service and support from Royal Pas Reform’s agent in Poland, Jarmax – which provides rapid supply of spare parts from its locally held stock. Royal Pas Reform’s Sales Director Niels Stam says: “We are very proud to have worked with Jan Wasikowksi, and now his daughter and son-in-law, for so long, and we look forward to continuing that strong relationship in the future.”
Niels Stam, sales director, Royal Pas Reform
Optimising hatcher conditions
By Maciej Kolanczyk – Senior Hatchery Specialist, Royal Pas Reform
Hatching is the last part of the incubation cycle and optimal conditions in the hatcher are essential for best hatch results.
Whether a single or multistage incubation system is used, the hatcher is always a single stage machine. Eggs can be transferred from setter to the hatcher between the 15th and 19th day of the cycle, the optimum being days 18-19. Regardless of when the transfer is done, the total incubation time will not change.
A hatcher is a small cabinet, usually loaded to full capacity with eggs, all in their last incubation phase. The embryos as well as the hatched chicks require a lot of cooling and fresh air. As the baskets hamper the air circulation more than the setter trays, a high airflow helps to create a uniform environment. An efficient cooling system and a good supply of fresh air that reaches all parts of the hatcher are therefore necessary for the chicks to survive. The hatching process consists of three periods:
• Period 1 - before pipping • Period 2 - from beginning of pipping until peak humidity • Period 3 - after peak humidity
Period 1 is simply an extension of the incubation process in the setter. The set points can be fixed, and typical values are: 40-55% relative humidity (RH), 97.5-98.50�F temperature, 0.4-0.5% CO2. The actual values depend on the breed, design of the hatcher and local conditions. During Period 2 the leading parameter to be watched in the hatcher is the RH. This is the best indication of when pipping has begun and when hatching is complete. It can be followed by simply watching the graphs, if these are available. Pipping and hatching take several hours. During the process, a hatcher – even if all eggs are very uniform– will contain ready chicks and still closed eggs. As the hatchlings are wet, the RH raises spontaneously (period 2), reaches its maximum and starts dropping after the last chicks have hatched and dry off (period 3).
The time between the first and the last chicks hatching is called the ‘hatch window’. It can last between 12 and 40 hours, depending on the uniformity of the load (age of the flock, storage time), egg prewarming and the uniformity of conditions in the setter. As short a hatch window as possible is desirable. The maximum RH value reached depends on the rate at which the chicks are hatching and the amount of ventilation. Many chicks hatching at the same time can push the RH up as high as 85%. Once the RH peak is clearly over, which will be indicated by a 3-5% reduction in humidity, the initially selected set points can be adjusted. A very slow reduction of temperature (by 0.2-0.30F) followed by more intensive ventilation helps to keep the chicks in a comfort zone. The final temperature is usually around 97.00F and the final CO2 set point 0.25%. The aim is a comfortable environment in the hatcher with sufficient fresh air. The best way to judge the conditions is to closely watch the chicks themselves. When they are comfortable they will be calm and silent, and sleep much of the time.
Advice
– Load the machine in a way that provides the most uniform and effective air distribution and flow. This will differ depending on the design of the hatcher. – Don’t open the hatcher during the hatching process unless really necessary. – Aim for optimum fresh air supply; follow the machine supplier’s recommendation. – If operating manually: - Keep the set points fixed until period 3, - Correct them very slowly after RH peak, - Make sure after RH peak that RH doesn’t drop below 55%, - Observe the chicks’ behaviour (noise, panting) – and respond.
SmartCare™ service and support
Royal Pas Reform’s job is not only to supply fully integrated hatchery solutions, but also to ensure that the equipment continuously delivers the best results for our customers. To achieve this, we have introduced SmartCare™ - a menu of 21 services from which our customers can tailor exactly the support they need, to maintain uninterrupted performance at every level of hatchery operations.
AgroKush, the largest poultry production company in the Kyrgyzstan Republic, has chosen single-stage integrated hatchery systems from Royal Pas Reform for its all-new broiler hatchery in Sary-Kamysh village in the Issyk Kul region.
The integrated new facility includes a hatchery and poultry houses, together with a new feed plant, and a slaughterhouse with a capacity of 3,000 poultry per hour. Initial meat production capacity will be 8,500 tons of live weight per year, rising to 20,000 tons per year when the second phase expansion is implemented.
The poultry farm is fitted throughout with modern European equipment and built in accordance with HACCP and ISO 22000 standards. When fully operational, it will create 200 jobs and have capacity to meet 30% of the domestic market’s poultry meat demand. It will also reduce the volume of poultry meat needed to be imported – increasing the country’s level of food security. Askat Abdarakhmanov, general director of AgroKush says: “We were looking for an integrated approach to the development of our new hatchery and we favored working with a single-source industry supplier. Royal Pas Reform company met these requirements – as they not only developed the project and supervised installation of the equipment, they remained onsite with us to provide support and training. This approach helped us to achieve exemplary hatch results recently, and we are looking forward to building on this cooperation to scale-up our production in the future.”
Wim Schaafsma, the general director of Pas Reform Russia, is impressed with the commercial and modern approach of AgroKush’s team. He says: “It’s a pleasure to work with such a forward-thinking company, and it gives us further proof that our integrated approach delivers the right strategy for our customers. We wish AgroKush every success in their ambitious plans for future growth.”
Watch the movie!
Wim Schaafsma, general director, Pas Reform Russia Anna Kolygina, commercial director, Pas Reform Russia
Pilgrim’s Georgia hatchery performance excels with SmartPro™ from Pas Reform North America
Pilgrim’s, the second largest poultry producer in the USA, and part of JBS Foods, chose Pas Reform North America for renovation of its hatchery in Talmo, Georgia. The installation includes 11 SmartSetPro™ NF18 setters, with 9 SmartSetPro™ NF6 hatchers, operating on a 54-egg tray platform. A SmartCenterPro™ hatchery management system provides complete monitoring and control of the equipment and also allows for remote support and advice by Pas Reform Academy specialists.
Joe Steed, Director of Hatchery Technical Services at Pilgrim’s, comments: “Pas Reform North America has been an excellent partner throughout this project. They have been very helpful training our team and strengthening our ability to maximize performance. As everyone knows, there is a learning curve when transitioning to single-stage incubation, and Pas Reform has done an excellent job of making this as smooth as possible for us.” “The opportunity to bring single-stage incubation to Pilgrim’s Talmo hatchery has been a great experience,” says Steve Warren, President of Pas Reform North America. “We have worked alongside the Pilgrim’s team both during the project concept phase and installation, and we continue to work closely together in the operational phase. Regular visits have proven to be very helpful, and we are excited about the performance we have been able to achieve and what we can still accomplish in the future.”
Pilgrim’s Hatchery Manager, Timothy Taylor, comments: “The renovation has been operational since the first quarter of 2021 and the results have been excellent. We have seen improved hatch results and feed conversion, and our hatchery-performance ranking within the company has improved tremendously.”
Georgia-based Warrior Systems joins Pas Reform North America
Pas Reform North America has successfully completed the integration of the staff and operations of Warrior Systems – a family-owned business based in Gainesville, Georgia. by Pas Reform North America handled only certain types of setter trays and hatcher baskets. The integration of Warrior Systems allows it to deliver and service integrated hatchery projects for any tray or basket size. washers for setter trays, hatcher baskets, chick boxes, setter and hatcher dollies and farm trolleys.
Steve Warren, President of Pas Reform North America, says: “The US market will continue to invest in both refurbishing existing hatcheries and building new ones. A large portion of setters, hatchers, climate control systems and automation equipment currently installed is rather aged. As a result, we see substantial demand coming from the market to develop integrated projects in the coming years. critical components for a smooth-running hatchery. Now, with Warrior Systems incorporated in Pas Reform North America’s operation, and Warrior’s sales, production and service operations centralized in Pas Reform’s headquarters in Jacksonville, Florida, we can better serve our customers – providing quick and robust service and solutions.”
Rungta Group chooses SmartPro™ for its new hatchery in Nepal
Nepal-based Rungta Group has chosen Royal Pas Reform to build its new, single-stage integrated hatchery in Hetauda, Bagmati Province. The state-of-the-art installation – with a capacity of thirteen-million day-old broilers per year – includes SmartPro™ incubators, climate control and automation, making it one of t Rungta Group, which is headquartered in Kathmandu, is a large and diverse agri-business. Founded in 1968, the company’s ambition is to play a major role in the future growth of the Nepalese poultry industry, and it has recently made significant investments in a breeder farm and hatchery – to supply day-old chicks throughout Nepal.
Rajesh Roongta, Managing Director of Rungta Group, says: “When we came to make our investment in these state-ofthe-art facilities, our plan was to ensure the best outcomes for our customers. We believe that supplying high-quality broiler chicks ¬ produced in a single-stage incubation process, giving superior post-hatch performance in the field, in terms of growth, mortality and feed conversions – is pivotal for the farmers of Nepal.”
Venkitakrishnan, Royal Pas Reform’s Sales director India & Nepal comments: “This is an important next step in our growth plans for the entire Indian sub-continent. We are delighted that such an important company as Rungta Group has chosen to work with us. I am sure that, as an integrated hatchery solutions supplier, we can prove to be a leading partner for Rungta Group across Nepal.”
Japfa chooses Smart™ for hatchery extension on Bali
PT Japfa Comfeed Indonesia Tbk, one of the country’s leading integrated agri-food businesses, has further expanded production capacity at its hatchery in Tukadaya, Bali by installing a range of Smart™ technologies from Royal Pas Reform. The facility now has a total capacity of 32 million day old chicks per year.
The project was for 6x SmartSetPro™-6 setters, including Adaptive Metabolic Feedback™(AMF™) and Energy Saving Modules™ (ESM™). AMF™ fine-tunes incubation environments to the needs of growing embryos, and Energy Saving Modules™ (ESM™) reduce energy consumption.
In addition, the company has installed 6x SmartHatchPro™ hatchers, including SmartWatch™, Hatchery Automation and Climate Control. SmartWatch™ is a unique tool for hatch-window control, which creates ideal conditions for chicks to hatch – by optimizing the humidity and CO2 inside the hatcher. It monitors and adjusts the hatching process automatically – from the day of transfer, through to the hatching of the last chicks – eliminating any need for human intervention.
Japfa Comfeed launched its Tukadaya operation in 2014, when it installed 12 SmartSetPro™ setters, 12 SmartHatchPro™ hatchers and a full climate control system. A SmartCenterPro™ hatchery information system was installed to monitor and record every incubation cycle. Royal Pas Reform also provided hatchery management training, together with ongoing service and technical support.
Mr. Gusi Ketut Wirata, Japfa Comfeed Indonesia’s east area hatchery lead, says: “We chose to extend our use of Royal Pas Reform’s advanced SmartPro™ single-stage incubation technologies to help us deliver premium quality broilers with high uniformity throughout the integration and achieve a superior retail product.”
Hatchery manager Mr. Mustiko Nur Setyo, has been a happy man since the installation of Pas Reform’s SmartPro™ incubation technologies: “Results are superior and have exceeded our expectations in terms of hatchability percentage and chick quality”, he says.
Japfa Comfeed Indonesia’s core business activities include animal feed manufacturing, chicken breeding and poultry processing, as well as aquaculture farming. It already commands a significant share of the domestic poultry market and is the country’s second largest integrated poultry company.
Sun Food chooses SmartPro™ for their expansion in Thailand
Thai-based broiler producer Sun Food International Co. Ltd is fueling its next stage of growth with a new single-stage expansions from Royal Pas Reform at its Wangmuang broiler hatchery in Saraburi.
The order includes 12 SmartSetPro™ setters and 12 SmartHatchPro™ hatchers. Royal Pas Reform’s SmartCenterPro™ hatchery information system will provide end-to-end monitoring, control and reporting across every level of hatchery operations – to enhance workflow efficiencies and quality control, and to deliver complete traceability for every hatch.
“With this order, Sun Food is embarking on a two-phase expansion programme that will enable a production increase of 20 Mio day-old chicks,” says Chamlong Termglincham, the company’s CEO.
Established in 1995, Sun Food is today a major poultry producer, supplying quality chicken meat to customers all over the world. Fully integrated with animal feed mills, parent stock farms, hatchery, broiler farms, processing and further processing plants, the company controls every single step in producing nutritious and hygienic chicken meat.
“Royal Pas Reform is delighted to have been selected for this pivotal project in Sun Food’s continuing development,” says Michael Kampschoer, Sales Director Asia of Royal Pas Reform. “We look forward to continuing to partner with Sun Food company to realise its future growth plans.
Steve Warren, President of Pas Reform North America and Warrior System’s founder, Richard Storer
