ISA
The Netherlands ISA chooses SmartPro™ for new (Grand) Parentstock Hatchery > p. 21
Erpiliç
Turkey Erpiliç supersizes with SmartPro™ > p. 9
Pas Reform Times Pas Reform Hatchery Technologies
Pas Reform Innovations
Cherkizovo
Russia Cherkizovo chooses Smart incubation for Russia's largest hatchery > p. 4
PT QL Trimitra Indonesia PT QL Trimitra expands with Pas Reform > p.13
Centurion
USA Centurion Poultry Inc. chooses Pas Reform for a new single-stage hatchery in Iowa > p. 6
Dynamic times demand inspiration, innovation and change In a rapidly changing world, with a growing population – and a growing appetite for poultry - the poultry sector must not only keep pace, but also anticipate where change is leading us.
From the First Pas incubator, to the advanced capabilities of today’s modular single-stage SmartPro™ incubation systems, anticipating where change will lead has driven Pas Reform innovations for more than 90 years.
Pas Reform sees the impact of these changes through the experiences of our customers and partners in different countries and cultures around the world.
Today, our technologies extend into HVAC systems, to maximise energy reduction and support exemplary hygiene; the web-based SmartCenter™ information system, to monitor and analyse every production cycle with quality data, and hatchery automation, to maintain the same levels of care for massively increased numbers of day old chicks.
Numbers alone are no longer sufficient. Quality counts. Uniformity and robustness are the new standards, with expectations of sustainable solutions that consume less energy, improve hygiene and promote food safety with respect for animal welfare. As hatcheries grow larger to handle many millions of day old chicks each week, every aspect of operations must be supported by information technology, to provide high quality data throughout the poultry production chain.
It is in automation that our latest innovation, SmartCount™, introduces a revolutionary new system for handling large numbers of day old chicks, using vision technology and pattern recognition, to reduce stress for the chicks and support the highest standards of animal welfare. From combating rising feed prices to providing sustainable, non-toxic alternatives for disinfection and hygiene, Pas
Reform is committed to excellence and innovation, for sustainable growth in the hatchery sector - and throughout the poultry production chain. We are privileged that our customers, partners and colleagues share the same commitment. Many have contributed to this latest edition of Pas Reform Times, to share their experiences, their expertise and the latest news from their hatcheries around the world. These are dynamic times: I hope you find inspiration for today – and for what tomorrow will bring - in this extraordinary edition of Pas Reform Times. Bart Aangenendt, CEO Pas Reform Hatchery Technologies
Pas Reform Times Dynamic times demand inspiration, innovation and change 1 Pas Reform’s visionary chick counting system 2 Pas Reform’s hatchery automation goes global with LAN acquisition 2 Cherkizovo, Russia 4 Sofia, Bolivia 4 New Pas Reform office in Indonesia 4 Pre-storage incubation 5 VH Group, India 5 Simultaneous transfer of multiple setter trays 6 Centurion Poultry, USA 6 Serfontein Kuikens, South Africa 6 ‘Red Dot’ Award for design quality 6 Pas Reform granted exclusive use of Microban in hatcheries 7 Nutriza, Brazil 7 ‘On Monday they are …’ 8 New Anthoney’s Farms, Sri Lanka 8 Pas Reform launches web shop 8 Erpiliç, Turkey 9 Belpticeprom, Belarus 9 Balance for perfection 10 Pindos Cooperative, Greece 10 New poster charts embryonic development of the chick 10 SmartTray™: Driving performance and uniformity in the hatchery 11 Ross Breeders Anadolu, Turkey 11 Watter® Safe, sustainable disinfection for the hatchery sector 12 New Representative in Peru 12 PT QL Trimitra, Indonesia 13 Miratorg, Russia 13 ESM™ Energy Saving Module: Substantial energy savings for rapid payback 14
Innovations in automation Pas Reform’s visionary chick counting system
When eggs are stored too long 15 Granja Pinheiros, Brazil 15 Pas Reform innovations in print and pdf 15 Assuming that ‘anything is possible’ in the hatchery 18 Paragon Group, Bangladesh 18 iPad technology for hatchery managers 19 IKO, Poland 19 Worry-free ventilation for constant chick quality 20 Akyem, Turkey 20 ISA, The Netherlands 21 Kurskiy Agrokholding, Russia 21 Smart™ Incubators: delivering top performance worldwide 22 International appointment 22
Hatcheries are growing in line with increasing demand – and with them, the need for innovations in automation, to improve the handling and welfare of the millions of chicks hatched every week. After three years in development, Pas Reform’s SmartCount™ represents the most advanced development to date for the high capacity counting, vaccination and analysis of day old chicks.
Pas Reform introduces web-based upgrade for enhanced hatchery HVAC control 23 Amvrosiadis, Greece 23 Fresh Air: a prerequisite for life! 24 PBPF, Kazakhstan 24 Pato Branco, Brazil 25 Provita, Bangladesh 25 UKPF, Kazakhstan 25 New representative in Colombia 26 Chicks make their own “humidity peak” 26 Inzhavinskaya, Russia 26 Sary Bulak, Kazakhstan 27 Namib Poultry, Namibia 27 Okskaya, Russia 27 Timashevskaya, Russia 27 Misr Poultry Group, Egypt 27 Adaptive Metabolic Feedback (AMF™) 28 BNA Building of the Year 28 Arax, Armenia 29 Nutripollo, Mexico 29 Agrobueyca, Venezuela 29 Circadian Incubation™: a new feature of single stage incubation 30 Service Centre Indonesian hatcheries 30 Aviagen, Russia 31
Pas Reform’s hatchery automation goes global with LAN acquisition
LAN’s expertise, says Pas Reform
Pas Reform has acquired Dutch
complex handling systems,
company LAN, a specialist in custom-made handling and
hatchery industry access to new applications, especially in
robotics and vision technology.
transport solutions –
Founded in 1970 and based in
globalization within its hatchery
well known in Europe and the
accelerating plans for automation division.
2
CEO Bart Aangenendt, gives the
Tilburg, The Netherlands, LAN is USA, with a reputation built on
the design and development of
Hatchery automation: a growing market for innovation
Improved efficiency, uniformity and chick welfare
Market demand for modular, single-stage incubation has increased substantially in recent years, with growing recognition in the poultry industry that a short hatch window and uniform, robust chicks are critical factors for obtaining the best performance.
Pas Reform’s SmartCount™ applies Vision Technology – a complex pairing of digital imaging and pre-defined algorithms, to count and analyze groups of day old chicks on their way to the chick boxes.
Pas Reform has produced a full-
Image sequences are interpreted using these criteria, pre-set by Pas Reform Academy, to process day old chicks in stress-free conditions. With an accuracy of two chicks per thousand, SmartCount™'s nett system capacity is 60,000 chicks per hour.
info@pasreform.com or download
To keep pace with growing demand for high-quality chicks, hatcheries large enough to produce more than two million day old chicks per week are no longer unusual. These growing hatcheries have become highly automated, to handle chicks in such large numbers and to promote short ‘throughput time’ - another key measure of chick quality, for its influence on post hatch performance. The case for automation is further strengthened by the growing cost and reduced availability of qualified labour. At the core of these transitions in the poultry industry, lies a duty of care to the retailer and ultimately to the consumer, to deliver the highest standards of animal welfare and offer complete traceability, from egg production and hatchery all the way down the poultry production chain. Together, these factors create increasing demand for innovation, to support and improve standards of animal welfare - and to increase the availability of information from source. In response, Pas Reform Academy has looked for more intelligent, innovative ways to handle valuable, day old chicks, with minimum impact on their health and wellbeing, while at the same time reducing their throughput time.
colour, fully illustrated brochure
to describe SmartCount™ in detail. For your own free copy
of the brochure, please email
in pdf format from Pas Reform
online at www.pasreform.com
The same level of intelligence and accuracy defines a range of key parameters, including smart pattern recognition for even, gentle distribution in the right numbers into the chick boxes at the end of the conveyor and precise, optimised spray vaccination. SmartCount™’s chick analysis system incorporates calculations for uniformity scoring – and by integrating SmartCount™ statistics with SmartCenter ™ hatchery information system data, the hatchery is equipped with the most detailed level of data analysis and batch reporting available today. For more information on Pas Reform’s visionary chick counting system, please visit www.pasreform.com or contact us directly at +31 314 659 111 or by e-mail at info@pasreform.com
Integrating Vision Technology for high capacity counting, vaccination and the analysis of day old chicks
This focus has placed Vision Technology at the heart of a new system for chick counting and quality analysis, to produce significant increases in efficiency, chick uniformity and standards of animal welfare. Pas Reform has named this latest innovation SmartCount™.
customized solutions and
LAN Handling Systems will
“For LAN, collaboration with Pas
expertise in hatchery
centre of hatchery automation
and pharmaceutical industries.
solutions to the food and
exceptional opportunity to
generation of total hatchery
solutions and an engineering
innovative systems for the food Key customers include Kraft, Mars, Del Monte and Nestlé. An experienced team of 60,
including engineers and worldclass production, testing and service capabilities, joins Pas
Reform’s Hatchery Automation Technologies division.
continue to deliver logistics pharmaceutical industries. In
collaboration with Pas Reform’s
experienced, international team – and under the new name of
LAN Hatchery Automation – the
company’s expertise will also be
focused on hatchery automation systems for the hatchery sector worldwide.
Reform represents an
further develop Hatchery
Automation products and
services in an industry primed
for growth”, says Harm Langen,
Managing Director of LAN. “The combination of specialist
handling solutions for hatching eggs and day old chicks,
partnered with Pas Reform’s
technologies, will deliver a new automation solutions.” Pas Reform’s CEO Bart
Aangenendt concludes: “Pas
Reform has worked with LAN for a number of years now. It is
rewarding to see this developed
worldwide, with innovative
capability that can handle even the largest ‘super-hatchery’
automation project, anywhere in the world.”
into such an exciting new
Harm Langen, Managing
places Pas Reform right at the
Systems.
partnership: a collaboration that
Director of LAN Handling
3
Cherkizovo chooses Smart™ incubation for Russia’s largest hatchery L - R: Mr. Sergey Mikhailov, CEO of Cherkizovo Group and
Mr. Dmitriy Aveltsov, Cherkizovo’s First deputy CEO of the poultry division
Russia’s Cherkizovo Group will place Pas Reform’s Smart™ single-stage incubation and hatchery technologies at the heart of Russia’s largest and most progressive new poultry complex. The installation, due towards the end of next year, will include 108 SmartSetPro™ setters, each with capacity for 115,200 eggs, 20 smaller 57,600 capacity SmartSetPro™ setters and 152 SmartHatchPro™ hatchers. The comprehensive installation also includes a complete line of hatchery automation systems, with automated egg receiving, egg transfer and chick handling and a hatchery climate control system that incorporates energy-saving heat recovery systems. Each setter will be equipped with Pas Reform’s Adaptive Metabolic Feedback (AMF™) – the company’s latest innovation to ensure that specific conditions are maintained throughout the metabolic development of each embryo. AMF™ maximizes uniformity by optimizing airflow, the evaporation of moisture and air redistribution. With annual production set at 240mn eggs per annum, high levels of automation have been commissioned, to reduce labour costs and save time, while delivering accuracy and efficiency in production and promoting high quality in the day old chicks. The integrated project, being hailed as a ‘live-work-play agroindustrial campus’, will also include broiler and parent stock farms, slaughter plant, waste and recycling plant, feed mill and other facilities. It is anticipated that around 5,000 people will live and work on the ‘campus’ when it becomes fully operational, in 2015.
“In a project of such a large scale, Cherkizovo was looking for a partner who would not only deliver full technical and technological support up to and during installation,” he says, “but who would continue to provide ongoing support, to finetune implementation, processes and routines, as well as the assurance of (round-the-clock) access to service, technical back up and parts availability. Sergey Mikhailov, CEO of Cherkizovo Group comments: “This project marks a new stage of development not only for our company, but also for the poultry production sector in Russia generally, as Cherkizovo Group introduces progressive standards of effective, competitive production.” Cherkizovo’s new poultry production and processing cluster will include five broiler sites with a combined capacity of 10 million birds, four parent stock and reproduction sites for 900,000 birds and a slaughtering complex with a 24,000/ hour capacity. At full capacity, the new Cherkizovo complex will produce more than 125,000 tonnes of poultry and meat products per annum. “We are very proud to have been selected for this important new development”, says Bart Aangenendt, chief executive of Pas Reform. “This is even more rewarding after Cherkizovo Group’s rigorous evaluation process highlighted the reliability and safety of Smart incubators, hatchery automation and climate control systems.”
Bolivia’s Avicola Sofia, the largest poultry producer in the
country, has recently signed a contract with Pas Reform do Brasil, for the supply of a complete, modular, single stage incubation project and HVAC ventilation systems.
The new hatchery will be located at Santa Cruz de la Siera,
to comprise SmartSetPro™ incubators and SmartHatchPro™
hatchers, with a complete HVAC system to include air hand
ling units, humidity and pressure control and a SmartCenter™ hatchery information system, for detailed analysis and remote diagnostics throughout the new installation.
Mr. Mario Anglaril, general manager of Avicola Sofia, says: “In looking for a state of the art incubation system that
Dmitriy Aveltsov, Cherkizovo’s First deputy CEO of the poultry division, says that sound experience with Pas Reform as a company and the reliability and performance of its SmartPro™ single-stage incubation technologies, were the determining factors in choosing the project’s hatchery equipment supplier.
would be suited to our conditions, we found Pas Reform do Brasil’s engineers and technicians to be extremely wellinformed in their use and understanding of the latest
technologies. This combined with the local knowledge that Pas Reform’s team could bring to an incubation project in a country like Bolivia was extremely valuable to us.”
Pas Reform appoints new office in Indonesia
that forms an important focus
as a sales and service centre,
Bas graduated in 1996 with an
“This is an important step in my
Pas Reform has further
international strategy. Mr. Bas Kanters MSc, 39, joins the
customer response and
Wageningen University (The
pleased to be taking it with Pas
bolstered its sales force in the Asia-Pacific region, with the
appointment of a new Sales
Director and the opening of a
fourth sales and service office.
The Dutch hatchery technology company has a strong and
4
Sofia chooses SmartPro™ from Pas Reform in Bolivia
growing presence in a region
within Pas Reform’s
company’s existing Asian Sales team from the newly opened Indonesian office – where his
responsibilities extend beyond
Indonesia, to include customers in South Korea, Thailand,
Australia and New Zealand.
Pas Reform Indonesia operates
with the focus on swift, direct technical follow up. Customers also have access to Pas Reform Academy – and Bas and the
Indonesian team work closely with Pas Reform’s existing
offices in Malaysia, India and Thailand.
With more than 10 years’
livestock industry experience,
MSc in Animal Science from
Netherlands). He has lived and
worked in Asia for 5 years, with previous roles as area sales
manager for Hybro BV and more recently area sales manager for VDL Agrotech equipment from the Netherlands.
career”, says Bas, “ and I am very Reform’s dynamic team in Asia.
Great work has been done here,” he says , “ and I have been
impressed, especially in recent years, by the Company’s
progress since the introduction
of Smart single-stage incubators – and by its commitment to its customers.”
Pre-storage incubation: a matter of routine? By Dr. Marleen Boerjan, director research & development, Pas Reform Academy
The care of hatching eggs during storage – at the farm, in transit or at the hatchery - is an important aspect of hatchery management that aims to preserve the vitality of the embryo. With optimum temperature and relative humidity, hatching eggs can generally be stored for one week without significantly reducing hatchability or chick quality. Eggs stored for longer than this are known to benefit from lower storage temperatures (12-14 °C) (Fasenko, 2007; personal experience). Pre-storage incubation, i.e. incubating hatching eggs before they are placed in the storage room, is a new approach to storage management that aims to develop the embryo to the so-called hypoblast stage: a stage of embryonic development that is better able to survive storage. According to Fasenko (2007), broiler hatching eggs reach the hypoblast stage after six hours of pre-storage incubation, turkey embryos after 12 hours. Layer hen hatcheries have reported improved performance, seeing 3-7% more females after pre-storage incubation for 3-6 hours, when eggs are stored for more than 11 days (Lohmann Tierzucht, Management Guide). In the broiler industry, positive pre-storage incubation results show at least a one per cent increase on expected hatchability, when the eggs undergo pre-storage incubation of 3-6 hours on arrival at the hatchery (Fasenko et al., 2001; Fasenko, 2007). Eggs scheduled for storage for more than seven days after production benefit most from pre-storage incubation. However, many questions, mainly concerning timing and duration, continue to surround the adoption of pre-storage incubation in routine management practice. Considerations for the practice of pre-storage incubation Pre-storage incubation is only beneficial if the embryos in the eggs are in a very early stage of development. For example: if nest temperatures are high and the eggs stay in the nest too long, the embryos may develop beyond the storage resistant stage, when pre-storage incubation will increase early embryonic mortality.
Small-scale experiments will help identify the best timing and length of pre-storage incubation for your own hatchery and egg types (see below). To assess results in your own hatchery: • Place eggs for pre-storage incubation on setter trays in setter trolleys, to ensure uniform egg temperature during incubation. • Do not incubate eggs on paper trays or in boxes. This guarantees heterogeneous egg/embryo temperatures, resulting in high levels of early mortality. • Disinfect eggs as long as pre-storage incubation is performed in a setter located in the setter room (‘clean area’). Ideally use a specific incubator, located close to the egg storage room • Pre-storage incubation can be applied when eggs arrive at the hatchery 3-4 days after production and are scheduled for more than 4 days extra storage at the hatchery.
VH Group hosts Pas Reform lecture program in Bangalore
Guidelines To assess performance benefits and establish pre-storage incubation protocols in the hatchery: 1 Egg selection: per egg type, three trolleys for pre-storage incubation with one trolley (same batch) for the control. 2 Disinfect: if the eggs are incubated in a normal routine setter. 3 Pre-storage incubation: place trolley(s) with (disinfected) eggs in a running setter at incubation temperature. Incubate the eggs for 3, 6 and 9 hours. Control eggs stay at storage temperature. 4 Return pre-storage incubated eggs to the storage room (with control eggs) for at least seven days before starting the normal incubation cycle. 5 Run normal incubation with both the pre-storage incubated eggs and the control eggs. 6 Evaluate: compare hatchability - pre-storage incubated eggs vs. control eggs. 7 Repeat this experiment with eggs from at least three different flocks. 8 Evaluate all results. If positive, adopt pre-storage incubation routine as indicated by results.
Pas Reform CEO Bart
sales and service centre in India
years ago, realizing the current
worked here for a number of
Aangenendt comments, “A few and future potential of Asia within our world wide
operations, we set out a new
strategy for Asia that focused on local presence in the region.” “We started that journey in
2008 with the opening of the
office in Kuala Lumpur and have continued to grow, opening a
in 2009. Bas has lived and
India’s ‘Garden City’ Bangalore provided the dynamic
backdrop for a lecture programme presented by Pas Reform recently, when India’s VH Group hosted a seminar for technical and support staff.
VH Group’s General Manager for Breeder Sales & Service,
Dr. Shetty, has worked with Pas Reform’s sales director, Dr. Tan Ee Seng, and director of R&D at Pas Reform Academy
and leading embryologist Dr. Marleen Boerjan, to develop
the programme around a series of four lectures on hatching egg storage, embryonic development and optimising
incubation. More than 40 staff members from VH Group breeder farms and hatcheries, Bala Industries and recent
SmartPro™ single-stage customer Sahayadri Hatchery, from Pune, attended the seminar.
Pas Reform emphasised its commitment to Indian customers
in 2009, when the company continued its expansion in Asia with the launch of a dedicated country sales and service center in Udumalpet, to deliver localised support.
Contact details for Pas Reform’s new office in Indonesia are:
years. He understands the
Raffles Hills, Blok J8 No.5
the poultry industry - and we
Depok 16954, Indonesia
challenges and opportunities for believe his skills will help us to
Kel. Sukatani, Kec. Cimanggis
achieve further growth in Asia
Mobile +62 811 998 162
technologies.”
E-mail Kanters@pasreform.com
with advanced, single-stage
Telephone/Fax +62 21 8459 9187
5
Simultaneous transfer of multiple setter trays SmartTransfer™ is one of the latest hatchery innovations from Pas Reform: an ergonomically designed, fully automated setter trolley loader that enables a single operator to safely transfer all 32 trays from a farm trolley to the setter trolley simultaneously, in less than two minutes. The new system is one of the first applications to take advantage of recently acquired subsidiary LAN’s expertise in custom-made handling systems. Unlike other systems, the SmartTransfer™ setter trolley loader saves time and manpower with a simple, ingenious push mechanism that transfers every tray in a trolley simultaneously. A smooth, gliding action protects fertile hatching eggs from any sudden movements or shocks, to prevent hairline cracks or other damage to the eggs.
Centurion Poultry Inc. USA chooses Pas Reform for new single-stage hatchery in Iowa
Easy to operate, SmartTransfer™ is designed for operator comfort during this normally highly repetitive task. A filled farm trolley is pushed into the SmartTransfer™ trolley loader and locked into position. With the door closed, the operator sets SmartTransfer™’s electronically operated pusher into action, transferring all the trayed eggs onto a tray collector simultaneously.
Centurion Poultry Inc., the second largest producer of
The operator then opens the door and replaces the farm trolley with a setter trolley. Tray collector guides adjust automatically to the correct pitch for the setter trolley – and all the filled trays are pushed into the setter trolley at the same time. The whole process is completed in under two minutes.
BOVANS and DEKALB brands. Since its inception in 1991,
With a footprint of just 1860 x 2775 mm, SmartTransfer™ is constructed from easy-to-clean stainless steel and requires minimal maintenance. For further information, please visit our website or call +31 314 659 111.
Dekalb Layer Breeder producer Serfontein Kuikens will extend its collaboration with Pas Reform Hatchery
Technologies this year, with the expansion of hatchery
operations at Potchefstroom, to meet growing demand for the Dekalb Amber Link breed in South Africa.
commercial egg layer chicks in the USA, is building a new 18
A new contract was agreed during the South African Poultry
with hatchery technologies from Pas Reform.
in Johannesburg. Present for Serfontein Kuikens’ were
million capacity single-stage hatchery in the State of Iowa,
Headquartered in Lexington, Georgia, Centurion Poultry’s
Commercial Layer Division holds about 25% of replacement chicks for the egg layer market in the USA, mainly with
the company has grown steadily, to incorporate satellite
operations in Alabama, Iowa, Missouri, Pennsylvania and Wisconsin.
The new Iowa hatchery will comprise 28 SmartSetPro™
setters and 24 SmartHatchPro™ hatchers, with an annual
production capacity of 18 million day old pullets, which will make this one of the largest layer hatcheries in the USA.
Association’s Annual Show, held recently at Emperors Palace directors Jan Serfontein Snr and Jan Serfontein Jnr, with
Bouke Hamminga, Pas Reform’s director of International
sales and business development, and Pas Reform’s South African representatives, also a family concern, Jankees Sligcher and his son Adriaen.
Serfontein Kuikens’ hatchery expansion will occur in two phases. The first, coming into operation by the end of
November this year, will include three SmartSet™ 115 Setters with one SmartSet™ 38 and six SmartHatch™ Hatchers. In
the second phase, two further SmartSet™ 115 Setters will be added, bringing the hatchery’s total capacity to 8.8 million pullets per annum.
Pas Reform’s SmartPro™ incubator wins international ‘Red Dot’ Award for design quality
In a statement from the
The red dot design award dates
Pas Reform’s award is for
latest development in single-
the world’s largest and most
and crafts’ category, emerging as
Pas Reform’s SmartPro™
incubator manifests a clear,
incubator has been awarded a prestigious international ‘red dot award’ for high design quality.
6
Serfontein Kuikens expands with Pas Reform in South Africa
awarding Jury, Pas Reform’s
stage incubation was highly praised: “The SmartPro™
comprehensible design and
fulfils the highest demands
back to 1955 and is now one of distinguished design
competitions, attracting more
than 4,500 nominations from 58 countries in 2012.
“product design” in the ‘Industry a winner out of more than 1,800 entries from renowned
designers and emerging international talent.
expected of technologies for
Pas Reform received its red dot
and user-friendliness.”
at Aalto Theater, in Essen,
incubation in terms of reliability
award during a ceremony held Germany.
Pas Reform granted exclusive use of Microban in hatcheries
Microban antibacterial technology is finding new applications in the hatchery sector, through an Agreement that gives Pas Reform sole use worldwide. Pas Reform has incorporated Microban into the polymer used to manufacture setter trays, hatcher baskets and other hygiene-critical hatchery consumables. “Pas Reform’s use of Microban technology represents an important development in minimising contamination by bacteria and pathogens in hatcheries”, explains Gerd de Lange, Senior Poultry Specialist of Pas Reform. “Millions of hatching eggs are transferred every day, between breeder farms and hatcheries. From the hatchery, day-old chicks are then transferred in their millions, to multiple points of delivery in the poultry chain. “The constant flow of eggs and chicks in hatcheries can, without proper hygiene practices, increase the potential for cross contamination and bacteria transfer during transportation. Improving the hygiene throughout this process is an absolute priority” explains Mr de Lange. Optimising the hatchery’s hygiene status is fundamental to good incubation. Bacteria can double in number every 20 minutes, so that within just seven hours, every bacterium can multiply into more than a million organisms. While disinfection is effective in the short term, it does not prevent the re-growth of micro-organisms once the surface dries and the disinfectant has evaporated.
Pas Reform’s director of international sales and development, Bouke Hamminga, has monitored performance and market response to the new products. He says, “We strongly believe in the partnership we have developed with Microban and have extended our territory market relationship from EMEA to further include Central and South America and the AsiaPacific region, including Australia and New Zealand.” Following the success of Pas Reform’s Microban-treated setter trays and hatcher baskets, the antibacterial technology will be incorporated in an extended range of consumables and into new applications in Pas Reform’s hatchery planning, design and installation services portfolio, such as hatchery flooring and joint sealants. Paul McDonnell, managing director at Microban Europe, concludes: “Pas Reform has achieved remarkable growth with its innovative incubation technologies and we are pleased that our antibacterial technology is now part of this success. “Certainly, this would appear to be a market sector where antibacterial protection brings a genuine and very high degree of benefit. We are looking forward to working with Pas Reform, to further extend its use of our technology.”
Brazil’s Nutriza chooses SmartPro™ for expansion
Nutriza AgroIndustrial de Alimentos S/A has chosen Pas Reform’s SmartPro™ incubation technologies for an expansion programme that will boost the poultry
integration’s production capacity to 100 million hatching eggs or 1.6 million day old chicks a week.
Pas Reform: working
Nutriza’s CEO and managing director Mr. Tomazini says the
antibacterial technology
incubation technologies was based primarily on quality and
decision to invest in Pas Reform’s SmartPro™ single-stage
with Microban®
the Company’s very clear commitment to the Brazilian market, through Pas Reform do Brasil. “Expanding the
By incorporating Microban technology into hatchery consumables such as setter trays and hatcher baskets, Pas Reform has created a unique and highly effective means of combating cross-contamination in modern hatcheries. Contact with the Microban treated polymer fatally disrupts the biological function of bacteria, to provide continuous protection between wash cycles.
Nutriza hatchery is central to our strategy, to bolster
hatchery operations at the core of our poultry integration,” he says. “When we looked at how best to reliably deliver greater numbers of uniform, robust day old chicks
alongside modern requirements for hygiene and bio-
security, we found Pas Reform’s SmartPro™ incubation
technologies to be the most comprehensive and viable investment for Nutriza’s future needs”.
www.pasreform.com/youtube/pasreformbv The official home of Pas Reform on YouTube. Check in for regular updates
and new content from around the world.
7
New Anthoney’s Farms adopt SmartPro™ singlestage incubation
New Anthoney’s Farms (pvt) Ltd has contracted Pas Reform to supply a SmartPro™ single-stage incubation system for its new hatchery in Attanagalla, Sri Lanka. The company, one of the country’s foremost poultry producers, will install SmartPro™ 77 incubators, with a full climate control system and automated Candling and Transfer to complete the commission. As an independently developed producer, committed to quality, New Anthoney’s Farms is in a unique position, with the new single-stage hatchery joining associated broiler houses, breeder houses and a feed mill (in Indolamulla and Thiththapaththara) and processing (in Hanwella) up to international standards, to complete the integration. Mr. K.A. Emil Stanley, the company’s chairman and managing director, said “New Anthoney Farms selected Pas Reform’s SmartPro™ technologies to support our vision and commitment to providing the best quality, hygienic chicken products to health conscious consumers in Sri Lanka.”
By Martin ‘Tiny’ Barten, senior hatchery specialist, Pas Reform Hatchery Technologies During a recent trip to the tropics, I had the chance unexpectedly to visit a hatchery that was due to host a Pas Reform Academy Seminar. My unplanned visit was well received, giving the hatchery manager the chance to talk to me about chick quality, which was not, he said, entirely satisfactory. Culled chicks and first week mortality were slightly high by their standards. Four hatch days each week meant that I could witness chick take-off during my visit. The newly hatched chicks presented with full bellies - and too many unclosed navels. Other signs confirmed that 502-504 hours of incubation were not enough: the chicks were being pulled too early. At the end of my short visit, we agreed that relative humidity set points would be reduced from 53 to 50%, with incubation starting 4 – 6 hours earlier. A month later, as the hatchery welcomed delegates from all over the region to the Academy seminar, our host’s General Manager asked if I would join him and his team in the evenings. It seemed that while there had been some improvements in chick quality since my previous visit, results were still not quite as they should be. During the day, we were fully occupied with the Seminar programme, taking part in practical sessions, attending
Martin ‘Tiny’ Barten, senior
hatchery specialist, Pas Reform Hatchery Technologies
Pas Reform launches web shop
original, high-quality incubator
The web shop can be accessed
Pas Reform is launching a new
illustrated, with a powerful
zoom function, to enable the
on www.pasreform.com. Here
web shop, as a global service for the ordering of genuine
Pas Reform spare parts anytime, from anywhere in the world. The new web shop provides
Pas Reform’s customers with a
comprehensive, online platform
8
‘On Monday they are …’
for ordering a wide range of
spare parts. Every part is fully
checking of parts in close detail if necessary, before placing an order.
by clicking on the web shop tab you can browse and request for a quotation online in just a few easy clicks. Searching for spare
parts is intuitive, by application
area, keyword or article number. All requests are acknowledged
directly to the registered email address.
presentations and enjoying lively discussion. In the evenings, I joined the hatchery manager and his team and together, we reviewed all the hatchery data. When we looked at the climate histories for the hatches pulled earlier that week, a pattern started to emerge. For each cycle, relative humidity immediately after transfer was very high, gradually decreasing to set point then rising again sharply with the emergence of the chicks. When asked if the hatcher baskets were always 100% dry at transfer, there was a lengthy discussion before agreeing on their reply: “On Monday they are ……”. I concluded that the baskets were not, therefore, completely dry on the other hatch days. When it was also confirmed that chick quality was indeed usually much better on a Thursday, the solution was clear. Evaporating water from wet baskets was reducing the temperature and increasing humidity in the hatcher, resulting in chicks with thick bellies and poor navels. We agreed that an extra set of hatcher baskets would quickly pay for themselves. And to maintain good chick quality in the future, a golden rule would be applied: transfers would always be made in dry baskets!
Turkey’s Erpiliç supersizes with SmartPro™ Turkey’s expanding Erpiliç has awarded its fourth, singlestage hatchery development contract to Pas Reform, for the company’s advanced, SmartPro™ hatchery technologies. The new hatchery in Mudurnu - Bolu, Turkey, has been awarded as a virtually turnkey project and will be boosting production capacity by 61 million day old chicks per year. The contract comprises 36 SmartSetPro™ 115 setters, each with a capacity of 115,200 eggs and 36 SmartHatchPro™ hatchers. Pas Reform’s project team has designed the entire hatchery layout and will remain onsite to deliver training for Erpiliç hatchery personnel, while refining and programming the hatchery’s systems. The decision to work with Pas Reform came, says Project Director Mustafa Ericek, after careful and rigorous comparisons of hatchery equipment manufacturers.
“Pas Reform delivered on every level, not only with a complete, highly advanced single-stage solution on SmartPro™, but also by consolidating their role with a full range of hatchery automation systems and climate control equipment - and the project management capabilities to fully support the development of the hatchery.” Erpiliç was founded in 1969 by the Ericek family, beginning production with just 200 chicks. Now with headquarters in Bolu, Turkey’s broiler capital, Erpiliç’s annual capacity is 80 million hatching eggs per year, with integrated operations that include breeding, incubation, slaughterhouse, processing, parent stock houses and feed factories. Operations are divided for the separate production of delicatessen and processed products. With a string of ISO accreditations, including for Halal production, Erpiliç is fully HACCP Food Safety Certified and places great importance on the maintenance of the strictest hygiene standards, in accordance with Islamic rules, at all its facilities. Erpiliç’s decision has, says Sake Yalcin, president of Refarm A.S., Pas Reform’s representative in Turkey, put the company firmly on the map as the number three poultry producer in the country.
“We wanted a fully integrated approach to the development of our new hatchery project”, he says, “our preference was to work with a single industry partner.”
With all the ease of ordering
Features
catalogue, Pas Reform’s new
Pas Reform’s new web shop
maximum uptime in the
• Open 24/7, 365 days a year –
online from a fully illustrated web shop will help to maintain hatchery. Every spare part
supplied carries Pas Reform’s
guarantee of quality assurance.
offers many useful features:
to order parts anytime, any place
• Easy, intuitive navigation • Every item illustrated
• Spare parts are easily verified with a powerful zoom tool
that allows a close inspection
“Erpiliç’s exacting and progressive approach sets extremely high standards both in Turkey and in those countries they export to. This project is a very good example of futurefocused design – with the emphasis on results for an ambitious and expanding company.”
of the detail in the images
from PCs, Macs and mobile
matically for ease of reference
netbooks and tablets.
• Saves previous orders auto
and speed of repeat ordering
browsers, to smartphones,
• Guaranteed reliability from
Pas Reform’s webshop has been
of costly downtime from
to ensure that all page features
genuine parts avoids the risk using uncertified parts.
Customers are visiting
www.pasreform.com from
an increasing variety of devices,
Smart hatchery boosts Belpticeprom growth in Belarus
Forward-looking parent stock hatchery Belpticeprom has cemented an important Agreement with Aviagen, to
become the sole distributor of Ross parent stock for the Belarusian domestic market.
The Agreement came just months after Belpticeprom’s
investment in a new state-of-the-art hatchery, designed and equipped by Pas The new ‘Smart™ Hatchery’ was and equipped byReform. Pas Reform. The new ‘Smart™ Hatchery’
planned withwith inputinput fromfrom Aviagen’s European team, to to was planned Aviagen’s European team, include SmartSet™ setters, SmartHatch™ hatchers, Pas
Reform’s Automated Hatching System and SmartCenter™
hatchery management, for the production of up to 4 million hatching eggs per annum.
The installation also includes Hatchery Automation and
Climate Control Systems from Pas Reform, with full onsite
training and hatchery management training provided by the Pas Academy. LastLast year,year, Belpticeprom further the Reform Pas Reform Academy. Belpticeprom further
extended the hatchery complex to increase production up to 6 million hatching eggs a year.
Visit Pas Reform’s web shop at www.pasreform.com
created using responsive design, and functionality can be seen
and used no matter how large (or small) the display.
9
Balance for perfection Stuck at Mumbai Airport because of a volcanic ash cloud, I found myself thinking about how, during my visits to so many different hatcheries, certain aspects of incubation remain a recurring point of discussion. One such point is the impact of under-loading setters and hatchers, which can cause problems if the less than full machine is not loaded “in balance”. I recalled visiting a customer’s hatchery, where the hatchery manager took me to the setter room, explaining as we went that in some machines, although egg shell temperatures in one section were good, the temperatures in another section of the same machine were too high. We entered a setter containing 17 day old embryos and immediately I noticed one completely empty section, although all the other sections fully loaded, each with four trolleys. On measuring egg shell temperature in the section opposite the empty one, I found an average of 102 ºF, with more variation than normal. Temperatures in the other loaded sections were fine.
again, we found normal values in all sections of the machine, which would definitely improve chick quality and help to reduce the hatch window. Similar situations have occurred in other hatcheries, irrespective of incubator brand, in both the setters and the hatchers. In a hatcher, when baskets are stacked higher on one side, it is easier for the air to circulate on the side with fewer or no baskets, where resistance is much lower. In this scenario, air passes less effectively through the baskets with the heat producing embryos, resulting in an overheated micro-climate. Careful observation during chick take-off will reveal reduced chick quality, or in the worst case, baskets with a higher incidence of unhatched eggs.
“Pindos” Ioannina Agricultural Poultry Farming Cooperative, the largest poultry sector cooperative in Greece, has awarded the development of a new hatchery complex to Pas Reform. In conjunction with Pindos’ existing hatchery – commissioned with Pas Reform in 1994 – the new facility doubles production to 1 million day old broiler chicks per week.
For optimal results, machines should always be loaded according to the manufacturer’s instructions. When machines are fully loaded, there is little room for mistakes. But when machines are loaded at less than full capacity, it is important to consider the flow of air - which in the daily practice of the hatchery means loading both setters and hatchers in a balanced pattern, to give each embryo an equal opportunity to thrive.
As President of Pindos Cooperative, Mr Michael Kasses represents the interests of 560 member poultry producers, in a vertically integrated organization that currently delivers 25 million broilers each year. He says, “With 5,000 retail outlets to serve currently, demand for poultry and poultry products is growing here in Greece. The Cooperative has chosen Pas Reform for its innovation, reliability and cost-efficiency, as we focus on meeting home demand while at the same time expanding our export operations to the Balkans, Europe and Asia.”
I explained that the imbalance in the way the machine had been loaded was having a negative effect on air flow. To restore balance and optimize air flow, we moved two trolleys towards the ventilator-side of the opposite section. Several hours later, when we measured shell temperature
New poster charts embryonic development of the chick Pas Reform’s new poster
illustrates each of the 21 days of chick development during
incubation. Large, clear, colour
Each image includes 'daily
notes', to describe key changes.
To receive your free copy, please email info@pasreform.com
Embryonic development of the chicken Pas Reform Hatchery Technologies Pas Reform is an international company, which has specialized in the development of innovative hatchery technologies for the poultry sector since 1919. The company has earned its position as one of the world’s leading hatchery equipment manufacturers, through decades of research into the biological and physiological aspects of embryo development, combined with a thorough understanding of all aspects of the poultry production chain – and a dedicated focus on the future.
Embryo
Day 1
Day 2
[0-24 hours]
Phase 1 - Differentiation • A primitive streak and headfold are visible in the embryo • Sub-embryonic fluid forms a concentric ring around the embryo
phases of embryonic
10
Eye pigmentation
Head
Eye pigmentation
Day 3
[25-48 hours]
Phase 1 - Differentiation • Head and heart structures are formed • First signs of blood ring • Sub-embryonic fluid formation is clearly visible in the yolk
Knee
Umbilical cord
Eye
Heart
Sub-embryonic fluid
Leg
Area vasculosa
Blood ring (Area vasculosa)
images help to observe the key development, a day at a time.
First signs of blood ring
Sub-embryonic fluid
Day 4
[49-72 hours]
Phase 1 - Differentiation • Blood ring (Area vasculosa) • Heart beats • Head is turned to right
Ear
Amnion
[73-96 hours]
Phase 1 - Differentiation • Embryo turned to its left side • Wing and leg buds develop • Eye pigmentation: distinct
Albumen proteins
Day 5
Day 6
Day 7
Phase 1 - Differentiation • Elbows and knees develop • Area vasculosa covers 50% of yolk sac
Phase 1 - Differentiation • Beak becomes visible • Autonomic movement begins • Albumen proteins are concentrated in the sharp end of the egg
Phase 2 - Growth • Egg tooth and comb appear • Digits and toes are visible • Legs move
Umbilical cord
Eyelids
Ear
Digits and toes Wing
Egg tooth SmartPro™: optimising embryonic development
Feather primordia
Yolk sac
Thigh
Day 8
Day 9
Day 10
Day 11
Day 12
Day 13
Day 14
Phase 2 - Growth • Three rows of feather primordia are visible • Calcification of bones is initiated • Upper and lower beak
Phase 2 - Growth • Chorioallantois covers 80% of embryo and yolk sac • Mouth opening appears
Phase 2 - Growth • Rhythmic contractions of the amniotic muscles rock the embryo in the amniotic fluid • Feather follicles are visible • Toes are now completely
Phase 2 - Growth • Scales on legs can be recognized • First feathers • Volume of amniotic cavity maximum
Phase 2 - Growth • Eyes open • Chorioallantois complete and closed • Albumen proteins transported in yolk sac
Phase 2 - Growth • Head in yolk sac • Metabolic heat production and oxygen consumption increase exponentially • Periods of embryonic activity
Phase 2 - Growth • Embryo starts turning towards air cell
Phase 1 - Differentiation In the freshly laid egg, the embryo consists of a sheet of cells segregated into groups that will eventually form specific tissues and organs. Differentiation of embryonic cells begins in the oviduct, continuing during incubation at the optimum temperature of 37.8 ºC (100 ºF). Extra-embryonic tissues, e.g. yolk-sac membrane and chorioallantois, grow to form the different fluid compartments. The blood vessel rich yolk-sac membrane supplies nutrients to the embryo. The chorioallantoic membrane is involved in the exchange of gases (O2 and CO2) through the shell and forms the allantoic cavity, where metabolic waste products are collected. Phase 2 – Growth Half-way through incubation, bodily organs have reached 95% of their final form and need only to increase in size and mature in functionality. Growth therefore occurs in the second half of incubation as the functional maturation of tissues and physiological control systems and continues until the bird is ready to hatch. During this time, extraembryonic fluids are absorbed by the embryo. Phase 3 – Maturation The embryo has reached its final size, but the physiological control systems are yet to
www.pasreform.com
By Martin ‘Tiny’ Barten, senior hatchery specialist, Pas Reform Hatchery Technologies
Pindos Cooperative targets growth with Pas Reform in Greece
SmartTray™ 126, capacity 126 turkey eggs
SmartTray™ 126, capacity 126 duck eggs
SmartTray™ 150, capacity 150 hen eggs
SmartTray™ 162, capacity 162 hen eggs
Smart expansion for Ross Breeders Anadolu in Turkey In response to continuing growth, Aviagen-owned Ross Breeders Anadolu (RBA) is to step up its domestic production of parent stock chicks, with the commissioning of a new Smart™ single-stage grandparent stock hatchery from Pas Reform. Located at Elmadag, the new hatchery will include SmartSet™ setters, SmartHatch™ hatchers and a SmartCenter™ hatchery information system, with automated egg receiving, egg transfer and chick handling and a hatchery climate control system that incorporates energy-saving heat recovery systems. The hatchery, Turkey’s leading supplier of broiler breeder day old chicks, will more than double annual production for RBA’s domestic market, bringing total capacity to 13 million day old breeder chicks each year. Pas Reform will also provide a comprehensive hatchery management training programme, to ensure that production and performance are quickly optimised.
SmartTray™ Driving performance and uniformity in the hatchery “It’s quality that counts!” Midway Chickens’ Lee McGrath was very certain of what he expected for his hatchery, when he placed his first order for Pas Reform’s antimicrobial Smart™ setter trays in Bela Bela, South Africa, a year ago. Today, as he receives two containers of Microban® treated SmartTray™’s, his view has not changed. After Midway, others followed. From Opti Chicks in Lichtenburg and Supreme Poultry in Bloemfontein, to Eagle’s Pride in Pretoria and Rainbow in Worcester. Since its introduction in 2008, SmartTray™’s success in South Africa has been repeated around the world. Some resourceful customers and their partners have even re-purposed SmartTray™ for the transfer of hatching eggs to the hatchery, while customers of other equipment manufacturers are also seeing the benefits of using Pas Reform’s setter trays in their equipment. Designed to cradle hatching eggs of any size safely, the open construction of Pas Reform’s SmartTray™ delivers uniform airflow during incubation. This helps to create an ideal environment for each embryo, to produce day old chicks, ducklings or turkey poults of the highest quality. Improved setter tray design delivers greater comfort and uniform airflow Genetic selection for high post-natal growth has produced higher levels of metabolic heat production by modern chick embryos. This additional heat makes greater demands of setter management in order to achieve optimum hatching results.
Pas Reform’s SmartTray™ has been designed to help nurture modern embryos during the critical phase of incubation. An open, spacious grid prevents the development of ‘dead spots’, allowing air to flow freely for the homogeneous distribution of heat and humidity. With integral supports for hatching eggs at two levels, the tray is suitable for eggs of all sizes, with stable, self-centering egg positioning to protect the eggs, prevent hairline cracks – and promote pinpoint accuracy when injecting the eggs during in-ovo vaccination. The incorporation of Microban® antibacterial protection means that using SmartTray™ actively reduces the risk of cross contamination by food poisoning bacteria, in the hatchery or in the farm, by up to 99.9%. Safe and secure in handling, stacking and storage SmartTray™ was designed to withstand the demands of the highly automated hatchery, from frequent washing and disinfection, to transport, load, impact and temperature changes. A blind find bottom design finds its own secure locking position for fast, stable stacking, and with a completely smooth finish for easy, thorough cleaning, this HACCP compliant, ergonomically designed setter tray is still lightweight, comfortable and secure in handling.
Pas Reform Southern Africa L-R: Jesse Bunge, Adriaen Sligcher, Adriaan Gebhardt, Jankees Sligcher
11
Watter® Safe, sustainable disinfection for the hatchery sector
Simple, safe and sustainable In simple terms, Watter’s patented Nontox unit produces a safe, powerful disinfecting solution by adding salt and electricity to water. The result can be described as ‘electro lysed oxidizing water’ and with a Nontox unit installed, the hatchery can continue to supply as much of this solution as it needs, for the routine disinfection of facilities and equip ment - and for fogging to sanitise hatching eggs prior to setting. The disinfectant leaves no residues on surfaces, and no build-up of resistance has been encountered in bacteria. Nontox is effective against fungi, including Aspergillus Spp. It leaves no residues on surfaces, and no build-up of resistance has been encountered in bacteria. Putting Nontox to the test With certification for on-farm use that confirms both claims and regulatory compliance for Nontox, leading Dutch hatchery Probroed & Sloot was the first commercial operation to test Watter’s system in a live hatchery situation. The Nontox system has a minimal footprint and in this hatchery is plumbed to an 80 litre tank that holds the readyto-use disinfecting solution: a reserve to be drawn upon as required, for washing, fogging and other hatcherydisinfection applications – and topped up again between cycles and when demand is low. The system is capable of producing 70-80 litres of disinfecting solution per hour and the salt tablets are supplied in sealed, conveniently sized ‘whole-use’ polythene bags, which go straight into the unit’s hopper. Modular configuration means that simply adding additional units to feed a larger reservoir will produce larger quantities of Nontox. And by delivering a sustainable source, on site, the Nontox system provides a convincing return, not only by reducing the costs associated with frequently repeated orders for chemicals and disinfectant over time, but also for its associated benefits to the welfare and performance of the chicks and the health of hatchery personnel.
With more than 90 years invested in its global development, Pas Reform has witnessed many changes in the poultry sector, both in The Netherlands and worldwide. One of the key debates to emerge in recent years has surrounded the use of formaldehyde and other chemical preparations, to meet increasingly stringent regulations surrounding health and hygiene in the commercial hatchery. There is evidence that the use of formaldehyde, originally and accidentally discovered in 1859, represents a risk both to human health and to chick welfare. Yet despite mounting international pressure to eradicate its use in the hatchery, formaldehyde persists as a solution for disinfection largely for the lack of a suitable alternative. Pioneering alternative to chemicals In October 2011, Pas Reform signed an exclusive agreement with Watter, an award-winning Dutch company that has pioneered a clean, efficient alternative to chemical preparations, including formaldehyde. Watter’s ‘Nontox’ Electrical Chemical Activation (ECA) disinfection technology harnesses the power of naturally occurring oxidants using water, salt and electricity to produce a powerful, highly sustainable and non-toxic
Independent tests carried out by Dutch Organisation for Applied Scientific Research (TNO) and the Dutch National Institute for Public Health and the Environment (RIVM), have found Watter’s ECA system to be effective in six key EN standards for the disinfection of Food, Hands, Medical Instruments, Rooms, Surfaces and Water Sources. TNO laboratory studies showed that Nontox delivered at least the required 5 log reduction of various bacteria, including E.coli, Staphylococcus aureus, Enterococcus hirae and Pseudomonas aeruginosa, in accordance with European standard EN 1276. A screening test based on EN1276 test principles showed the same convincing results with MRSA and Salmonella Typhimurium target bacteria. The fungicidal effect of Nontox, including the inactivation of Aspergillus niger, was also effective to >4 log reduction, to meet EN standard 1650.
Pas Reform appoints representative in Peru
Company’s Smart™ techno
support, with direct access to
experienced poultry industry
With strong growth in the Latin
training services has soared in Latin America. As a major
support services for Peruvian
experience of managing agro
American market, Pas Reform
has appointed Balanceados y Saneamientos to represent
Smart™ single-stage incubation
logies, project management and
poultry producer, Peru is an
important contributor to Pas
Reform’s growth in the region.
technologies in Peru.
Balanceados y Saneamientos
production facility Pas Reform
distributor in the country,
Since the launch of its new
12
disinfectant that neutralizes bacteria, fungi and viruses. The disinfecting action is the effect of combining free radicals with active chlorine compounds, such as HClO and ClO, which are produced when electricity is passed through the brine solution created by adding the salt tablets to the water.
do Brasil, demand for the
will operate as Pas Reform’s sole delivering sales and technical
spares and a full range of hatchery customers. Founding director of
Balanceados y Saneamientos,
Eng. Luis Dulanto will, he says,
employ an incubation expert to support customers locally, with the business being managed
day to day by Oscar Buenano, an
professional with 13 years industrial projects.
A sustainable alternative Nontox represents an exciting and genuine route to abolishing the use of formaldehyde in hatcheries, while respecting and protecting the welfare of people and chicks. Hatchery personnel need no longer be exposed to its harmful effects and day old chicks can be protected from the detrimental effect of formaldehyde on the tracheal microvilli. With previous innovations including, for example, the incorporation of Microban® into setter trays and hatcher baskets and the integration of cooling pipes into the anodized aluminum walls of Pas Reform’s SmartPro™ incubation system, The Watter system represents another important step in creating safer, cleaner hatchery environments. Pas Reform has worldwide distribution rights for Nontox in the hatchery sector, and is collaborating actively with Watter to develop a variety of new applications: still further innovations that underpin Pas Reform’s commitment to delivering exemplary hygiene in the modern hatchery.
PT QL Trimitra expands with Pas Reform
QL Group has recently invested in 18 SmartSet™ 115 setters and 18 SmartHatch™ hatchers, to expand operations. Mr.
Cecep, Group COO says: "Everyone in the decision-making
process at QL Group was unanimous in selecting Smart™", based on the quality of performance, reliability and
technical service support that we have always received as a customer of Pas Reform."
The Watter® system – Plug and play device for effective, ready-to-use disinfectant
– Bactericidal, fungicidal, virucidal
– Sustainable and inexpensive
production: on demand supply
– Compact, robust design
– Large internal 85 liter storage tank
– Integrated softener, pressure
Pas Reform’s SmartPro™ the logical choice for Miratorg
reducer and water filter
– Self cleaning, without chemicals
– Saves time and reduces the need for secure storage
– Simplifies Health and Safety procedures
Miratorg Agribusiness Holding has commissioned a 75mn eggs per year hatchery from Pas Reform. The new installation will incorporate forty-two SmartSetPro™ setters, six with a capacity of 38,400 eggs and thirty-six with a capacity of 115,200 eggs each. The comprehensive installation also includes a complete line of hatchery automation systems: automatic candling and transfer, back filling unit and setter trolley loader/ unloader, with climate control systems throughout the hatchery.
Watter® System demonstration
Pas Reform is also delivering a full package of specialised engineering services and online training for Miratorg hatchery personnel.
“This is an important new
to Zeddam (The Netherlands),
our products and services to
results follow up, support and
products”, says Oscar, “ and I am
management training at Pas
it was quickly evident that the
online, to hatchery customers
addition to our current range of very pleased to be working
alongside the other Pas Reform team representatives in Latin America.
for the week-long hatchery
Reform Academy - and their
feedback has underlined the
importance of this aspect of the service we provide.”
“SmartPro™ incubation techno
Pas Reform Director of Inter
for this market. I have already
Development, Bouke Hamminga,
logies are clearly an excellent fit taken several of my customers
Latin America several years ago,
analysis via SmartCenter™
Contact details for Pas Reform’s new office in Peru are:
in Peru.
S.I.B.S.A.
training programme from the
“We look forward to working
y Balancead
key to our growth.
customers, to augment Pas
combination of state-of-the-art
equipment backed up by a solid Pas Reform Academy would be
national Sales & Business
“Balanceados y Saneamientos
concludes, “When we brought
capability, together with onsite
now brings that combined
with Luis and Oscar and their Reform’s position in this
dynamic and growing market.”
Saneamiento de Ingredientos Av. Manuel Olguin No. 335 - Of 607
Santiago de Surco, Peru T +511 637 36 37
E sibsa@sibsaperu.com
13
ESM™ Energy Saving Module Substantial energy savings for rapid payback Spiraling costs have placed energy consumption under the spotlight for us all – and for growing, modern hatcheries, highlighting energy as an expensive commodity that puts increasing pressure on the bottom line. Yet while costs may appear to be rising inexorably, technological advancement is easily keeping pace. The example below illustrates how ESM™ translates into savings for the hatchery, based on results in a hatchery with European climate conditions, to estimate energy usage over one year (see Table 1) for 70.9 million day old chicks produced during that time. What is immediately clear is the impact of electricity consumption by the setters: a striking 42 per cent of total energy consumption in the hatchery. This is not in fact so surprising, as these setters run 24 hours per day, seven days a week. However this factor creates a priority focus on where savings can be made – and the question must be whether it is feasible to deliver significant savings on setter electricity consumption, without having an adverse effect on the hatchability, uniformity and robustness of the day old chicks. Annual
consumption (€) Electricity for Setters:
150,000 (42%)
Heating for Setters & Ventilation:
60,000 (17%)
Cooling for, Setters, Hatchers &
59,000 (17%)
Electricity for Hatchers:
51,000 (14%)
Electricity for Ventilation & Various:
33,000 (9%)
Total:
€ 353,000 (100%)
Ventilation:
Table 1. Traditional yearly energy
consumption, 70.9 million DOC hatchery
There is a direct relationship between rotation speed and the energy consumption of fans. Behind the formulae, an example for reducing rotation speed by 25 per cent is represented by the following data: n1 = 180 rpm n2 = 25% lower = 0.75*180 = 135 rpm P1 = 1000 W
Pas Reform’s Energy Saving Module (ESM™) therefore produces energy savings of (42%x58%x50% =) 12 per cent for the entire hatchery, by providing finite control of fan RPM and actively controlling ventilation speed in the setter.
Power: 1.000 = 421 W n1 = rotations per minute at original pulsator speed
n2 = rotations per minute at pulsator speed reduced by 25% p1 = power at n1 pulsator speed
p2 = power at n2 pulsator speed
This example shows the significant impact of reducing rotation speed on shaft power – 75% x 75% x 75% = 42% energy consumption, a reduction of 58%. For optimised incubation, it is important to maintain a good incubation climate. Pas Reform Academy therefore studied the following: 1. By what percentage can we safely reduce fan speed, without affecting hatchability and day old chick quality? 2. When during the 18-day setter cycle can fan speed be reduced safely and effectively? Energy Saving Module (ESM™) In recent years, we have seen that using the ESM™ module saves energy and does not undermine chick quality in any way, due to the incubator’s innovative fan design and the metabolism-based RPM control of the Energy Saving Module. Heat exchange between the embryos and their incubation environment is high during the first and second days of incubation (heating), low during days 3-12 and increases to high levels again from day 13-18 (cooling).
Next generation design for the future-focused hatchery
Tests show that with SmartSet™’s Delta Pulsator and SmartSetPro™’s Vortex™ airpump, it is indeed possible to reduce RPM for 50 per cent of the time in the setter – and during days 3-12, to reduce RPM by 25 per cent, without adversely affecting hatchability rates, hatch window or day old chick quality.
Pas Reform Academy Putting science into practice
The impact of energy costs on ESM™ payback time Of course, energy prices vary from one country to another – and this will have an impact on these savings. Pas Reform Academy has also calculated savings per setter for different countries in the world, to illustrate respective payback times (see table 2). From these comparisons, we can see that on average, payback time on investment in an ESM™ upgrade is well below two years. Easy installation means rapid access to savings To upgrade Pas Reform setters with ESM™ is a simple procedure, that can be undertaken by the hatchery’s own technical personnel. Specialist skills or a visit from a Pas Reform technician are not required. The ESM™ upgrade kit comes ready for installation, with clear instructions in a simple, step-by-step manual for the installation of the ESM™ module and the required software update process. Within hours, you could be making substantial energy savings every day.
SmartTrayTM Incorporating Microban® antibacterial product protection
Designed to cradle hatching eggs of any size safely, the open construction of Pas Reform’s SmartTray™ is proven to deliver a uniform airflow during incubation. This helps to create an optimal environ ment for the growing embryo, to promote day old chicks, turkey poults or ducklings of the highest quality.
Watter®
Integrating Vision Technology for high capacity counting, vaccination and the analysis of day old chicks
Hatchery disinfection system Patented Nontox Electrical Chemical
Nontox is available exclusively from
Activation (ECA) combines salt and
Pas Reform in the hatchery sector.
electricity with water, to produce a powerful, highly sustainable and non-toxic disinfectant that neutralises bacteria, fungi and viruses in accordance with key EN standards for disinfection.
Pas Reform Hatchery Automation 2nd Edition | Including 21 day embryo development poster
Pas Reform Hatchery Technologies
14
Pas Reform Hatchery Technologies
Pas Reform Hatchery Automation
When eggs are stored too long
Country
Price of KWh
Savings per
Pay back time
Brazil
0,10
1.488
1.3
India
0,11
1.637
1.2
Indonesia
0,06
893
2.2
Italy
0,13
1.934
1.0
Mexico
0,08
1.191
1.6
Netherlands
0,09
1.339
1.5
Russia
0,09
1.339
1.5
Spain
0,09
1.339
1.5
South Africa
0,06
893
2.2
South Korea
0,06
893
2.2
USA
0,07
1.042
1.9
(in €)*
year (in €)
(in years)**
Table 2. ESM™ investment pay back calculation for different countries
* Based on the energy consumption of a setter with 115,200 egg
capacity/year; Energy usage without ESM™ per year in KWh: 41,714; Energy usage with ESM™ per year in KWh: 26,830; Savings per year (in KWh): 14,884
** Based on Investment price for ESM™ upgrade kit
More questions? For SmartSetPro™ Setters or SmartSet™ setters with capacities of 76,800, 57,600, 38,400 or 19,200 eggs, or varying KWh prices for your location, please contact your nearest Pas Reform representative, who will be happy to calculate potential savings specifically for your hatchery and location at no charge to you – or contact Mr. Erik Meijer, service manager Pas Reform Hatchery Technologies, by telephone on +31 314 659111 or by email at e.meijer@pasreform.com
By Martin ‘Tiny’ Barten, senior hatchery specialist, Pas Reform Hatchery Technologies Last year, I visited a hatchery that was fully dependent on imported hatching eggs. To ensure a constant supply of eggs, the hatchery had an export agreement for 1,600 boxes to be flown in every week. Egg age at setting averaged 7 – 9 days, from which the hatchability of eggs set was 86 per cent. During the first day of my visit, the egg storage room was still quite full, despite the fact that a delivery of eggs had been cancelled the previous week, due to extremely bad weather. The hatchery manager explained that reduced setting rates, due to the upcoming Christmas season, were due to the processing plants having fewer working days and reducing the numbers of eggs set, as a smaller number of broiler farms needed to be supplied 2 - 3 weeks later. The following day was “egg delivery day”, and this time, two planes landed, one carrying the batch that should have arrived the previous week. That day, six truckloads of eggs arrived at the hatchery - and clearly the egg storage room’s capacity was not able to cope with that. The oldest eggs, still left behind from the previous week, had already been transferred to setter trays the day before and were now wheeled to the setter room, waiting to be set a day later. However the newly arrived boxes still did not all fit into the storage room, and some had to be placed in uncooled corridors and even outside, under a roof with an external temperature of 30 - 32 ºC . I advised the removal of the empty (folded) egg boxes that were piled up, ready for sale, in the egg storage room, and to give the highest priority to storing the hatching eggs under optimal conditions. In the following weeks, hatch results gradually dropped to a low of 65per cent. I explained that the policy of setting the oldest eggs first, then adding further, large stocks of eggs every week, was resulting in an average egg age being too high.
Pas Reform innovations: in print and pdf
All new publications are fully
your chosen publications in pdf
Pas Reform is introducing a
descriptions and available in full colour printed or downloadable
at www.pasreform.com
series of new publications to
support our new innovations for
illustrated, with detailed
For your own free copies, please
SmartTray™ and Pas Reform
details of the publications you
Academy.
SmartPro™ for Brazil’s expanded Granja Pinheiros hatchery
Granja Pinheiros is the latest hatchery in Brazil to
commission SmartPro™ hatchery technologies from Pas
Reform, for the refurbishment and expansion of its hatchery at Nova Petrópolis, in the Serra Gaúcha region of Brazil.
The Project, delivered by Pas Reform do Brasil, has included the installation of SmartSetPro™ setters, SmartHatchPro™
hatchers, a SmartCenter™ hatchery information system and
climate control for the newly expanded hatchery, in a region that averages almost 600m above sea level.
format from Pas Reform online
pdf formats.
the hatchery: SmartPro™, SmartCount™, Watter®,
A drop of 1.5 – 2 per cent in hatchability per extra day of storage after the first 7 – 9 days is not unrealistic. The best and most practical solution was, I advised, to send one entire delivery of the oldest eggs for consumption to the egg industry - and bear the losses. This proposal was accepted – and despite the short, sharp pain of repurposing hatching eggs for eating, the hatchery is now back to delivering their original, profitable results.
email info@pasreform.com with would like and where we can
send them to you, or download
15
SmartSetPro™
Projective capacitive touch screen technology
AMF™ adaptive metabolic feedback
Modular machine control
SmartHatchPro™
Modular hatcher design
SmartTray™ 150, capacity 150 hen eggs
SmartBasket™ and SmartCover™
SmartTray™ for free movement of air vortices
SmartTray™ 126, capacity 126 turkey eggs
iPad technology for hatchery managers
Watter® hatchery disinfection system
61
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SmartCount™
16
Accurate counting and stress-free chicks
Uniformity scoring for batches of chicks
SmartTouch™ human interface
Vortex™ air pump system
ESM™ energy saving module
Inspection window
SmartWatch™ hatch window module
Vortex™-based airflow
SmartTray™ 162, capacity 162 hen eggs
Vortices flow parallel with turning direction of trays
Easy accessibility
Smart™ spare parts information and ordering system
SmartTray™ 126, capacity 126 duck eggs
SmartTransfer™ setter trolley loader
Integrated, accurate spray vaccination
Detailed data analysis and batch reporting
SmartCenter™ for total hatchery control
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Assuming that ‘anything is possible’ in the hatchery By Martin ‘Tiny’ Barten, senior hatchery specialist, Pas Reform Hatchery Technologies From time to time, a customer describes a problem that at first seems “impossible”. However over the years, I have learned that ‘impossible’ is rarely, if ever, the case – and thorough investigation will usually identify the cause of the problem. I remember a case when a customer had complained that, although the chicks from his single-stage machines looked fine and hatchability was excellent, the chicks were not performing well in his customers’ broiler houses. This was in contrast to the performance of chicks from the hatchery’s traditional, locally produced multi stage machines, which were performing as normal. During a visit to the hatchery, I could at first find little if anything wrong, especially not in the egg handling room and setter room. With no previous experience of single-stage incubation, the hatchery manager was using our Incubation Guide for reference which, he explained, had helped him considerably in getting used to the concept. As our investigation continued, we looked at the hatcher. Here I found something that was a concern: temperature was in my opinion set far too low. This, it transpired, was based on previous experience, working with the traditional machines, which were dependent mainly on air-cooling. It was not, I explained, a good idea to assume that a set point working well in a particular brand of incubator will automatically do so in another type of machine. With this
caution, I advised him to increase the temperature in the hatchers to 98 ºF. The next day, we visited several broiler houses with chicks of one week old, maximum. Here indeed, the chicks were very inactive. Many of them were lying down with their necks stretched out. Clapping my hands produced almost no reaction from them. Temperature measurement in these houses revealed that brooding temperatures were higher than normal. This explained the chicks’ inactivity, resulting in low feed intake and accordingly poor performance. The farmers said they did everything as they normally did, when receiving chicks from the old machines. In general, traditionally incubated chicks are exposed to warmer conditions during the maturation phase of incubation. Consequently, chicks incubated in this way are more comfortable with higher temperatures on the farm. In the single stage incubator, however, chicks hatch at a lower temperature and therefore are more comfortable if the temperature in the broiler farm is reduced by several degrees centigrade. This was especially so in this case, where the temperature set point in the hatcher was also lower than recommended. Farmers due to receive chicks from this hatchery later that week were informed accordingly and indeed, I was later advised that the performance of chicks from the single stage incubators had improved remarkably and they were behaving normally and actively in the broiler houses.
Pas Reform has many faces Pas Reform do Brasil around the world – all committed to innovation, quality and results, and all working to build sustainable futures in the modern poultry sector.
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Paragon Group in Bangladesh commissions further hatchery expansion with Pas Reform
Paragon Group of Bangladesh has commissioned the third and final phase of its current GP Hatchery expansion with Pas Reform.
Two breeder hatchery expansion projects employ Smart incubation, Hatchery Automation and Climate Control
systems from Pas Reform. With a capacity of one million
day old chicks per week, these two projects will bring the
company’s breeder hatchery production to a total weekly output of 1.5 million.
Paragon Group was the first poultry breeding company in Bangladesh to adopt Pas Reform’s Smart hatchery
technologies in 2004, when a new hatchery was commis sioned for its Hubbard broiler GP operations. In 2008, the company expanded its broiler GP hatchery, again with
Smart systems from Pas Reform, with a second expansion
phase completed last year to increase capacity still further.
IKO Poland chooses SmartPro™ incubators
Established on the Polish poultry market since 1999, IKO
Kompania Drobiarska is a forward-looking integration that
has built a reputation for high quality poultry meat products, including the distribution of fresh and frozen ranges in Europe and Asia.
Quality product has driven expansion in all its markets, and IKO is expanding accordingly. The company has once again commissioned hatchery expansion through Pas Reform, after looking closely at proposals from a number of suppliers.
In 2008, Pas Reform specified and installed an extension to IKO’s existing hatchery operations, adding 12 SmartHatch™
hatchers to work inline with their 30-year-old predecessors. In 2011, IKO selected SmartPro™ incubators, to more than double its hatchery capacity in 2012, to 750,000 day-oldchicks per week.
Along with the production increase, the plant has moderni sed its cooling system, slaughter livestock unloading
process, production management and packaging methods. All poultry are produced, reared and slaughtered under regular veterinary supervision, in a fully integrated
environment that controls quality and conditions from the egg right through to meat production.
The company has established a daily distribution network for around 100 different, fresh and frozen products,
including barbecue and smoked ranges. Besides using
traditional trayed packaging with stretch plastic wrap,
vacuum and bags, IKO Kompania Drobiarska also offers safe MAP, or ‘modified atmosphere’ packaging.
Ross, Cobb and Hubbard Flex eggs are transported to the hatchery from IKO’s seven breeder farms in specialised
transport, with precise microclimate control during storage. Seven broiler farms, all operating under strict veterinary supervision and to high standards of animal welfare,
Pas Reform launches iPad technology for hatchery managers Pas Reform has called on the latest iPad technology, to dynamically link hatchery managers to their SmartCenter™ Hatchery Information Systems.
Hatchery Operations
The iPad displays a customized, multi-touch onscreen layout of the hatchery, serving as a control panel to SmartCenter™, the hub of real-time data from the entire hatchery.
Hatchery Management
Virtually every function and parameter for each incubator can be accessed and controlled from easy-to-read, colour coded incubator icons on the iPad screen. With a single click, each icon opens a full status screen and real-time information for the corresponding SmartSetPro™ setter or SmartHatchPro™ hatcher. Specific Application or App downloads are not needed. The tablet dynamically links hatchery managers to their SmartCenter’s™ Hatchery Information System by means of three main program tiers:
To fine-tune settings for optimum incubation conditions.
To manage key hatchery functions, from alarm management to breed specific incubation programming. Hatchery Analysis To produce real-time hatchery management reports for analysis and decision-making. With integrated WIFI connectivity through a secure SSL connection, the iPad can be used anywhere, in or outside the hatchery, to monitor and actively manage operations, from responding to alarms to fully customizing individual incubation programmes, analyzing results or producing reports.
specialise in the production of high yield chicken.
The company produces 4,000t of feed each month,
exclusively of plant origin, with cereals characterised by
high nutrition values, to meet or exceed all national and
international sanitary, ecological and production standards.
Pas Reform Russia
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Worry-free ventilation for constant chick quality By Martin ‘Tiny’ Barten, senior hatchery specialist, Pas Reform Hatchery Technologies Several years ago, I was involved in reviewing the incubation programme for a newly constructed hatchery in the humid tropics. The main issue was that, although hatchability was excellent, chick quality was not - primarily due to thick bellies. Lowering humidity set point in the setter from 53% to 50% delivered the quality this hatchery was looking for, with first week mortality in the farm reducing to significantly below their standard. However as soon as “winter”, with daily temperatures of 18-25 °C, was over, October brought a combination of high temperatures (30 °C) and high humidity (upto 80%). Phone calls described the same thick-belly problem again. By logging-in to the hatchery’s control system remotely, I could see that relative humidity remained well above the previously advised set point during the first days of incubation. Only when valve positions were opened in accordance with the incubation program, did relative humidity reduce to the required point. This was not so strange. Given that inlet air was both warm and humid, it needed little warming after entering the setter and therefore retained high humidity. Combined with water evaporation from the eggs, there was too much water in the air to achieve sufficient weight loss.
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My advice was to open the air valves a further 10–20% during the first days of incubation, to allow relative humidity to drop to its lowered set point. This once again resolved the issue of thick bellies, also demonstrating to the hatchery manager the importance of responding to external climate by running “winter” and “summer” ventilation programs. However external climatic conditions can change frequently – and unexpectedly. In daily hatchery practice, responding quickly enough to compensate for these changing conditions can be difficult. In this case, a newly developed upgrade for the setter’s ventilation control provided a reliable solution. With this in place, humidity becomes the leading parameter for valve position, providing CO2 remains below the designated maximum set point. This is usually reached during the second half of incubation, as the embryo’s metabolism increases. The next time I received a call, the hatchery’s manager reported that life was much improved. With valve positions responding quickly and reliably to changes in external climatic conditions, chick quality was exactly where it should be, and now constantly, throughout the year.
A Smart first for Akyem in Turkey
Turkey’s Akyem has recently invested in a new Smart
hatchery from Pas Reform. The contract comprises 16
SmartSet™ 115 setters, each with a capacity of 115,200 eggs and 18 SmartHatch™ hatchers.
“Pas Reform’s very professional team have been instrumental in helping us draw up plans for our new hatchery”, explains Owner Mr. Süleyman Çaliskan, “with comprehensive engineering drawings and a project management
programme that facilitated rapid, efficient construction.”
(L-R) Thijs Hendrix, President of Hendrix Genetics and Bouke
Hamminga, Director International Sales & Business Development of
Pas Reform Hatchery Technologies
Kurskiy Agrokholding commission Pas Reform for new Smart™ hatchery in Russia
ISA chooses SmartPro™ for new (Grand) Parentstock Hatchery Pas Reform will equip ISA’s brand new (Grand) Parent Stock
hatchery in the Netherlands with the latest generation SmartPro™ incubation technologies, to produce Grandparent (GPS) and
SmartPro™ incubation technologies in the new hatchery will
incorporate Adaptive Metabolic Feedback (AMF™), for simultaneous humidity and CO2 control, and the ability to use Circadian
Parentstock (PS) for the egg industry worldwide.
Incubation™ for more robust day old chicks.
ISA recently signed an Agreement with Pas Reform and other
ISA selected climate control solutions from Hollander Techniek, Pas
of the art new hatchery will be constructed on the site of ISA’s
heat recovery systems in Western Europe. The system’s design
partners, at its headquarters in Boxmeer, The Netherlands. The state current GPS and PS hatcheries , to include 50 SmartSetPro™ setters and 18 SmartHatchPro™ hatchers.
Reform’s strategic partner for climate control, energy saving and
reflects the very high-level bio-security requirements of a pedigree hatchery.
Pas Reform has been commissioned by Kurskiy
Agrokholding, part of Belay Ptica group in Russia, to install a new hatchery in Gorshechnoye, Kursk region.
The commission includes Smart™ incubators, hatchery
automation and climate control systems, to produce 90 mln eggs per year.
Smart™ hatchery automation includes the automatic
transfer of setter trays from farm trolleys into setter trolleys, fully automatic candling and transfer system, setter tray
washing machines and a vacuum offal system. The HVAC system includes a complete climate control system
throughout the hatchery and pressure regulated, integrated heating and cooling systems with outdoor cold water chillers.
With a capacity of c.5 million Parent Stock per year, the new
Energy-saving and environmental concerns were an important
General director of the enterprise is Sergey Vasilievich
the last couple of years, but also a commitment to serving the
water heaters and water cooling systems for heat recovery. Fresh
window was an important factor in selecting Smart™
hatchery not only reflects the growth that ISA has experienced over global egg industry in the most sustainable manner possible.
“The new hatchery will mark the success we have enjoyed in recent
years, yet at the same time, fully supports the ambitions we have to expand our business in the face of a number of global welfare challenges”, said Servé Hermans, ISA’s Managing Director.
The 4,082 m2 parent stock hatchery will showcase a number of state of the art technologies, to produce day-old chicks in a highly efficient, bio-secure and environmentally friendly manner.
element of ISA’s brief. “The hatchery will be equipped with solar
incoming air will be fully conditioned before entering the facilities, to avoid cross-contamination at all costs”, said Ron Jöerissen, ISA’s Production Director.
Erik Hollander, CEO of Hollander Techniek BV, comments, “The
strategic partnership that we embarked upon with Pas Reform
Hatchery Technologies has resulted in this agreement. We are very excited to be building this project with our partner in the
Shelaikin, who says that effectively managing the hatch incubation technologies from Pas Reform. “We know that uniformity and the overall quality of the day old chicks is essential, not only for a good start but also to promote
optimum growth throughout the whole growing period”, he says. “Hatchery Kurskiy Agrokholding has ambitious plans
for the future – and our new Smart™ hatchery will play an important role in helping us to realize those aims.”
Netherlands.”.
Bouke Hamminga, Director of International Sales & Business
Development of Pas Reform Hatchery Technologies, concludes:
“This is a future-focused project, with absolute clarity in terms of human and animal welfare, bio-security and environmental responsibility.”
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Smart™ Incubators: delivering top performance worldwide Field Results: Darling Fresh Chickens, Darling, Western Cape, South Africa SmartSet™ incubators, SmartHatch™ hatchers Hatchery manager Robin Lindt has received a Cobb award for outstanding hatchability figures on consecutive Cobb 500 breeder flocks. Four consecutive flocks, T19, T20, T21 and T22 averaged hatchabilities (from 25 - 62 weeks) of 88.5%; 88.6%; 87.9% and 88% of total eggs set. These flocks hatched on average 10 weeks above 90% of eggs set, an outstanding result says Robin Lindt. Darling Fresh hatchery has been equipped with Smart™ setters and hatchers since 2007 - and producing great results ever since. Mr Lindt attributes this to a combination of good hatchery management, collaborating with Pas Reform Academy and good equipment, as a reliable recipe for the best results.
Field Results: Erb hatchery, Oberdiesbach, Switzerland SmartSet™ incubators, SmartHatch™ hatchers Seven years of operation in Oberdiesbach were concluded with another excellent year of operation for Erb hatchery this year. Built and operational in 2005, Erb hatchery produces day old broilers for the Bell Integration. Over the course of the last five years, the hatch of transferred in the breeder flocks average 96.5 ; 96.2; 95.9, 96.2 and 96.3%. These outstanding results are repeated on a weekly basis, with minimal deviation throughout the year. Resulting day old chick quality is also of consistently high standards. With average first week mortality below 0.5%, Erb hatchery is setting standards for uniformity. Field Results: Agrodanieli, Tapejara, RS, Brazil SmartSetPro™ setters, SmarthatchPro™ hatchers, HVAC system After 18 months in operation, poultry integrator Agrodanieli is reporting excellent results from its new broiler hatchery. Commissioned in 2010, the hatchery incubates mainly Cobb eggs and results are, says hatchery manager Clovis Gottardi, always above breed standard. “Results are superior to multi-stage operations and have exceeded our expectations in terms of hatchability percentage and chick quality,” he says, “with post hatch performance in terms of EPI (European Production Index) outperforming flocks hatched before the new hatchery went into operation.”
Mr. Robin Lindt, hatchery
manager Darling Fresh Chickens, received a Cobb award for
outstanding hatchability figures.
(EPI = ((weight (g) x (1- mortality%))/(number of days x fcr))*10.)
International appointment for Pas Reform
Bob brings almost two decades’
Bob De Rycke (47) recently joined
most recently as a sales director,
Born into the family that owns
in EMEA, with previous
Belgium, Bob has been around
Pas Reform to represent the
company in Belgium, France and francophone Africa. He joins an
international team, with respon sibility for market development and the distribution of Smart™
incubation, hatchery automation
22
and climate control systems.
hatchery sector experience to his new role. Having worked
he has spent the past ten years experience also including sales management roles for Chore-
Time in the Benelux, UK, Ireland, Greece, Turkey and Middle East, and Kemin Industries, again in the Middle East. Bob speaks
German, English, French and Dutch fluently.
Derco Layer Hatchery in
poultry all his life. Trust, he says, is a quality that he greatly
values – and central to his new
role. “In Pas Reform, I see quality in every aspect of the business. That commitment to care at
every stage of the incubation
process has produced some very long-standing relationships around the world.
I am looking forward to pre senting Smart™ incubation
technologies to my prospects
and customers, to deliver many more such rewarding partner ships.”
Amvrosiadis consolidates its position in Greece
Greek poultry company Amvrosiadis S.A. recently
consolidated its position as one of the country’s leading poultry integrations, with a new SmartPro™ hatchery
installation from Pas Reform, capable of producing 250,000 chicks per week immediately, with expansion to 300,000 per week in the short term.
Amvrosiadis has commissioned the new hatchery to include the very latest SmartSetPro™ Setters, SmartHatchPro™
Hatchers with SmartWatch™ Hatch Window Module and
Adaptive Metabolic Feedback™ and a full suite of Hatchery Automation and Climate Control Systems throughout the new facility. Pas Reform will also deliver bespoke onsite Hatchery Management training.
Amvrosiadis S.A.’s works predominantly with contract
farmers, although the company’s own broiler farms still
produce 2 million birds a year. In addition, the integration
includes feed mill, slaughterhouse and frozen warehousing, to supply fresh poultry products of the highest quality
under the brand name ‘Kotopoula Exohis’ (Countryside
Chickens). A Company-owned distribution network delivers fresh produce directly to consumer outlets in central and northern Greece every day. The company has ambitious
plans for future exports to Bulgaria, Romania, Albania and the former Yugoslav Republic of Macedonia (FYROM).
Company President Mr Ioakim Amvrosiadis comments: “For
a consistently high quality product, managing the hatchery climate effectively is very important for us here. With a
climate that changes from dry, high temperatures to much colder or more humid conditions relatively quickly,
SmartPro™ and its advanced features will allow us to
produce consistently high quality chicks throughout the year.”
Pas Reform introduces web-based upgrade for enhanced hatchery HVAC control Pas Reform has introduced enhanced operation for HVAC systems throughout the hatchery, with a dedicated Siemens HVAC web server that provides fully remote control and monitoring via the internet. The Siemens HVAC web server is a compact device that can be integrated directly into Pas Reform’s SmartCenter™ climate control systems or configured to operate independently. Easy to install using USB and Ethernet connections, a full visualisation of the hatchery’s complete HVAC layout is displayed in a browser window, making the full range of HVAC systems information and functionality, including alarms, systems alerts and maintenance instructions available via SmartCenter™, PC, laptop, iPad or any mobile device that supports a web browser. With access to up-to-the-minute status for up to 64 devices and their associated data points on the HVAC system, the web server includes a library of more than 100 applications (devices), for example air handling units, heat recovery systems and buffertanks with pumpsets – and associated circuit diagrams for each device. Each of these may be tailored to the hatchery’s specific installations.
The HVAC web server automatically recognises and selfconfigures connected devices throughout the HVAC installation, which contributes significantly to smooth running and cost-efficiency in the hatchery. In addition, webbased connectivity makes it possible to remotely optimise hatchery HVAC, for frequent, thorough monitoring of process conditions to increase reliability and promote greater energy efficiency. Fault messages can be sent directly to up to four email addresses, for rapid response in the event of an emergency. System reports can also be sent to the four nominated email recipients periodically, with consumption data available for up to two email addresses. Emails are fully encrypted for security. Because the system is web-based, the customer also has the full back up of Pas Reform’s technical team, to provide rapid, remote intervention in the event of a serious fault or technical issue. For more information, please contact us directly at +31 314 659 111 or by e-mail at info@pasreform.com.
Bob De Rycke will be based in
Belgium. His contact details are: Belgium
Bois 4 - 7880 Flobecq Belgium
T +32 68 44 52 80
M +32 476 67 81 82 F +32 68 45 65 22
E-mail bob.derycke@skynet.be
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PBPF signs up for Smart™ hatchery expansion
Fresh Air: a prerequisite for life! By Martin ‘Tiny’ Barten, senior hatchery specialist, Pas Reform Hatchery Technologies Earlier this year I visited a hatchery that has expanded to its current size since Pas Reform installed our first Smart™ machines seven years ago. A new hatchery manager, well educated but lacking practical experience, had recently been appointed, with ample time for his predecessor to pass on his skills.
Priirtyshskaya Broilernaya Ptitsefabrika LLP (PBPF) has
recently refurbished its hatchery in Eastern Kazakhstan Oblast, with Smart incubation from Pas Reform. The
commission includes SmartSet™ setters, SmartHatch™ hatchers, a pressure controlled ventilation system and
hatchery automation systems. PBPF is a subdivision of AFK Ardager LLP.
It appeared from the records that results were well above standard initially. Yet gradually, as the hatchery expanded, the situation had deteriorated. In the setter room, the climate felt so unpleasant that I even developed a headache. In the hatcher room, the hatchery manager showed me some hatcher climate history graphs. Relative humidity raised spontaneously as the chicks started to hatch, but after reaching a peak of 70–75% it did not drop again, even with the in- and outlet valves opened almost completely. Suspecting that the problem was caused by the air supply to the machines, I asked to see the air handling unit. This was supposed to supply fresh, pre-conditioned air to the entire hatchery, as well as maintaining recommended pressure set points in the various rooms, by pressure controlled dampers. To my surprise, air pressure in the air preparation room was set to only 15 Pa instead of the recommended 35 Pa. It looked like this set point had never been changed since being set up for the hatchery running at minimum capacity, when this had provided sufficient air. However with the hatchery now running at expanded capacity, this was no longer the case.
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Upon increasing the set point, the air handling unit could still barely raise the pressure. On opening the unit, the reason for this was clear; the filters were totally clogged up. Luckily a spare set of filters was available on site - and after replacing them, we rapidly achieved recommended pressure. The control boxes for the dampers were all turned to “manual”. Again, this probably sufficed originally, but I convinced the hatchery manager to turn them all to “automatic”, to ensure constant pressures in all the rooms, independent of air demand to the incubators - and also necessary to provide good climatic conditions on hatch days during chick processing. Now that the air supply was being controlled properly, the machines started to respond as would normally be expected. These simple but essential recommendations not only raised hatchery results, but also the confidence – and performance - of the new hatchery manager.
Provita targets rapid expansion in Bangladesh Provita Group has once again commissioned leading Dutch
hatchery technology company Pas Reform, to fuel ambitious plans for the further expansion of its hatchery operations in Bangladesh.
In its first phase, the company installed the Dutch supplier’s
most advanced SmartPro™ incubation, hatchery automation and climate control systems, to expand existing hatchery operations to 50 million day old chicks per annum. The
second phase, due to be operational early next year, will bring annual capacity up to 70 million.
Smart™ Gains for Pato Branco with Pas Reform in Brazil Avícola Pato Branco, recently celebrating 40 years in the Brazilian
“Aside from the company’s reputation for innovation,” she continues,
technologies for its new hatchery development at Pato Branco,
from sales and commissioning, hatchery planning, project
poultry sector, has commissioned SmartPro™ single-stage Paraná state.
SmartSetPro™ setters and SmartHatchPro™ hatchers deliver an
annual capacity of 50 million hatching eggs in the new hatchery’s first phase of development, with a second phase scheduled to increase capacity up to 100 million hatching eggs per year.
The new hatchery employs Pas Reform’s hatchery automation and
“we also found a supplier that delivers throughout the process -
Smart™ collaboration for UKPF with Pas Reform in Kazakhstan
management and installation to after sales, technical back up and
training services.” Mr Thomas Calil, Managing Director of Pas Reform do Brasil, has led the introduction of SmartPro™ into Brazil, where the adoption of single stage hatchery technologies is seen
increasingly as an important factor in the evolution of the poultry business, in line with similar transitions that are occuring in other Latin American countries.
climate control systems, including bacterial and fungal filtration,
Pas Reform do Brasil has invested substantially in its warehousing,
optimised hygiene in the flow of eggs and chicks. Microban®
Technical and commercial staff are locally based, to deliver onsite
New collaborations continue to develop for Pas Reform in
services. Virtually everything is sourced by and from local suppliers,
Kamenogorskaya Ptitse Fabrika (UKPF) in Kazakhstan.
pressure control in all hatchery production rooms and planning for enhanced flooring and hatcher baskets further aid the prevention of contamination, by a continuous action that stops the multiplication of bacteria.
According to Production Director Mrs Odilete Rotava, Pas Reform do Brasil was the only company in the country that could deliver the complete, turnkey, single-stage solution Avícola Pato Branco
hatchery was looking for. “We chose Pas Reform for its advanced technologies and its worldwide reputation. Also, as a Brazilian
Company delivering Brazilian-made products, FINAME finance was
viable for incubators and HVAC ventilation for the expansion, which made Pas Reform do Brasil the best option for us.
assembly, stock keeping, spare parts and delivery capabilities.
training and the full range of project management and back up
says Mr Calil, while meeting the stringent quality standards and expectations of Pas Reform in The Netherlands.
Central Asia and Eastern Europe, most recently with Ust-
As a fully integrated poultry business, UKPF is the only
chilled chicken meat producer in the country. The company has commissioned Pas Reform to install Smart incubators, hatchery automation and climate control systems, as part of an expansion programme that will increase UKPF’s production to 16,000 tons at per annum. Pas Reform
Academy further supports the poultry producer with a
programme of hatchery management training services. UKPF is a vertically integrated company, incorporating
breeding facilities, a hatchery, broiler houses, feed milling and broiler processing facilities. Established in 1976 as a state poultry farm, UKPF was privatized in 1997 and has
since developed into one of the country’s leading poultry companies.
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Smart™ hatchery consolidates Inzhavinskaya in Tambov poultry sector
LLC Pticefabrica Inzhavinskaya’s has contracted with Pas
Reform Hatchery Technologies to supply a complete Smart™
Chicks make their own “humidity peak”
Incubation system for its new hatchery in Russia’s Tambov
By Martin 'Tiny' Barten, senior hatchery specialist, Pas Reform Hatchery Technologies
The new broiler hatchery delivers 84 million eggs per year.
During a seminar just before the summer holidays in Brasil, one of the participants asked about the order of importance for the three factors of temperature, humidity and ventilation, in order to achieve optimised incubation. I replied that all three are relevant, but that while great attention is traditionally paid to temperature, the importance of humidity is sometimes forgotten.
region.
The hatchery is part of Inzhavinskaya’s broader operation, which includes 8 broiler farms including 165 houses with total capacity of 8 mln day-old chicks, a slaughterhouse
which processes 10.500 chicks per hour and a feed-mill with annum capacity of 200.000 ton. In all, the poultry complex produces 100,000 ton of poultry meat (live weight) a year and employs more than 2200 personnel.
The question reminded me of a trip to Eastern Europe, where major improvements were achieved by changing humidity management. Here I visited some long-standing customers, with machines purchased some years ago, so without the more recent innovations in our incubation systems. At first glance, the chicks looked good sitting in the hatcher baskets. But on feeling their bellies, I found them to be very full to the touch, with navels that were not properly closed. The chicks also appeared to be largely sitting and inactive – and on closer inspection, I observed too many red hocks, most likely as a result of difficulty in moving around in the egg to open the shells due to their very full bellies. A break-out of unhatched eggs revealed too many late mortality, caused by “drowned embryos”. Initially I thought the cause may be insufficient weight loss. But with further investigation, the main cause was the humidity set points in the hatchers directly after transfer. Set at 80% relative humidity (= approx. 92°F WB), the hatcher’s
Pas Reform appoints new representative in Colombia
kg per capita per year, Colombia
For more than 20 years,
Pas Reform has further
market for the Dutch supplier of Smart™ single-stage hatchery
livestock industry. With specific
expanded its Latin American
network, with the appointment of Mr. Rodrigo Pardo of R&M
Corporation, to deliver sales and technical support services in Colombia. With 45 million
inhabitants and an average
26
poultry consumption of over 25
represents an important growth
technologies.
Under Mr Pardo’s direction,
R&M Corporation will provide Colombian customers with
direct access to spares and a full range of sales, technical,
training and project manage ment services.
Mr Pardo has worked in the expertise in agricultural
industrial refrigeration and
processing, he brings a wealth of knowledge on project
management and technical
installations to his new role.
humidifiers brought it to that level without any problem. The hatchery manager did that, he explained, to avoid “humidity high alarm” during the actual hatch and to avoid membranes becoming too dry and tough after the chicks started to pip externally. I explained that better results can be expected by keeping the relative humidity set point after transfer similar to the set point in the setter. As the chicks start pipping, relative humidity increases spontaneously and by definition, at exactly the right moment, by the remaining water evaporating at a faster rate from inside the eggs - provided the hatcher is not over-ventilated. This keeps the membranes soft and supple and avoids the chick getting stuck inside the egg. “Humidity high alarm” can be prevented by a single increase of relative humidity to 60%, after natural humidity has exceeded that level. A few weeks after my visit, our agent advised me that our customer was happily surprised with increased hatchability and very much improved chick quality. Moreover, first week mortality in the farm reduced dramatically.
Sary Bulak selects Smart incubation from Pas Reform
Smart Hatchery to fuel explosive growth for Namib Poultry Industries
Sary Bulak Ltd has commissioned Pas Reform to equip its
new broiler hatchery in Chapaevo, Republic of Kazakhstan, with Smart™ single-stage incubation and hatchery
automation systems. The hatchery is part of an integration
that produces 10,000 metric tonnes of broiler meat per year.
A comprehensive Smart™ hatchery has been commissioned from Pas Reform by Namib Poultry Industries, for an
ambitious new project that aims to satisfy Namibia’s total demand for poultry and poultry meat products.
Russia’s Okskaya extends hatchery operations
Timashevskaya brings Smart to Russia's Samara region
Pas Reform supplied SmartSetPro™ setters and
SmartHatchPro™ hatchers, to deliver a start-up capacity of
300,000 d.o.c. per week. The new installation also features Pas Reform’s HVAC systems, for the finite control of air
handling, humidification, ventilation and pressure control within the hatchery.
Upgraded SmartCenter™ technology facilitates remote
operation and control of Namib’s hatchery HVAC systems, such that monitoring, control and intervention for all
HVAC devices can be managed off site as required, either from Namib’s main office complex or even from The Netherlands.
Okskaya Pticefabrika, in Russia’s Ryazanskaya region, has
Timashevskaya PF, in the south-eastern Samara region of
new 40 million egg layer hatchery.
with a Smart™ single-stage hatchery development, designed
commissioned Smart™ technologies from Pas Reform for a The hatchery is the latest expansion to the collaborative integration, with installation including 20 SmartSet™
setters, each with a capacity of 115,200 layer eggs and 24
Russia, is leading the region’s poultry sector reconstruction,
and installed by Pas Reform to be constructed in two phases, with a final capacity of 115 million eggs per year.
SmartHatch™ hatchers, Hatchery Automation Systems
Phase one construction will deliver more than 56 million
automatic tipper, washing machines and a vacuum system.
setters, 36 SmartHatch™ hatchers, a hatchery automation
including chick take-off, sexing and vaccination carousels, An advanced climate control/HVAC system ensures the
finite control of temperature, climate and fresh air supply throughout the hatchery.
eggs a year. Installation will include 28 SmartSet™ 115
system with chick counting and take-off line and basket
tipping and washing machines. Climate control with free-
cooling system will be implemented through the hatchery.
The new hatchery delivers high quality, day old Lohmann
Pas Reform’s project team has worked closely with
addition the facility supplies Okskaya’s layer farms with a
project, designing not only the systems installation, but also
and H&N layer chicks to farms in Russia and CIS countries. In capacity of 1.5 million table eggs per day.
Okskaya PF was founded on 12,000 chicks in April 1972, growing to an output of one million eggs just fifteen
Timashevskaya’s senior personnel while planning the the new hatchery’s product flows, flooring, drainage,
ventilation, water, electricity and waste management systems.
technologies for its new hatchery at Ras Ghareb, Hurghada.
have delivered strong, consistent growth ever since.
“With successful projects in
Development, Bouke Hamminga,
Sustained growth in the region
“Colombia is an important and
course Brazil, Pas Reform’s
Mr Pardo and his team. “When
Reform do Brasil, Pas Reform’s
Hamminga, “and we very much
Smart™ hatchery technologies have had a real impact on the Latin American market ”,
Mr Pardo says. “We look forward to furthering that success here in Colombia.”
Pas Reform Director of Inter national Sales & Business
will be working closely with
Pas Reform opened its first Latin American office in Mexico in
2002, we had ambitious targets”,
says Mr Hamminga, “but we still did not imagine the level of
market penetration that would
be accomplished in such a short time.”
Misr Poultry Group, one of Egypt's major poultry and egg
producers, has selected Pas Reform's SmartPro™ hatchery
months later. The hatchery and its associated operations
Venezuela, Ecuador, Chili, and of
Misr Poultry Group Egypt
prompted the launch of Pas
first-ever production facility outside The Netherlands, in
2008 - and with that, a strong, strategic focus to develop a
network of localized offices and technical support facilities throughout the Region.
growing market”, concludes Mr
Contact details for Pas Reform’s new office in Colombia are:
look forward to working with Mr
R&M de Colombia Ltda.
where our combined vision will
Calle 24 N. 69C-19 Sur.
Pardo and his team, to see
take us here in the future.”
Sr. Rodrigo Pardo Herrera Bogotá, Colombia
T +571 420 06 03 / 420 10 49
M +57 310 2400271 /310 8147248 F +571 420 48 27
E rpardo@rmcolombia.com
27
Trialling Adaptive Metabolic Feedback (AMF™) systems on Smart™ Setters By Hector Santos, Hatchery Manager, Cargill Honduras
Adaptive Metabolic Feedback™ (AMF™) was developed by Pas Reform to precisely manage moisture and CO2, in line with the metabolic needs of each growing embryo, during incubation. By continually ‘reading’ the time-varying metabolism of a specific batch of embryos, AMF™ adapts control parameters (humidity and CO2) to fine-tune the incubator environment accordingly. Ultimately AMF™ maximizes uniformity by optimising airflow, the evaporation of moisture and air redistribution, to achieve an ideal weight loss pattern. Cargill’s Honduran hatchery carried out trials, to observe how AMF™ simultaneously provides better and more stable control over relative humidity and CO2 during the first 18.5 days of incubation, to provide day old chicks of favourable quality. Methodology Flocks of similar age were compared over a similar time period. Some setters were operated with conventional controls, some machines with AMF™ control on SmartSet™ incubators. During the tests, we looked at the following variables: embryonic mortality, pipped not hatched, rejects %, contaminated, hatch of fertiles % and weight loss at 18 days.
Conclusions
The incubators with AMF™ control were much more stable in terms of humidity. This is of great importance in the Honduran climate, with relative humidities from 70 – 80 % RH.
Adaptive Metabolic Feedback (AMF™) results in better, more stable control of humidity in the incubator, which produces a more accurate weight loss pattern at 18.5 days. Improvements in early embryonic mortality (-/- 1.2%) and in cull chicks at hatch (-/- 0.2 %) were observed.
Hatch of fertiles (HOF %), rejects, contaminated No difference in the hatch of fertiles or contaminated eggs was observed in this trial. However, a reduction of 0.2% in cull chicks was observed. This was due to better chick quality, with less inflated bellies, due to better humidity control. Comparison AMF™ system vs conventional setter control System
Hatch of
Cull chicks (%)
Contaminated
AMF™
89.3%
1.0%
0.1%
Conventional
89.2%
1.2%
0.1%
fertiles (HOF)
System
Weight loss (%)
EEM 1-7 days
MEM 8-14 days
LEM 15-21 days
Pipped not
AMF™
11.95%
3.2%
0.6%
2.4%
0.4%
Conventional
11.4%
4.4%
0.4%
2.5%
0.5%
hatched (%)
It may ‘only’ be a distribution
said, have been a relatively banal assignment – a
innovation in buildings of this
high when the BNA judges visited Pas Reform’s Global Distribution Center at
Doetinchem, as one of three projects shortlisted for the
Building of the Year Award in The Netherlands.
park – the architects have
created a super-functional yet
exceptionally beautiful building, that inspires curiosity and raises its function to a higher level.
A 0.2% improvement in cull chicks for Cargill’s operation in Honduras represents an annual gain of US$50,000, giving the system a pay back time of around 1.5 years.
Comparison AMF™ system vs conventional setter control
The prominent use of daylight in
distribution centre on a business
Financial impact: 1,382,400 eggs * 0.2% = 2765 doc/wk = 144,000 doc/year at a price of US$0.35/doc = US$50,000 per year.
Better weight loss by 0.5% was observed in favour of the setters with AMF™ control. We also observed a 1.2% reduction in early embryonic mortality (days 1-7), and a 0.1% reduction of pipped not hatched, which can confidently be associated with better weight loss at 18 days.
The jury was unanimous in its
decision. From what could, they
eggs (%)
Weekly set: 1,382,400 eggs (12 setters of 115,200); Cull chicks improvement: 0.2 %
Weight loss, embryonic mortality, pipped not hatched.
Pas Reform wins BNA Building of the Year
centre, but expectations were
28
Results
the design was welcomed as an type, with transparency
promoting greater interaction and communication between
the people who work in this very large building.
The jury was impressed with the craftsmanship and quality
embodied in Pas Reform’s global
Armenia’s Arax chooses Smart from Pas Reform
Leading Armenian poultry farm Arax has elected to work
with Dutch hatchery technology specialist Pas Reform for a new turnkey hatchery project delivering 15 million day old chicks a year.
Mexico’s Nutripollo looks to the future with SmartPro™ incubators from Pas Reform
Venezuala’s Agrobueyca chooses Smart for ambitious new single stage hatchery
The new hatchery includes SmartSet™ and SmartHatch™
incubation systems and a full suite of hatchery automation equipment, as well as comprehensive climate control and water conditioning systems.
Arax is an integrated complex, with a market-leading
reputation for the highest quality product. The company’s operations span the complete production cycle, from egg production to meat processing and with onsite facilities
including vaccination, chiller, a well-equipped lab and feed factory.
With high quality outputs from birds fed on natural, non-
additive products, demand for Arax products continues to
Integrated poultry producer Nutripollo has commissioned
rise, prompting the decision to invest in the new Smart™
Pas Reform to renovate and expand its hatchery operations
hatchery complex.
in Aguascalientes, Mexico.
During phase one of the project, Nutripollo’s existing
The poultry farm produces more than 70 per cent of poultry
30-year-old incubation equipment with SmartSetPro™
short-term, Arax will enter the Georgian market, with plans
meat and meat products for its domestic market. In the
hatchery was being completely renovated, to replace
setters and SmartHatchPro™ hatchers. In phase two, a new extension, also equipped with SmartPro™ incubators, will double hatchery capacity.
Nutripollo is a long-established and well-respected poultry business in Mexico. Founded in 1963 by Mr. Jorge Quesada,
the completion of this project will mark the company’s 50th anniversary year.
Agrobueca, Venezuala’s leading integration and feed
manufacturer, has expanded operations with a brand new
Smart™ single-stage hatchery from Pas Reform, capable of producing 1.3 million day old chicks per week.
The new hatchery incorporates SmartSet™ setters,
SmartHatch™ hatchers, an entire hatchery climate control
system and a comprehensive hatchery automation line, to deliver one of the largest and most modern broiler hatcheries to date in Latin America.
also to extend its product range with semi-finished items
and sausages, sold throughout the Trans-Caucasian market. Pas Reform’s Representative Mr. Mushegh Mkrtchyan has been most impressed by the progressive and quality-
focused approach of Arax. “This is a company with an
exemplary reputation for healthy products of the highest quality and a firm focus on the future.
“Pas Reform is delighted to be involved in the further
development of Arax Poultry Farm, to meet its future goals.”
Scan the QR code to see
Agrobueyca’s 3D animation
distribution centre. Notable
routing and layout and an
efficiency, and it is future-
We are delighted with the
loading and unloading areas for
that cleverly integrates storage
and increasingly limited use of
distribution center can achieve
design features include the
trucks, which are integrated into the façade; the huge, pivotal
internal supporting structure to maximise space.
proofed, ready for expansion energy.
entrance and the raised office,
“The architects, Cepezed,
“But it was also designed for the
warehouse. Inside, the
distribution center with great
time here. Design is an inherent
which looks out over the
architecture provides a safe,
healthy working environment,
by day and night and supports the logistics, with optimised
translated our vision for a smart skill and understanding,” says
Pas Reform’s Marketing Director, Henry Arts. “The building embraces economy and
staff and visitors who spend
part of Pas Reform: an asset, not something that is merely
Award. It seems fitting, that a exemplary status in the
Netherlands as an exporting
country - and highly rewarding that such a project can be
regarded as inspirational beyond the industrial environment.”
cosmetic or superficial.”
29
Ear
Yolk sac
Day 13
Day 14
Day 15
Phase 2 - Growth
Phase 2 - Growth
Phase 2 - Growth
Circadian Incubation™ A new feature of single stage incubation By Dr. Marleen Boerjan, director research & development, Pas Reform Academy We know that a combination of genetic and environmental factors shape the embryonic body as well as the formation and maturation of functional tissues and organs. While the genetic make-up of the chicken embryo contains basic instructions for the development and formation of the body, developmental fine-tuning occurs through the interaction of environmental factors and the expression of genes. In chicken, embryonic differentiation starts during egg formation and continues in the incubator, after a period of cooling and storage of the eggs. At the end of the second week of incubation, the embryo has almost reached its final size and shape. In this phase of development, differential gene expression guides the maturation of physiological control circuits. The maturing embryo is sensitive to environmental stimuli such that physiological control systems can be trained or ‘adapted’, to cope with stressful environments for the long term.
From left to right: Mr. Pebri Patekawa, Service and
Maintenance Manager and
Mr. Deddy Kurnia, President
Director, of PT Berdikari Sarana Jaya, with Mr. Bas Kanters,
Sales Director Asia of Pas Reform Hatchery Technologies and
Mr. Zein Yaldi Saleh, Sales & Marketing Director of PT Berdikari Sarana Jaya.
30
It has been proven that incubation temperature influences the expression of genes involved in the maturation of body temperature control. Chronic, continuous temperatures that are too high or too low negatively affect maturation. Conversely, short, daily temperature stimuli (Circadian Incubation™) produce long-lasting effects by training or ‘imprinting’ the thermoregulatory system – and it has been shown that training the thermoregulatory system during the maturation phase reduces the basic metabolic needs of the growing chicken. Temperature training induces a lowered body temperature at the thermoneutral zone - and thereby the amount of nutrient required to maintain the chick’s body temperature.
Amniotic cavity
Yolk sac Day 16
Day 17
Day 18
Phase 2 - Growth
Phase 3 - Maturation
Phase 3 - Maturation
Figure 1. Average feed conversion
Circadian Incubation™ in a commercial single-stage setter
rates (FC 1500) of broilers from
Average feed conversion (FC 1500) per flock (35-56 weeks)
three different breeder flocks.
Circadian incubation™ 1,3900
For each flock, four different
Control incubation
Circadian Incubation™ cycles
were performed in a large scale
1,3700
commercial single stage
incubator. For each flock,
1,3500
experiments were performed at
1,3300
flock ages 35, 42, 48 and 56
Mean FC 1500
1,3100
respectively. For both Circadian™ and Control incubation, the
1,2900
growth and feed consumption
1,2700
of 4560 chicks were followed for
1,2500
A
B
C
35 days.
Smart™ delivery from Pas Reform for world’s largest poultry breeder in Russia
flock
Consequently, short daily temperature stimuli have a positive effect on economical parameters, such as hatchability, robustness, final bodyweight and feed conversion ratios. Temperature stimuli applied during the embryonic maturation phase also have a long lasting effect on resistance to heat stress in adult birds. However long lasting adaptation by Circadian Incubation™ only occurs if temperature stimuli are applied during critical, sensitive phases of development. In the chicken, this is during the final days of incubation, and further investigations are being carried out to define the optimum intensity and length of temperature stimulations for different egg types. Circadian Incubation™ has already demonstrated positive effects on hatchability and feed conversion rates in commercial hatcheries and broiler farms, although interaction with breeder farms limits routine application. Figure 1 shows the variability in feed conversion rates in chicks hatched from eggs produced by different breeder farms. Future investigations will help to further understand the variable responses found in commercial practice.
Advice – Optimize hatchery results using Circadian Incubation™ if single stage incubation practice is routine in your hatchery. – Ensure accurate climate control in setters, to promote optimised temperature uniformity and sufficient cooling capacity that the incubation temperature can be reduced quickly and uniformly at the end of each temperature stimulus. – Start Circadian Incubation™ on day 16.5 (2 hr at 100 °F set point) and continue through days 17.5 and 18.5 (1 hr at 100 °F) of incubation. – Evaluate the results of Circadian Incubation™ in the hatchery and on the farm for each batch of eggs separately. – Find the optimum length of temperature stimulation by undertaking trials on different batches of eggs of differing quality. – Evaluate hatchability, chick quality and farm results after each trial of Circadian Incubation™.
Pas Reform has supplied a full range of Smart™
technologies, consultancy, project management and
training services for Aviagen’s new state-of-the-art parent stock hatchery in Yasnogorsk, South West Russia.
The flagship facility, located in the Tula region, is a crucial element of Aviagen’s European strategy and, says Brian
Whittle, President of Aviagen’s European Operations, central to the breeding company’s long term commitment to growth in the country.
Aviagen’s Yasnogorsk hatchery opened with a launch
capacity of 5.5 million day-old female parent stock chicks
per annum – and room for further expansion to 7.5 million chicks a year.
In support of this extensive installation, Pas Reform also
delivered comprehensive training for hatchery personnel, as well as a bespoke hatchery management training programme.
New Pas Reform Service Centre for Indonesian hatcheries
Yaldi Saleh (Sales & Marketing
Agent and Hatchery Specialist,
The new Service and Projects
specifying maintenance
provide customers with the full
growth in Indonesia’s growing
of Pas Reform Academy in The
single-stage hatchery
In response to continuing
specialist team, with access to
growth in Indonesia, Pas Reform is launching a new Service and Projects Centre at BSD City in
Director), the new Centre will
back up of a local technical and the full range of spare parts for rapid delivery.
Jakarta, in cooperation with PT.
Mr. Bas Kanters, Pas Reform’s
Headed by Mr. Deddy Kurnia
new Centre: “Working with Mr.
Berdikari Sarana Jaya.
(President Director) and Mr. Zein
Sales Director Asia, says of the Santad Dentstaporn as our
Pas Reform has delivered strong poultry sector.
“We are delighted to be building further on this success with PT.
Berdikari Sarana Jaya, to provide an enhanced, localized level of
commitment to the Indonesian hatchery sector.”
Centre will have the full backing Netherlands, with
administration, a fully stocked
programmes for Pas Reform’s customers.
spare parts department and a
Mr. Pebri Patekawa joins PT.
BSD City.
Indonesia, as Service and
Projects department on site at
The Projects department will
Berdikari Sarana Jaya in Maintenance Manager.
provide consultation, advisory and design services, as well as
31
Pas Reform setting standards for uniformity worldwide The Netherlands Pas Reform BV Head Office Bovendorpsstraat 11 7038 ZG Zeddam The Netherlands T +31 314 659 111 F +31 314 652 575 E info@pasreform.com I www.pasreform.com Argentina Forklima s.r.l. Instalaciones Avicolas Av. Gral. Paz 13.713 1752 Villa Insuperable, Pcia. B.A. Argentina T +54 11 4655 1960 F +54 11 4652 6931 E forklima@forklima.com.ar Armenia / Georgia Morris Group Armenia Davidashen 3th Dist. #21 Apt. 22 375010 Yerevan Armenia T +374 91 555771 F +374 10 368 307 E armenia@morrisbg.com
Chile Agrocomercial Safratec Chile Ltda.
Latin America Sr. Ranulfo Ortiz
Russia Pas Reform Russia
Syria / Lebanon ACMAVED
USA Morris Hatchery, Inc.
Badajoz Nª 12 Of. 303 Edificio Maule Las Condes - Santiago Chile
Nueva Bélgica 6 Col. Recursos Hidraulicos 62245 Cuernavaca, Morelos Mexico
Esenina Street 20V 308036 Belgorod Russia
18370 SW 232nd Street Goulds, 33170-5399 Florida United States of America
T +56 2 2202034 / 2299902 F +56 2 2246726 E fernando@safratec.com
T +52 7773 176 401 F +52 7773 134 419 E ranulfoortiz@gmail.com
T +7 4722 58 90 50 F +7 4722 58 90 51 E info@pasreform.ru I www.pasreform.ru
Visiting address: Al Ameen St. Outly Boulevard Damascus
Colombia R&M de Colombia Ltda.
Malaysia Suenfa Farming Trading Co.
Serbia Iradia DOO
Calle 24 N. 69C-19 Sur. Bogotá Colombia
Jalan Kulim 1418 14000 Bukit Mertajam, Penang Malaysia
Gavrila Principa 53 21208 Sremska Kamenica Serbia
T +571 420 06 03 - 420 10 49 F +571 420 48 27 E rpardo@rmcolombia.com
T +60 45399823 F +60 45390076 E suenfa_10@yahoo.com
T +381 21 461 170 F +381 21 464 113 E jasmina.atlic@iradia.co.rs
Egypt Alpha Trade Co.
Mexico Evolución Tecnológica Agropecuaria SA de CV
South Korea Il-Seung Co. Ltd
Mosadek Street 50 Dokki-Cairo Egypt T +20 23 749 6337 F +20 23 760 4343 E alpha.grp@gmail.com Greece Intervaz S.A.
Baltic States JSC Skogran Mr. Lukas Sederevicius
P.O. Box 41 19100 Megara Greece
Lakunu Str. 24 LT-09108 Vilnius Lithuania
T +302 2960 90250 F +302 2960 90533 E vazaiosn@gmail.com
T +8 370 5 27 000 27 F +8 370 5 27 000 29 E info@skogran.com Bangladesh Axon Limited Apt.1B, House-541/4, Road-12 Baridhara DOHS Dhaka 1206
Hungary Dr. László Korösi AgriAl Bt Béri Balogh Adám u.42 2100 Gödöllo Hungary T +36 309 820 054 F +36 284 206 40 E korosidr@gmail.com
T + 880 2 8417331 F + 880 2 8417330 E info@axon-group.net
India Pas Reform India
Belarus Neoforce Ltd Commerce and Consulting
1/99 A Ganapathi palayam (PO) Udumalpet (TK), Tirupur Dt. Tamilnadu 642122 India
Visiting address: Pulichova Street 29-97 220088 Minsk
T +91 93 44 00 5887 E venkatesh@pasreform.com
Mailing address: P.O. Box 99 220088 Minsk Belarus
Indonesia Pas Reform Indonesia
T +375 17 200 05 31 F +375 17 211 02 15 E neoforce@nsys.by Belgium/France/Francophone Africa De Rycke sprl Visiting address: Bois 4 7880 Vloesberg-Flobecq Belgium T +32 68 44 52 80 F +32 68 45 65 22 E bob.derycke@skynet.be Bosnia-Herzegovina Iradia DOO Branka Copica 2 78250 Laktasi Bosnia Herzegovina T +387 51 530016 F +387 51 535345 E iradia@blic.net Brasil Pas Reform do Brasil Avenida 16, no 2072 B. Jardim São Paulo 13.503-020 Rio Claro - SP Brasil T +55 19 3524 3681 F +55 19 3524 3681 E calil@pasreform.com.br Bulgaria Ecomat Ltd. Krum Kyulavkov Str. 11, at. 4 1172 Sofia Bulgaria T +359 888 857550 F +359 9627716 E info@ecomat.biz Canada Mr. Jeff Pierce 2534 Marion Anderson Rd. Hot Springs, AR 71913 United States of America T +1 501 767 4949 F +1 501 767 8822 E theeggman@northstarhatchery.com
Raffles Hills Blok J8 No. 5 Kel. Sukatani Kec. Cimanggis Depok 16954 Indonesia T +62 811 998 162 F +62 21 845 99 187 E kanters@pasreform.com Iran Vala Sanat Nab Visiting address: First Floor, No.15, Ghadr Alley North Kargar St, Enghelab Sq, Tehran Iran T +98 21 6656 2010 F +98 21 6656 2003 E kamalnazari@ymail.com Italy Avimpianti di Goffi N. Via Alessandrini, 71 47121 S. Lorenzo in Noceto - Forli' Italy T +39 0543 488 427 F +39 0543 488 427 E info@avimpia.it Jordan Mr. Jamil Al-Khawaja P.O. Box 1709 13110 Zarka Jordan T +962 6515 8214 F +962 6515 8214 E jamil_al_khawaja@hotmail.com Kazachstan Crown Central Asia Ltd.
Nueva Bélgica 6 Col. Recursos Hidraulicos 62245 Cuernavaca, Morelos Mexico T +52 7773 176 401 F +52 7773 134 419 E ranulfoortiz@gmail.com Morocco Agri Art 38, Hay Medouaz Témara Morocco T +212 5 37 64 30 61 F +212 5 37 64 35 78 E agriart@agriart.ma New Zealand Sonoma Enterprises Ltd 50 Hakanoa Street, Grey Lynn Auckland 1021 New Zealand T +64 9551 0959 F +64 9579 6371 E sonoma@xtra.co.nz Nigeria Terudee Farms Nigeria Ltd. Km 15, New Ife Road Idi Omo Village, Ibadan Nigeria T +234 8055 005 709 F +234 2231 6207 E terudee@yahoo.com Pakistan Bird Care House No. 460, Block-B, Faisal Town, Lahore 54700 Pakistan T +92 42 35204161-3 F +92 42 35204164 E birdcare@brain.net.pk Peru S.I.B.S.A. Av. Manuel Olguin No. 335 - Of 607 Santiago de Surco Peru T +511 637 36 37 E sibsa@sibsaperu.com Philippines Inoza Industries Inc. No. 179 Marlano Ponce St Calooncan city, Metro Manila Philippines T +63 2 332 6621 F +63 2 364 2362 E alfonsocojr@yahoo.com Poland Dr. Marek W. Pospiech ul. Mielzynskiego 27/29 61-725 Poznan Poland T +48 601 743080 F +48 61 851 5923 E marpog@gmail.com Portugal Avisilva AS Estrada Velha da Avessada, 5 Apartado 101 2669-909 Malveira Portugal
Hotel Ramada Plaza 47, pr. Abaya, Office 705 Astana 010000 Kazachstan
T +351 219 663 700 F +351 219 663 709 E avisilva@mail.telepac.pt
T +7 7172 57 69 68 F +7 7172 39 01 02 E office@cca.kz
Rumania Sembodja Romania s.r.l. Iancu de Hunedoara Nr. 2 B1, H6, Sc. 1, Et 1, Ap. 1 Sector 1 Bucharest 011731 Rumania T +40 21 317 45 65 F +40 21 311 32 94 E office@sembodja.ro
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