ROTECNAWORLD NUMBER TWENTY EIGHT 2016
SUMMARY TECHNOLOGY
PROFILES FOR PANELS AND HALF-PANELS MODELOSINSTALACIONES
THE WELFARE OF THE WORKERS ON PIG FARMS PIGPRODUCTIONIN...
THE PIGS INDUSTRY IN PERU, GROWTH AND MODERNISATION ROTECNANEWS
LETTER FROMTHEEDITOR On this occasion, I want to take this opportunity to communicate great news for Rotecna, that we have finally incorporated two financial partners into the
INJECTION SECTION
company to undertake the expansion plan I have referred to on several occasions. With 25 years of experience and six years of steady growth, from Rotecna we have given the Talde and Oquendo funds access to our shares, with the aim of
SOMETHINGABOUT
carrying out an ambitious growth plan that we expect to double the company’s Gener Romeu
THE AGRAMUNT NOUGAT
SCAN ME WITH YOUR SMARTPHONE
ROTECNA
DOWNLOAD ANY APPS FOR READER QR CODE & VIEW ROTECNA.COM
Rotecna's President
sales in a period of six years with the launching of new products and lines of business. Moreover, I also want to acknowledge the success of the 25th anniversary
ROTECNA WORLD 28
celebration of Rotecna last June, in which more than 500 customers from 60
OCTOBER 2016
countries took part. It was an excellent party, with many of the people who are
EDITION: ROTECNA, S.A.- POL. IND. NAU-3, 25310 AGRAMUNT (LLEIDA) SPAIN
part of the great Rotecna family, who we hope will also accompany us in our project for growth.
DIRECTOR: GENER ROMEU PRODUCTION/DESIGN: MONTSE GUERRERO EDITORS: TAMARA LOMBARDO FRANCISCO GARCÍA TRADUCTION: CHRIS BOSWELL PRINT: IMPRENTA BARNOLA L-41-2007
DIGITAL VERSION / issuu.com/rotecnapress Rotecna's World's editors accept no liability for contributor's opinion.
Thanking the trust that our customers have always shown in us and looking to the future, from Rotecna we will continue to offer our support for the pig sector. Thus, aware of the importance of being close to the professional and attentive to the needs of farmers, next November, we will be present at some of the leading industry events nationwide, such as Sepor and the Golden Pig awards, and we will go to Hanover, Germany, to participate in EuroTier, one of the most important international fairs for the livestock sector. Indeed, this year in Germany, we will introduce new product lines that will shape the future of our company. See you at EuroTier. Gener Romeu
ROTECNAWE CELEBRATE 25 YEARS WITH...
INJECTION products in the factory and take on production of large pieces such as the biggest feeders. This investment has also led to the launch of a new product line for Rotecna panels for pens.
• PROFILE: • Year of creation: 1994 • Maquinària: 15 injection machines and three welding centers. • Number of workers: 45 which were very heavy, were changed with the help of a forklift, as there was no gantry crane, etc.
Ramon Petit, the person in charge of the injection section. Photo: RotecnaPress
Injection machines with the latest technology, allowing Rotecna to manufacture its range of products and continue growing. Shortly after the creation of Rotecna, the company acquired its injection machinery and created its own molds to be able to inject the products. This step marked the beginning of the injection section, one that has evolved over the years, and has more future potential. In its beginnings, the section had only three workers per shift, who had to manage to carry out all the tasks: changing molds, repairs, preparing the machines, etc. In addition, years ago, all the work was done manually: injection machines had no automatic power supply systems, the molds for the products,
SOMETHINGABOUT...
Thus, with time and taking advantage of periods when production was higher, Rotecna has acquired more automated injection molding machines that have contributed to the creation of new products, and therefore also more molds. Twentyfive years after the creation of the first mold, the grow feeder, the one that has been the most injected, Rotecna has grown to have more than 300 molds with which it currently injects its range of products for pig installations. Recently, given the company’s demands for growth, part of the injection machinery has been renewed. The new machines, which feature the latest technology, have enabled Rotecna to inject many more
How do the injection machines work? The operation of the injection machines, which work with hydraulic technology, is like a syringe in which a dose of plastic heated to approximately 220ºC is loaded. This material is pushed through a very small hole, inside a mold cooled with water circuits. Once the piece is cold, the ejectors integrated into the mold eject it at a temperature of 70ºC. Then the piece is placed in a beamformers that prevent it from deforming as it must maintain specific measurements to be able to fit other components well. These machines are fed with polypropylene, a ductile material whose properties are ideal for the manufacture of Rotecna products. This raw material arrives in the factory as small plastic balls in a neutral color that, once injected, means the piece comes out in a
THE AGRAMUNT product acquired the denomination of Torró d’Agramunt.
HAZELNUTS, HONEY, SUGAR, EGG WHITE AND WAFERS ARE THE BASIS INGREDIENTS OF AGRAMUNT NOUGAT 2
From the nineteenth century on, Agramunt nougat gained wide recognition and prestige through nougat fairs, gatherings and markets, but especially in the stalls they ran for Christmas in Barcelona. That was where Agramunt nougat had to face competition from Valencia makers who flooded the market with new varieties and forced Agramunt to match and improve the offer. In addition, to differentiate themselves from Jijona, the Agramunt nougat makers dressed in peasant “Sunday best” and the men covered their heads with berets, while women did so with white silk headscarves. The making of nougat tiles. Photo: Agramunt Town Council
The Agramunt nougat (torró) is the most popular and loved traditional nougat and probably the oldest of those currently being produced.
History The town of Agramunt has a long tradition of making nougat. The Torronaire tradition is first documented from 1741 in a letter from one of the noblest families of the town. At that time, the nougat making was already a deeply rooted tradition, which was maintained over the following years, until the nineteenth century, when this
During the Civil War, the nougat making suffered the consequences and came to a halt. After the conflict, the nougat makers went back to work, but the problems of the supply of raw materials affected them, and for some years, they suffered severe problems with the supply of hazelnuts. This caused some families to stop making nougat, although other continued to the present, maintaining the typical ingredients and process of preparation of this tradicional sweet.
ROTECNANEWS
SECTION translucent white. To get the pieces to acquire a certain color, colorants made from gravel added to the polypropylene and with a polypropylene core. This enables Rotecna to manufacture the same products in different colors so that they can be distributed by other firms. With the manufacture of all its products, Rotecna injects a total of 5,000 tons of polypropylene per year.
design have to be injected. For this reason, the operators continually improve their performance in order to continue growing with more human and technical resources, and overcome the complexities of the most complicated products.
Rotecna, as part of an ambitious plan for growth and development in the coming years, has allowed the Talde fund to join its shareholders and has enjoyed the support of the Oquendo fund in this operation. Rotecna has been consolidating its growth and market position to reach sales of over 30 million euros with 70% of its turnover going to customers in more than 80 countries. The Spanish pig sector has developed and professionalised very significantly in recent years, making Spain the leading European producer and third in the world behind China and the United States. Accompanying its customers, Rotecna has developed a full range of products with a clear focus on efficiency and productive savings for its customers.
What is it like to work in this section? To organize the workflow, the head of the section meets every week with planning, who decide how much of each product has to be manufactured. Then the operators in each shift are assigned to different machines, although some, like the person charge of the welder, always work in the same post. When the product has been injected, the joker is responsible for protecting the product with a film, putting the label with all the technical manufacturing specifications and sending it to logistics where it is then sent to the corresponding destination.
ROTECNA ADDS NEW SHAREHOLDERS
Ramon Petit, the person in charge of the injection section. Photo: RotecnaPress
Ongoing growth
Ramon Petit, in charge of the injection section
After overcoming the latest economic crisis, Rotecna has continued to grow and the injection section plays a very important role in this expansion. All products that R & D
Ramon Petit joined Rotecna in 1996 with extensive experience and training in the electronic field and specialised in the agrotechnological sector.
Gener Romeu, president and founder of Rotecna, will continue to lead the company in this new phase maintaining control over it together with the financial partners. Furthermore, the current management team has taken a stake in the capital of the company in a clear commitment to the development of Rotecna. With 25 years in the market and a proven capacity for innovation and the development of new products, Rotecna is ready to start a new phase of growth with the support of its new partners where the company expects to double its sales over a period of six years with the launch of new products and lines of business as well as reinforcing its international growth.
NOUGAT In 1984, the Government of Catalonia granted Agramunt nougat a designation of quality (Denominaciรณ de Qualitat), and in 2002, it was recognized at the European Union level with a Protected Geographical Indication (PGI).
Making nougat The Agramunt nougat is a mix of high-quality ingredients: hazelnuts or almonds, honey, sugar, egg white and wafer. A careful selection of ingredients and slow and precise preparation are the secret the process. Traditionally, the first step was to toast hazelnuts in a spherical or cylindrical metal container rotated horizontally on its axis with the handle turned by the torronaire. This container was placed over a kind of stove fuelled by wood. Once cold, the hazelnuts were peeled. Then, the heated in were fully previously
honey and sugar were a pot, and when these mixed, the egg whites, beaten until they were
stiff, were added. When the mixture was at the exact point of cooking, it was removed from the fire and the hazelnuts were added. Stirring continued making sure that there were no clumps of hazelnuts where the honey had no penetrated, and when it was homogeneous, part of it was removed and put on a floured board to begin the process of weighing and manual preparation of tablets of nougats. With the mix still warm, it was given the characteristic shape of Agramunt nougat, in round tiles, between two wafers in various sizes and weights. Although the process of preparation of nougat craft is still the same as in the past, nowadays it is done by new machinery, and the work is lighter.
Stone chocolate The Stone Chocolate (xocolata a la pedra) is one of the most renowned specialties of Agramunt. The name derives from the process of grinding the cocoa beans, a process that was done on a stone with the aid of a rolling grindstone. Cane sugar and
The making of Agramunt nougat. Photo: Agramunt Town Council
vanilla flavouring were then added. Finally, it was given the form of a thick tile with marked dice, a process that still exists today.
Nougat Fair Nobody doubts that Agramunt is the Catalan nougat capital, so for the past 27 years, the town has organized an event dedicated to this product. The beginnings of the Nougat and Stone Chocolate date back to 1988
when the Agramunt and District Market Promotion Board organised a market dedicated to nougat. The good response it generated encouraged the organizers to extend participation to other sectors, and on October 12th the following year the first edition of the Nougat and Stone Chocolate Fair (Fira del Torrรณ i la Xocolata a la Pedra) was held. Since then, this event has evolved and is now a reference point in the calendar of fairs in the province of Lleida.
3
TECHNOLOGY
PROFILES,
FOR PANELS AND HALF-PANELS Rotecna launches a new line of PVC profiles, which facilitate rapid construction of modules with panels and half-panels, with a better finish, very hygienic environments and more stable structures.
ADVANTAGES • Exclusive system for damping contraction and expansion of the panels. • Quick and easy installation. • Provide stability to the panels. • An aesthetically pleasing finish. • Easy to clean, ensuring optimum hygienic conditions.
Profiles for panels
U profile
Rotecna has designed two models of profiles for joining panels. The first is H-shaped with an innovative and unique system to absorb the expansions and contractions that the panels may undergo from temperature changes. Manufacturing by row extrusion, it allows the farmer to order these profiles to the desired height for the construction of high walls. Moreover, the U-shaped profile enables the panel to be attaching to the wall.
Upper half-panel profile (1)
Profiles for half-panels Rotecna offers the possibility to coat the walls of holdings to provide insulation against cold and damp, and avoid friction of animals against abrasive surfaces. This is the best choice from the point of view of health, as its smooth, non-porous surface is ideal for quick and easy cleaning and disinfection of the installations.
H profile panel (1) With a system to absorb expansion and contraction.
24
So, Rotecna has developed three profiles for bonding the halfpanels: two for fixing the half-panel to the wall by at bottom and top, and a third model in an asymmetric H shape to secure it to the wall, while it is serving as a join between half-panels. The upper wall profile and the H-shaped profile also have the exclusive system designed by Rotecna internal fins to dampen oscillations of the panels.
Lower half-panel profile
Perfil H semipanel (1)
TECHNOLOGY
MORE SWING R3
EACH FARMER HAS HIS SWING R3 SWING R3 FEEDERS COMMON FEATURES • Monoblock design - robust and easy to assemble. • Stainless steel chassis • Inclined loading door with cover: Facilitates manual filling. • Rounded angles without corners to prevent accumulation of feed. • 2 drop systems: pendulum and tube. • Different ways of supplying water. • Very precise adjustment with 24 positions.
Rotecna’s objective in continuing the development of the Swing R3, which already has six different models is to ensure that farmers can choose the hopper model that best suits their needs.
Multiphase Swing R3 Tube with polymer plate The new polymer plate of the Swing R3 Tube is longer so more animals can access at a time. This MULTIPHASE plate (for weaners, fattening and wean-to-finish) combines the characteristics to be suitable for farms seeking profitability with the use of a single hopper for all phases of growth.
Being a porous material, the dish polymer plate can be fixed to the ground with cement, which can be useful in those farms that have a radiant heating system, since the risk of holing one of the underground tubes during installation of the feeders is eliminated. The Swing R3 Tube with polymer plate is a dry feed feeder. The plate has a central space for the feed and two sides for water.
Swing R3 MIX for weaning Rotecna has designed a new dish 100% stainless steel for the Swing R3 in weaning and wet feeding, designed with two tanks: one, with a lateral trough to mix the food with water, and a second with a separate drinker so that the animals always have clean water. It also has a pendulum drop system to prevent clogging with the feed mixture. The plate is 35 centimetres wide and 8 cms high, facilitating the access for smaller piglets to the feed drop mechanism and avoiding them occupying the inside of the bowl.
MODELS OF SWING R3 FEEDERS
DUO
WET
POLYMER
TUBE FINISHING
TUBE WEANING
MIX
3 5
PRODUCTIONIN...
THE PIGS INDUSTRY IN PERU,
GROWTH AND MODERNISATION
Sources: Minagri / Senasa
Finishing room in Peru with Rotecna feeders and slats. Photo: Francesco Pacussich.
The Peruvian industry and government are working on creating business plans and disease-free zones to establish the pig sector. The growing importance of pork as a foodstuff has led to the evolution of breeding in Peru, from domestic production to intensive methods and even to the development of breeds optimised for meat production. In the country, there are more than 600,000 families engaged in rearing pigs, 70% of who do so at home. However, Peru’s pork industry is undergoing a process of development that should help to ensure the growth of many farmers and meat industries through business plans, promoted by the Ministry of Agriculture of Peru (Minagri), and which are aimed at modernising the breeding, improving infrastructure and genetic improvement.
In January 2015, domestic pork production was 15,000 tons, 5% higher than the same period the previous year. During the first months of 2016, the pig meat sector has experienced growth of 1.9% compared to 2015. According to forecasts, the year could end up with a 3% rise. With regard to prices, in 2013 the average amount paid was 1.63 euros/kg, 12.83% higher than the average price of 2014. The average carcass price in the Lima region in June 2014 was 3.88 euros/kg, 14.1% more than in June the previous year.
Production
Foreign trade
According to data from 2015 from the Ministry of Agriculture of Peru, Lima is the largest pork-producing region of the country, and accounts for 42% of the total of such food nationwide, with about 600,000 pigs. Arequipa, meanwhile, is the second producer, with about 150,000 pigs. These regions are followed by La Libertad, Piura and Cajamarca. Taken together, the five areas represent almost 70% of pig meat production in Peru.
According to figures from 2015, imports of pork totalled 3,363.5 tons, while there were no exports.
As the Association of Pork Producers of Peru reported in the country there are currently 3.4 million pigs, with a yield of 65 kg
6
of meat per animal, totalling an annual output of over 200,000 tons of meat.
Peru imports meat from the United States, Canada and Chile, countries with which it has trade agreements that allow them to send their products with no tariffs. These countries buy the corn cheaper and reduce production cost, while Peruvian meat producers must pay extra for imported corn, due to the application of the Andean Price Band System (APBS), which significantly affects the final price. Although the production cost of imported pork is lower than for
domestic meat, prices are similar in supermarkets. It is expected that there will be batches of pork for export in 2018, by declaring the area free of Classical Swine Fever (CSF), a disease that currently affects pigs in the country. For this reason, the National Agrarian Health Service (Senasa) has already begun implementing a programme to eradicate the disease in the south. According to Minagri, potential export markets for Peruvian pig meat would be China, Japan, Korea, the United States and the European Union.
Consumption Per capita consumption of pork in Peru has been increasing since 2000, reaching 5.5 kg (Figure 1) in 2015. While that food consumption was 7.5 kg per capita in the Lima region, in Arequipa the figure was 15 kg per person per year. If we consider the per capita pork consumption in Peru and compare it with other countries in the region, we see that is far lower. The difference is greater if we consider the major consumers of pork, such as Japan, where about 66.5 kg is consumed per person per year.
Gestation room with Five dispensers. Photo: Francesco Pacussich.
PRODUCTIONIN... DATA ABOUT PERU • Capital: Lima. • Area: 1,285,216 km2. • Population: 31,151,643 • Population density: 24/km2 • GDP: $217,607 billion • Economy: Natural Resources. • Agriculture and livestock: 20.8% of GDP
Newly built farm in Araporo, Perú. Photo: Archivo RotecnaPress.
Given the growth the Peruvian pig industry is undergoing, and the consumption data, the Ministry of Agriculture of Peru is seeking to double pork consumption by 2021. To this end, the Ministry has been carrying out actions aimed at boosting the production and consumption of healthy, nutritious and safe pork meat, through a series of measures to achieve
greater consumption, such as the institutionalisation of the National Peruvian Chicharrón de Cerdo Day on the third Saturday of June. Chicharrón is a dish generally consisting of fried pork belly or pork rinds.
Health (OIE) as free of Foot-andMouth Disease. However, the Senasa continues to work to maintain that status, so vaccination has intensified in the northern part of the country.
Animal health
In the case of Classical Swine Fever, since 2010 the Minagri has a control and eradication programme, under which an
In 2013, Peru was recognised by the World Organisation for Animal
THE WELFARE OF THE WORKERS ON PIG FARMS
As well as ensuring the welfare of the animals, in the construction of new farms the space destined exclusively to the employees is becoming increasingly important, so that they can work in comfort and thus improve their working conditions and rest breaks.
A clear example of this can be found in one of the farms in the province of Huesca, Aragon (Spain) recently equipped by Rotecna and owned by Explotaciones Ganaderas Estiche. In this sense, this holding
Offices on the livestock farm. Photo: RotecnaPress
has an area reserved for offices and services for the staff, an aspect that is vital if we start from the premise that to achieve excellent production targets, it is essential to provide employees with and area services and comfort that meets the expectations of the company.
What spaces must it have? When designing appropriate facilities for employees, it is important to consider two aspects: On the one hand, provide facilities for staff to use with two areas of
average of 2,760,000 pigs are vaccinated annually, and that benefits more than 261,000 smallholding farmers nationwide. In addition, the Senasa is working to implement the second phase of project to control and eradicate the diseases in pigs, whose main objective is the recognition of disease-free zones.
MODELS OF INTALLATIONS changing rooms and showers, one for men and one for women, and furthermore, ensure that all biosecurity measures are met. This objective is achieved with a clear delineation of the dirty and clean areas. Thus, it is important that at the entrance into these facilities, there is a space where employees have lockers for clothes and outside shoes and, after passing through the shower, they enter the clean area where they have another space to their farm clothes on. This ensures that operators have changing facilities perfectly conditioned to comply with both the security protocols and for personal hygiene. Adjacent to this room, you can locate the
View of the kitchen-dining room with all the equipment for the staff. Photo: RotecnaPress
laundry area for the clothes used on the farm. Beyond this essential toilet area, it is important that employees also have other areas where they can eat, relax ... In this sense, depending on the space, you can create a dining area with kitchen, a bathroom, a bedroom for resting in, an office area and even a meeting room, where farm employees can meet to discuss issues related to their duties and hold training courses. Ultimately, the goal of these facilities is to dignify the profession of the farm worker making them feel comfortable in their jobs and proud to work on a farm.
View of the room for the staff to rest in. Photo: RotecnaPress
3 7
THE MOST EXTENSIVE RANGE
PANS MAXI PAN MAXI HOPPER PAN MAXITAINER FOR MAXI PAN TECNA PAN INITIATION PAN EASY PAN INITIATION PAN MINI PAN MINI HOPPER PAN MINITAINER
OF PRODUCTS FOR PIG EQUIPMENT
FEEDERS GROW FEEDER MAXI GROW FEEDER MINI SOW FEEDER SWING R3 DUO SWING R3 WET SWING R3 TUBE TR2 FEEDER TR5 FEEDERS SOW BOWL FEEDING BALL
DRINKING BOWLS & VRH-3 VALVE VRH-3 SWING DRINKER EASY DRINKER DUO EASY DRIKER MINI EASY DRIKER MIDI
DISPENSERS CLUTCH DISPENSER DOSIMATIC SIMPLEX D-2 FOUR FIVE ADAPTER LINE DISPENSER OUTLET ADAPTER
COVER NI-2 POR PIGLETS NI-2 CORNER NI-2 MOBILE LAMPHOLDER LID WITH LED LIGHT, 5W
FLOOR DELTA BEAM PROFILE T PROFILE DELTA NET SYSTEM ERGOFIX BASIC POST BEAM CLICK-IN
PVC PVC PROFILES (50,25,10 CM) CLOSE PVC PEN DIVIDERS OPEN PVC PEN DIVIDERS DOORS FAST LOCK BRACKETS U BRACKETS SOLID GRIP
PANELS BLIND PANEL 1200X1000 VENTILATED PANEL 1200X1000 BLIND PANELS MADE TO SIZE VENTILATED PANELS MADE TO SIZE MIXED PANELS MADE TO SIZE FAST DOOR KIT POLIAMID UNION BRAKETS FOR PANELS
CHAIN AND DISK SYSTEM
• SHOCK ABSORBING TEETH SYSTEM. • EASY ADJUSTABLE CHAIN TENSIONING SYSTEM WITH GRADUATION SCALE. • CORNERS WITH EASY APERTURE SYSTEM. • SILO EXTRACTION SYSTEM WITH AN AGITATOR.
AUGER SYSTEM
SLATS WEANER BLIND PARTIAL BLIND SOW TRAP SLAT WEAN TO FINISH ELECTRIC HEATED PLATE WATER HEATED PLATE CAST IRON FERROCAST LEVEL BED / RAISED
THE SILO OUTLET SYSTEM CONSIST OF A SILO BOOT, A TRANSFER UNIT AND A SLIDE GATE ASSEMBLY THAT ALLOWS HORIZONTAL AND INCLINED INSTALLATION.
SPLAYLEG STOP