ROTECNAWORLD NUMBER FORTY 2019
SUMMARY TECHNOLOGY
NI-2 MOBILE FENCE FAVOURS THE CONSERVATION OF THE TEMPERATURE INSIDE THE NEST GLOBALPIG
ECONOMIC BENEFITS OF MECHANICAL SLURRY SEPARATION ROTECNANEWS
PURCHASE DEPARTMENT PIGPRODUCTION
THE PRICE OF PORK IN CHINA IS FALLING DUE TO ASFV
LETTER FROMTHEEDITOR African Swine Fever (ASFV) remains the industry’s primary health concern. While new outbreaks of ASFV are emerging in Asian countries beyond the borders of China, such as the Philippines, Hong Kong, Burma, Mongolia, Cambodia, Laos,
SOMETHINGABOUT
Vietnam, North Korea and now, recently South Korea, in Spain we are still safe from this disease, but vigilant to what may happen around us. We cannot let our
SITGES FILM FESTIVAL
SCAN ME WITH YOUR SMARTPHONE
ROTECNA
DOWNLOAD ANY APPS FOR READER QR CODE & VIEW ROTECNA.COM
guard down, and that is why it is crucial to set the biosecurity measures on our Gener Romeu
farms as high as possible.
Rotecna's President ROTECNA WORLD 40
On the other hand, in the business world, we continue to invest in the circular
OCTOBER 2019
economy through the development and advertising of our TecnaPur line of
EDITION: ROTECNA, S.A.- POL. IND. NAU-3, 25310 AGRAMUNT (LLEIDA) SPAIN
products, a brand specialising in slurry treatment. As reflected in this edition,
DIRECTOR: GENER ROMEU EDITOR: NOELIA BURGOS TAMARA LOMBARDO
proper animal waste management can lead to significant cost savings. This investment is particularly important given the outlook envisaged by the new legislation governing the application of slurry, which makes it especially
IMAGES EDITION: DAVID MERCADO
important to have equipment that allows slurry to be managed most efficiently.
TRANSLATION: SAM SMITH
We at Rotecna are aware of this, and we continue to work alongside
PRINT: IMPRENTA BARNOLA L-41-2007
DIGITAL VERSION /issuu.com/rotecnapress Rotecna's World's editors accept no liability for contributor's opinion.
stockbreeders and offer solutions to face the new challenges the future may bring to the industry.
Gener Romeu
ROTECNANEWS
PURCHASE DEPARTMENT PROFILE: · Year the department was created: 1991 · Number of employees: 3
Every company requires a wide range of materials for its production and daily operations. Since its beginning, Rotecna has had a purchasing department responsible for ensuring that all the inventory, goods and services necessary for the operation of the company are in the warehouse on time.
Objectives, tasks and staff of department Currently, the purchasing department is made up of a team of three people. On the one hand, there is Josep Mª Solsona, who has seen the department expand and is now the coordinator, has control over the company’s production and stocks of the most significant products already on sale in international areas. On the other
Josep Mª Solsona, Sandra Beranus and Mireia Oromí are the purchase department team. Photo: Rotecna.
SOMETHINGABOUT...
WITH A SOLID BACKGROUND, THE SITGES FILM FESTIVAL IS ONE OF EUROPE’S MOST RECOGNISED FILM AWARDS The Sitges Film Festival, also currently known as the International Film Festival of Catalonia, is one of the most recognised film awards in Europe and is the first fantasy film festival in the world. It is at the same time, the cultural manifestation with the most media impact in Catalonia. It is held in Sitges every year, a Spanish town and municipality in the province of Barcelona.
One of the film screenings. Photo: Festival de Cine de Sitges.
2
With a solid history, the Sitges Festival comprises a stimulating universe of encounter, exhibition, presentation and projection of fantastic cinema from all over the world, and has become the venue for
SITGES the annual awards of the European Fantastic Film Festivals Federation. In Spain, it is one of the most prestigious film festivals together with the San Sebastian Film Festival or the Valladolid International Film Week. Around 180,000 spectators have attended the last editions. Within this framework, more than 25 separate prizes are distributed in different sections to pay tribute to cinema. The Festival is financed, mainly, by the contributions of sponsors and collaborating companies and businesses, which see their cooperation with the Festival as an excellent means to gain status and exposure.
The 52nd edition This year, the event reached its fiftysecond edition, which took place, as always, at the beginning of October. This unmistakable event paid tribute
ROTECNANEWS hand, Sandra Bernaus, who has been working in Rotecna for over 20 years, is together with Mireia Oromí, in charge of the purchase/sales and also of the production lines, to make sure that Rotecna’s services are efficient, fitting the requirements of each section. The purchasing department also manages material movements and interdepartmental relationships within the company. It works with different areas such as marketing, finance, production and distribution to ensure that they are all in sync with each other.
Real-time stock information The logistics sector is changing and relies heavily on the evolution and use of new technologies by companies. The technological advance led to an increase in stock control skills in Rotecna, as the company went from having an inventory based on obsolete manual
stock control methods to implementing new computer systems that eased this task. “Today, we can have a very accurate picture of our warehouse, which allows us to optimise the storage”, says Josep Maria. Currently, this process is done with the help of various software; one of which is called MRP, which stands for Material Requirements Planning. Not only does purchasing represent a significant risk of economic loss for the company, but it also involves sharing the benefits and transferring the risk to a supplier or commissioning service from a third party. “The real challenge is to get the supplier to invest in a long-term relationship with Rotecna,” explains Josep Maria.
Josep Mª Solsona, Purchases Coordinator In 2000, Josep Mª Solsona joined Rotecna with the desire to broaden his experience with the evaluation of the number of suitable existing stock
Josep Mª Solsona: “Today, we can have a very accurate picture of our warehouse, which allows us to optimise the storage”.
Josep Mª Solsona, Rotecna Purchases Coordinator. Photo: Rotecna. levels following the company’s production strategy; a job that he sees as a personal challenge. “As the company grew, there was a need to strengthen the department, and Sandra Bernaus joined shortly”, explains Josep Maria, who adds that “many people have been part of the purchasing team in the past. Rotecna is a place where the evolution of society has been experienced over the years, some stage changes I have
lived and, based on sharing my experience with other members of the department, I have become the purchasing chief”. Thus, the current purchasing coordinator of Rotecna emphases that “as a department, we give as much as we can of ourselves and much more. I think I can share my amassed professional experience and learn from colleagues to guide the team in achieving the best possible results.”
FILM FESTIVAL to “Mad Max” on its 40th anniversary, the film that inspired the poster, a retrospective look back in time: the official book of the Festival and that permeated Sitges for eleven days, from 3 to 13 October.
First edition Although the Sitges Fantastic Film Festival had its first edition in 1968, its beginnings can be traced back a year earlier to the First (and only) Film, Photo and Audiovisual Week. This first edition of the event, also known as the Cinema School Days, which given what happened there, was a delicious mixture between Berlanga’s Austro-Hungarian Spain and intellectual activism in pursuit of a democracy that would still take a long time to arrive. The origin was touristic. The City Council wanted to promote the very profitable low season climate of the town and Antonio Rafales, then
Some Spanish actors on the red carpet of the event. Photo: Festival de Cine de Sitges. president of the Cine Foto Association, proposed the idea of a very, at first, humble film exhibition. They contacted Antoni Kirchner and Pere Fages, active organisers of the first cinema clubs, who in turn contacted Romà Gubern to organise it.
The project became a showcase of film school works and, to justify the widely sought after internationality, a few foreign academies were invited to present their work (among them, the first work of Roman Polanski, for example).
International Show Currently, among the most relevant presences at the Festival are those of international filmmakers such as Anthony Hopkins, Quentin Tarantino, David Cronenberg and Woody Allen.
33
TECHNOLOGY PATENTED
NI-2 MOBILE
FENCE
Rotecna expands its range of possibilities in the design and management of maternity wards with the launch of the fence for the mobile Ni-2. This accessory, already available in the Ni-2 corner, favours the conservation of the temperature inside the nest and facilitates the management of piglets by the operators since it is possible to keep them locked or to allow them to enter and leave the comfort area through the door.
Nests are an idyllic tool to achieve a higher survival rate and higher weight measurements of piglets at weaning. They help to create a protective space for new-borns, free from air currents and to ensure optimal temperature for piglets, as they maintain a suitable temperature for sows in maternity wards. Furthermore, having nests fenced facilitates the work of the operators in the different tasks they perform with the piglets, such as split nursing, carrying out specific treatments or helping them to recognise their comfort area and safety against the risk of being crushed.
It is essential to preserve the ideal temperature of the piglet inside the nest during lactation to ensure that all its energy is used for growth, instead of it being used for thermoregulation. The thermoneutrality range of the piglet decreases proportionally to its growth. The benefits of working with nests in farrowing pens are increased when they offer the possibility of fencing.
The mobile Ni-2, available in opaque or transparent, is portable and can be easily moved from one place to another, allowing its use in the positions required according to the age of the piglets. Besides, its adjustable height maximises the microclimate effect generated inside. The inclusion of a fence as an accessory increases the benefits of the nest, such as improving the wellbeing of the piglets, reducing mortality rate, achieving higher weight at weaning and reducing the energy cost in maternity wards.
NI-2 MOBILE FENCE ADVANTAGES: • During birth, it helps organise the tasks of drying and improving the body temperature of new-born piglets, especially the weakest and smallest. • It allows for split-nursing so that in large litters, no piglets are left behind. • It facilitates the carrying out of specific treatments, such as vaccine administration, animal control and the filing of teeth. • It creates a safe area for piglets, which increases their thermal comfort, growth and, at the same time, reduces energy consumption. • Reduces the risk of being crushed by the sow by reducing the learning time and the period of the piglet’s permanence in the nest.
4
PIGPRODUCTIONIN...
THE PRICE OF PORK IN CHINA IS FALLING DUE TO AFRICAN SWINE FEVER Source: ICEX. España Exportación e Inversiones.
The positive drift of the trade in the Asian country experienced a decline of up to 2.6 million tonnes. The Asian nation is the world’s largest pork producer, with just over 54 million tonnes in 2018, representing almost 48 % of world production, according to data recorded by ICEX. Besides, it has more than half of the world pig population.
The country with the highest pork consumptuion The consumption behaviour in China also positions the country as the largest pork consumer in the world. With 54.75 million tons in 2017, representing 49.6% of world consumption. Besides, pork is the most widely consumed meat in the country, with a market share of more than 62%. Annual per capita intake is 30.29 kg, relatively high by world standards. However, the Chinese government is trying to mitigate the setbacks in the pig sector associated with the decline in production levels in their country since 2014 through a rationalisation program. This decline is why China has become the primary importer of pork globally, with a 56% increase in the value imported between 2013 and 2018, from 2,155 to 3,354 million euros. In 2016, they achieved a record figure of 3.2 million tonnes, an increase of 78 % over the previous year. However, the progression of imports is experiencing substantial volatility, subject to the process of rationalisation of the local industry, changes in consumption habits and health problems that the sector experiences regularly.
More than one million pigs have been slaughtered by African Swine Fever In 2017, the porcine sector’s positive trend in China experienced a fall of up to 2.6 million tonnes and
Some pig farms in China are built in concrete buildings.Foto: Rotecna. 4,190 million euros. Later, in 2018, imports fell to 3,354 million euros and 2.3 million tons, representing a decline of 20% over the previous year in terms of value and 13.5% volume. This restriction in imports has been less pronounced as a result, among other reasons, because of the impact African Swine Fever detected in August 2018 has had on local production, which has so far spread to 31 provinces, with 123 outbreaks overall. China is taking significant steps to eradicate the disease, albeit at a high cost and without results. More than one million pigs have already been slaughtered, although the numbers may be higher.
trade war has led to a severe narrowing of US imports and has created opportunities to increase the market share of other competitors. Brazil meanwhile, has been significantly growing its market share for the last two years, especially in the frozen meat industry, going from seventh place in 2016 to the third-largest supplier in 2018.
Of the 34 regions in which China is divided, cases have now been spotted in 31 areas, so it can be said that African Swine Fever is now widespread throughout the country and it is a pandemic with incalculable consequences, although it is giving first-hand opportunities to other countries. Currently, the leading suppliers of pork to China are Germany, Spain, the United States, Canada, Denmark, the Netherlands and Brazil. The US-China
Source: 3tres3.
Gestation in a farm in China.Foto: Rotecna.
5
GLOBALPIG
CARLOS ALBUIXECH:
“TECNAPUR IS A STRAIGHTFORWARD, LOW-CONSUMPTION SYSTEM” The management of 184 sows and 2,100 weaning places at Quesa (Valencia).
More than 30 years ago, Carlos Albuixech García took over the generational relay of pork production, originaly from the paternal line. It was in 1986, at the end of his professional training, when Carlos got wholly involved in the running of the farm, demonstrating his commitment to sustainability.
How long ago did you decide to install a system for mechanical separation of slurry? In 2008, I decided to move the farm two kilometres from Quesa, to increase biosecurity measures. Besides conforming to the laws, my goal was to have a self-reliant farm with plans for the future. So, I considered the option of separating livestock droppings, as I use a lot of the slurry mixed with water in my working setup to irrigate alfalfa and other crops. If I hadn’t decided to separate the slurry, I would have had to do the manual mixing with water and work with a bucket. It was then, that same year, at the Zaragoza Trade Fair, that I discovered the Rotecna TecnaPur system. I had been working with the company for several years, and they had told me about it. When I saw that the procedure presented by the product was simple, I decided to try it, and the truth is that it works very well. Now, we are considering the installation of the next phase, the physicochemical treatment. My idea is to complete the cycle, as I would like to install a sprinkler irrigation system to use less water. I have one hectare of alfalfa, which means that it is a plant that needs a lot of water and nutrients, and the slurry covers this. When I installed the first phase of TecnaPur, I had already planned its distribution with the possibility of accommodating the second level soon. Today, although I have not yet started the process, I have a pending visit to a nearby farmer who has installed the physicochemical reactor on his farm and is very satisfied with the results.
Why did you decide on TecnaPur Solids Separator? I had several offers from other systems on the table and had started estimating the costs. The problem is that all the prices, including the cost of maintenance, were very high, and the machinery seemed too complicated. Then, as I have already mentioned, Rotecna suggested the TecnaPur system at the Zaragoza Trade Fair, where I was able to
6
Phase 1 of TecnaPur installed at the Umbriporc farm in Quesa, Valencia. Photo: Carlos Albuixech.
verify the simplicity of its mechanics and see how it worked.
What other advantages would you highlight of the TecnaPur system compared to others in the market? Besides the simplicity of the mechanics, its low maintenance and energy consumption. It is also necessary to make sure that energy consumption is minimal, as it takes many hours to process the slurry. Aside from that, another thing that convinced me was the technical advice, the guarantee and the bespoke assistance offered..
How many cubic metres of slurry do you process per day?
than the rest. In that case, I take out the slurry with a bucket and add it to the pool. In this procedure, I can extract up to three barrels a month.
Compared to the initial volume, what percentage do you get from each segment? The separation makes it possible to reduce the volume of the slurry by up to 15% and to obtain, for every 1,000 litres, 150 litres in solid form with a 20-25 % dryness and 850 litres in the overflow. The solid phase is odourless and takes up to 20% total Kjeldahl nitrogen (NTK), 50% total phosphorus (PT), and 20% potassium (K) from the original slurry. Therefore, it separates up to an overall 55 % of solids.
What makes each of the divisions?
Every week we reach about 60,000 cubic meters. Regarding solids, we obtain between 6 and 7 tons. These results can be attributed to the entire production model of my farm, as we have the Rotecna level valve installed, and therefore there are very few water losses, which means significant savings.
Most of the slurry I get is liquid, which I use to irrigate crops and alfalfa. Although the solid portion is not for sale, I distribute it free of charge to different people in the town, since in Quesa most people have crops, and so I don’t have to carry the excrement to any deposit.
From how many different fittings does the slurry treated by the separator derive?
At an operational level, what is the separation cost?
It proceeds from maternity, from the gestation room which measures up to 50x22 meters wide, from the covering phase and then from the weaning shed. As a result, the slurry comes from four places. The replacement section is not connected to the system because it is a room which is more isolated
The machine has an electrical consumption of less than 0.75 kW/hour, as it is composed of a single motor of 1 CV at 220/380 V. It works automatically, with very little maintenance and doesn’t require a skilled workforce. The maintenance of the machine is minimal.
GLOBALPIG
ECONOMIC BENEFITS
OF MECHANICAL SLURRY SEPARATION Oscar Toledano. Marketing and BI Manager.
SOLID - 186 liters (18,6%): - 1,1 kg of NTK (22% separated) • 0,5 kg of NH 4+ (14,3 % separated) • 0,6 kg of N.O. (40% separated) - 1, 3kg of P2 05 (33,3 % separated) - 0,8 kg of K2 O (27,6 % separated) - 35 kg of Total Solids (46,7 % separated)
In 1 m3 of slurry (100%):
LIQUID - 814 liters (81,4%):
- 5kg of NTK (0,50% composition) • 3,5 kg of NH4+ (0,35% composition) • 1,5 kg of N.O. - 3,9 kg of P2 O5 (0,39% composition) - 2,9 kg of K2O - 75kg of Total Solids (7,5% composition)
- 3,9 kg of NTK (78% separated - 0,48% composition) • 3kg of NH 4+ (0,37% composition) • 0,9 kg of N.O. - 2,6kg of P2O5 (66,7% separated, 0,32 % compsosition) - 2,1 kg of K2 o (72, 4 % separated) - 40kg of Total Solids (53, 3% separated)
The comparative analyses between the initial slurry compared to the liquid and solid phases segregated during the operation analysed, show the advantages offered by mechanical separation as it improves the application and fertilising qualities of the slurry. Besides, it has economic benefits that make the separator an excellent investment.
Liquid-phase We reduce the volume of liquid slurry to be transported by 19% (estimated application cost of 2.00/m3). We reduce the total Kjeldahl nitrogen content by 4% (NTK, from 0.50% to 0.48%), thus increasing the amount of slurry that can be applied per hectare in fertilisation with nitrogen. However, the proportion of inorganic nitrogen (NH4+, ammonium) also increases by 6 % (from 0,35 % to 0,37 %), which is what the plants absorb directly, so we significantly improve the fertilisation coverage (done on newly born crops, when their nitrogen needs are at their peak). The phosphorus composition is reduced by 18% (P2O5, phosphate, from 0.39% to 0.32%), so we minimise the amount of phosphorus supplied per unit of nitrogen. The absence of large solids is ideal for application by hose or injectors; thus, it is applied homogeneously and reduces the time and cost of implementation.
Solid-phase We generate a compostable solid of high added value with a high concentration of nutrients, especially organic nitrogen (NO) and phosphate (P2O5), which make it ideal as a base fertiliser (which is applied to the crop before planting). After a composting process of three to six months, which
COSTS WITHOUT SEPARATOR
16.800 € / year 8.400 m3 slurry /year
42.000 kg NTK / year
247 ha for nitrogen fertlization
1,2 m3 place / year
5,0 kg / m3 . 6,0 kg / place * year
170 kg N / ha. 2 € / m3 aplication 16,800 € /year
COSTS WITH SEPARATOR
3.510 € / year
22% less land
LIQUID
6.840 m3 slurry / year
32.770 kg NTK / year
193 ha for nitrogen fertlization
4,8 kg/ m3
170 kg N / ha. 2 € / m3 aplication 13.680 € / year
SOLID
OPERATION
1.560 m3 manure / year
780 t composting / year
11.700 € / year
50% composting performance
15 € / m3
1.200 h of separation
4,5 kW / h (agitator + pump + separator)
594 € / year
7 m3 / processed
0,11 € kWh
1h / weekly cleaning
936 € / year
18 €
involves a mass reduction of 50%, it can be sold as an organic fertiliser at a market price that, depending on the area, ranges between 10 and 20 / T.
Overall, this results in a saving of around 1.90€/ seat/year to repay the installation cost and requires 22 % less land for the management of liquid slurry.
If we extrapolate these data to a typical farm of 7,000 fattening spaces from 20 to 110 kg, we obtain the results represented in the following cost table.
Separation becomes popular as the main slurry rertrival system
Conclusion With a mechanically separated slurry application at 170 kg N/ha (maximum for an exposed area with winter cereals), we would need 193 ha of land instead of 247 ha. This whole process would mean an annual application, operation and maintenance cost of 15,210 instead of 16,800, and a profit of 11,700 would be generated from the compost sale.
Two years after its launch, the TecnaPur solid-liquid separator has become a highly efficient product for the treatment of slurry due to its performance, low operating costs and benefits. Livestock farmers all over the world are now investing heavily in this technology to process their animal excrement, turning a problem into a benefit and boosting the economy.
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 TR3D FEEDER SF3D FEEDER TR5 FEEDERS SOW BOWL FEEDING BALL
DISPENSERS CLUTCH DISPENSER DOSIMATIC SIMPLEX D-2 FOUR FIVE SIX-D SIX-S ADAPTER LINE DISPENSER OUTLET ADAPTER SPLAYLEG STOP ANTI-STRESS FEEDER ANTI-STRESS CHAIN
COVER NI-2 POR PIGLETS NI-2 CORNER NI-2 MOBILE LAMPHOLDER LID WITH LED LIGHT, 5W
DRINKING BOWLS & VRH-3 VALVE VRH-3 SWING DRINKER EASY DRINKER DUO EASY DRIKER MINI EASY DRIKER MIDI
ELECTRONIC FEED MANAGEMENT SYSTEM DOSITRONIC M DOSITRONIC G
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 PROFILES 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 THE SILO OUTLET SYSTEM CONSIST OF A SILO BOOT, A TRANSFER UNIT AND A SLIDE GATE ASSEMBLY THAT ALLOWS HORIZONTAL AND INCLINED INSTALLATION.
PVC PVC PROFILES (50,25,10 CM) CLOSE PVC PEN DIVIDERS OPEN PVC PEN DIVIDERS FAST LOCK BRACKETS U BRACKETS SOLID GRIP
SILOMETRIC
SLATS WEANER BLIND PARTIAL BLIND SOW TRAP SLAT WEAN TO FINISH ELECTRIC HEATED PLATE WATER HEATED PLATE CAST IRON FERROCAST LEVEL BED / RAISED
FLOOR DELTA BEAM PROFILE T PROFILE DELTA NET SYSTEM ERGOFIX BASIC POST BEAM CLICK-IN
TECNAPUR SOLID-LIQUID SEPARATOR AGITATOR