Pas Reform Times
Pas Reform Hatchery Technologies
Morris Hatchery USA goes single-stage with
Smart incubation systems Ed Morris explains: ‘we have set our mind to single-stage incubation. It will produce better uniformity in our day old broilers’... > page 2
Aviagen’s Ross EPI The Netherlands gives
parent stock hatchery a Smart overhaul with single-stage specialists Pas Reform. The newly updated
hatchery has a total capacity of more than 10 million female chicks each year, making Ross EPI the largest Parent Stock hatchery in Western Europe. … > page 6
Bounty Fresh Philippines launches first single-stage Smart hatchery project in the country.
Anhalzer, Ecuador 7 Suguna, India 8 Bell AG, Switzerland 10 Wasikowsky, Poland 12 Dar El Fellous, Morocco 13 Mironovsky, Ukraine 14 Prioskolje Group, Russia 27
Chen says: ‘The time is now right to capitalise on the benefits in terms of broiler uniformity and feed conversion ratios… > page 31
Hubbard, South Africa 21 Halim & Company Ltd., South Korea 4
We are privileged to work with many of these people – all of whom share our passion for the future of single-stage
incubation as essential to hatchery success in the future.
It is their success that has propelled Pas Reform’s continuing
expansion and investment in people – engineers, technicians, specialists – to help drive their businesses and ours forward. Around the world, growth in the poultry sector is creating massive opportunities for commercial hatcheries: Single minded about single-stage: it’s the people that make the difference
Every day, I am reminded that our success does not rely solely
opportunities that - experience has shown us - are best met by shared knowledge and a single-minded commitment to innovation, quality and results.
on the strength and viability of our hatchery technologies.
Technology will change and evolve. But it’s the people who
that choose our Smart single-stage incubation systems, to
As importantly, it also relies on the success of the hatcheries fuel their own growth and expansion.
develop it, understand it - and use it - that will really make
Welcome to this ‘extraordinary’ edition of Pas Reform Times:
From the USA to the Philippines, Morocco to Mexico and
a celebration of the many and varied people we meet in
people who know their business – and understand what a
sincere wishes for every success in the future.
beyond, that choice is being made by experienced hatchery hatchery needs to grow.
hatcheries around the world - with our compliments and
Bart Aangenendt CEO
Pas Reform Hatchery Technologies
Pas Reform Times Morris Hatchery, Inc., USA 2 New Representative for USA, 2 Economics of improving chick quality 3 Halim & Company Ltd., South Korea 4 Creating the ideal hatching climate 5 Lisko Broiler, Russia 6 Aviagen’s Ross EPI, The Netherlands 6 New Representative for Thailand 6 Anhalzer, Ecuador 7 Suguna, India 8 New Business Development Manager Middle East 8 Poor performance due to transportation 9
Mr. Ed Morris, Owner and CEO of Morris Hatchery, Inc. and Bouke Hamminga, Director International Sales & Business Development Pas Reform
Bell AG, Switzerland 10 New Project Manager 10
Hatchery Technologies, sign the contract for Pas Reform’s first state-of-the-art single-stage Smart hatchery in the USA.
New Russian-language website 11 Wasikowsky, Poland 12 New Representative for Sri Lanka 12 Dar El Fellous, Morocco 13 Mironovsky Hliboprodukt, Ukraine 14 How effective is your hatchery cleaning and disinfection programme 15 New Technical Engineer 15 Pas Reform Sales Team 16 New Distribution and Inspiration Centers 18 The importance of preventing ‘sweating eggs’ 18 New Service Manager 18 Krasnayarugsky Broiler, Russia 19 Hatching at high altitudes 20 Pas Reform Russia 20 Hubbard SA, South Africa 21 Ptitsefabrika Lebiazhe, Russia 22 New Representative for Iran 22 When incubation is an art 23 Odessa Chicks LLC, Ukraine 24 New Senior Poultry Specialist 24 Relevance of turning 25
Morris goes single-stage with Smart in the USA Single-stage incubation specialist Pas Reform makes its operational debut in the USA in New York State, with a new agreement from Morris Hatchery, Inc. for the delivery and installation of a state of the art single stage hatchery. The hatchery, due to start operations in Spring 2008, will have an opening capacity of half a million day old broilers per week. This is, says CEO Bart Aangenendt, a landmark signing for Pas Reform – signaling the next phase in the European company’s global expansion as a leading manufacturer of incubators, hatchery climate control and hatchery automation systems. The hatchery will be built during spring 2008 - and equipped with SmartSet™ 77 setters, each with a capacity of 76,800 eggs, and SmartHatch™ hatchers with capacities of 19,200 eggs each. Broiler incubation programs will be mainly for Morris Hatchery’s clients in Canada, as well as for deliveries within the USA. Ed Morris, owner and CEO of Morris Hatchery, Inc. explains: 'We have made rigorous comparisons on the different systems available, and had set our mind to single stage incubation because it will produce better uniformity in our day old broilers.
Their commitment to technical service, incubation knowledge and training will be geared to ensuring that we immediately see the results not only from incubation, but also during the first week of the broiler’s life.' The new hatchery will, says Mr. Morris, be a showcase operation for the sector in the USA. Bouke Hamminga, Pas Reform’s Director International Sales & Business Development, confirms that this is probably the most important step Pas Reform will take during 2007-2008. 'Entry to the USA is a key strategic ambition for Pas Reform. We could not have envisaged a better scenario, than to develop a complete, fully equipped, state of the art customer hatchery as our debut in America', he says. CEO Aangenendt concludes, 'This new Agreement is absolutely a landmark for Pas Reform, not only in the USA – but as part of our fullscale international expansion strategy. And we are fully committed to building a strong, sustainable presence in North America over the coming years.' Family owned and operated Morris Hatchery, Inc. was founded in 1962, as a poultry breeding, hatching and growing business. Expansion and business development have seen Morris Hatchery become a major breeder of many different poultry strains, all housed in more than 250,000 sq. ft. of breeding and growing space, as well as expanding their operations to become one of the world’s leading exporters of hatching eggs.
'With 35 years’ experience in developing and delivering single stage hatchery systems and technologies, Pas Reform stood apart as the most compelling and convincing partner for us in this new venture. The quality and durability of their machines, combined with ease of operation, seem to offer a good fit for the US market.
Lohmann Breeders 26 New Business Development Manager for Central & Eastern Europe 26 Prioskolje Group, Russia 27 Suguna Group, India 28 When and how to transfer eggs to the hatcher 29 Maintaining the ideal climate for chick handling and transport 30 Bounty Fresh Foods Inc., Philippines 31
Pas Reform appoints dedicated Representative to support Smart growth in the USA Since launching its industry- leading Smart single-stage incubation system in the USA in January 2007, Pas Reform announces further expansion to its worldwide network, with the appointment of Mr. Dave Neff to
drive the company’s commercial activities in the USA. Mr. Neff will deliver the full range of Pas Reform products, including Smart single-stage incubation technology, through out the USA. His main area of responsibility is to work in partnership with Pas Reform’s American customers, partners and colleagues, to enhance the
range and depth of commercial services. From the supply of products to technical support and services following the installation of Smart incubation systems, Dave Neff becomes the first point of contact with Pas Reform Hatchery Technologies in the USA. In addition to supplying Smart single-stage incubators, hatchery automation and climate control
systems, Dave will also ensure that Pas Reform’s relations in the USA have full and reliable access to dedicated project and hatchery management training programs, from the widely acclaimed Pas Reform Academy in Holland. Dave was born and raised on his family’s turkey and broiler farm in the Southern Ozarks area of Missouri. He obtained his
Martin Barten, Senior Hatchery Specialist Pas Reform
Economics of improving chick quality A few months ago, we visited a hatchery that was part of one of the larger poultry production integrations in Europe. It was our first meeting, and as such, we expected discussions to be slightly guarded. Hatchery managers - and others who are ultimately responsible for commercial results - are often reluctant to speak about what is really going on in the hatchery, let alone to speak about any particular problems or to allude to suboptimal results in hatchability or chick quality. As anticipated, our meeting began fairly typically, with the hatchery manager telling us that everything was okay and results were fine. Hatchability on average was running at a respectable 82 per cent. But then we started asking more detailed questions about the quality of the day old chicks: Do you ever see red hocks in your chicks? Do you sometimes observe sticky chicks, big bellies, or red dots on the chicks’ beaks? In other words, was the reality in fact that sometimes chick quality was indeed below expectations? It has been our experience that every hatchery manager, wherever they are in the world, does sometimes encounter reduced quality in their day olds. The reasons for this can lie outside the hatchery. But in particular, when the reasons for suboptimal quality are in the hatchery managers’ hands, not to use this valuable information to improve hatchery management procedures is an opportunity missed. Especially when improving results can be relatively easy!
With more direct questions, our customer began to speak a little more freely. Yes, he had indeed sometimes observed a larger number of red hocks and badly closed navels in his day old chicks. So we asked if we could see the single stage incubation programme the manager was using. He was surprised: 'Why, can you solve this problem by adjusting the incubation programme?' Because a high percentage of bad navels was one of the primary reasons for discarding day old chicks, and therefore very costly, now he really was willing to talk. First, we suggested we look more closely at the two problems that this hatchery manager had observed from time to time: a high ratio of chicks with badly closed navels, or a high percentage of red hocks. While severe cases of badly closed navel cause chicks to be discarded, other losses can and do often result from infection, as bacteria can be introduced through the unhealed navel. Badly closed navels are often linked to chick losses as a result of yolk sac infection, commonly caused by E. coli and other pathogenic infections. There is little published evidence on the relationship between day old chick quality and leg problems in young chicks. But logic dictates that chicks with suboptimal leg condition will naturally be less mobile - and therefore less likely to visit the feed pans as much as chicks with good legs. Continued on page 4.
Mr. Dave Neff, Representative Pas Reform Hatchery Technologies in the USA
ndergraduate degree in Agriu culture/Business and graduated in Poultry Science. He has an extensive background in the poultry industry, having worked in several areas of pullet, breeder, hatchery, live, technical and executive management positions throughout his career, including his current role with Morris Hatchery, Inc., the leading US producer of fertile
broiler hatching eggs. Dave is married and has three adult children. Dave Neff is enthusiastic about Pas Reform’s future prospects in the USA: ‘Pas Reform is a worldleader in the development of single-stage incubation tech nologies. 'The company has pioneered in this field for more than 30 years and, combined with the support
of dedicated Project Management and Hatchery Management Training Programmes from the Pas Reform Academy, we have excellent prospects for significant growth here.' Mr. Bart Aangenendt, CEO of Pas Reform, is delighted with the appointment: 'Dave knows and understands the US market extremely well', he says. 'We will dedicate substantial time and
energy to supporting Dave’s activities in the USA with an ongoing recruitment and training programme for technicians, as well as regular, follow-up visits by our hatchery specialists, to provide comprehensive support in helping them to make the transition from multi- to singlestage hatching operations.'
Dave Neff can be contacted at: 4090 Campbell Road Gillsville, Georgia 30543 USA E-mail: firstname.lastname@example.org Office phone: (770) 532 4334 ext. 102 Office fax: (770) 532 0241 Cellular: (678) 5410 1946 Home phones: (770) 536 4050 or (770) 536 8318
Dr. Marleen Boerjan, Director Research & Development Pas Reform
Continued from page 3. Research undertaken by the Pas Reform Academy, in collaboration with Wageningen Agricultural University has, however, found that red hocks in day old chicks lead to a higher incidence of leg problems in broilers at 40 days of age. It is also well documented that high incubation temperatures during the last two-thirds of incubation can produce chicks with poorly closed navels and red hocks. When we examined the incubation programme that this hatchery was currently using, the incubation temperatures did indeed seem fairly high. Analysis of egg shell temperatures showed the same, and we decided to lower the temperature set point during the last eight days in the setter by 0.5°F. This adjustment alone led to a three per cent increase in the number of saleable chicks, mainly as a result of lowering the percentage of chicks being produced with poorly healed navels and red hocks. Without access to post-hatchery data, we cannot support the hypothesis that broiler growers would also see improvements in terms of reduced mortality and improved feed conversion ratios as a result of improved chick quality. But we can certainly assume decreased mortality during the first week. And this hatchery manager’s experience shows us once again that investing a little time in checking and improving chick quality soon pays dividends. An average hatchability of 82 per cent against eggs set is a respectable percentage, but there is still plenty of room for improvement. Let’s look at the economic consequences of improving hatchability by even just one per cent. One incubator with a
Halim & Company Ltd. Korea’s largest broiler integrator recently contracted Pas Reform to supply single-stage Smart incubators and hatchery automation systems for their GPS hatchery in Jeonbuk.
Mr. O.K. Kang, Representative South Korea
capacity of 115,200 eggs in single stage operation is used 17 times per year. Assuming a one per cent improvement of saleable chicks, from 82 to 83 per cent this single machine will produce 115,200 x 17 x 1% = 19,584 more saleable broilers per machine, per year. If we assume a day old chick price of €0.25, this equates to an increase in income of almost €5,000 from one single machine! And sure enough, several weeks after our first visit, we had the opportunity to speak with the hatchery manager again, when he told us that the increase in hatchability had been sustained, increasing the hatchery’s income by approximately € 60.000,00 per year! Advances in hatchery technology have brought us a long way toward recreating optimum conditions for the most successful incubation programmes. But there is no substitute for the knowledge and experience that comes from observing the process and the resulting chicks. In this way, any problems are quickly identified – and the hatchery will reap the economic benefits of that vigilance.
Creating the ideal hatching climate The transfer of eggs from setter trays to hatcher baskets is routine in the hatchery, while the embryo continues to develop. In the final days of incubation, the embryo prepares for hatching and while embryonic growth slows down at this stage, the maturation of most of the organs continues. The embryo turns its body along the long axis of the egg, with the beak under the right wing and the neck bent towards the blunt end of the egg. Residual yolk is retracted within the abdominal cavity and the navel closes. Simultaneously, blood flow through the chorion allantois membrane ceases - and the chick uses the egg tooth to penetrate the inner membrane of the air cell. Exposure to this gaseous environment in the air cell stimulates the lung and air sacs to be filled. And after a period of time, the chick pierces a small hole in the egg shell, defined as external pipping. Time elapsed between internal and external pipping varies according to breed, flock ages, storage and incubation conditions in the setter. However, it has been shown that external pipping is triggered by the partial pressure of carbon dioxide in the air of the air cell. The higher the partial pressure of carbon dioxide, the shorter the interval between internal and external pipping. External pipping is known to be delayed in porous egg shell or by a hole in the egg shell.
Hatching is a stressful and critical period, influenced by the physiological condition of the chick as well as by climatic conditions in the hatcher. If, for example, energy stores in the embryo are low because of poor climate conditions during the last days of setting, the fully developed chick dies shortly after external pipping. If, during external pipping, humidity in the hatcher is lower than 70 per cent, the shell membranes dry out, leaving the chick stuck in the egg. When temperature is too low, chicks chill during drying - and when carbon dioxide levels are too high, the chicks will gasp for fresh air when they have hatched and dried. Advice - Control ventilation based on carbon dioxide (CO2) levels. CO2 set points of 0.5% +/- 0.1 are recommended as optimum for high hatchability and good chick quality. - If the valves are controlled by CO2 levels, humidity will rise automatically when the first chicks hatch (see figure 1). - Humidity will decrease when most of the chicks have hatched and dried. If using a SmartHatch™ hatcher, the hatcher’s display panel will read: ‘chicks are ready to be pulled’. - Do not lower the temperature before all chicks have dried. - If the hatch window is longer than 24 hours, review the management of setting. The hatch window will become larger when batches of eggs from different flocks and storage conditions are mixed in one setter and hatcher. - If the hatch window is longer than 24 hours, review the temperature distribution in the setter. In general the hatch windows will be larger after multistage incubation compared with single stage incubation, because temperature distribution in a multistage incubator is not homogenous.
set point carbon dioxide 0.5% 60
relative humidity (%) valve (%) carbon dioxide (% *100) Figure 1. Automated Hatching System (AHS™)
References available on request.
Mr. Nikolai. V. Belokonev, General Director of Liski-Fitting, Mr. Igor V. Zamyatin, Deputy General director of Liski-Fitting, Mr. Michaël Kampschöer, Sales Director Pas Reform
Hatchery Technologies, Mrs. Anna N. Kolygina, Commercial Director Pas Reform Russia, Mr. Willem E. Schaafsma, General Director Pas Reform Russia
Lisko Broiler sign-up to Smart for new poultry integration in Russia Pas Reform signed a new contract with Lisko Broiler, from Voronezh region, Russian Federation, for the supply of a turnkey hatchery with a capacity of 60 million eggs per year. Lisko broiler - a newly founded subsidiary of JSC Liski-Fitting, better known for industrial metal fittings used in gas and oil pipelines - is expanding its portfolio into poultry production for the domestic market. Lisko will develop a complete integration, with a production volume of 60,000 metric tonnes of poultry meat per annum. The Greenfield project includes a parent stock farm, hatchery, seven broiler sites, two feed mills, slaughtery and processing plant. The new integration will target production of 150,000 broilers per day, six days a week.
Pas Reform looked not only at development for the new hatchery, but also at how best to integrate the hatchery into planning for the wholly integrated operation. Mr. Belokonev continues: 'Pas Reform has comprehensive experience in the Russian market, combining the best of technologies and practice from both east and west. And when we surveyed users of different brands of incubators in the Russia – we found Pas Reform customers the most enthusiastic and compelling. Without exception, they were the most forthcoming about their hatcheries and were happy to talk to us openly about the results being achieved with Smart incubation systems, the feed they save in the farm as a result of homogenous temperature levels during incubation and the extra quantity and quality of uniform chicks they get from their hatchery.' Mr. Willem Schaafsma, who leads Pas Reform’s Russian team, has been very impressed by the professional and commercial approach of the Lisko broiler team. 'It is a pleasure to work with them. They are eager to learn and have invested in some very experienced poultry specialists, so that every link in the poultry production chain is clearly understood. Mrs. Anna Kolygina, Pas Reform commercial director in Russia, has great expectations for Lisko Broiler, based on the drive and professionalism with which the negotiations and discussions have progressed to date. She concludes, 'With their care and attention to planning and the calibre of their new team, we think Lisko broiler will rapidly become a leading player in the Russian poultry market.'
General Director Mr. Nikolai Belokonev says that it was not an easy task to select a supplier for the turnkey project. 'Since we are new in this field, there were many discussions with different suppliers. But ultimately, we felt Pas Reform to be most competent and professional in meeting our needs and certainly they proved themselves most adept in answering any questions from our team.'
Goodspeed gets up to speed for Smart Expansion in Asia
Goodspeed International, Pas Reform’s Representative in Thailand, has geared up for further expansion in Asia with an intensive program to train the company’s growing number of technicians and support personnel.
The training program, developed by the Pas Reform Academy, was designed to arm Goodspeed’s personnel with an in depth understanding of the Smart Incubation System, so that they can not only deliver comprehensive training for their customers onsite, but also to enable onward inhouse training programs, as the company’s
support team continues to grow. With 16 years’ experience in the Thai poultry sector, Goodspeed’s Managing Director Mr. Somnuk Hophaisarn is a respected and highly regarded partner in the industry. And having represented one of the largest poultry busi nesses in Thailand for 15 years, Goodspeed is now focused on developing the range and depth
of Pas Reform’s commercial services throughout Thailand – and beyond. Somnuk comments: 'Pas Reform is realising important growth in Asia, reaching from India in the west all the way to South Korea in the east - and with substantial inroads also being made into Australia.
Aviagen’s Ross EPI now largest single stage PS hatchery in Western Europe To accommodate its plans for further expansion, Parent Stock hatchery Ross EPI, part of the Aviagen Group, has completed a comprehensive refurbishment of its Dutch hatchery operations, working with single stage hatchery specialists Pas Reform. Situated in Roermond, Ross EPI’s Dutch hatchery has been refurbished with the latest in single stage equipment and technologies. The new installation includes a full single stage Smart incubation system, comprising SmartSet™ setters and SmartHatch™ hatchers, combined with a SmartDrive™ incubator control system, to accommodate the management of individual conditions per egg type and SmartCenter™, Pas Reform’s powerful hatchery management information system. The newly updated hatchery has a total capacity of more than 10 million female chicks each year, making Ross EPI the largest Parent Stock hatchery in Western Europe. Ross EPI’s refurbishment is a strategic expansion project for Aviagen, with the company focusing not only on supplying top class day old breeders for the Western European market, but also now extending deliveries to Poland and selected central European markets.
'By developing our technical support capabilities in this way, Goodspeed will be well placed to support this growth with local teams of installation specialists, incubator mainte nance technicians and troubleshooters.' Goodspeed’s intensive training programme, the 25th such
program to be run by Pas Reform since the launch of its Smart incubation system in 2004, was held at the single stage hatchery specialists’ Zeddam headquarters, in The Netherlands. Covering all aspects of Smart incubation technologies, and including the latest updates on
Anhalzer gets supersized with Smart in South America Massive investment in Smart incubation systems and technologies from Pas Reform is set to put Ecuadorian poultry integration Incubadora Anhalzer firmly on the map as one of the largest single-stage incubation broiler hatcheries of South America. The new single-stage hatchery will be built in Guayaguil, Ecuador. The decision to work with Pas Reform came, says Anhalzer CEO Mr. Pablo Anhalzer, after careful and rigid comparisons of hatchery equipment manufacturers and suppliers. 'We wanted a fully integrated approach to the development of our new hatchery' he says, 'and our preference was to work with a single industry partner'. 'We found that Pas Reform not only delivered a very complete solution in their state of the art setters, hatchers and ventilation systems, but also that they could offer a full range of hatchery automation and climate control equipment - and the project management capabilities to fully support the development of the project'. It is Anhalzer’s intention to develop a highly automated, state of the art hatchery in Latin America: a goal that Pablo Anhalzer says his company will certainly achieve, with the completion of the Guayaguil project. The installation comprises 18 SmartSet™ 77 setters with a capacity of 76,800 eggs each and 12 SmartHatch™ hatchers. Pas Reform’s project team has designed the entire hatchery layout and provided detailed plans for the hot and cold water plumbing and drainage systems and a complete ventilation system. Installation will include Pas Reform’s transfer and candling equipment, sexing and vaccination carousels.
'This is virtually a turnkey project', explains Ranulfo Ortiz, Pas Reform business development manager in Latin America. 'The only part of the project to be sub-contracted is the physical construction of the hatchery building. All design, planning and the installation of hatchery systems and equipment will be fulfilled by a multi-disciplined project team from Pas Reform, including autocad drawing engineers, ventilation engineers, hot and cold water engineers, hatchery automation engineers and overall project management specialists.'
Pas Reform’s CEO Mr. Bart Aangenendt, concludes: ‘Working with partners of this calibre is central to our strategy for growth going forward. A project of this magnitude enables us to deploy our full range of products, technologies and services. Anhalzer’s Guayaguil hatchery will, we believe, make an impression not only on the South American market, but quite conceivably throughout the western hemisphere.
At the end of the build and installation phases, Pas Reform’s team will remain onsite with Incubadora Anhalzer hatchery personnel, to deliver onsite training while refining and programming the hatchery’s systems to accommodate an ambitious and varied hatch plan. The Anhalzer hatchery project is, says Ortiz, one of the most comprehensive projects ever contracted to Pas Reform in South America - and one which will serve as an important showcase operation for the entire region.
Goodspeed International technicicans travelled to Pas Reform’s Dutch HQ, to hone their skills for further expansion in Thailand and South East Asia.
hatchery automation and climate control, the training program’s key focus was to provide sound, hands-on knowledge transfer related to hatchery design, equipment start-up, maintenance and trouble-shooting. 'Mr. Somnuk and his team have greatly enhanced Pas Reform’s
localised technical support capabilities in Thailand, ' commends company CEO Mr Bart Aangenendt: 'We have great admiration for Somnuk’s decision to further develop Goodspeed’s technical skills and for his ambitions for the company as a premier service provider and partner to Pas Reform in South East Asia'.
From left to right: Mr. Sirintron Khamenkhetkit, Mr. Joris Meijer (Pas Reform’s Software Engineer), Mr. Phiphat Dusadipong, Mr. Somboon Hophaisarn and Mr. Somnuk Hophaisarn
Planning for expansion in South East Asia. Mr. Somnuk Hophaisarn, Managing Director Goodspeed International
Goodspeed International can be reached at: 825/253 Moo.1 Pracha-u-tid Rd. Thungkru Bangkok 10140 Thailand Telephone +66 2 873 6800 Mobile +66 1 815 6623 Fax +66 2 873 4901 E-mail email@example.com
Smart collaboration fuels Suguna expansion in India Leading Indian broiler integrator Suguna Poultry will work once again with single-stage hatchery specialists Pas Reform – to realise a massive, national expansion program that will double Suguna’s hatchery capacity to 6.4 million day old broilers each week by the end of next year. Suguna has worked with Pas Reform since 2004, when the company’s then newly launched ‘Smart’ incubation systems were selected for the development of four hatchery sites. By 2006, Pas Reform had installed four complete hatcheries, with a combined capacity of close to 3 million day old broilers per week – and the inbuilt capacity to expand operations as needed. The Dutch company sent a handpicked team to India, to work with Suguna personnel to setup the new hatcheries, providing onsite training while developing tailored breed programs. Mr. B. Soundararajan, managing director of Suguna Poultry, comments: 'Since 2004, we have seen impressive pay-off from Pas Reform’s Smart single-stage technologies, both in terms of technical incubation and day old chick performance. 'We value the entire collaboration, not only for the quality of the Smart equipment, but also for the fact that Pas Reform delivers comprehensive hatchery equipment and automation packages – and an exceptional commitment to training and technical service.'
Mr. Bouke Hamminga, Director International Sales & Business Development Pas Reform continues: 'It is enormously rewarding to reap the fruits of all our labours during 20042006. And it is a massive confirmation that our integrated approach (incubators, automation systems, climate control, R&D and training) delivers the right strategy for such forward-thinking customers. 'In recent years, we have seen the enormous impact that our Pas Reform Academy has on our operations worldwide. The Academy’s training courses serve not only to guide our business partners, but also to provide a channel through which we can analyse feedback for future product development. This has been – and will continue to be – of vital importance to customers like Suguna, as they ramp up the scale of their operations to accommodate future growth.' With Asia’s population set for massive growth up to 2010, Suguna is, says Mr. Soundararajan, intent on maintaining a lasting and highly successful contribution to India’s rural development in the future. Headquartered in Tamil Nadu’s capital Coimbatore, Suguna is one of the fastest growing companies in India’s broiler sector. The vertically integrated Group has operations in eight States, covering GP and PS breeding, broiler farming, feedmills, processing and the export of hatching eggs and processed chicken.
It is, concludes Mr. Soundararajan, Pas Reform’s commitment that has helped Suguna to achieve exemplary results in their existing hatcheries. Suguna’s growth in the Indian broiler sector has come about for many reasons, not least its readiness to adopt new technologies, and the proactive multiplying of its contract farms to acknowledged standards throughout the country.
Mr. G. B. Sundararajan, Managing Director Suguna Poultry
New Business Development Manager for Pas Reform in the Middle East
Pas Reform’s international expansion continues in the Middle East, with the appointment of respected poultry sector veteran Maciej Kolanczyk ´ to the key role of business development manager throughout the region.
Mr. Kolanczyk ´ will focus on
business, Maciej has also owned
From 1975, Maciej worked as
With more than 30 years’ experience in the poultry
In 1971, Maciej graduated from the Academy of Agriculture in Poznan, Poland – carrying out an extensive post-grad study on population genetics and breeding in Switzerland, Germany and Holland from 1974-75.
During 17 years with Hybro, Maciej held a number of key positions, from regional manager
developing the range and depth of Pas Reform’s commercial services in the Middle East, with responsibility also for the registration and management of customer field trials, following the installation of their Smart incubation systems.
and run his own parent stock farm, with a capacity of 60,000 broilers, since 1987.
chief geneticist for the national broiler breeding programme at the Poultry Breeding Institute of Poland until 1989, when he moved to take up a new role with Dutch broiler breeding company Hybro BV.
Central Europe, with responsi
bility for operations in Poland, Slovakia, Czech Republic, Hungary and Romania – to a technical secondment with Bachoco in Mexico, and finally working as a technical advisor with Hybro’s customers throughout the Middle East, when he also published a number of technical articles on breeder flock mana gement and chick uniformity.
development. Many ‘early dead’ embryos can point to a problem arising from extended storage periods, suboptimal conditions during handling or storage, or the conditions under which the hatching eggs are transported. Storage conditions
Poor performance due to transportation! During one of our recent trips to the southern Americas, we visited a hatchery that overall was achieving pretty good results. Yet despite average hatchability being well within the ‘normal’ range, the hatchery’s managers were not entirely satisfied with performance - and on investigation, it was not difficult to understand why. Even though operating within what is usually regarded as the ‘norm’, hatchability was in fact highly variable, leading too frequently to either an oversupply – or worse – a shortage, of day olds chicks for this commercial hatchery. Predictions were based on the hatchery’s experience of working with a specific breeder flock, with age-related data and the results of egg analysis during candling to base order planning on. Same badges At first sight, we could not really see where the problem lay. Hatchery management was apparently in good hands – and incubation settings, duration and climate conditions also looked fine. But after speaking with some of the hatchery’s employees, the problem started to unravel. The largest variations, sometimes down to as much as 10 per cent below predicted hatchability, seemed to be occurring in particular batches of eggs from the same breeder farms. Plant employees told us that often they knew which eggs were going to show poor results, based on their candling data. A break out analysis was carried out as standard on approx. 5 per cent of candled eggs at day 18, thereby recording the stage at which the embryos died. Most of the time, we were told, many eggs from the ‘bad batches’ appeared to be fertile, but were found to contain embryos that had died in a very early stage (<2 days) of
L-R, Director International Sales & Business Development, Bouke Hamminga, and Sales Director Michaël Kampschöer, welcome Maciej Kola´nczyk onboard as Business Development Manager for Pas Reform in the Middle East.
As the hatchery did not usually need to store the eggs, the hatchery manager handed us his listed registrations of transport conditions. Most of the 6-8 hour journeys were undertaken at night by trucks without air conditioning or any other climatic controls. The conditions of most roads traveled during these journeys were, he told us, reasonably good in this part of the country. But the climate also created a challenge. While night-time traveling was often cooler, outside temperatures were variable - and it was not uncommon to see temperatures of up to 25°C in the morning, when the trucks arrived at the hatchery. Although data on the temperature of eggs upon departure from the breeder house and upon arrival at the hatchery was provided, registrations of conditions during actual transportation were lacking. Egg temperatures on arrival varied between 18-23°C, which is certainly too large a variation. But even this did not fully explain the exceptionally poor hatchability in certain batches. Poor road conditions Closer investigation revealed that these particularly large variations in temperature occurred in batches of eggs produced in a minority of the breeder farms, all of which were located in the same part of the country. These eggs traveled roughly the same distance as other batches, and likewise - there were no registrations of the transport, nor any logged egg temperature data from departure at the farm. Road conditions in this particular area were actually very poor: in some places, the road was not paved or surfaced - and in particular, it was noted by my hatchery colleagues that the entranceways to the breeder farms in this area were often extremely rough and uneven. It became clear that, without exception, every one of the batches delivering poor hatchability had one interesting factor in common: all these eggs had been transported by the same driver. Before long, we also discovered that this particular driver was especially sociable - visiting with people along the way, while his precious cargo - the hatching eggs – languished in his parked truck! Yet again, we were reminded how - when looking for reasons behind poor performance in some instances – the answer can sometimes be so simple as to be very easily overlooked. And this case reminded me of some very important – and too often forgotten – issues.
Temperature recording Our recommendations focused around maintaining temperature at between 16-18°C inside the truck or trailer during transit and preventing abrupt temperature variations or shocks. It is important to ensure that sufficient, temperature controlled air is circulated evenly in the cargo area around the eggs. Both the eggshell and the embryo are extremely vulnerable to shocks and jolts. Using trucks with effective suspension systems provides an excellent barrier to losses from damage during transit. And where necessary, we advised our customer to level and pave or otherwise surface rough areas around the farms. We also advised that equally, packaging material must be shock proof. Further advice included recording egg temperature not only on departure and arrival - but also during transportation. On arrival, it is wise to allow the eggs around 12 hours at rest before starting the incubation process. Driver behaviour In the hatchery business, a company’s drivers are its ambassadors. Truck drivers should understand the importance of quality when transporting their precious cargo. So we suggested that our customer explain to his drivers how their job affects not only the embryo, but also the impact this could have on the success of his and his customers’ companies. Stop-overs or unscheduled/unofficial delays during each trip must be prohibited for the good of the eggs. Large variations in hatchability always have a root cause! And as a rule, ignoring such variations - or any other failing in performance - will not improve your results. This sociable driver had to transport eggs from a remote area every four weeks. For the sake of calculating the impact of his ‘unscheduled delays’, let’s assume a loss of 5 per cent hatchability due to the combination of bad roads, rough driving conditions and delays. The unventilated truck he was driving had a capacity of 60,000 eggs. In this region of South America, the day old chick price fluctuated around $0,25, which equates to a cost of 13 x 0,05 x 60,000 x $0,25 = a total cost to their business of $ 9.750 each year! In this particular case, the manager of this South American hatchery decided to start with the least expensive measure: investing time in training the company’s truck drivers, teaching them the importance of time-sensitivity in the job they do – and how their work influences the results of the company. With these measures in place, average hatchability in breeder flocks located in this remote area increased by about 2 per cent in the following months – and the company is now discussing investment in air-conditioned vehicles.
There is little sense in producing high quality hatching eggs - to then undermine their quality by transporting them in unconditioned trucks, on poor roads with unnecessary delays. The importance of egg transportation cannot be underestimated, especially on longer journeys.
After working in the broiler sector
for more than three decades, Maciej is, he says, looking forward to working in the hatchery technology sector. 'This is a dynamic, technologically-driven market', he says, 'and certainly in the Middle East, there is a massive commitment to – and investment in – emerging technologies that focus on delivering uniformity.
'Pas Reform’s growing strength
in recent years has been most convincing – and with a clear vision that blends both tech nical and technological excellence with the biological aspects of incubation, I am very excited to be joining such a dynamic, fastgrowing company.' 'Maciej is a very welcome addition to our team in the Middle East,' concludes Pas
Reform’s Director International
Sales & Business Development, Bouke Hamminga. 'His experience in this part of the world will be invaluable – both to us and to our customers, and we are looking forward to working with him, to further consolidate our plans for international growth.'
Maciej Kola´nczyk can be contacted at:
Ul. Drzewieckiego 1 60-408 Poznan Poland Telephone +48 61 847 15 19 Mobile +48 600 296 830 Fax +48 61 847 15 19 E-mail Kolanczyk@pasreform.com
Swiss pioneer uses Dutch technology Originally published in International Hatchery Practice, 2007, volume 21, number 7. Just under two years ago Bell AG opened their new hatchery at Aeschlen near Oberdiessbach in western Switzerland. The business was established by Paul’s father in the early 1960s and in its early days the hatchery produced both broiler and table egg chicks for the local area. Since then the business has grown into Switzerland’s leading producer of broiler chicks. Catering for the Swiss market Currently, some 95% of production is Ross PM3 and the remainder of the chicks are Sasso and destined for the Swiss free range sector. In a typical week approaching half a million chicks are produced. The eggs come from some 20 small breeder farms in the area and all the resulting chicks stay in Switzerland. When it was apparent that a new hatchery was the best way forward for the business the decision was taken to build on the site of the previous hatchery. This avoided many of the potential problems that can arise under Swiss planning rules and regulations when a ‘greenfield’ site is chosen for such a development. In addition, to use Paul’s words, the old hatchery was ‘a patchwork that hindered effective product flows and good hygiene practices’. The key decision that then had to be taken was which incubators to put in the new hatchery. In coming to this decision Paul spent a lot of time looking at the options that were then available and evaluating how they would cope with the company’s current and future predicted requirements. The decision was made to run with the then relatively new Smart technology from Pas Reform. This included their SmartSet™ setters, SmartHatch™ hatchers coupled to their SmartDrive™ incubator controls and SmartCenter™ hatchery information system.
Wim Hazekamp, Project Manager
In addition, Pas Reform were responsible for the planning of the project and the design of the hatchery, which encompassed product flows, flooring, drainage, ventilation, water, electricity and waste management systems. So, why was the choice made to run with Pas Reform? In essence this was because of several reasons, but key among these was the relatively narrow hatch window that the combination of the SmartSet™ setter and SmartHatch™ hatcher delivered. This they were told would give them several advantages – all of which have now been delivered. The first of these was improved hatchability. Today young flocks are hatching 2% better than their counterparts did before the new hatchery was built and an even better figure of over 3% is being achieved on eggs from flocks late in lay. Today, the Ross PM3 is consistently providing an average hatchability of fertiles of 96% and the Sasso is delivering a figure of 97%. To date the best figure achieved is 97.55%. In addition, the chicks that are produced perform better when they are placed on the farms. Typically, first week livability is 99.5% or better or, to put it another way, first week mortality is less than 0.5%. 'We give our customers a better product,' Paul told us, 'but we do not get a better day old chick price for supplying a better product – our benefits come from the better hatchability figures which give us more chicks to sell.' Impact of high wages In Switzerland good staff are hard to find and, if you can find them, wages are expensive. Therefore, another consideration was to look at minimising staffing levels. This has been achieved by a level of automation that is unusual for a hatchery of this type and size. This was a realistic option when one considers the cost of labour saved and the fact that the nature of the Swiss market means that it has some of the best day old chick prices in Europe.
In a separate activity the remaining hatcher basket is transferred to a tipper where all the contents are tipped down a funnel into the vacuum based waste removal system. The baskets are then restacked and taken to the wash room. Here they go through the washer and are sprayed with disinfectant before moving into a holding room adjoining the transfer area. Single stage The incubation process was a major change for the hatchery. In the past they operated a multi-stage incubation system, but now, with the new Pas Reform machines, they operate a single stage system. Eggs are typically set after three or four days storage and the SmartSet™ setters effectively provide each trolley with its own controllable microclimate. This means the eggs on each trolley can be given the incubation conditions that will provide optimal embryonic development and provide the beneficial narrow hatch window. Beneficial modular design The modular design of Pas Reform incubators helps meet this requirement. Each incubation section has a capacity of 19,200 hen eggs and is equipped with separate heating, cooling, ventilation and humidification. These setters also have a reduced heating up time which impacts favourably on subsequent chick uniformity and performance. These machines also have an increased cooling capacity, which is beneficial for today’s high breast yielding breeds and, as is the case with Paul Erb’s hatchery, when exceptional hatchabilities are being achieved. In effect, the SmartSet™ setters have an integrated heating and cooling system that provides an homogenous temperature distribution throughout the setter and this also impacts positively on the subsequent hatch window.
Hatchery automation The hatchery automation equipment is focused on three areas. Firstly, the eggs which come into the hatchery on setter trays are automatically washed and sanitised and the trays are then placed in the same process on to the setter trolleys. Here the eggs are washed from above and below. Secondly, three people do the whole process of candling and transfer. One feeds the setter trays containing the eggs into the machine and the empty hatcher baskets, a second checks all trays as they leave the candling/ transfer unit and the third member of the team removes and stacks the filled hatcher trays. Finally, the whole chick handling process is automated. The hatcher baskets are placed on to a roller conveyor and the chicks are manually removed and graded in a single action before being dropped down a funnel which feeds the chicks on to a conveyor which then takes the chicks through a counter and boxes them off. Today, the whole hatchery operates with a team of 10 – five full time staff (of which three are family members) and five part time employees.
Pas Reform appoints international project manager Pas Reform is expanding its international Project Management Team, with the appointment of Mr. Wim Hazekamp to the role of project manager.
In his new position, Wim will manage the entire lifecycle of hatchery projects, from the development of initial project plans and design recommendations, to carrying out on-site evaluations and final testing. Wim will be in day-to-day communication with Pas Reform’s customers around the
Finally, the SmartHatch™ hatchers with their automated hatching system, or AHS™, and the best possible hatcher environment also impact positively on uniformity of hatch. Paul explained to us how in the first few months of managing the new machines they had to fine tune the hatch windows and how the expertise of the technical team at Pas Reform was invaluable. Bell AG and the Erb hatchery found that they could easily deliver the short hatch windows and improved chick quality and livability by integrating all stages of the incubation cycle through Pas Reform’s SmartCenter™ Information System. Integrated system In addition to optimising the incubation cycle this system also integrates all the data from the automation systems, automatically alerts alarm events, provides preventative hatchery maintenance programmes and produces real time management reports for analysis and decision making by Paul and his team. All of this is coupled to the SmartPortal™ which gives the hatchery an interactive web based customer support service from Pas Reform. This includes services such as hatching data analysis, troubleshooting, spare parts information and ordering systems and updates on the latest information and news from Pas Reform.
Pas Reform launches Russian-language Website Pas Reform is pleased to announce the launch of its new Russian-language website, www.pasreform.ru, developed locally through the company’s Belgorod office in Russia. The new site replicates the wealth of information available currently through pasreform.com, including details of Pas Reform’s products, projects and partners throughout Eurasia - and has already attracted more than 100,000 visitors. 'Pas Reform’s customer-base has grown substantially throughout the region,' explains Marketing Director Henry Arts, 'and we felt it was time to support our Russian speaking partners in their own language. 'The new site provides easy access to a full range of materials online, including product guides, technical data and the latest incubation information from the Pas Reform Academy and other academic institutions.' The site also serves, says Arts, as a portal for the many documents, papers and guides that are now available in Russian-language from the world’s fastest growing hatchery technology company. The site will be regularly updated, to reflect the latest news, information and articles and a wealth of content relevant to the Russian poultry sector.
Henry Arts, Marketing Director Pas Reform
Automatic Candling/ Transfer machine
world, providing professional consultancy services to help customers build highperformance hatcheries. As a Graduate in Waste Water Management with an Engineering degree, Wim has gained extensive Project Management experience over the past 10 years. Most recently he worked for Contour Covering
Technology, an international business based in The Netherlands. Prior to that, Wim worked as a project manager for six years at Nijhuis Water Technology, another Dutch company, specialising in the design and supply of industrial waste water treatment systems, predominantly for food processing plant applications in feedmills and slaughterhouses.
Wim will, says Pas Reform’s CEO Bart Aangenendt, bring fresh focus and energy to the hatchery company’s next phase of development. 'As our operations continue to demonstrate strong growth worldwide', says Aangenendt, 'the work of experienced Project Managers like Wim, with an eye for the big picture as well as for the detail, will continue to ensure that we
deliver relevant, highly efficient solutions for our customers'. Speaking about his new appointment, Wim Hazekamp concludes: 'I am genuinely excited to be joining this very dynamic and innovative company.
'The opportunity to work at the forefront of hatchery technologies in the fast growing global poultry industry is a new challenge for me – and one I’m very much looking to.' Wim can be contacted by email at Hazekamp@pasreform.com
SmartDrive™ incubator control system
Smart investment pays dividends for Wasikowski hatchery in Poland Since opting for the use of single-stage incubation processes with Smart Technologies from Pas Reform last year, Specjalistyczne Gospodarstwo Rolno-Drobiarskie (SGRD) owner Jan Wa˛sikowski in Czarne, Poland, is reporting significant increases in production. Originally founded in 1967, Wa˛sikowski adopted Pas Reform incubation systems almost 20 years ago. Then, in a bid to increase production inline with growing opportunities in their domestic market, the owner-operated hatchery recently took the decision to transfer operations to singlestage, closed door Smart technologies. Owner and director Mr. Jan Wa˛sikowski says that investment in the Dutch hatchery technology company’s SmartSet™ setters and SmartHatch™ hatchers is already paying dividends.
New Representative for Pas Reform in Sri Lanka
Pas Reform’s unprecedented international expansion continues in Sri Lanka, with the appointment of Mr. Palitha Balasuriya of BAP Agri (Pvt) ltd. as the leading Dutch hatchery technology supplier’s country representative.
'With the switch from multi- to single-stage incubation last year,' he says, 'we have immediately gained three per cent growth in peak hatchability from eggs set. 'On an annual turnout of 22 million d.o.c., that is equivalent to 660,000 additional d.o.c per annum – approximately €165,000 each year.' Wa˛sikowski went full steam ahead with their new investment, incorporating Pas Reform’s Automated Hatching System (AHS™), a SmartCenter™ Hatchery Information System, Hatchery Automation and Climate Control Systems.
Serial entrepreneur Mr. Jan Wa˛sikowski, continues to establish new businesses, while handing over the management of his modern hatchery into the hands of second generation Wa˛sikowski ownership. Wiesäawa Wa˛sikowska-Lewandowska and Marek Lewandowski have, he says, the benefit of a strong heritage and great drive and energy, combined with Smart, future-focused technology, and to take his company well into the future.
'With a small team of six working in the hatchery, the improvements gained by automating key functions have been further assisted with the installation of SmartCenter™, so that today, our hatchery is fully programmable to optimize production across a variety of breed- and agerelated incubation programs', he concludes. Wa˛sikowski’s partially integrated operations also include parent stock farms, to produce Hubbard and Ross day old broiler chicks for selling into the domestic poultry meat production market.
With eight years of experience in the Sri Lankan poultry sector, Palitha Balasuriya is a well known and respected figure in the industry, having represented several international poultry sector equipment suppliers. Having gained his experience in broiler equipment, Palitha says he is looking forward to working in the hatchery technology
sector. 'The market is constantly changing, with the invention and introduction of new technologies', he says, 'In Sri Lanka, the mood now really is for advancement in hatchery operations, most notably to make the transition to singlestage incubation.' The new Pas Reform hatchery installed by Fortune farms has,
says Palitha, been hugely important to that transition, having proven to give superior results with single stage incubators. Mr. Balasuriya will focus on developing the range and depth of Pas Reform’s commercial services in Sri Lanka.
'It is of enormous benefit to have someone of Palitha Balasuriya’s caliber and experience on our team in Asia,' concludes Pas Reform CEO Bart Aangenendt. 'His knowledge and skills will be invaluable – both to us and to our customers. Our goal, as elsewhere in the world, is to grow in the Sri Lankan poultry sector. Palitha will play a key role in helping us to achieve this'.
Smart expansion in North Africa After working with Pas Reform for many years, leading Moroccan integrator Dar El Fellous has renewed its commitment to the Dutch hatchery technology company by choosing its Smart Incubation systems for a major new hatchery project in El Jadida. The company has built two new state-of-the-art hatcheries, one for its layer operations and the second as a broiler hatchery, which have been equipped with 24 new SmartSet™ setters 115 with integrated heating and cooling system and 24 Smarthatch™ hatchers. Dar El Fellous has commissioned an entire ventilation system from Pas Reform for the new broiler facility, which incorporates air handling units, pressure controls for the different parts of the hatchery, and a fully automated chick handling, counting and boxing system. First phase operations out of the new broiler production site will have capacity for 40 million d.o.c. per annum. For the layer facility, previous generation Pas Reform incubators have been upgraded to include a warm water heating system, with new build including ventilation and automation systems to streamline operations. Dar El Fellous president, Mr. Guenoun, comments: 'We have worked for many years with Pas Reform to our full satisfaction- and the introduction of their new Smart Incubation system has coincided well with our plans for these new green field projects. 'Our own experience has shown us that the Pas Reform machines are highly durable – and now the Smart systems are proving that the latest incubation technology can be deployed to deliver significant benefits in chick uniformity, which is all the more powerful when combined with operational reliability.' Pas Reform’s commitment to serving the North African market with ready access to service engineers and stocks of spare parts are, says Mr. Guenoun, also very compelling reasons to continue to enjoy working with the Dutch company. 'It is a real boost when such a long-established customer chooses to continue working with us, and we are delighted that Dar El Fellous has awarded us these two new hatchery projects', says Mr. Bart Aangenendt, CEO of Pas Reform. 'Pas Reform is targeting strategic growth for the coming years in the North African region, and we trust this expansion programme with Dar El Fellous will serve to illustrate the benefits of partnering with Pas Reform, both in terms of the quality of the hatchery systems we manufacture, and in terms of our comprehensive service network there in the years to come'.
Mr. Balasuriya can be contacted at: BAP Agri (Pvt) Ltd 121/5, Thummodara Road 10700 Puwakpitiya, Avissawella Sri Lanka Telephone +94 362 232 602 Mobile +94 777731510 Fax +94 36-4921020 E-mail Srilanka@pasreform.com
Ukraine’s Mironovsky chooses Pas Reform for total, state-of-the-art hatchery automation Ukraine’s leading integrated poultry producer, Mironovsky Hliboprodukt, has contracted Pas Reform to supply new equipment and training for a major new expansion project over the next two years. Pas Reform will supply 102 SmartSet™ setters and 144 SmartHatch™ hatchers to the ambitious Project, targeting the production of over 175 million day old chicks per year – and taking Mironovsky Hliboproduckt’s outputs to 227,000 tons of chilled poultry products per annum, including whole birds, cutups, giblets and other meat products, by 2008. In addition to the installation of the hatchery equipment, Pas Reform is also Mironovsky’s chosen supplier for a total, state-of-the-art hatchery automation system – creating what will be one of the largest hatcheries of its kind in Europe.
The Mironovsky hatchery automation project consists of: - Three separate lines for automated hatching egg handling, to place eggs automatically on setter trays. - Automated candling and transfer operation, in collaboration with Embrex to facilitate the possible incorporation of inovoject operations in the future. - Automated chick take off, culminating in chick counting lines for total throughput of 90,000 doc/h - A hatch basket tipper, macerator and vacuum system for waste disposal - Automated washing lines (with pre-wash) for hatcher baskets, setter trays and chick boxes - Stackers and destackers for chick boxes, hatcher baskets and setter trays - Automatic vaccination carrousels, with vaccination equipment 'Working with a multi-disciplinary team has been essential for this Project,' says project leader Jan Peter Eil, 'to achieve the required scalability not only to meet today’s needs, but also those of the future.' Pas Reform has the skills and expertise to mobilise a truly integrated team of embryologists, hatchery management and production specialists and fully qualified engineers. 'By this integrated approach, our project team delivers a balanced solution,' says Mr Eil, 'that enables maximum hands-off operation, geared entirely to producing the highest output of quality, day old chicks.' Working in collaboration with Mironovsky, Pas Reform has used the newest release of One Space Designer, a 3D modelling package that has revolutionized the conceptual drawing stages of hatchery planning and design. 'Poultry consumption is growing rapidly in the Ukraine,' says Mr. Y.Kosyuk, President of Mironovsky, 'and we envisage a situation in the next five years, whereby the poultry sector here will satisfy not only our domestic needs, but it will also begin exporting to neighbouring markets.' In view of these developments, he says, Mironovsky intends to be ready and able to drive its production facilities to meet world standards.
For almost a century, Pas Reform has combined the science of embryology with cutting-edge engineering expertise. The result is reliable, cost-effective hatchery automation - and real benefits in terms of chick quality, performance and results. The Dutch company has, says CEO Bart Aangenendt, taken a strategic decision to grow as a complete solutions provider to the incubation industry. 'Hatchery automation is, in our view, an integral part of producing top quality chicks in the modern hatchery,' he says – a belief well supported by the success of Pas Reform’s recently formed, specialist hatchery automation department. 'Our hatchery automation team has its own product managers and project teams, which has given great confidence to our clients worldwide - and in turn, significantly increased our turnover in this area of our operations.' And according to Director International Sales & Business Development Bouke Hamminga, Pas Reform will continue to leverage what it sees as a core, strategic strength. 'We have made a firm commitment to the sector with our Smart machines in the global arena,' says Hamminga, 'and through our dedicated automation department, we see similar opportunities for growth.' Pas Reform’s Hatchery Automation Systems are flexible and easy to clean. Minimal maintenance delivers less downtime and improved hygiene, efficiency and reliability, while reducing labour costs. And improvements in the quality of the working environment mean that hatchery personnel benefit too. From stand-alone machines, to complete, turnkey solutions that fully automate the hatchery, Pas Reform is committed to providing equal care and commitment to all customers.
Chick counting and boxing system
Project leader Jan Peter Eil
Based on Rodac plates with a diameter of 5,5 cm; Number of samples and locations are specified.
How effective is your hatchery cleaning and disinfection programme? Cleaning and disinfection are fundamental to effective hygiene in the hatchery. Cleaning can remove up to 85 per cent of micro-organisms, preventing their development by removing their food sources, or 'dirt'. Any remaining microorganisms can then be eradicated by disinfection. Yet monitoring the efficacy of a cleaning and disinfection programme is like fighting an invisible enemy. And even having established the presence of micro-organisms, it may also be important to distinguish between pathogenic or non-pathogenic, specific (eg. S. enteritidis), non-specific (eg. E. Coli) or disease-causing bacteria, viruses, fungi or mycoplasma.
Three options for effectively monitoring hatchery hygiene 1. Visual inspection Regularly take a critical look at levels of cleanliness throughout the hatchery and its equipment. Use a checklist, on which dirty spots can be indicated and recorded. Pay special attention to hard-to-reach areas, like backside cooling coils, door rubbers, ventilation pipes and the suction heads of the transfer machine. When dirt is visible to the naked eye, there will certainly be many micro-organisms present. 2. Agar cultures for non-specific bacteria Make the enemy visible using a non-specific bacteria count. When compared with a reference (see example, table 1), this will illustrate the efficacy of your cleaning and disinfection programme. Remember that pathogenic bacteria and other micro-organisms are likely to co-exist alongside non-specific bacteria, and some fungi can also be revealed by this procedure.
Average hatchery score
0.0 – 0.5
1 – 40
0.6 – 1.0
41 – 120
1.1 – 1.5
121 – 400
1.6 – 2.0
2.1 – 2.5
Table 1: evaluation of bacterial counts according to Dutch standards (1999 Poultry Farming Hygiene Regulations).
Methods for inspecting flat surfaces (e.g. walls, ceilings) include: - Swab and streak procedure: rub a sterile swab, moistened in a sterile solution or a manufactured sterile culturette, over a 2.5-5.0 cm area of sample surface. Gently streak the used swab over the surface of an agar plate several times, in a zig-zag fashion. - Rodac plate procedure: Rodac plates are pre-filled with agar gel, which is slightly higher than the edge of the plate, so that direct contact can be made with the surface to be sampled. Remove the cover of the plate, press the agar gently onto the surface to be monitored (do not move the plate while contact is made), then replace the cover, taking care not to touch the agar. Whether you use swabs or Rodac plates: - Keep one agar plate unopened as a 'negative sample', to test the sterility of the plates and act as a ‘control’. - Clearly mark where each sample was collected on the outside base of each plate. Predefine the number of samples per room - and test a variety of locations within each room/ area (e.g. door handle, candling table, hatching egg). - Store collected samples and your ‘negative’ sample upside down at 37°C-37.5°C in a laboratory incubator or setter, taking care to place the plates in a plastic bag and set them down where they will not be disturbed. Agar contains nutrients that bacteria thrive upon. A single bacterium - and to a lesser extent, a fungal spore - will multiply under these conditions, to become visible as a colony.
3. Specific bacterial and fungal monitoring To test for particular bacteria and fungi, specific plates contain a selective agar, formulated specifically to encourage growth or colonisation by the bacterium/fungi being investigated. Fluff, chick paper and other hatchery materials may also be prepared for monitoring in this way. For specific monitoring, it is often advisable to contact a specialised laboratory for sampling and/or an accurate interpretation of results. Advice To fully benefit from this type of monitoring programme, the results should be discussed with staff responsible for cleaning and disinfection and/or with your supplier of detergents and disinfectants. Depending on results, you may need to change procedures and/or consider a change of the cleaning and disinfection products being used. It is good practice to maintain records of all results, so that any changes occurring over time can be observed in the different areas monitored. It is also recommended that results are carefully compared with hatchability and liveability data. References available on request.
After 24-48 hours, count and record the cultures. The number of colonies present indicates the hygienic state of the surface sampled. The evaluation of these counts should be based on the hatchery’s own criteria, or by the terms of a national or integration-wide quality programme.
Mr. Natarajan Venkitakrishnan recently joined Pas Reform’s engineering services division in Asia, to support customers throughout the region. 'Natarajan brings more than 20 years’ experience in the hatchery sector to this role,' says Pas Reform CEO Bart Aangenendt, 'We are delighted to have his technical skills and expertise onboard, as we pursue market leadership in all our Asian markets.'
For your own free copy of our brochures, please email firstname.lastname@example.org
Homogeneous temperature in the egg is vital to optimal
embryo development – and this is exactly what Pas
Reform incubators provide. Their modular design reflects
Embryos have different needs during the various phases of the incubation period. Pas Reform understands those needs and has
Future focused incubation
The modern hatchery faces three key challenges to future growth and profitability: genetic progress, uniformity and post hatch performance.
designed incubators to the
Hatchery of the future Commercial hatcheries face three key challenges in the
highest standards to provide
Pas Reform has met these
optimal incubation condi-
challenges in the development
embryo, maximising hatch-
tions that maximise hatcha-
and design of our next
ability and chick quality.
bility and chick uniformity.
Incubators from Pas Reform
Genetic progress demands
Meet the future. Meet Smart.
management of hatchery
a deep understanding of the needs of the growing
Hatching quality chicks
Each 19,200-egg incubator section is equipped with
promote the best chick qua-
future: genetic progress, uniformity and post hatch performance.
greater control over the
separate heating, cooling and
lity, maximising growth and
minimising feed conversion
conditions, to maximise the
rates, which are essential for
potential of modern poultry
the profitability of poultry
breeds, while high chick
uniformity will continue to
be an essential precursor to outstanding post hatch
performance. In this series of articles, originally published by Pas Reform in 2004, we share our insights into meeting these challenges for future growth and profitability with you.
Pas Reform Hatchery Technologies
Pas Reform Hatchery Technologies
Pas Reform Hatchery Technologies
Pas Reform has many faces around the world – all committed to innovation, quality and results, and all working to build sustainable futures in the modern poultry sector.
Wim Hazekamp Project Manager
Kitty Bekken Office Manager
Jan-Peter Eil Project Manager
Iwan ter Wiel Project Manager
Bouke Hamminga Henry Arts Director International Marketing Director Sales & Business Development
Helga Derksen Office Manager
Henk Markhorst Sales Director
SmartCenter™ Information System
SmartPortalTM Online Hatchery support
SmartCenterTM is a dynamic web based information system from Pas Reform, which gathers real-time data, to deliver unrivalled uniformity in management
Driving performance & uniformity in the hatchery
Get technical support, place orders, look up references and read the latest news and research – whenever and
and operation at every level
wherever you need to.
in the modern hatchery.
Hatchery Climate Control
SmartCenterTM - Driving performance and uniformity in the hatchery
Driving performance & uniformity in the hatchery
Maximise growth and promote uniformity, with carefully balanced climate control and effective protection from harmful pathogens throughout the hatchery: a breath of fresh air from Pas Reform.
Pas Reform Hatchery Technologies
Pas Reform Hatchery Technologies
Martin Barten Senior Hatchery Specialist
Marleen Boerjan Director Research & Development
Noortje Verhoeven Office Manager
Pas Reform Hatchery Technologies
Bart Aangenendt CEO
Hatchery Automation Systems
Sander Koster Project Manager
Erik Meijer Service Manager
Martine Onnes Office Manager
Driving performance and uniformity in the hatchery
From standalone machines to complete turnkey projects, hatchery automation systems from Pas Reform improve quality, reduce costs and fuel growth, to set new standards for uniformity in the modern hatchery.
Pas Reform Hatchery Technologies
Michaël Kampschöer Sales Director
Anita Huijting Receptionist
Gerd de Lange Senior Poultry Specialist
Mr. Bart F.A. De Haas, member of Pas Reform’s board of commissioners, Mr. Bart Aangenendt, CEO Pas Reform Hatchery Technologies and Mr. Egbert ten Cate, member of Pas Reform’s board of commissioners, in the new Distribution Center at Zeddam, The Netherlands.. Eggs will ‘sweat’ if the relative humidity (% RH) outside the storage room is higher than the temperature of the storage room. Temperature of storage
Temperature outside the storage room:
> 85% RH
> 83% RH
> 71% RH
> 89% RH
> 74% RH
> 60% RH
> 74% RH
> 64% RH
> 53% RH
> 44% RH
1 Assuming that the temperature of the eggs equals the temperature of the egg storage room.
The importance of preventing ‘sweating’ eggs
New Distribution and Inspiration Centers: Pas Reform invests to grow with global demand As a result of rapid and continuing expansion over the past two years, Pas Reform launched a new Distribution Center and state-of-the-art Inspiration Center at its European headquarters in Zeddam, The Netherlands during 2007.
The new Distribution Center has been purpose-designed to deliver maximum efficiencies, for an international sales and service network that has more than doubled in the past 24 months. With enhanced shipping and receiving functions, flexible loading bays and quadrupled capacity will ensure that Pas Reform’s Warehouse and Shipping operation reflects best practice in the service of the company’s rapidly growing global customer base. 'Pas Reform has delivered such significant increases in turnover, that additional distribution space became an absolute necessity,' explains Pas Reform’s CEO, Bart Aangenendt. 'Exporting to more than 60 different countries requires the most sophisticated support and logistics. With this expansion, we are underpinning Pas Reform’s commitment to continuing growth – and to raising standards on every level of product, support and accessibility.' Pas Reform’s ambitious expansion and redevelopment also included the building of a brand new, state-of-the-art ‘Inspiration Center’. Here, in a model hatchery setting, recreated complete with incubators (setters and hatchers), hatchery automation and climate control systems, Pas Reform demonstrates its globally acclaimed Smart singlestage hatchery systems and technologies for customers, prospects and partners from all over the world.
Pas Reform boosts Customer Service for worldwide projects
To meet the demands of increasing numbers of new hatchery projects worldwide, Pas Reform has boosted its customer service and support department with the appointment of Erik Meijer to the role of Service Manager.
Meijer brings with him considerable experience in technical support and customer relations, having managed the service department of Machielsen Interlift Group, a technical service provider in the West of The Netherlands.
‘Sweating’ of eggs is the result of condensed water sitting on the egg shell surface. This occurs when cold eggs are suddenly exposed to a higher environmental temperature. The warm air with a certain moisture content cools down rapidly directly around the colder eggs. Since cold air contains less water than warm air, relative humidity will increase until the air is saturated. And at that moment, condensation will take place on the cool egg surface. The term ‘sweating’ is, if taken literally, misleading, because the water on the shell does not in fact come from within the egg. The same physical process is seen when a bottle of water is removed from a refrigerator on a warm summer day. Sweating of eggs should be avoided because moisture on the shell surface weakens the egg’s natural defence mechanisms, providing as it does an ideal environment for the growth of micro-organisms, and further facilitating their penetration through the shell pores. Once inside the pores, micro-organisms are protected from most routine egg sanitising operations, therefore presenting a potential risk for contamination. Bacteria and fungi which manage to pass through the shell membranes will multiply at a rapid rate when they are exposed to incubation temperature, because the defence mechanism in the albumen is no longer able to protect the growing embryo. This of course will lead to increased embryonic mortality, ‘exploders’ and infected day-old-chicks (increased first week mortality).
Meijer’s main role is to be the primary point of contact for both customers and project engineers at installation level. Erik will be involved with projects throughout the sales, delivery, installation and sign off stages, to ensure that customers and project engineers alike are familiar with all key aspects of each installation.
In this context, he will be responsible for design meetings to explain the Pas Reform installation procedure, planning and supervision of each installation, swift implementation of related component orders and plant start-up services to assist clients with the commissioning of their new hatchery.
Sharing knowledge for success Because we never underestimate the importance of people to the success of any hatchery operation, we have developed a dedicated training centre to provide tailor made training programmes for hatchery professionals.
Conclusion Clearly moisture on egg shells should be prevented. Egg sweating is prevented when the difference in temperature between the egg storage room and 'the outside' (e.g. loading platform of the truck, egg traying room, setter) is small and the 'outside' humidity is low. The table can be used to predict whether sweating will occur if no additional measures are taken. For a wider range of temperatures and humidities, a so called ‘Mollier’ diagram or psychometric graph provides a useful tool. There is also a risk of eggs sweating if they are set too cold in setter that is already running to temperature, as is the case in multi-stage incubation practice. Advice
- If the risk of sweating is high, pre-warm eggs gradually at least 6 hours prior to removing them from the egg storage room. This is achieved by switching off the chiller several hours before taking out the eggs. It is important to realize that not all eggs warm up at the same, uniform speed, especially with low air circulation and if stored on pulp trays and stacked closely together. - Store at a higher temperature, combined with a shorter storage period, whenever possible. - Connect the truck picking up the hatching eggs directly with the storage room to minimise any temperature differences from the outside environment. - Ensure that the climate in the truck is the same as in the egg store. - Maintain humidity below the levels indicated in the table. - Prior to placement in the setter, place the filled setter trolleys at a room temperature of 25 °C with good air circulation for several hours. This pre-warming of the eggs before setting is particularly important when using multistage incubation. References available on request.
Pas Reform futureproofs new GPS hatchery for Krasnayarugsky Broiler expansion Building on the success of previous projects, Dutch hatchery technology company Pas Reform has been contracted to build a new GPS hatchery for Krasnayarugsky Broiler, a subsidiary of Prioskolje – the fastest growing broiler integration in Russia. Mr. Genaddy Bobritskij, Prioskolje’s general director, says Pas Reform was the clear choice for the supply of a turnkey hatchery project. The Dutch company – being hailed as the fastest growing hatchery company in the world – has exclusive Agreements for the supply of hatchery equipment into Prioskolje companies, having already built four turnkey broiler hatcheries for the Group, with a total capacity of around 150 million eggs per year.
'Pas Reform’s project team came with the idea of building an air preparation room above the transfer room. So that only after the air meets all the correct temperature and humidity parameters, will it be brought into the incubation rooms.' As an additional safeguard, all air entering the Krasnayarugsky hatchery is filtered twice, to remove dirt and bacteria, then UV-disinfected in the air preparation room, before being brought to optimum quality for streaming into the incubation rooms. Krasnayarugsky’s aim was, says Mr Tolstoi, not just to build the most modern and sophisticated hatchery in Russia, but in the world! 'We have the perfect opportunity with a project of this caliber,' he says, 'to do it right from the outset. Using the very latest technologies and know-how – we have future-proofed the hatchery, to set standards and assure our customers the absolute pinnacle of supply in the broiler sector for many, many years to come.' The Krasnayarugsky project was created in close cooperation with Grazvydas Grigaliunas (Managing Director of ISABALT), Gennady Syedin (General Manager of BALTISA) and Nicolas Neyra (Senior Technician Hubbard). ISABALT is the exclusive distributor of Hubbard PS into Russia and CIS countries.
The Krasnayarugsky GPS hatchery has an annual capacity of 12 million eggs and is expected to produce 3.5 million parents per year, with expansion plans doubling that number to seven million. Due to the phenomenal growth of Prioskolje, almost half of that expanded production capability will be dedicated to Krasnayarugsky’s mother company. A key feature of the new GPS hatchery is its unique ventilation system. 'We wanted the best possible solution,' explains Krasnayarugsky’s first deputy director Mr. Tolstoi, 'because the use of a pressure controlled system to direct flows between the cleanest room (highest pressure) and the dirtiest room (lowest pressure) in the hatchery, was insufficient for our needs.
Erik Meijer, Service Manager
Bart Aangenendt, CEO at Pas Reform Hatchery Technologies, comments: 'Erik brings a wealth of experience in service management to the role. With thousands of customers worldwide, our Project Division is a critical area of the business, and with Erik’s leadership we will continue to maintain the very high standards of customer
care and post-installation backup that our client hatcheries expect.' 'I am delighted to have joined Pas Reform at this exciting time', says Erik. 'The company has an impressive track record. The high caliber of the Smart incubation system, coupled with the quality of Pas Reform’s
clients, creates many opportunities to build a successful career with Pas Reform Hatchery Technologies way into the future.' Erik can be reached at email@example.com
Hatching at high altitudes The effects of hatching at high altitude on hatchability and chick quality depend largely on the altitude at which the hatching eggs are produced - and how the hatchery manager adjusts the incubation programme. Barometric pressure declines with altitude, as does the partial pressure of oxygen and absolute humidity. Fresh ventilating air will tend to be colder and drier than at sea level. Oxygen availability The oxygen content of air is always 21 per cent, but reduced partial pressure at altitude provides less oxygen from a given volume of air. This pressure reduction results in lower levels of oxygen for the embryo, which is partially compensated by the embryo’s higher capacity for binding oxygen to blood haemoglobin. At altitudes above 2000 meters, it can help to inject oxygen into the setter and the hatcher, to raise the oxygen level from 21 to 23 – 25 per cent. The main drawbacks of using oxygen are cost and safety. Its use may, therefore, be limited to hatching parent stock.
It is already two years since Dutch Hatchery Technology Company Pas Reform, in its commitment to global expansion and close market cooperation, opened a new subsidiary, Pas Reform Russia, to serve growing markets in Russia and Belarus.
Pas Reform Russia is headed by General Director Wim Schaafsma and Commercial Director Anna Kolygina, who are permanently based in Belgorod, the centre of one of the country’s main poultry producing regions some 600 km south of Moscow. Since opening its doors for business, Pas Reform Russia has demonstrated enormous
Age breeder flock
Optimum weight loss
10 – 11 %
11 – 12 %
12 – 13 %
2. Eggs produced at same altitude as hatchery (1000 – 2000 meters) In general this will give good results. Ventilation rates should be higher than normal for sea level. During humid external conditions, increase ventilation even more, as humidity reduces oxygen levels in the air still further. This higher ventilation rate may cause reduced humidity in the setters and hatchers. To avoid constant humidifying, humidity set points should be lowered and the resulting more than optimal weight loss (eg. 14 - 15%) is preferred in this case. 3. Eggs produced at altitude; hatchery at sea level Generally, this will give good results. The set points for relative humidity need to be reduced to achieve optimum weight loss as the eggs have a reduced effective pore area.
It is reasonable to assume that the drier air at altitude will result in increased moisture loss from the eggs. However, it is important to realize that breeder flocks adapt to altitude by producing eggs with a lower effective pore area. This offsets increased diffusion and therefore water vapour loss through the egg shell at any altitude remains the same as at sea level.
Exact set points for relative humidity are dependent on a.o. altitude and egg shell conductivity (age flock, nutrition, genetics). It is therefore recommended that relative humidity set points are fine-tuned by weighing trays of eggs before setting and again at transfer at 18 – 18.5 days. Optimum weight loss for good hatchability and chick quality is indicated in the table.
Alternatively the size of the aircell provides an indicator of weight loss. If during an egg-breakout too many wet, fully developed embryo’s that fail to pip are observed, this indicates insufficient weight loss and/or a shortage of oxygen. In this case, set points for relative humidity should be reduced and/or ventilation rate should be increased.
The following three scenarios are considered: 1. Eggs produced at sea level: hatchery at altitude (1000 – 2000 meters) Of the three scenarios, this is the least desirable because it will definitely result in reduced hatchability. Eggs produced at sea level have a relatively large effective pore area and will therefore lose more water at higher altitudes. To compensate, setters and hatchers should be operated at a higher relative humidity. This is best achieved by preconditioning the inlet air to a relative humidity of 75 per cent, with a temperature of 24 - 28°C (optimum). At the same time, increase the ventilation rate from normal for sea level, to accomodate the reduced oxygen levels.
Pas Reform – working Smart in Russia
Optimum weight loss for good hatchability and chick quality based on
growth - to become the unchallenged market leader in the CIS countries. By the beginning of 2007, a hatching capacity of more then 750 million eggs per year has been supplied in CIS countries. ‘Russia and the C.I.S. countries are still major importers of poultry meat,’ explains Mrs. Kolygina. ‘Despite having the capacity and capability to meet
demand with domestic production, in Russia for example almost 50 percent of the poultry meet is still imported.' ‘If we take into consideration that the consumption of poultry meat in Russia, per capita, is only half that of western Europe, and less then a quarter of that in the USA, the opportunities are enormous.’
References available on request.
Pas Reform Russia anticipates major growth in the coming years, as producers gear up to capitalize on the opportunities and meet the challenges - of increased demand. Pas Reform Russia fully reflects its parent company’s commitment to working in partnership with customers, delivering the full range of products, parts, technical
support and services for the region, for the much acclaimed Smart hatchery systems (incubators, hatchery automation systems and hatchery climate control systems). Comprehensive project management services include full hatchery planning and design services - either to expand on existing facilities, or
Documentation is compiled specifically for each of our customers, to combine the latest genetic and embryonic knowledge with the right tools to deliver optimum performance from modern breeds.
State-of-the-art hatchery places Hubbard SA for superior GP delivery With the hatchery structure starting to take shape and the building project running according to schedule, the future holds great promise for the team at Hubbard SA. The new 1,178sqm hatchery, which is under construction at Curry’s Post in the KwaZulu Natal Midlands, has been developed cooperatively by the Hubbard EU and Pas Reform design teams. The hatchery design incorporates some revolutionary features that will enhance the whole hatchery process, from the setting of eggs to the shipment of day old chicks. Solving the split placements issue ‘During the initial drafting phase, we spent a lot of time identifying our specific needs with both the local and international design teams,’ explains Jim Gray, MD Hubbard SA. ‘One of the key challenges for us was to solve the issue of split placements’. ‘We know that historically, local producers really battle when forced to take split placements - as this creates stress not only for the birds but also for the producer who is forced to manage different ages within a house. We wanted to design a hatchery that could somehow accommodate the variations in a producer’s house/flock sizes - without disrupting other customers’ placement schedules. Quite a tall order.’
Managing fluctuating order sizes Traditionally, hatcheries install equal setting capacity for each week of the three week cycle. This has not worked well in the past, as there’s no flexibility in these old hatchery systems for fulfilling larger placements without disrupting either the previous or following weeks’ capacities. ‘We’ve always understood the challenges of differing customer requirements, but until now, there has never been an alternative. By working closely with the Hubbard and Pas Reform design teams, we’ve found a solution that we believe will be welcomed by the industry’, Gray continues. ‘We’re installing a fourth ‘week’ of single stage machines, to provide us with greater capacity to handle extraordinary placements, without affecting our usual production schedule.’ This provides the producer with: – Flexibility in order size – Elimination of split placements – Peace of mind. Partnerships that add real value ‘We chose Pas Reform as our equipment partners, not only because they have worked extensively with Hubbard worldwide, but also because they have a thorough understanding of the hatchery environment, practical industry experience - and an in-depth understanding of the processes and integration economies. These, we felt, were critical, non-negotiable elements when building a hatchery that must be able to deal with both current and future hatching challenges.’
The hatchery at Curry’s Post in the KZN Midlands starts taking shape as progress is closely monitored by Mr. Jim Gray, Managing Director Hubbard South Africa and Project Leader Mr. Marco van der Leij
Pas Reform’s single stage SmartSet™ machines are, says Gray, perfect for Hubbard SA’s requirements. Homogenous temperature distribution and advanced pre-heat functions mean that eggs can be brought on temperature for an even start, so narrowing the hatch window. And by installing different sizes, Hubbard SA is able to mix and match settings to meet customer demands. Pas Reform’s experience and highly competitive pricing has enabled us to build within budget and achieve a first rate result,’ concludes Gray. Designed for expansion The new hatchery has been designed with the capacity to double in size at phase two, even before phase one is completed. This phase two expansion can be completed without interrupting phase one production in any way - and without compromising hatchery biosecurity. Strict adherence to hygiene procedures has been planned into the design and layout of the hatchery, with four sections of egg handling, setters, hatchers and chick processing located in individual, self contained units – each with its own individually controlled air conditioning system. Focus at the GP level With controversy around the practice of hatcheries competing with their own customers, Hubbard SA’s strategy is to remain focused solely on delivery at GP level. ‘There are plenty of producers already operating at parent stock and broiler levels,’ says Gray ‘But we believe the gap exists in delivering superior parent stock to the poultry industry - and we are not looking at any other aspect. ‘We’ve learned that to establish a loyal and supportive client base, you need to build credibility and trust – and that’s what we’re after.’ If you would like to discuss the Hubbard Hatchery operation or Hubbard’s plans in South Africa, please contact Jim Gray on firstname.lastname@example.org or 033 330 6381.
to develop new Greenfield sites. And customers of Pas Reform Russia also have access to the Pas Reform Academy, a dedicated training facility that shares the combined knowledge of a team of recognized authorities on embryology, incubation, genetics, hatchery management and technical training. Academy training can be provided either onsite or at
Pas Reform’s Dutch headquarters. The ‘Academy’ has become an important contributor to the success of Pas Reform’s commercial partnerships worldwide in recent years, and Wim Schaafsma believes that in Russia too, these highly practical and relevant training programmes, together with the highest lever of service and support, are already proving
their value to customers. ‘The Academy delivers the most upto-date intelligence in such a way that it can be easily incorporated into daily practice, to deliver tangible results in the hatchery,’ he says. Pas Reform Russia already has a string of successful projects to its credit, with leading hatcheries in Russia, Ukraine, Kazakhstan and other C.I.S. countries.
The company can be contacted at: Pas Reform Russia Korolevastreet 2a Office 510 Belgorod 308033 Telephone: +7 4722 52 84 26 Fax: +7 4722 52 81 79 E-mail: email@example.com
Integrated heating & cooling system To achieve homogeneous temperature distribution throughout the setter, SmartSet™ has a combined
heating & cooling device with 34 parallel coils per section, supplied with hot or cold water for optimum energy transmission to and from the incubating eggs.
L-R: Mr. Wim Schaafsma, General Director Pas Reform Russia and Mr. Kuksov, Lebiazhe’s General Manager
Ptitsefabrika Lebiazhe’s new GPS Hatchery targets 50pc market share in Russia with Smart from Pas Reform Ptitsefabrika Lebiazhe has contracted Pas Reform to supply a complete Smart Incubation system for its new grand parent stock hatchery in Shondorova Village, near St Petersburg (Russia). The new hatchery will target the production of nine million parents per annum, with capacity for 24 million eggs each year using 12 Smartset™ 77 setting machines, 12 Smartset™ 38 setters and 16 SmartHatch™ hatchers, a complete climate control system and a fully automatic chick processing line. Pas Reform has also provided all engineering.
‘Communication was greatly simplified,’ continues Mr Kuksov, ‘by the experienced, well-educated team that works through Pas Reform’s local office. This – coupled with the excellent back-up provided by specialists from the Pas Reform Academy in Holland – went a very long way to reinforcing our confidence in Pas Reform as a turnkey supplier.’ One of the greatest challenges for Lebiazhe, is to manage differing flock sizes for supply to their customers. With order flocks ranging from 15,000 to 60,000 parents in one batch, installing different sized incubators will enable Lebiazhe to combine incubators with different capacities, to fulfil specific order requirements.
Optimised cooling system Thanks to a detailed understanding of the impact of metabolic heat production on the growing embryo, Pas Reform has calculated the cooling capacities for SmartHatch™ not only for today’s breeds, but also for projected breed requirements in twenty years from now. SmartHatch™ incorporates 12 parallel cooling circuits that surround the incubating eggs (SurroundCooling™), to deliver an added 20 per cent cooling capacity. The circuits are fully integrated into the aluminium cabinet panels to massively increase the cooling surface area for even temperature distribution.
’Prior to commencing this project,’ explains Mr. Kuksov, ‘we investigated every candidate supplier very thoroughly. Pas Reform was most impressive from the outset – and instilled in us great confidence that they could indeed meet our exacting requirements for a turnkey project of this scale. ‘With great professionalism, Pas Reform demonstrated their capabilities as the most progressive supplier for the modern hatchery in the Russian market.’ Following initial discussions about the needs of the new GPS hatchery, Pas Reform’s project team produced a first draft layout for the new facility, accompanied by detailed production schedules and a complete offer for the total turn key project.
Pas Reform has established a new partnership that will enable the import of its Smart hatchery technologies to Iran. From Tehran, Mr. Kamal Nazari has been appointed to represent the full range of Pas Reform
Lebiazhe is the production company for Baltisa, Hubbard’s broiler breeder representative in Russia. With the supply of nine million parents per year, the company expects to take a 50 per cent marketshare in the country.
Grand parent stock operations must not, says Mr. Kuksov, compromise anywhere in the building or in the equipment selected. The new hatchery has been designed to meet or exceed the highest standards of bio-security - with three different zones, one each for egg handling, incubation and chick handling. Each zone has it’s own dedicated access point with showers.
Grand parent hatcheries are not, says Mr Kuksov, Lebiazhe’s general manager, all that common in Russia. And as the key stone to a client’s poultry integrations, all parent stock must be delivered with an absolute assurance of the highest possible standards of hygiene and care in monitoring optimum incubation parameters.
New partnership brings Smart Hatchery Technologies to Iran
Of equal importance for Lebiazhe in selecting equipment, is to keep eggs from different flocks and with different storage times separately in the incubators, each with their own respective setpoints. Pas Reform’s unique Smart design provides independently controlled sections within each incubator: ideal for meeting this requirement.
products, including Smart incubators, hatchery automation and hatchery climate control systems. Mr. Nazari’s extensive hatchery sector experience will, says Sales Director Henk Markhorst, be of unparalleled value in establishing modern hatchery practices in the country. ‘It is
great news that Pas Reform is extending its global network even further,’ he says. ‘ With Mr. Nazari’s expertise and forwardthinking, and the support of a superbly qualified team locally, we are very much looking forward to working with Pas Reform Iran to bring the latest technological developments and practices to hatchery owners throughout the country.’
Mr. Nazari’s agri-career began when he joined WestfaliaSurge at the age of 20. The past 15 years has seen Mr Nazari turn his skills and knowledge to poultry – and specifically to the hatchery sector, where he has an impressive record for the development of major installations.
‘Pas Reform has really emerged as a leader and innovator in the last few years’, says Nazari, ‘and in a country where our own ambitions extend not only to updating our hatchery industry, but to ramping up production for domestic purposes and for export, I believe the Smart technologies will put Pas Reform in a very strong position here very quickly.’
L-R: Project managers Iwan ter Wiel en Sander Koster
When incubation is an Art At a site visit recently, we met an exceptional manager - and a hatchery operation that is probably the finest example of how to gain maximum results in modern poultry business that we have seen in many years. Impressive hatchability As part of a large poultry meat supplier in Western Europe, this hatchery was newly installed with incubators and hatchers, and a complete hatchery automation system with transfer/candling and climate control, in 2004. The hatchery stands out for its consistent and exceptionally high hatchability. During the last two years, the hatchery manager and his team have achieved an average hatch of fertile eggs of 96 per cent. These figures are based on eggs from 12 different breeder flocks - and remain consistent throughout the year. Chick quality is excellent, with mortality always below 0.5 per cent over the first seven days. The secret: the people Naturally we wanted to understand the secret of the hatchery managers’ outstanding results! Of course, with the benefit of a newly designed hatchery, deploying the very latest technologies – the hatchery could expect good results. But compare this to having an excellent car: it is the driver that makes the tour a success. Likewise, much of the extraordinary success of this hatchery is due to the people who manage it. Yet during the past four years, we have visited the plant many times. And the truth is that this hatchery manager does not appear to employ any mysterious or unorthodox management practices. The company’s success seems based simply on the fact that hatchery personnel here work according to a couple of very ordinary ‘rules of thumb’, concerning hygiene and the strict follow-up of all processes and procedures. But then, perhaps this hatchery managers’ approach is the magic ingredient. For as the owner of the company, he has a real passion and devotion for the profession of hatchery manager. ‘Infertile’ and unhatched eggs are recorded and analysed as standard practice. And this manager puts the information he gathers with every hatch to very good use, to directly and tangibly improve hatchability and the quality of the chicks.
For example, on noticing that the chicks seemed listless on collection – and suspecting they may be suffering from insufficient oxygen – he adjusted the ventilation in the hatcher to allow a slightly higher intake. After several hatching cycles - and some fine-tuning - he found the optimum ventilation programme for his specific situation, confirmed and rewarded by the excellent quality of the chicks. Communication This hatchery manager observes what is going on in his hatchery. He speaks with his team daily, reviewing results and visiting every part of the plant. Because he communicates with every party he works with, every party willingly communicates with him. Broiler growers fill out daily reports on the number of chicks dying during the first week of life. In the event that mortality trends seem unusual, possible causes or actions are immediately discussed with all the parties involved. Similar agreements exist with suppliers, including those of the hatching eggs, feed producers – right the way through the production chain. When our observant hatchery manager noticed that the chicks’ legs were a little short, veterinary examination showed that the chicks also had deformed breastbones. Discussion with the feed supplier identified a small deficiency of manganese. Short lines of communication enable rapid recovery, which benefits everyone in the chain.
programmes and management methods – the results speak for themselves. And practical knowledge is a prerequisite for constructive discussions and resolution throughout the production chain. For a skilful employee whose key responsibility is to continuously monitor procedures and improve results, let’s assume an annual salary of €30.000. Take the day old chick price of €0.25. A simple calculation € 30,000 / € 0,25 = 120.000 day old chicks is the yearly quantity needed to counterbalance salary costs. For a medium sized hatchery of 14 million chicks per year, such as this particular plant, hatchability must be increased by 14,000,000 / 120,000 x 100 = 0.85% to make good sense of employing this one person. No excuses ‘Lack of time’ is never a good enough reason for not paying this kind of attention to active hatchery management! As we can see, the increased percentage of fertiles hatched easily justifies the employment of a skilled, conscientious hatchery management professional - who allows for more time spent in his working day to actively monitor and improve results.
Actively folow the process The hatchery manager’s role is a busy and demanding one. So often, we see that they either do not have the time – or perhaps lack the ambition – to leave their desks and go check on progress and results in the plant. Yet by following processes – actually using the results from analyses of unhatched eggs and chick quality, to fine-tune incubation
Pas Reform Iran and its customers will have the full backing of the Dutch hatchery technology company’s international sales and project management teams, as well as the training facilities provided by Pas Reform Academy, in Holland.
Kamal Nazari can be contacted at: P.O. Box 1587 – 8194, First Floor, No. 23, Mohammadi Alley, Golbar St., Towhid Sq, Tehran, Iran. Telephone: (+98 21) 664 30222 – 66942536 Fax: (+98 21) 6643 5438 E-mail: firstname.lastname@example.org
Mr. Kamal Nazari, Pas Reform’s new Representative in Iran and Henk Markhorst, Sales Director Pas Reform
On a site totalling 28 hectares, Odessa runs a fully integrated poultry complex, including a hatchery, feed mill, five poultry farms with a total of 100 poultry houses, and a processing plant.
Chick uniformity fundamental to major expansion for Odessa in Ukraine Ukrainian integration Odessa Chicks LLC has contracted leading Dutch supplier Pas Reform to install SmartSet™ setters, SmartHatch™ hatchers, and a full range of hatchery automation and climate control systems. The new hatchery is central to an ambitious expansion programme that will target the production of 12 million day old chicks per annum initially, with further expansion projecting 40 million d.o.c. by 2010. Odessa Chicks is a vertically integrated broiler operation. Established in 2000 and with 45 employees, the company is located in the Kominternovo district, Odessa Oblast – in the heart of Ukraine’s grain region, a factor that guarantees the most competitive grain feed ingredient prices. On a site totalling 28 hectares, Odessa runs a fully integrated poultry complex, including a hatchery, feed mill, five poultry farms with a total of 100 poultry houses, and a processing plant. This, explains Odessa’s managing director, Mr. Nikiforov Stanislav Antoljevich, gives Odessa total control across all operations, and an assurance of the highest quality products.
Gerd de Lange named Senior Poultry Specialist for Pas Reform Academy
As part of its ongoing, strategic programme to improve customer service and make further advances in its research activities, Pas Reform has appointed Dutchman Gerd de Lange as Senior Poultry Specialist to the Pas Reform Academy.
De Lange works alongside Hatchery Specialist Martin Barten and Embryologist Marleen Boerjan, to deliver comprehensive training programmes in all key aspects of modern hatchery management, for Pas Reform customers worldwide. His role includes the organisation and coordination of hatchery management
SmartCenter™ Hatchery Information System
'We have been meticulous in electing a supplier for this new hatchery project,' he says, adding, 'We were keen to work with a leading partner in the field of incubation technology. Having evaluated various offers, we found that Pas Reform was best placed to deliver the benefits of the most current incubation technology, combined with a strong commitment to the Ukrainian market.' Pas Reform Sales Director Michaël Kampschöer is delighted with Odessa Chicks’ decision: 'With longstanding experience and 82 per cent marketshare here, Pas Reform offers unrivalled commitment to the Ukrainian poultry market,' he says. 'This, combined with our advanced hatchery technologies mean we are well placed to identify substantial cost reductions for Odessa, as well as high levels of practical, logistical and technical support – which will translate into greater efficiencies, to ultimately deliver improved chick uniformity and posthatch performance.'
courses and visiting customer and partner sites in the field, to guide personnel through hatchery operation postinstallation, and to focus on the key areas of hatchery management that impact on efficiency and quality. And because of his extensive Parentstock management and broiler growing experience, Gerd also undertakes research
activities in this field. Gerd has degrees in Livestock Health and Production from the Royal Veterinary College in London, the Practical Training Centre for Pig and Poultry Husbandry in Almelo (The Netherlands) and the University of Professional Education in Deventer (also The Netherlands). His broad practical experience has been gained from the
Odessa Chicks’ main buyers are supermarkets, wholesalers and other retailers, about 10 per cent of whom are from the Russian Federation, Tran Caucasian countries and other former Soviet Union countries. Total capacity of the Ukrainian poultry meat market is estimated at over 450 thousand tons, primarily in chicken meat. Today, 65 to 70 per cent of total volume is produced in Ukraine. Imports continue to decline as a result of increased domestic broiler meat production.
Gerd de Lange, Senior Poulty Specialist Pas Reform
Fully adjustable turning programmes. Studies have revealed the benefits of different turning principles during incubation – and SmartDrive™ offers the ultimate in flexibility, for adjusting turning programmes as and when required (frequency of turning, 2 or 3 auto-turning positions, start/ stop timing)
Relevance of turning Broody hens provide optimum conditions for embryos developing in the eggs they are sitting on. The brood patch provides heat from one direction only, which means that eggs at the side of the patch are cooler than those in the middle of the nest. However because the broody hen regularly turns and moves the eggs in the nest, uniform egg temperature is achieved. In commercial incubation, we try to mimic the natural conditions in the nest. From the point of view of uniform egg temperature turning of eggs seems to be of less importance in modern incubators. Are there other reasons for turning eggs? As summarized by Deeming (2002), egg turning is essential to normal development for several reasons. Egg turning - prevents adhesion of the embryo to the inner shell membrane - stimulates the rate of development of the area vasculosa (the membrane which grows around the yolk and is rich in blood vessels). The area vasculosa is important for subembryonic fluid formation, as well as for yolk uptake later in incubation. - allows normal transfer of albumen proteins into the amniotic fluid, promoting optimum use of the albumen. - supports the growth of the chorio-allantois (the blood vessels right under the shell) to maximise oxygen absorption. - embryos in unturned eggs grow at a lower rate compared to embryos in eggs turned each hour over 90° - facilitates movements of the embryo into the normal hatching position and reduces the incidence of malpositions in unhatched embryos.
Recently Elibol and Brake (2004) confirmed the finding of New (1957), that the most critical period for turning broiler hatching eggs is during the first week of incubation. Elibol and Brake observed differential effects due to an absence of turning between 0 to 2 days (primarily increased early mortality) versus 3 to 8 days (primarily increased late mortality). The effect of not turning during the first half of incubation is only seen during the second half of incubation, but by then it is too late to take corrective actions. Turning failures during the second half of incubation will generally have less dramatic effects, although the growth rate of the embryo can be affected, depending on the moment and duration of the turning failure. The angle through which the eggs are turned is important. Hatch of fertiles was significantly better in eggs turned over an angle of 45º either side of the short axis of the egg, as compared to turning of 30º and 15º. Hatched chicks from eggs turned 45º weighed more and had less dry matter in the residual yolk. (Cutchin et al, 2007) Advice - Check the turning device before the start of each incubation cycle, as turning failures, depending on the moment of occurence, are detrimental to results. - Check and maintain the turning device regularly, to prevent a breakdown during incubation. - Make sure that turning does not produce shocks or jolts, as this adversely affects hatchability and chick quality. - If necessary, check and adjust the turning angle: 45º is optimal. - Not turning for the first 12 hours in the setter is advised, based on our practical experience and especially when eggs are transported to the hatchery on the same day as setting. Eggs need some rest time to restore their 'internal balance'. - Turning is not absolutely necessary after 15 days of incubation. Especially in incubators with insufficient cooling capacity, it can be beneficial to leave the eggs in a horizontal position to facilitate increased air flow (cooling over the eggs). In some modern setters, there is also the option of turning to three different positions, e.g. 45 minutes each in. right, horizontal and left position.
SmartPortal™ Online Hatchery Support
References available on request.
ground up, working at cattle, pig and poultry farms in his native Holland, before working as a trainer for national and international clients, with assignments taking him from Vietnam and Sudan, to the Caribbean, Ethiopia, Ghana, Kenya and Tanzania. Prior to joining Pas Reform, Gerd worked at PTC+ (formerly known as IPC Livestock
Barneveld College) as Trainer on the Small Livestock and Feed programme. In this position, he trained clients on poultry production management, hatchery management and more specialised aspects of hatchery practice. ‘We are delighted to have Gerd on board’, says Bart Aangenendt, CEO of Pas Reform Hatchery Technologies. ‘With experience
gained in Europe, The Middle East, Asia and Africa, Gerd’s great breadth of practical knowledge on Poultry Production Management in a range of environments will be invaluable to our customers worldwide – and to expanding the knowledge-base provided by our Academy still further.' De Lange joins a distinguished team at the Pas Reform
Academy, where specialists are world-class technicians, engineers, hatchery specialists, embryologists and integration experts in their own right, and each is well respected in their own field. Any enquiries regarding Pas Reform Academy’s hatchery management and poultry production training courses or materials may now be directed
either specifically to Gerd de Lange at Delange@pasreform. com, Marleen Boerjan at Boerjan@pasreform.com or Martin Barten at Barten@pasreform.com - or the Pas Reform Academy’s general email address at Academy@pasreform.com.
Practical sessions allowed participants to try out every aspect of their training program on a small scale in Pas Reform’s brand new Inspiration Center. Here, in a model hatchery setting, Pas Reform demonstrates its globally acclaimed Smart single-stage hatchery systems and technologies for customers, prospects and partners from all over the world.
Lohmann and Pas Reform Academy deliver exemplary training for hatchery managers Lohmann Breeders recently teamed up with Pas Reform Academy and PTC+ in Barneveld (The Netherlands) to deliver a bespoke training program for 15 hatchery managers from eight businesses in former Soviet Union countries Russia, Armenia, Ukraine, Latvia and Lithuania. Pas Reform Academy and PTC+ provided a unique, tailormade training program, translating the latest concepts of incubation and hatchery management for hatchery professionals. The format proved highly effective. According to participants, the combination of theory and practice was exemplary, with teachings being trialed immediately in a series of practical exercises - and reviewed within the course framework so that participants could immediately see the results of their new-found knowledge. Practical sessions allowed participants to try out every aspect of their training program on a small scale in the PTC+ School training rooms and Pas Reform’s brand new Inspiration Center, with ‘life-size’ sessions then held at the Probroed hatchery in Lievelde, the Netherlands, where approximately 3,7 million chicks are hatched per week. The course introduced the latest findings in all areas of hatching in great detail – from collecting eggs for incubation, through embryo development, egg disinfection and storage, to state-of-the-art incubation techniques.
To facilitate the practical sessions, Lohmann Brown and LSL eggs were set three weeks prior to the training program. This allowed for detailed work in the areas of hatching egg management, egg quality, embryology, egg break out analysis and the quality scoring of day old chicks. Thanks to the inspiration of Dr. Marleen Boerjan, Pas Reform Academy’s embryologist, the hatchery managers were able to see the embryos at every stage of their development, following the embryos’ development every day – and seeing at first-hand how mistakes in transportation, storage and incubation can influence the development and quality of the hatched chicks.
Gerd de Lange, Pas Reform Academy’s Senior Poultry Specialist and one of the organizers of the hatchery management training program says: ‘At Pas Reform, we recognize that hatchery success can never be fully dependent on technology. Today’s commercial poultry industry is fast-moving and dynamic – driven by rapid progress in poultry genetics. Training through the Pas Reform Academy means that hatchery managers have access to the most up-to-the-minute thinking, delivered in a practical, working environment for the benefit of their own hatchery operations’.
One participant commented: ‘This kind of training is truly helpful for my work back home. It perfectly illustrates why I have to do certain things, and when. I think we have all come away with a much greater appreciation of the importance of creating ideal conditions: it is possible and it produces outstanding results in terms of quality and uniformity. 'This superb work by PTC+ and Pas Reform has provided me with a starting point. Now it’s up to me to out it into practice!'
Pas Reform appoints new Business Development Manager for Central & Eastern Europe
As part of its continuing inter national expansion programme, Pas Reform has appointed Mr. Marek W. Pospiech Dr.Sc, Dipl. Eng.Agr, as new Business Development Manager for Central & Eastern Europe.
In his new role, Mr. Pospiech focuses on growing Pas Reform’s range and depth of commercial services in Central & Eastern Europe, with responsibility also for the registration and management of field trials with Pas Reform customers, following the installation of their Smart incubation systems throughout the region.
Marek Pospiech has more than 30 years’ experience in the poultry business. Since gradua ting as Master of Science and Agricultural Engineer from the Academy of Agriculture at Poznan (Poland) in 1973, he has held numerous positions in the poultry industry on both sides of the Atlantic, including poultry specialist, economist, geneticist and breeding production
manager. During his scientific career at the Polish Research and Development Centre, Mr. Pospiech received his Doctorate in Animal Breeding and successfully introduced several commercial laying hen strains to market, becoming Visiting Professor at the Poultry Science Department of the Virginia Polytechnic Institute and State
Smart growth for Russia’s Prioskolje Based on performance since launching in 2004, Russia’s fastgrowing Prioskolje Group has confirmed that it will continue to work in partnership with leading hatchery technology company Pas Reform, for the development of a fourth new hatchery complex that will bring the company’s total capacity for hatching eggs up to 150 million per year. Since the company was founded just over three years ago, Prioskolje has invested for growth, to rapidly become one of Russia’s largest poultry integrators. The company was among the first to adopt Pas Reform’s Smart hatchery technology when it was first launched in 2004. The new 60 million egg hatchery – the fourth in the Prioskolje Group’s integration - comes as part of a much broader investment programme that also includes a new feedmill, slaughtery, rendering plant, water treatment system and dedicated new housing to accommodate both parent stock and broilers.
'Belgorod region has a leading position among other regions in poultry meat production, which is not an easy position to maintain. But with the support of the regional Government and in particular the Governor of Belgorod region, Mr. Savchenko, we are able to contribute to the development of Russia’s own agricultural poultry sector, by providing for a future less dependent on meat imports.' Mr. Bobritskij pays tribute to the hard work and dedication of people, not only within Prioskolje, but also those building Russia’s agri-business economy, who strive daily to promote the highest of standards in poultry meat production.
L-R: Prioskolje’s General Director, Mr. Bobritskij and the Governor of Belgorod, Mr. Savchenko
From the outset, Prioskolje’s vision was to create a most modern, technologically advanced, high performance integration. And Pas Reform’s then newly launched Smart incubation technologies seemed to offer the most advanced capabilities in single-stage incubation. And Mr Nikolai Tolstoy, First Deputy to the General Director, describes the results gained with Smart at the company’s three existing hatcheries as no less than ‘astonishing’. He explains: 'To achieve the highest efficiency and lowest cost price, Prioskolje’s research team has maintained an ongoing test programme, to identify and understand the influence of incubation and chick quality on growth and performance in the farm.' 'Results were astonishing,' he continues. 'Feed conversion was influenced up to 8 points, when compared with the results gained in our previous [non Smart] hatchery operations.' Prioskolje’s General Director, Mr Bobritskij, concludes:
Mr. Marek Pospiech, Business Development Manager for Central & Eastern Europe
University in the USA in 1990. In 1991, Marek Pospiech started his commercial activities as Country Manager for Euribrid in Poland, where he finally achieved the position of Area Manager for Central & Eastern Europe. Alongside his commercial activities, Mr. Pospiech has been Director of the Polish-Swiss Foundation for the Development
of Agriculture and the Food Industry since 2000, while working as technical expert and market development consultant for The Cobb Breeding Company and, later, Cobb Europe. 'Marek is a strong addition to our team in Central and Eastern Europe,' concludes Bart Aangenendt, president of Pas Reform, 'we are delighted with the confidence he has expressed
for our Smart incubation system, and very much look forward to working with him to further consolidate our plans for international growth.'
Many of Suguna’s hatchery managers, project engineers, maintenance managers and broiler contract growing managers travelled from all over India, to be joined by the Group’s joint managing director Mr. Sundararajan, who also took part in the course.
From its worldwide headquarters in Holland, Pas Reform Academy seconded two specialists, senior hatchery specialist Mr. Martin ‘Tiny’ Barten and senior poultry specialist Mr. Danny Garvey, each of whom have more than thirty years’ experience in the sector with Nutreco and Cargill respectively, to train Suguna staff.
Suguna focuses on the future with Pas Reform Academy With information and education at the core of its developing hatchery technologies for customers worldwide, Pas Reform’s dedicated Academy recently held a seven-day postgraduate course in incubation management and first week broiler management for leading Indian integration Suguna Group. The course was held in Nasik, India. Headquartered in Tamil Nadu’s capital Coimbatore, Suguna is one of the fastest growing companies in India’s broiler sector. The vertically integrated Group has operations in eight States, covering GP and PS breeding, broiler farming, feedmills, processing and the export of hatching eggs and processed chicken. The company attributes its success to a focus on efficiency - and its readiness to adopt new technologies.
The week-long course covered all aspects of modern day incubation, from setting, egg handling and hatching to the production of high quality day olds, shifting to a focus on management strategies for optimal first week broiler results. Each day was divided into classroom sessions of several hours, followed by practical, hands-on training at Suguna’s Nasik hatchery complex. Mr. Sundararajan continues: ‘The course provided a very strong mixture of classroom sessions and practical training, geared specifically to our circumstances - and all the more valuable for being delivered in our own operational complexes.’ Mr. Sundararajan congratulated Pas Reform on being the first hatchery manufacturing group to have included the first seven days in the broiler house within its planning of the incubation process. Pas Reform Academy will deliver a new series of incubation management courses each quarter from its headquarters in Zeddam, The Netherlands. Anyone interested in taking part should contact Pas Reform on Tel: +31 314 659 111, or email Academy@pasreform.com.
Mr. Bouke Hamminga, Pas Reform’s Director International Sales & Business Development, explains: ‘Pas Reform has worked in partnership with Suguna Group to build new hatcheries for several years now. During this time, we jointly identified the need for a continuous professional training programme - and this postgraduate-level course was developed specifically for Suguna by the Pas Reform Academy.’ ‘Our strategic partnership with Pas Reform was forged primarily to support Suguna’s projected growth in the years to come, with the realization of multiple hatchery complexes’, explains Mr. Sundararajan. ‘However to fully leverage both current and emerging technologies, we also believe that building the competences and confidence of our staff is of paramount importance. Pas Reform Academy has served us well in developing this first course as a valuable and highly proactive first step towards achieving that goal.’
Henk Markhorst, Sales Director
Mr. Pierre Joris, Representative Belgium, France and Francophone Africa
Mr. Jankees Sligcher, Representative Southern Africa
Pas Reform’s distinctive stand houses a full scale SmartSet™ setter and SmartHatch™ hatcher
When and how to transfer eggs to the hatcher It is common practice to place eggs in the setter for the first 18 days, before transferring them to the hatcher for the last three days of incubation. Generally, this occurs between the embryonic ages of 17 days and 12 hours and 18 days and 12 hours, to coincide with the normal working schedule of the hatchery (see table), whereby hatchers are used twice a week. In this scenario, incubation time is measured from the (assumed) moment the eggs reach optimum internal temperature for embryonic development, and not from the moment the eggs are placed in the mulistage setter or from the moment the single stage setter is switched on. Depending on the setting system, heating capacity and initial egg temperature (in relation to the method and duration of preheating) corrections must be made if one wants to express incubation times from machine start-up. For example, in the table, corrector time equaties to six extra hours. Fluctuations in production planning may dictate transfer either earlier or later than in normal practice. Transfer to the hatcher can happen as early as 15 days (= 360 hours of incubation), as there is no evidence to suggest that stopping turning after 15 days of incubation in domestic fowl has any deleterious effects on development and hatchability (Deeming, 2002). However, it is our practical experience that transferring to the hatcher at this moment can reduce hatchability by 0.5 – 1 per cent . Transferring to the hatcher should not occur after 19 days (456 hours) of incubation, because disturbing the eggs at this time adversely affects the act of internal pipping.
Mr. Sergio Morelli, Representative Italy
1st hatch (21 d + 6 h)
2nd hatch (21 d + 6 h)
3rd hatch (21 d + 6 h)
4th hatch (21 d + 6 h)
3rd transfer (18 d + 12 h)
4th transfer (18 d + 12 h)
2nd start (0)
3rd start (0)
4th start (0)
1st start (0)
1st transfer (17 d + 12 h)
Advice - Transfer eggs after 17 days and 12 hours of incubation to the hatcher, but not later than 19 days (= 456 hours). Only in exceptional or unavoidable circumstances, should eggs be transferred as early as 15 days (=360 hours). - Adjust hatcher climate in relation to the age of embryos, if transfer must occur before the recommended minimum of 17 days and 12hrs. In practice, the setpoints of the setter should be followed. However as there is increased airflow over the eggs once they are positioned horizontally in the hatcher baskets, it may be necessary to increase setpoints by, for example, 0,2 ºF. - Maximise the time from setter to hatcher to 20 - 30 minutes. - Maintain a good climate in the transfer room (approx. 25 ºC and avoid draught). - Leave the setter switched on as long as there are still eggs inside! Failure to do so will impede the cooling of the eggs, which is likely to produce late mortality due to overheating. - Empty setter trolleys from top to bottom, to avoid exposure to high temperatures in the topmost trays as a result of rising heat from the embryos in the lower trays. - Handle the eggs carefully during transfer. Eggs cracked during transfer have reduced hatch potential due to dehydration. - Make sure the hatcher baskets are dry. - Fill the warmed hatcher with trolleys according to the manufacturers recommendations. This is particularly important when the hatcher is not filled to capacity.
2nd transfer (17 d + 12 h)
Table: Working schedule for hatchery with 4 hatch days per week, whereby weekend workdays are avoided. The 1st hatch and 3rd hatch are in the same hatchers. Incubation time is measured from the moment internal egg temperature has reached optimum incubation temperature.
References available on request.
Mr. Lukas Sederevicius, Representative Baltic States
Marco van der Leij, Research & Development
If carbon dioxide levels are too high, the chicks will gasp for air and try to stick their heads out of the chick boxes. This blocks the passage of air into the boxes, so compounding the problem.
Maintaining the ideal climate for chick handling and transport Good post hatch performance and low first week mortality can best be expected from chicks kept in ideal conditions between leaving the hatcher and placement in the farm. When pulled, chicks leave an ideal climate, with hatcher temperature of approx. 97.5 – 98 ºF (36.4-36.7 ºC), relative humidity at around 60 per cent and air circulating at high speed. Movement to the handling room exposes the chicks to a very different climate. And boxed chicks are often kept for some time in the chick despatch room, before being transported to the farm. Normal rectal temperature for a day-old-chick is 40 – 40.5 ºC (100.4 – 104.9 ºF). Newly hatched chicks are dependent on climatic conditions to regulate their body temperature for the first few days. And good ventilation will drive excess body heat out of the chick boxes, while also preventing a build-up of carbon dioxide. Chick behaviour is the best indicator of climatic conditions during chick handling and transport. Under ideal conditions, day old chicks breathe quietly through their nostrils, losing only a little water. They spread evenly in the boxes, make little noise and are relatively inactive.
Recommended post hatch climate settings Temperature (ºC)
Relative humidity (%)
Chick handling and dispatch room
22 – 28
50 – 60
500 – 600
22 – 28
50 – 60
500 – 600
Air: 32 – 35 Floor: 28 - 30
50 – 60
500 – 600
Pas Reform is a prominent contributor to many leading poultry events and expositions around the world
When environmental temperature is too low, or there is too much draught, the chicks huddle together to try to maintain body temperature. Chicks are especially prone to chilling if pulled too early ('wet chicks') or after spray vaccination. Too high an environmental temperature causes chicks to open their beaks and pant, which evaporates water from their lungs and air sacs. Short term, panting will help the chicks to lose excess body heat, but it also leads to faster dehydration. When the chick’s water reserve is depleted, this control mechanism becomes redundant. With further increases in environmental temperature, the chicks become progressively more noisy, spreading their wings to try to reduce body temperature. But if environmental heat remains excessive, this too will fail to keep the chicks’ body temperature down - and inevitably some chicks will be lost. Trying to prevent dehydration by increasing relative humidity only makes it more difficult for the chicks to evaporate water. Excessively low relative humidity also leads to dehydration. Advice Recommended post hatch climate settings are shown in the table. Specific recommendations include: – Look, listen and respond accordingly to the chicks’ behaviour. It may help to record the rectal temperatures of a representative sample of chicks occasionally. – Remember that the room and/or truck climate is secondary: it is the climate in the chick boxes that matters. Temperature at chick level should be approximately 32 – 35 °C (89.6 – 95.0 ºF). – Avoid chilling by pulling chicks too early or after spray vaccination – and beware of draughts! – Reduce the number of chicks when temperature during transport and (un)loading is too high – To provide sufficient ventilation in the chick-despatch room, position the chick boxes in uninterrupted rows with 30 cm (min) between each row, and a fan blowing preconditioned air in alternate corridors between the rows. – Ensure that trucks are loaded correctly, based on the ventilation principle of the truck-type. – Review the output of 'climate loggers' from the chick boxes during transit: the temperature in the boxes can be between 8 – 14 ºC higher than the air temperature in the truck. – Have the driver measure and record climatic conditions, including floor temperature, in the receiving farm. – Unload the chick boxes immediately on arrival at the farm, as the house temperature is high and ventilation is too low to drive the additional heat produced by the chicks out of the boxes.
Kenneth Chen, Tennyson’s brother and business partner, adds, 'We have seen the impact that Pas Reform has had on single-stage with the introduction of its Smart incubation system over the last couple of years'. Working in partnership with Pas Reform, says Chen, the time is now right to capitalise on the benefits of single stage incubation in terms of broiler uniformity and feed conversion ratios. 'Working alongside Pas Reform’s hatchery management specialists, we are confident that we will achieve the technical results to deliver superior chick quality, and with that, superior broiler performance'.
Bounty Fresh launches first single-stage Smart hatchery project in the Philippines Having monitored the development of single-stage incubation technologies for several years, Bounty Fresh Foods inc. (formerly Tyson Agro) has elected to install its new broiler hatchery project in Cagayan d’Oro, Mindanao, with single-stage, closed-door Smart Incubators from Pas Reform. The new hatchery, which is the first single-stage operated broiler hatchery in the Philippines, will produce 200,000 day old chicks per week in its first phase. Bounty Fresh has installed SmartSet™ setters, SmartHatch™ hatchers and Pas Reform’s hatchery ventilation system. 'We have been looking at the introduction of single stage incubation in our broiler operation for some time now', explains Tennyson Chen, President of Bounty Fresh. 'When we made our last investment in Tarlac some seven years ago now, we were at that time still not convinced about the benefits of single-stage incubation - and consequently chose multi-stage equipment for that project.' Now, with improvements and developments both in genetics and in single-stage methodology, Bounty Fresh is, says Tennyson, excited about introducing single stage incubation practice in Mindanao for the first time.
The Mindanao project represents a new entry into a new market for Pas Reform. 'Having been close to the Philippine poultry sector for the last 13 years' says Bouke Hamminga, Director International Sales & Business Development Pas Reform, 'I have seen Bounty Fresh rise up, from a very small parent stock and commercial layer operation to become the second largest broiler integration with production of approx. 2,5 million day old broilers per week throughout the Philippines. 'This is a rare and exciting opportunity - and based on the marked improvements in broiler performance that we have seen in other Smart installations around the world, we are confident that the results will justify this major investment in single stage incubation equipment for Bounty Fresh'.
AIC Mosselprom fuels growth with Dutch technologies Agro-Industrial Complex (AIC) Mosselprom is poised for massive expansion, with plans to ramp-up poultry production by more than 42 per cent, to increase outputs from 35,000 to 50,000 tonnes of poultry meat per annum. The vertically integrated closed joint stock company (CJSC) has identified a number of key Dutch suppliers – among them Pas Reform Hatchery Technologies - to equip its expanding complex.
Pas Reform: setting standards for uniformity worldwide
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Contact details: T +48 600 296 830 F +48 61 847 15 19 E email@example.com Morocco Agri Art Visiting/mailing address: 38, Hay Medouaz TÉMARA Morocco Contact details: T +212 3764 3061 F +212 3764 3578 E firstname.lastname@example.org Myanmar Yé Group Visiting address: No.23 5/6 Floor, Ma Po Street SanchaungTownship YANGON Mailing address: G.P.O. Box 275 YANGON Myanmar Contact details: T +95 1 500 647 F +95 1 536 014 E email@example.com Nigeria Terudee Farms Nigeria Ltd. Visiting address: Idi Omo Village Km. 15 New Ife Road AGODI - IBADAN Mailing address: P.O. Box 36048 AGODI - IBADAN Nigeria Contact details: T +234 8055 005 709 F +234 2231 6207 E firstname.lastname@example.org Pakistan Bird Care Visiting/mailing address: 1st Floor, 228-Ahmed Block New Garden Town LAHORE 54600 Pakistan Contact details: T +92 42 585 7387 F +92 42 520 4164 E email@example.com
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Contact detaisl T +966 1 477 5192 F +966 1 479 2647 E email@example.com Serbia IRADIA Visiting/mailing address Gavrila Principa 53 SREMSKA KAMENICA 21208 Serbia Contact details: T +381 21 461 170 F +381 21 464 113 E firstname.lastname@example.org South Korea Il-Seung Co. Ltd Visiting/mailing address 48-22 Muk 1-Dong Chungnang-Ku SEOUL 131-847 South Korea Contact details: T +82 29726562 F +82 29766303 E email@example.com
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Visiting/mailing address: 4090 Campbell Road GILLSVILLE, GA 30543 United States of America
Visiting/mailing address: 9, Sutherland Avenue CRAIGHALL PARK, J’BURG 2196 South Africa
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Venezuela Eurofeed de Venezuela c.a.
Spain Maker Farms, S.L. Visiting/mailing address Av. Alba Rosa, 55-57 17800 OLOT Spain Contact details: T +34 972 261 260 F +34 972 270 661 E email@example.com
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Portugal Avisilva AS
Sudan Coral Co. Ltd.
Visiting/mailing address: Estrada Velha da Avessada, 5 Apartado 101 MALVEIRA 2669-909 Portugal
Visiting address: New Extension Aiamarat Street No. 17 KHARTOUM
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Contact details: T +40 21 317 45 65 F +40 21 311 32 94 E email@example.com
Visiting/mailing address: 35 Windsor Way Brook Green LONDON W14 0UA Great Britain
Mailing address: P.O. Box 437 RIYADH 11411 Saudi Arabia
Mailing address: Cimen Sok. No. 64 ELMADAG - ISTANBUL 80230 Turkey
Visiting/mailing address: 121/5, Thummodara Road PUWAKPITIYA, AVISSAWELLA 10700 Sri Lanka
Visiting/mailing address: B19, L1-A, San Dionisio, DBB-1 Dasmariñas CAVITE Philippines
Mailing address: Jalan Kulim 1418 Bukit Mertajam PENANG 14000 Malaysia
Mexico Proyeccion Tecnica Agropecuaria SA de CV
Visiting address: Malaz, Arbeen Street, Mangoria Building RIYADH
Visiting address: Sanayi ve Ticaret A.S. Elmadag Cimen Sok. No. 64 SISLI - ISTANBUL 34373
Visiting address: Van Oldenbarneveldstraat 85 6828 ZN ARNHEM
Visiting/mailing address: Iancu de Hunedoara Nr. 2 B1, H6, Sc. 1, Et 1, Ap. 1 SECTOR 1 BUCHAREST Rumania
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Saudi Arabia Agricultural Development Company Ltd.
Turkey Refarm Kimya Laboratuvari
Sri Lanka BAP Agri (Pvt) Ltd
Philippines 7L Agri Food Systems Ent.
Visiting address: Jalan Kulim 1418 (1323) Bukit Mertajam PENANG 14000
Iraq TECHNETS LTD.
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Middle East Mr. Maciej Kolanczyk
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Bosnia-Herzegovina Iradia d.o.o.
Visiting/mailing address: 59, Dragan Tzankov blv. Entr. 7, flor. 1 SOFIA 1172 Bulgaria
Visiting/mailing address: B.P. 70 M.B.A. SFAX 3031 Tunesia
Central and Eastern Europe Dr. Marek W. Pospiech
Visiting/mailing address: P.O. Box 41 MEGARA 19100 Greece
Bulgaria Mr. Ilia Marinov Ecomat Ltd.
Tunesia / Algeria / Libya Poultry World
Russia Pas Reform Russia visiting/mailing address Korolevastreet 2A Office 510 BELGOROD 308033 Russia Contact details: T +7 4722 52 84 26 F +7 4722 52 81 79 E firstname.lastname@example.org
Mailing address: P.O. Box 1899 KHARTOUM Sudan Contact details T +249 183 469249 F +249 183 469248 E email@example.com Switzerland Globogal AG Visiting address: Tannlihag 5 LENZBURG CH CH-5600 Mailing address: Postfach 5847 LENZBURG CH CH-5600 Switzerland Contact details: T +41 627 69 69 69 F +41 627 69 69 70 E firstname.lastname@example.org Syria / Lebanon ACMAVED
Visiting address: Hochiminh office 02 Ngo Duc Ke St. - Dist. 1 MeLinhPointTower8floor-Unit806 HO CHI MINH CITY Mailing address: Me Linh Point Tower 8th floor - Unit 806 HO CHI MINH CITY Vietnam Contact details: T +84 88293503 F +84 88251021 E email@example.com Yemen Republic Hadwan Agri. & Poultry Est. Visiting address: 60W Str.Front of Azal Hospital Behind AlShark Resturant SANA’A Mailing address: P.O. Box 25125 SANA’A Yemen Republic Contact Details T +967 1 215 127 F +967 1 211 609 E firstname.lastname@example.org
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