The Netherlands Munsterhuis BV targets crossborder growth > p. 11
Brasil Cobb Vantress Brasil selects Smart incubation from Pas Reform for GGP facility > p. 31
Pas Reform Times Pas Reform Hatchery Technologies
Next generation design for the future-focused hatchery
Pas Reform Hatchery Technologies
Egypt Ommat signs up for Smart hatchery expansion > p. 6
Smart Team Work!
India Prestigious new Smart hatchery project for Sneha Farms > p. 20
Zeddam-based team is leading
the way in single-stage hatchery technologies
Russia Krasnoyaruzhskiy on-track to double capacity with Smart > p. 10
Next generation demands call for robust, futureproofed solutions In recent years, the poultry sector has seen many new innovations and technological advancement, in response to the evolving needs of modern poultry breeds. This sector is primed for continuing growth, which will be driven over the coming decades by forward looking customers. Super hatcheries are becoming a reality, as demand for healthy, safe poultry products outstrips existing production capacities. This generates a growing demand for hygienic, ergonomic, energy efficient incubation.
Pas Reform’s multi-disciplined,
In this future-focused landscape, adapting to new challenges, Pas Reform has emerged as an innovator and leader in hatchery technologies. With the commitment of dedicated, expert professionals in every area of poultry production, Smart Technologies are driving progress and growth for hatcheries in almost every country in the World. Pas Reform continues to lead the field, as 2010 sees the introduction of SmartPro™ next generation, single-stage incubation technologies.
SmartPro™ is the product of three years intensive study and analysis. Designed to deliver Circadian Incubation™, adapted technologies create homogeneous incubation environments capable of thermally conditioning each embryo, to produce large numbers of uniform, robust day old chicks. In this edition of Pas Reform Times, you will find more information on our new SmartPro™ incubation system, as well as insights from Pas Reform Academy and the latest news from many forward-looking hatcheries around the world. Bart Aangenendt CEO Pas Reform Hatchery Technologies
Pas Reform Times SmartPro™ 2 Pas Reform do Brasil 2 Kanev hatchery, Ukraine 4 Agro Danieli, Brazil 4 Dutch Poultry Centre 4 Handle hatching eggs with care 5 Ommat, Egypt 6 Optimising hatchery design 7 Green hatchery, Lybia 7 Finetuning for results 8 New film documentary 8 Hy-line, Mexico 9 Paragon, Bangladesh 9 PW Consolidated Bhd, Malaysia 10 Krasnoyaruzhskiy, Russia 10 Poultry Focus Asia 10 Munsterhuis BV, The Netherlands 11 Timing chicks for a perfect take-off 12 New Pas Reform service in India 12 Groupe Kherbouche, Algeria 13 Couvoir Francois, France 14 Kuzbasskiy Broiler, Russia 14 Weighing the benefits of automation 15
SmartPro™ 16 PT Panca Patriot Prima, Indonesia 18 Belgrankorm, Russia 18 Pas Reform Academy 18 Hama, Poland 19 Sneha Farms, India 20 Astana, Kazachstan 20 Granja Rosanda, Guatemala 21 Altona, Australia 21 Altaiskiy Broiler, Siberia 22 The true cost of chilled chicks 22 Poultry specialist joins Pas Reform in Hungary 22 Belaya Ptitsa, Russia 23 Incubadora Mexicana SA, Mexico 23 Driza Limited, Albania 24 Maroc Dinde, Morocco 24 Schotman Hatcheries, The Netherlands 25 New SmartTray™ 25 Marshall Poultry, Philippines 26 Mirza Kochekkhan Co., Iran 26 Pas Reform expands into New Zealand 27 The relevance of hatchery climate control 27
Next generation incubation technology from Pas Reform After three years of intensive research and development, Pas Reform is introducing Smart Pro™ – its latest and most advanced development for modular, single stage incubation to date. The modern hatchery manager’s goal is to produce uniform, robust day old chicks. Robustness is a health criterion, originating in the embryonic life stage of the chicken – and correlating directly with the performance and resistance of individual chicks under differing farm conditions. Research has shown that to achieve robustness, the embryo requires a specific trigger, eg. stimulation by heat or cold, during critical periods of the incubation process. Thus, so-called ‘embryonic imprinting’ takes effect on a physiological level, to produce a chicken that will thrive in its farm environment. This short-term thermo-conditioning is at the heart of Circadian Incubation™ – and known to improve hatching results, producing long-lasting effects that include 1 - 2 % increase in final body weight and 1 - 2 points better feed conversion rates. Batches of uniform, robust day old chicks also deliver uniformity at slaughter age, thereby improving efficiency and performance throughout the entire production chain.
Granja Crusvi, Spain 28 Smart growth for Pas Reform Russia 28 Managing the hatch window 29 CAB Group, Malaysia 30 Microban® 30 Smart new Logistics Centre 30 Cobb Vantress, Brazil 31
Pas Reform do Brasil opens new site Just months after a landmark Agreement to produce Pas
Reform’s complete range of hatchery equipment and
technologies in Brasil, Pas
Reform do Brasil has opened its new sales and manufacturing site at Rio Claro/SP.
However, to support the use of Circadian incubation™, the incubator must deliver precise climate control. To achieve truly homogeneous temperature distribution, the challenge is to exchange energy, CO2/O2 and moisture without affecting temperature uniformity around the eggs. To meet this exacting requirement, Pas Reform’s latest advancement for single stage incubation combines (1) modular incubator design, (2) a new Vortex™-based airflow principle and (3) Adaptive Metabolic Feedback™. Modular incubator design Modular incubator design creates sectional environments that can be individually controlled, which is the only way to guarantee homogeneous incubation temperature in incubators containing more than 100,000 hatching eggs. Each incubation section is equipped with separate temperature, heating, cooling, humidification and ventilation systems.
Vortex™-based airflow principle
Pas Reform has produced two
Intensive analysis using Computational Fluid Dynamics (CFD) has demonstrated that the most effective method of exchanging energy, CO2/O2 and moisture in the incubator, is to generate as many vortices as possible, of a specific dimension and intensity, in the wake of the air pump blade. CFD-aided research and development has produced a brand new air pump blade design: a design that Pas Reform has named ‘Vortex™’.
brochures to describe ‘Circadian
full-colour, fully illustrated new
Incubation™’ and ‘SmartPro™’ in detail. For your own free copies of the brochures, please email email@example.com or
Circadian incubation™ Next generation design for the future-focused hatchery
download in pdf format from Pas Reform online at
Adaptive Metabolic Feedback™ Adaptive Metabolic Feedback™ (AMF™) has been developed by Pas Reform to ensure that the hatching environment meets the needs of the growing embryo throughout incubation. With a focus on managing moisture and CO2, AMF™ continually ‘reads’ the time-varying metabolism of a specific batch of embryos, to adapt control parameters and fine-tune the incubator environment according to the embryo’s needs. Ultimately AMF™ maximizes uniformity, by optimising airflow and air redistribution to achieve the very precise temperature distribution required.
Pas Reform Hatchery Technologies
Next generation design for the future-focused hatchery
SmartPro™ Pas Reform has combined the use of these three features in its next-generation ‘SmartPro™’ incubator: advanced incubation that maximizes temperature homogeneity directly, to produce the highly precise environmental controls required. For a preview of how SmartPro™ can positively influence your hatchery’s future, go to the centre pages of this edition of Pas Reform Times!
Pas Reform Hatchery Technologies
The new venture, partnered by
Like it’s sister-operation in The
hatchery automation systems
president of Hygen Genética
Brasil includes an ‘Inspiration
To arrange a visit to Pas Reform
José Antonio Campos Fracasso, Avícola Ltda., sees the
manufacture of Pas Reform’s full suite of Hatchery Technologies
outside The Netherlands for the first time in the Company’s history.
Netherlands, Pas Reform do Centre’, which is open to
customers and has been created to represent a model hatchery setting.
The Inspiration Centre is fully
and hatchery climate control. do Brasil, or for enquiries or
Bart Aangenendt CEO Mobile +31 620 431 897 firstname.lastname@example.org
further information, please
contact Dr. Thomas Abdo Calil, at email@example.com
operational, showcasing the full working of a complete hatchery system for customers – with
incubators, setters, hatchers,
Mr. Boris Marchenko,
Picture (left to right)
Alessandro Martini (Marfrei representações)
Clovis Gottardi (Agro Danieli Hatchery Manager) José Antônio Fracasso(Pas Reform do Brasil) Adelírio Danieli (Agro Danieli)
Thomas Calil (Pas Reform do Brasil)
João Renato Zwetsch (Agro Danieli)
Agro Danieli Kanev Hatchery Mironovsky Hlebo Produkt, Ukraines largest broiler integrator, recently completed their broiler hatchery in Kanev. The largest hatchery in Europe has been equipped with more than 100 Smart modular single-stage incubators.
expands with Pas Reform in Brazil Agro Danieli recently signed a Contract with Pas Reform do Brasil, for the supply of a complete Smart incubation system that will expand the company’s production of day old chicks at their Ibiaça hatchery site. The new Smart system will comprise 18 SmartSet™ 77 setters and 12 SmartHatch™ hatchers, as well as a complete HVAC ventilation system throughout all areas of the hatchery’s operation. Plans also accommodate a doubling of capacity at Ibiaça, with a further 18 setters and 12 hatchers in the future.
Agro Danieli is an important new customer for Pas Reform do Brasil. The Hatchery Technology Company’s General Manager, Thomas Calil, says of the Contract: ‘With a very high level technical team in place, Agro Danieli’s decision to install Smart single stage incubation technologies came after a thorough evaluation of the options available, both here in Brasil and abroad. The project is being financed by FINAME – a Government scheme for the acquisition of new, domestically-manufactured machinery and equipment through accredited financial institutions.
Pas Reform welcomes the Dutch Poultry Centre to Zeddam
Under the umbrella of the Dutch
More than 50 DPC members
Aangenendt. ‘We see a powerful
orientated Dutch companies
presentation, which centred on
knowledge and innovation,
Pas Reform recently welcomed
reputation for their knowledge,
members of the Dutch Poultry Centre (DPC) to its Inspiration Centre in Zeddam, The Netherlands.
Poultry Centre, internationally and Institutes, each with a
quality and innovation, present
themselves on the international market.
attended Pas Reform’s an exploration of The
Netherlands’ role in the global future of the poultry industry. ‘Pas Reform believes in the
strength of The Netherlands, as a country expert in the
international poultry sector,’
remarked Pas Reform’s CEO Bart
opportunity for sharing
under the unifying banner of the Dutch Poultry Centre.’
Handle hatching eggs with care for profitability in the hatchery Prior to an Agricultural Trade Show in the Middle East recently, we were invited to visit a large, local poultry integration. On meeting at the company’s City Office, the CEO told us that their hatchery operation employed pretty old machines. Hatching eggs were produced at their own broiler breeder farms, all of which were doing fine, but the hatchery was not doing so well. He explained that early embryonic mortality was the greatest problem, with figures up to 20 % of eggs set. The CEO wanted us to have a look in the hatchery to find out what exactly was causing this problem – and as this case interested us, we did not need to be persuaded. We agreed that following our visit to the hatchery, we would meet later that week at the exhibition, where we would inform him about our findings. Bumpy road The hatchery was a short drive away from the city, but with good air conditioning, it was a pleasant drive. After an hour or so the driver announced ‘we are nearly there’ while leaving the main road and turning into a gravel road leading into the desert. This road had a ‘washboard-like’ appearance, causing a very regular up-and-down movement of the car – and causing a tough strain on our inners. Thinking about the CEO’s words, we wondered if we had discovered the cause of poor hatchery performance before even entering the hatchery! The fastest way to spoil a hatching egg is to give it one or two sudden shakes, while holding it between your thumb and index finger. In the hatchery we were welcomed by the hatchery manager, who took us directly to the chick handling room, where takeoff was in full progress. We asked him to put a few hatcher baskets aside with unhatched eggs. Chick quality appeared rather good and based on a random sample of the batch they were working on, a breeder flock of 42 weeks of age, we found an average PasgarScore of 9, which confirmed our first observation. While counting the unhatched eggs in the baskets they put aside for us, the hatchery manager explained that candling was only done on a sample basis and that these eggs had not been candled. We came to an average of 40 unhatched eggs per 150 eggs set (27 %) and an egg-break out revealed only eight late dead embryo’s and
two rotten eggs. Fertility was good; the majority of eggs showed signs of early embryonic mortality with enlarged white membranes and in some cases a blood ring and an occasional black eye. The hatchery manager agreed with these findings, as he got comparable results from candling. Outside problems Increasingly we believed the problem was not situated in the hatchery, at least not in the setters and hatchers. We suggested following the route the eggs travelled from the moment they arrived in the hatchery until placement in the setter. Twice each week, pulp trays full of eggs and packed into carton boxes were brought in from the breeder houses in a climate controlled truck. On arrival in the hatchery, they were placed on setter trays. We observed this activity for a while and concluded that on average 3 - 4 eggs per setter tray of 150 eggs were removed because of visible hair cracks: approximately 2.5 %. Thereafter eggs were placed in the storage room. An egg breakout in the storage room of six eggs from several batches each time revealed one egg with an excessively large germinal disc, indicating that embryonic development had advanced too far at the breeder farm. We asked the hatchery manager to explain the fumigation procedure and all seemed fine. By chance however, we took off our hairnet while the hatchery manager switched on the recirculation fan and did not detect any air movement. A technician was called upon to investigate, and discovered that the poles were wrongly attached, causing the fan to suck instead of blowing. This could cause poor formalin distribution – and we observed too that the opening for fresh air was too small, causing prolonged exposure time to formalin that would exceed the maximum recommendation of 20 minutes. Wet and hot To conclude our investigation, we had a brief visit to the parent stock farm, 40 kilometres away from the hatchery, to study the egg handling procedure. The breeder houses were equipped with 2-level litter nests that were generally clean, with a small incidence of floor eggs. During our visit, the nests at the lower level were quite full with an average
of 6 - 8 eggs, whereas the nests on the top level were practically empty. It was very difficult for hens to access top level nests, as the majority of the perches were broken or even missing. In the central egg handling room, we saw how the workers packed stacks of filled pulp trays in carton boxes. But the biggest surprise was waiting for us when we looked in the actual farm store. Here, we stepped into about 10 cm water and found the egg boxes stacked together alongside the wall on a slatted floor. The water was just a few centimetres away from the bottom of the lowest boxes – and these boxes were soft and soggy, collapsing under the weight placed on top of them. We asked permission to open a few boxes, which had been placed earlier that morning – and while opening them, felt the warmth on our face. Obviously eggs were placed into boxes before they had cooled down sufficiently, causing the embryos to develop too far. Later at the exhibition, we shared our observations with the company’s CEO, explaining to him that his hatchery manager and staff were doing a great job with the eggs they received. The real problem lay in the management of the eggs from breeder farm to setter. With improved egg management, it would, we advised, be realistic to expect an increase in hatchability of 5 %, while at the same time reducing the incidence of hair cracks by 2 % to 0.5 %. With a chick price of € 0.25 and a hatching egg price of € 0.15 for his 80 million eggs per year operation, this produced the following forecast: + 5 % hatchability = 0.05 x 80 million x € 0.25 = € 1 million - 2 % hair cracks = 0.02 x 80 million x € 0.15 = € 240,000 We agreed this represented substantial increases on the hatchery’s bottomline – and more than justified investment in an improved hatchery access road.
Bouke Hamminga Director International Sales & Business Development Mobile +31 651 064 250 firstname.lastname@example.org
Kitty Bekken Office Manager Telephone +31 314 659 111 email@example.com
Egyptian Arab Poultry Breeders Co. (Ommat) signs up for Smart hatchery expansion
Mr. Bart Aangenendt,
CEO of Pas Reform Hatchery Technologies and Ommat’s
Chairman Mr. Hussein Bahri
Egyptian Arab Poultry Breeders Co., also called Ommat, has commissioned the installation of Pas Reform’s modular single-stage incubators, hatchery automation systems, climate control systems, and a SmartCenter™ hatchery information system. Ommat targets high uniformity in its day old chicks, with good vitality and immunity. These demands, says Chairman Mr. Hussein Bahri, reflect the needs and growing demand of Ommat’s customers. ‘Expansion will double our capacity to 60 million chicks each per annum – and to achieve that, Ommat is keen to use modern technology, both in production and administration. We have selected Pas Reform’s Smart incubation system to further improve day old chick uniformity. In this way, we optimise farm management and can achieve the lowest possible feed conversion rates.’ Ommat specifically chose Pas Reform’s Smart incubation technologies, concludes Mr. Bahri, for the benefits of modular, single stage incubation in reducing the hatch window. Ommat-Egypt has sister companies in Saudi Arabia and Sudan, with Arab Poultry Breeders Co. being the sole agent for Lohmann Selected Leghorn (LSL) in the Kingdom of Saudi Arabia, GCC and Yemen. The company was established ten years ago to specialise in the production, marketing and sales of hatching eggs and day-old broiler chicks. With a focus on delivering premium quality products, Ommat’s exports have expanded to many Arab and African countries.
Pas Reform has earned its
position as one of the world’s leading hatchery equipment
manufacturers, by combining
the very latest intelligence with
a complete understanding of all aspects of the poultry production chain.
Dr. Badr El Emam, Managing Director Ommat
Optimising hatchery design for peak performance Having chosen a green field site for the new hatchery, it is important first to consider the lay-out of the facility carefully, followed by producing an engineering plan of drains, piping, ducting and cabling. Good design is crucial to cost-effective hatchery operation – and should avoid long walking distances anywhere on the site, to minimize the use of internal transport. To prevent cross-contamination, the plan should incorporate a unidirectional flow of people, eggs, air, trays, baskets and trolleys: ‘clean’ should never meet ‘dirty’. A well designed hatchery lay-out will set out five distinct areas for the eggs, incubation, newly hatched chicks, technical operations and personnel. In the egg area, will the eggs arrive on farm trolleys, paper/ plastic trays or egg boxes – and in what quantities? How long will eggs be stored – and will they require different temperatures? Will grading and selection take place at the hatchery or at the farm – and is egg handling automated or manual? Are eggs fumigated on arrival, or before setting? Should there be a room for storing discarded hatching eggs and are rooms for washing and storing trays or trolleys required? The incubation area will be subdivided into setter room, candling and transfer room and hatcher room. Depending on how many setters are installed, there will be one or more rooms to maintain a reasonable walking distance along the length of each row of setters. The size of the transfer room depends on the automation equipment being used and on the number of eggs being processed. Also consider how candling waste will be dealt with. Finally in this area, the number of hatchers in each hatcher room should allow efficient ‘all in-all out’ operation – and therefore depends on the setters’ capacity and the number of hatches produced weekly.
The chick area may need additional space for sexing and vaccination equipment. The size of the handling room also depends on the level of automation. Holding room dimensions should be based on the number of chicks stored and whether or not males and females are separated. In harsh climatic conditions, it makes sense to plan for loading onto trucks inside the building. And a soaking room for cleaning dirty chick boxes returned from the farm is also advised. Ideally, this is located adjacent to the storage area for empty chick boxes. Hatchery waste, e.g. empty shells, unhatched eggs and dead chicks, can be removed from the hatchery by a macerator and screw conveyor, situated near an outside wall. A vacuum waste system offers more flexibility and improved hygiene.
Pas Reform expands into Lybia Green hatchery has signed a long-term agreement with Pas Reform for the supply of its Smart incubation system at a hatchery near Tripoli, Lbyia.
Ideally the technical area is divided into separate rooms for electrical installation, hot water installation and ventilation. Technical operations should also be located on an outside wall, so that engineers need not enter the hatchery unnecessarily. Every hatchery should also have a small workshop for repairs and storing spare parts. Personnel require sufficient male and female showers and changing rooms to comfortably accommodate the number of people employed. Similarly, egg handling and chick handling personnel should ideally have separate canteens. A laboratory and an office for the hatchery manager, perhaps with additional offices for sales, transport and administration, are also advised. Advice
(L-R) Michaël Kampschöer, Sales Director Pas Reform Hatchery Technologies and Mr. Abdul
Magid M. Boskhouna, Managing Director of Green hatchery
–– C onsult a specialist for advice and guidance in designing the hatchery lay-out: someone qualified and experienced, who will consider the various options available to you. –– Treat the prevention of cross-contamination as a major factor when designing the hatchery lay-out. –– Avoid very long rooms, to minimize the use of internal transport –– Situate staff areas, particularly comfort areas, on outside walls for natural light whenever possible. –– Design with future expansion in mind, such that, for example, the addition of setter and hatcher rooms allows egg and chick areas to remain in their original location.
Sander Koster Project Engineer Mobile +31 653 269 372 firstname.lastname@example.org
Finetuning for results Experience pays off! Visiting new customers after the installation of their hatchery equipment is an important and enjoyable part of our day-to-day role. These visits are always most productive when the hatchery has already run several hatch cycles to their own parameters. Questions flow more readily – and we can actively help to improve hatchery results. One of these visits recently brought us to a newly established GPS hatchery in Eastern Europe. Here the hatchery manager and several of his staff accompanied us on a tour of the hatchery, eager to learn how they were doing with their new equipment. Finetuning for results While we walked, they explained their working routine. Eggs arrived from the GPS farms every day. Those from the male line were placed on setter trays of which the front and back was painted red. There were fewer eggs in the store room than we would normally expect for a hatchery of this capacity. But this new operation was still in its start-up phase, with just three GPS flocks in production. Accordingly, when we reached the setter room, the setters where only partially filled – sometimes only to 50 % capacity – with both male and female line eggs, from young and old flocks, stored from 10 to two days in one setter. Looking at the setter program, we were surprised to find temperature set points during the final days of the cycle – say day 12 onwards – were much lower than generally recommended. Of course, recommendations are only a guideline. But these low temperatures looked especially strange because the setters were not full. The hatchery staff explained that set points were low because there had been a complaint about high first week mortality, caused – they believed – by overheated embryos in the setter. However when we measured egg shell temperatures, we found them
to be significantly lower than advised in different setters with incubation times ranging from 12 to 18 days.
In the hatcher room, a highly motivated lady with responsibility for the hatcher operation told us that after transfer, she started the hatchers 1 ºF higher than normal. Set point was not reduced until the day before chick take-off, she explained, to avoid delaying the hatch – as had been experienced previously. As this lady was only responsible for the hatchers – and to avoid a late hatch (remember that hatch day in a GPS hatchery produces a lot of work e.g. sexing, Marek vaccination, toe cutting etc.!) – this seemed to be a good decision, to counter reduced temperature in the setter. A day later, during the hatch – and with all the above taken into consideration – results were acceptable. But still, there were unhatched eggs with too much liquid inside and the chicks presented rather large bellies with poor navels. We suggested using a different incubation program with elevated set points, in one machine only. We explained how to adjust these set points using average egg shell temperatures, which should be taken daily for the time being, to provide experience. Improved chick quality For the hatcher, we advised a flatter temperature profile, lower than currently applied. Hatcher temperature should only be reduced by 0.2 – then if necessary by a further 0.3 ºF, if completely dry, panting chicks are observed. When our visit came to an end, the hatchery manager agreed to keep us informed about results after we had left. To their surprise, and in addition to the already elevated temperatures suggested, they had to raise set points during the last three days in the setter by 0.5 ºF. Hatchability increased by 2 % in the first hatch using the new set points.
Improved hatchability of 2 % in a GPS hatchery produces 1 % more female chicks. If improved chick quality resulted in 5 % more saleable female PS and 0.5 % less first week mortality in the PS farm, the economic effect of finetuning the incubation temperature can be calculated as follows: Setter 77,800 eggs x 80 % filling rate x 17 times/year = 1 million eggs. 1,000,000 x 1 % more female chicks = 10,000 more female chicks, of which 5 % more saleable + 0.5 less first week mortality = 10,550 more chicks at end of first week x € 3/female chick = € 31,650/year at no extra costs. As time goes on and more GPS-flocks come into production in this hatchery, life will become easier for the hatchery staff. The setters will be loaded (closer) to capacity and batches of eggs will be more uniform in maternal age and storage days. The experience gained during this start-up phase will be of enormous benefit – and in the near future. In a GPS-hatchery – it’s never possible to fully depend on a routine. But with experience of what to look for in the chicks – and how to respond in incubation programming – it becomes much easier to finetune machine set points with confidence, and quickly make decisions that make all the difference between a good hatchery – and a great one!
New film documentary ‘Setting Standards for Uniformity’
Shot in collaboration with
in striving to meet that demand,
the film explores the future of
to deliver an affordable product’,
To mark its 90th anniversary,
includes interviews with some
Pas Reform recently introduced a commemorative anniversary edition DVD of its new film
hatcheries around the world,
the hatchery sector globally and of the world’s leading academics and experts in the field.
documentary, Setting Standards
‘With demand for poultry meat
English, Spanish, Russian and
more than 50 per cent by 2025,
for Uniformity (available in
And as importantly, chick quality was much better – a factor happily confirmed by the receiving farms. The relatively inexperienced hatchery staff was very pleased with this result: it brought a welcome restoration of confidence and improved awareness in the hatchery.
and products expected to rise by our sector faces serious challenges
while at the same time continuing explains Pas Reform Marketing Director Henry Arts. ‘Making these films has been a
fascinating and informative
process. We are looking forward to receiving feedback from our customers and colleagues.’’
On the picture, Mr. Jose Antonio
Gonzalez Franco, General manager of Hyline Mexico, Mr. Ranulfo Ortiz (R), Business development
manager Pas Reform for Latin
America and Mr. Bouke Hamminga (L), Director International Sales and Business development of
Pas Reform Hatchery Technologies
Smart expansion continues for Hy‑line Mexico with Pas Reform Hy-line Mexico, has selected Pas Reform’s modular Smart incubation technologies for the development of a brand new hatchery in Mexico. With continuing growth in the layer sector, Hy-line Mexico’s success with the Hy-line W36 has prompted the development of the new hatchery at Yahualica, Jalisco Mex., which will produce 300,000 day old pullets per week. The new hatchery, due for completion later this year, will be fitted with 18 SmartSet™setters, each capable of holding 115,200 eggs, 18 SmartHatch™ hatchers, and complete ventilation and hatchery automation systems. ‘We have studied our options thoroughly,’ says Mr. Jose Antonio Gonzalez Franco, general manager of Hy-line Mexico.’ Ultimately, it was our participation in Pas Reform Academy’s weekly courses that compelled us to invest in the new Smart systems. From these studies, we saw not only the benefits of using the very latest incubation technologies, but we also have access to the most comprehensive, up-to-date layer incubation data, through the Academy’s continuous programme of research.’
Paragon boosts Bangladesh layer sector with Novogen and Smart Mr. Moshiur Rahman,
Managing Director Paragon
Paragon, the leading broiler integration in Bangladesh, is launching a new venture under the name of Paragon Agro Limited. As a wholly owned subsidiary of the Paragon Group, Paragon Agro Limited, headed by Mrs. Yasmin Rahman, has invested in the first Novogen layer GP farm and hatchery in the country, to produce, market and distribute both brown and white layer parent stock. According to Paragon Group managing director Mr Moshiur Rahman, the availability of locally produced layer PS will lower egg prices in Bangladesh, boosting demand by a significant 35-40 per cent, while the availability of layer PS will reduce the Country’s current dependency on imports. For the new GP hatchery, Paragon has again chosen to work with Pas Reform. ‘We have enjoyed a highly professional and productive relationship with the engineering and commercial departments of Pas Reform over the years,’ he says, ‘resulting in superior technical hatching results, both in our broiler GP hatchery and in our latest broiler hatchery.
‘The Smart incubators, hatchers and hatchery climate control systems supplied by Pas Reform have proven their superior performance under Bangladesh conditions. Week on week, the quality of the chicks produced from these Smart machines reflects in our customers’ satisfaction with the quality of the day old chicks delivered by Paragon. Mr. Zahid Islam, representative for Pas Reform Hatchery Technologies in Bangladesh and Dr. Tan Ee Seng, Sales Director Asia for Pas Reform Hatchery Technologies, visited Paragon in Bangladesh recently to finalise plans for the new hatchery and discuss training requirements for Paragon Agro personnel, which will be delivered at Pas Reform Academy, in the Netherlands.
‘This quality of information combined with future-focused technologies and compelling performance are’, says Mr Jose Antonio Gonzalez Franco, ‘entirely in keeping with Hy-line’s approach to maintaining its position at the forefront of layer breeding worldwide.’ ‘Mexico remains a buoyant and growing market,’ he says, ‘and nonetheless competitive. We look forward to putting Smart Technologies to work in the new hatchery, to help us maintain that position of quality and leadership.’
Henry Arts Marketing Director Mobile +31 622 989 785 email@example.com
Featured interviews include
Gordon Butland, Director G&S
Boerjan, Director Research &
contributions from Dr. Marleen Development, Pas Reform Academy;
Agriconsultants Co. Ltd.,
Professor Dr. R. Michael Hulet, Penn State University, USA;
Professor Dr. ir. Eddy Decuypere,
and Dr. ir. Gerard Albers,
Technology Centre, Hendrix
Catholic University Leuven,
Director Research &
Genetics, The Netherlands.
‘The short hatch window
produced by Smart single-stage incubators was a highly
compelling factor in selecting equipment for PW’s new
Henk Markhorst, Sales Director
PW’s production manager.
hatcheries’, says Dr. Loh,
Pas Reform Hatchery
for Malaysia’s PinWee Malaysia’s PW Consolidated Bhd (formerly known as PinWee Group Bhd.) has signed an agreement for the supply of Smart incubators for a new state-of-the-art hatchery in Kedah, Malaysia.
‘The short hatch window produced by Smart single-stage incubators was a highly compelling factor in selecting equipment for PW’s new hatcheries’, says Dr. Loh, PW’s production manager.
The contract, signed by Mr. Dato’Siah Gim Eng and Mrs. Datin Law Hooi Lean of PW Consolidated with Henk Markhorst, Sales Director and Dr. Tan Ee Seng, Sales Director Asia, from Pas Reform Hatchery Technologies, also includes provision for the modernization of the Malaysian company’s existing hatchery in Malacca.
The wider the spread of hatch, i.e. the time between the hatching of the first and the last chick in a batch – the longer the first hatchlings must wait to access feed and water. In a competitive environment, this means that larger chicks grow faster while the smaller ones grow more slowly. This increases and exaggerates weight differences in the flock.
Short hatch window
Dr. Loh continues: ‘There are many factors affecting hatch time. Some of these, for example genetic variation, are outside our control. But the use of modular, single-stage incubators from Pas Reform allows us to actively influence the duration of the hatch window and subsequent chick uniformity, livability and growth rate’.
PW Consolidated Bhd. was incorporated on 19 February 1997 as a parent / investment holding company for the PW group of companies and listed on the Second Board of the Kuala Lumpur Stock of Exchange (KLSE) on 3 June 2002. The strong financial backing that resulted, coupled with consistent, solid performance, enabled the group to be transferred to the Main Board of the Bursa Malaysia Securities Berhad on 28 January 2004. PW commands a dominant position in Malaysia’s dynamically expanding livestock industry. Since its incorporation, the group has evolved into a fully integrated livestock operation. PW’s mission is to be a leading company in the livestock and food industry through constantly anticipating market needs and providing quality poultry products. Both PW’s hatcheries will be equipped with SmartSet™ setters, SmartHatch™ hatchers, and Pas Reform’s SmartCenter™ hatchery information system.
Pas Reform is a prominent contributor to many
leading poultry events around the World.
Henk Markhorst concludes: ‘Pas Reform’s Smart incubation technologies enable the hatchery to actively manage the developing embryo while it is still in the egg. Modular design and precise control allow a diverse range of incubation environments to be created and managed simultaneously. The result is homogenous conditions that produce the shortest spread of hatch, high uniformity and healthy, uniform progression throughout the broiler’s lifecycle.’
Krasnoyaruzhskiy on‑track to double capacity with Smart
Krasnoyaruzhskiy’s General Director Mr. Leonid Segal
Russia’s ZAO Krasnoyaruzhskiy Broiler continues to demonstrate remarkable growth, with the development of a further GPS hatchery designed and equipped by Pas Reform. With capacity for 12 million eggs per year, the new GPS hatchery mirrors an earlier GPS project, with the installation of a full suite of Smart hatchery technologies, including SmartSet™ setters, SmartHatch™ Hatchers, hatchery automation and climate control systems. A unique ventilation system, designed specifically for Krasnoyaruzhskiy’s first GPS hatchery in 2006 by Pas Reform, includes an air preparation room, situated above the transfer room, to ensure that rigorous temperature and humidity parameters are met before air is streamed into the incubation areas. The new facility brings Krasnoyaruzhskiy’s total capacity up to six million parent stock each year: growth resulting from the company having established its reputation, by consistently delivering PS chicks of the highest quality since Krasnoyaruzhskiy’s inception. Close collaboration with Pas Reform’s Academy has, says Krasnoyaruzhskiy’s general director, Mr. Leonid Segal, been fundamental to shaping the new GPS facilities. ‘Among our customers is our mother company Prioskolje, for which almost half of our production capacity is dedicated. The standards demanded of us are extremely high – and in turn, we expect a great deal from our partners and suppliers. ‘Pas Reform has demonstrated its commitment to those standards time and time again over the years, and we are fortunate to have a dedicated and vigilant project team from the Academy working with us.’ Aside from design and installation for the GPS hatcheries, Pas Reform’s senior poultry specialists conduct regular site visits each year, to monitor hatchery data and provide ongoing consultancy services for Kraznoyaruzhskiy’s management team. Besides the sale of parentstock, Krasnayarugskiy broiler also has it’s own parent stock farms, with capacity up to 120 million broiler eggs per year placing the company firmly as one of the largest egg producers in Russia.
Munsterhuis BV targets cross-border growth with Pas Reform
Bert en Ben Munsterhuis
Smart growth Specialist poultry hatchery Broederij Munsterhuis BV, in Saasveld, The Netherlands, has expanded operations by more than 30 per cent, to one million day old chicks per week, with Smart hatchery technologies from Pas Reform. The family-owned Dutch hatchery recently celebrated with an Open Day for customers, employees and suppliers. ‘This expansion puts Munsterhuis well on its way to our target of 1.4 million chicks each week,’ said general manager Bert Munsterhuis, who at 39 is the third generation of his family to take the reins of the business.
Munsterhuis BV has installed SmartSet™ setters, SmartHatch™ hatchers and chick counting and candling/ transfer equipment, all controlled and monitored by a SmartCenter™ Hatchery Information System. The new installation has fully automated the incubation process and all its controls in the hatchery. Multiple incubation programmes manage incubation for each of the various breeds simultaneously. Each supplier has a unique reference, enabling Munsterhuis to trace every hatching egg and manage the whole chain. Every group of day old chicks has a so-called chicken passport, which carries this data for full traceability, including information on the breeding company and the age and breed of the parent hen, for example. The hatchery, which is situated close to the German border, anticipates growth in Germany, where it is, says Mr. Munsterhuis, easier for broiler companies to expand. Sales are currently divided equally between the Netherlands and Germany (mainly North Rhine-Westphalia and Lower Saxony).
Henk Markhorst Sales Director Mobile +31 651 164 449 firstname.lastname@example.org
Petra Zimmerman Office Manager Telephone +31 314 659 111 email@example.com
Timing chicks for a perfect take-off A few months ago, we visited a new customer in Latin America who had only recently switched from multi-stage to single stage incubation. A week before our arrival, the hatchery manager informed us that having applied the set points we had recommended to start with, taking the requirements of the specific breed into consideration, he was generally quite happy with the results being achieved in the hatchery. Hatchability was 3 % better than before, although there seemed to be a higher incidence of first week mortality among the single-stage chicks in the broiler farm, when compared with the multi-stage chicks. He also informed us that chick weight seemed high, at 71 % of original egg weight – and now he was experimenting with reduced relative humidity set points in the setter. Over-active chicks As soon as we arrived at the hatchery, late in the afternoon, we were taken to the broiler farm where chicks of one and half days old were housed at that time. In the house with chicks from the original multi-stage setters, we saw over-active chicks, running around in groups. This, explained the broiler farm manager, was considered normal. He complained that by comparison, the chicks from the single stage incubators in a second house were slow and inactive. We understood his reasoning: he had received overactive chicks for many years now, and for this hatchery – that represented normal behaviour for the chicks.
appeared at the moment the hatchers were opened, he admitted that indeed, some chicks were still wet. We explained that 502 hours incubation time is acceptable for multi-stage incubation, where the first chicks hatch earlier and the hatch window is much wider – and delaying chick take-off leads to the dehydration of the early hatched chicks. In single stage incubation, the hatch window is much narrower (12 - 24 hours) – especially after preheating correctly and virtually all chicks will have hatched after 504 hours incubation time. A look through the window might suggest that the chicks are ready for take-off, especially because the active, fluffy chicks move towards the light. However, an additional 8 - 10 hours is still required for drying the chicks. When chicks are pulled too early, those that are still wet can easily become chilled – and this can contribute to increased mortality on the farm.
That evening during dinner, we talked ‘chicks’ of course. The hatchery manager told me more about how he ran the hatchery. The multi-stage routine was to set eggs at 5.00 am, taking-off chicks three weeks later at 3.00 am: an incubation time of 502 hours. This early start was, he explained, to ensure that the chicks were ready for transport during the cool morning hours. Since the change-over to single stage incubation, the hatchery followed the same routine. However, the setters were started seven hours earlier on the preheating programme. When we asked how the (single-stage) chicks
The next morning, we were up bright and early to be present during chick take-off at 3.00 am. On opening the hatchers, we looked in several baskets and noticed an average of 25- 30 chicks with a wet appearance, indicating that some of them had fully hatched only a few hours before. We could do no more at that moment than ask the hatchery manager to delay take-off by four hours, to give the chicks a chance to dry. In the hatcher room next door, chicks were expected a full day later and here – as an emergency measure – we increased the temperature set point from 36.7 ºC to 36.9 ºC: an increase of 0.4 - 0.5 ºF. At the same
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spareparts department and a
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rapidly in India, and our
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administration, a fully stocked Projects department onsite at Udumalpet.
The Projects department will
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However we explained to him that this kind of ‘over-activity’ was in fact related to heat stress experienced by the embryo’s during the last days of incubation – and that this behaviour would not contribute positively to production results for the broiler farm. In the second, ‘single-stage’ house, we observed chicks either at rest or drinking from the nipples. This, we explained, was far more preferable behaviour than that of the over-active chicks we had seen in the first house. However even among these single-stage day-and-a-half olds, mortality was already as high as 1.65 % and the broiler farm manager expected this to continue to rise to 2.5 - 3 % by day 4 or 5. On handling a good sample of these chicks, we found them to be quite ‘full’, with quite a number of them showing open navels. Something was obviously wrong in the hatchery, as all the other factors that may have explained the difference between the two houses were more or less the same.
provide consultation, advisory specifiying maintenance
programmes for Pas Reform’s
Smart turnkey collaboration time, we agreed that these chicks should be pulled three hours later. Any longer was not possible, due to logistics and labour planning. However this hatch yielded 2 % more saleable chicks – and after one day in the broiler farm, mortality was around 0.13 % in one house and around 0.26 % in another. It was a significant improvement! However we still felt that the chicks’ bellies were rather too full, which continued to indicate insufficient weight loss. Chick take-offs The hatchery manager accepted that the setters should be started earlier, finetuning timing based on observations during consecutive chick take-offs. The aim should be to ensure that 95 % of the chicks are dry, with only 5 % of chicks showing limited wet feathers in the neck area. He also agreed to raise temperature set points slightly around days 7 - 10, as egg shell temperatures were showing slightly below optimum in the hatchery’s records. Increasing set points thus would also, we assured the hatchery manager, increase weight loss sufficiently to reduce the incidence of thick bellies and open navels. Based on the hatchery manager’s experiences with single stage incubation so far, he was now confident of achieving at least 5 % more chicks surviving the first week in the broiler house, partially by improved hatchabilty – and definitely by reducing the number of culls and mortality. For this operation of 12 million chicks per year, this 5 % equates to 12,000,000 x 5 % x € 0.25/chick = € 150,000/year. Each additional one per cent added to this will produce a further € 30,000 – and this doesn’t take into account the added effect of improved broiler performance due to a better start in life. Per point of improved FCR, 22 grams of feed is saved for each broiler: 12,000,000 x 22g = 264,000 kg of feed saved across the entire operation each year. And with inflated feed prices continuing, this is an important factor, not to be ignored.
Mr. Edgardo Angel and Mr.
Soundararajan joins the
customers. Mr. Sathishkumar Company in India, as service
Fernando Varas, Representative
Groupe Kherbouche Groupe Kherbouche is to develop a new turnkey GP hatchery project in Algeria, with C-lines and Pas Reform Hatchery Technologies collaborating on the prestigious new project that has been approved by Aviagen. Groupe Kherbouche has secured the GP licence for their new Arbor Acres Project, to include Grand Parent farms and the completion of a new Grand Parent Hatchery in Tlemcen, Algeria. The new GP hatchery is a turnkey project, which will be constructed and fully installed by a future-focused consortium. C-lines will provide housing solutions, establishing the hatchery building, including panelled structure, drainage, doors, internal walls and electrical supplies. Pas Reform will supply a full suite of Smart incubation, including SmartSet™ Setters and Smarthatch™ hatchers and a complete hatchery ventilation system with airhandling units, humidity controls and pressure controls.
Mr Bouke Hamminga, Director International Sales and Business Development at Pas Reform, says this type of collaboration signals a bold and welcome approach. ‘Pas Reform has found C-lines to be an excellent partner,’ he says, ‘the spirit of the collaboration is one of absolute transparency and cooperation – and that is already evident in the work being undertaken by our engineering departments, who are working extremely well together.’ Mr. Jérémie Choisseau, owner of C-lines, concludes: ‘We have long been looking for a partner in hatchery construction and have found Pas Reform to be very p rofessional and e xperienced. This is an exciting new step for both our companies.’
Mr. Kherbouche, Director and
owner of Groupe Kherbouche
Mr. Kherbouche, director and owner of Groupe Kherbouche comments, ‘The building of this prestigious new Grand Parent project is a logical next step in our development in the Algerian poultry sector. The Arbor Acres breed is well suited to the Algerian market, it has gained widespread acceptance here. ‘In planning our new GP expansion, we have looked for partners who bring proven track record and experience in managing projects of this type with new, innovative p roducts. For us, Pas Reform and C-lines meet these criteria very well.’
Gerd de Lange Senior Poultry Specialist Mobile +31 641 075 498 firstname.lastname@example.org
and maintenance engineer.
Mr. Venkatakrisnan Natarajan can be contacted at:
Couvoir Francois choose Smart new start for Pas Reform for Kuzbasskiy Broiler Group renovation in France hatchery Innovative approach Couvoir Francois, a family-owned hatchery in Saint Hernin, France, will update its pioneering hatchery operation with Smart incubation technologies from Pas Reform. Owned and run by the family Glevarec, Couvoir Francois has been operational in the Bretagne region for three decades and specialises in the production of first class day old, premium strain broilers. The company has also diversified, with the commercialisation of Labelle broilers: a slower growing, quality breed for an increasingly popular and growing market segment in France. As a pioneer in Labelle production, Couvoir Francois been at the forefront in this niche market – and the family has always taken an innovative approach to its business. It is this pioneering approach, says owner and director Mr. Daniel Glevarec, that prompted Couvoir Francois to look at Pas Reform’s Smart incubation technologies. ‘We were in the process of studying the entire renovation of our hatchery,’ he says, ‘and Pas Reform’s innovative products seemed to represent an excellent fit with our approach. ‘The Dutch company has a knowledgeable and professional presence in the French market, with sound, reliable back-up for parts and service locally – and with French technicians. We were also impressed by Pas Reform Academy, for the support available to achieve superior, uniform quality in the day old chicks.’ Couvoir Francois’ renovation has been planned over two phases. The first phase – changeover to SmartHatch™ hatchers – was completed in January 2010, to be followed by the installation of SmartSet™ setters in phase two. Mr. Pierre Joris, Pas Reform’s Distributor in France, will oversee the project’.
Russia’s expanding Kuzbasskiy Group has selected Pas Reform’s Smart hatchery technologies for its new Novosafanovskaya Hatchery, in the Kemerovo region of the Prokopievskiy district. Pas Reform has supplied a full suite of hatchery equipment, including SmartSet™ Setters, SmartHatch™ Hatchers, hatchery climate control and automation systems. Less than two months after opening the hatchery, the first Novosafonovskaya-branded poultry meat products were available through Kuzbasskiy Group retail outlets. ‘Our start-up with the Smart single-stage incubation system has been smooth and very efficient’, explains hatchery manager Aleksey Svechnikov, ‘it is hugely satisfying for everyone at the hatchery – and indeed, for our parent group Volkov A.P. – to see our own, high quality product in retail so soon after operations began.’ From a starting capacity of nine million eggs each year, Kuzbasskiy Group and its parent company Volkov A.P. have ambitious plans for expanding the new hatchery, with plans to double poultry meat outputs by 2010, and to more than treble capacity by 2012. Novosafonovskaya’s CEO, Mr. Sergey Trifanov, brings further vision to those plans. ‘At present, we are still purchasing hatching eggs, which can be less reliable than we would like,’ he says, ‘but in the future, Kuzbasskiy will add a PS Farm to our Group, which will secure supply both in terms of quality and quantities, to fuel future growth in line with demand.’
Weighing the benefits of automation in the hatchery
A common rationale for investing in hatchery automation has traditionally been to reduce labour costs or to overcome the challenge of recruiting for monotonous, relatively strenuous work and long working days.
Yet the use of hatchery automation systems is growing rapidly in modern hatcheries – and not only in countries with relatively high labour costs. Hatcheries in low labour cost regions are also capitalising on the improved accuracy, workflow, overall quality and financial benefits that automation delivers. Improved performance There are many good reasons to introduce automated processes in the hatchery, and a range of (semi) automatic equipment solutions are available. These solutions reflect the variety of opportunities that exist in hatcheries of varying sizes, process plans and outputs, to improve productivity and performance. In the egg traying room, for example, eggs are transferred from small pulp or plastic trays to setter trays. Careful handling of the eggs, to avoid hairline cracks and ensure that the eggs are placed sharp-end down, is essential for good hatchery results. Well designed and adjusted automation achieves greater accuracy and consistency than manual egg handling. And when we consider that in an ordinary hatchery transferring 230,000 eggs/week, a one per cent increase in hatchability represents an additional 100,000 day-old chicks/year, it makes sense to weigh the cost of a manual v. automated process!
Care in handling during egg transfer is also critical. Here this is more challenging, because the egg shells are more fragile, due to calcium absorption by the embryo for bone development. Automated candling and egg removal save considerable labour, depending on the system chosen – and deliver better results, especially where the percentage of clears is higher than 10 - 15 %. Automation also allows for more effective waste separation: especially beneficial if, for example, clear eggs are being brought to value, e.g. as egg powder for use in pet food.
Inside the chick handling room, the equipment used depends largely on the size, type and local work force situation of the hatchery. The priority is to ensure that chicks leave the hatchery as fast as possible, in premium condition. If labour saving is the main priority, stackers/destackers, connecting conveyor lines, automated basket storage and automated chick separation may be a logical choice. In weighing up the options, consider also the cost of time needed, for cleaning, disinfecting and accurately grading chicks. Further automation in chick handling may include chick counters and boxing systems, sexing tables, vaccination tables and spraying systems.
Hatchery automation systems are becoming an essential factor in the operation of the modern hatchery. And cost rapidly becomes an investment, when the main benefits include a higher number of uniform, high quality chicks, accurate process planning and timely delivery. Advice
–– C onsult a specialist when planning hatchery automation systems, as many factors need to be considered and several options are available. –– Decide what has the highest priority in making the choice for which processes should be automated; labour saving or quality improvement. –– Invest first in egg handling automation for setting and transfer if the focus is on quality improvement, as this is where relevant benefits will be gained – mainly by reducing the incidence of hairline cracks and a greater accuracy in point-setting. –– If the aim is to save on labour, invest first in internal flow automation systems – from stackers/destackers, conveyor systems and automated chick separation, to fully automated basket storage.
Hygiene is another area of hatchery management wellserved by automation. A large range of automatic washing equipment is available for cleaning setter trays, hatcher and chick boxes and various trolleys. Systems are also available for dealing with hatchery waste, such as macerators and vacuum waste lines.
Jan-Peter Eil Project Manager Mobile +31 622 298 454 email@example.com
Modular incubator design: precise control
Adaptive Metabolic Feedbackâ„˘
Vortexâ„˘-based airflow for complete temperature homogeneity
These combined features
To maximize temperature
environmental controls needed
homogeneity for Circadian
Incubation™, Pas Reform has
developed SmartPro™, a new
incubator design concept that combines modular design, a new Vortex™-based airflow principle and Adaptive Metabolic Feedback™.
Tray design promotes free movement of vortices
produce the highly precise
to apply thermal stimulation
during incubation, optimizing temperature homogeneity in direct response to the timevarying metabolism of the
growing embryo, at each stage of the incubation process.
Modular machine control in one SmartTouch™ user interface
L-R: Martin 'Tiny' Barten, Senior Hatchery Specialist Pas Reform Hatchery Technologies,
Mr. Tranggono, Hatchery
Manager PT Panca Patriot Prima and Dr. Tan Ee Seng, Director Asia Pas Reform Hatchery
Technologies. Dr. Tan Ee Seng comments: ‘Following
installation, a tailor-made
training programme developed with the assistance of Martin 'Tiny' Barten, ensures that
hatchery personnel are fully
conversant with all aspects of the single-stage system,
for optimal performance
throughout the hatchery.’
New Smart Hatchery for Russia’s Belgrankorm Company In its most recent development, Belgorod Region’s Belgankorm Company has joined forces with Pas Reform to open the fourth hatchery in its diverse agribusiness portfolio. The new hatchery, located at v.Zavidovka in Belgorod region, was designed and installed by the Dutch hatchery technology company to produce 48mln day old chicks per annum in 36 SmartSet™ 77 setters and 24 SmartHatch™ hatchers. The installation also includes a complete line of hatchery automation systems: egg candling, egg transfer equipment, chick handling equipment and hatchery climate control. Belgrankorm Company was founded in 1998, initially as a feed mill factory. Over the next decade, the Company expanded and diversified - with a strong focus on modern equipment and innovative technologies. Belgrankorm’s integrated poultry operations today comprise two GPS-hatcheries, 11 broiler growing farms, three slaughter houses – and now four hatcheries, all overseen by a specialised poultry management department. A closed production cycle delivers high quality products for the domestic market, marketed under the ‘Yasnye Zori’ and ‘Selskie traditsii’ brands.
Pavel Vasilievich Tereshchenko,
the complete design and
Belgrankorm, signed the new
acting general director of Ltd.
Agreement with Pas Reform for
installation of the Company’s
After working for several years with Pas Reform, Indonesia’s fast-rising PT Panca Patriot Prima has become the latest Asian poultry business to adopt Smart single-stage incubation to fuel future growth. Pas Reform’s SmartSet™ setters and SmartHatch™ hatchers were selected for a brand new hatchery development, situated at Jabung, Malang, East Java. In its first phase this year, 12 setters and 12 hatchers have been installed in a closed house with a warm water heating system. A further six incubators are due to be installed – bringing the hatchery operation up to capacity at 180,000 PS level chicks by mid 2009. ‘We have always favoured Pas Reform’s machines’, explains Mr Dodik Yunarto, President Director of PT Panca Patriot Prima. ‘Our first hatcheries back in 2000 used previous generation Pas machines, and in 2003, we first started to work with single-stage techniques.’ The company has ambitious plans for growth and will look at developing further single-stage hatchery complexes (with Pas Reform) in the future. ‘Indonesia offers many opportunities, both in our domestic markets and in the development of exports’, explains Mr. Yunarto. ‘Our plan is to serve a larger geographical spread – and we have seen very clearly how single-stage incubation in our hatcheries will help fuel this growth.’
Pas Reform Academy Putting science into practice
with decades of practical,
Covering a broad spectrum of
Pas Reform Academy has
to meet new and emerging challenges in the modern
topics, from care for the eggs and
dedicated more than 30 years to studying the needs of the
hands-on hatchery experience –
growing embryo: to
In a new series of articles,
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to some of the questions most
understanding the effects of
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New ‘Smart’ stronghold in Indonesia
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Pas Reform Academy responds
frequently raised by commercial hatchery managers around the world.
practical hatchery procedures, to the placement of high quality uniform day old chicks - each article is based on the latest
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(L-R) Maciej Kola´nczyk, Senior
Poultry Specialist and Dr. Marek
Pospiech, Business Development Manager Central & Eastern
Europe of Pas Reform Hatchery Technologies
Hama: Smart hatchery partnership celebrates 10 years in Poland Hama Plus S.A. and Pas Reform are marking the hatchery’s tenth Anniversary and ten years in partnership, with the installation of a complete Smart incubation system. In 2007, Hama Plus undertook extensive modernisation of its existing facilities at Stary Widzim, near Wolsztyn, all of which have been equipped by Pas Reform since the hatchery was founded ten years ago. Further investment has developed a fourth production facility, bringing the hatchery’s annual capacity up to 60 million chicks, with the installation of SmartSet™ setters, SmartHatch™ hatchers and hatchery automation systems.
‘Pas Reform has always understood that. The knowledgebase of the Pas Reform Academy helps anticipate the needs of our customers, which enables us to realise their goals for uniformity – and growth.’ As the largest hatchery in Poland, Hama Plus currently holds about 10 per cent of its domestic market, with growing export partnerships in Ukraine, Belarus, Lithuania and Russia. The integration includes parent stock, hatchery and broiler farm operations, with proprietary distribution and qualified, certified onsite veterinary facilities. Hama Plus S.A. recently celebrated its tenth anniversary with invited customers, partners and other guests – including a senior team from Pas Reform - in Poland.
The new hatchery employs intelligent SmartCenter™ operability, for the simultaneous control of conditions for different breeds and batches. Pas Reform has also supplied and installed an energy-efficient ventilation system. ‘When we started the business, Hanna (co-founder Hanna Szy o) and I were determined to build this company on quality, borne of understanding and respect for our customers,’ explains Hama Plus founder and chairman, Marek Krzysztoszek.
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Pas Reform Academy Putting science into practice
Michaël Kampschroër Sales Director Mobile +31 653 266 126 email@example.com
Pas Reform online at
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Pas Reform Hatchery Technologies
(L-R) Dr. Tan Ee Seng, Sales
Director Asia of Pas Reform Hatchery Technologies and
Mr. Reddy, Sneha Farms’ Director
Prestigious new Smart hatchery project for Sneha Farms in India Sneha Farms has chosen Pas Reform as its partner for the development of a prestigious new hatchery project in Hyderabad, in the South Indian State of Andhra Pradesh. With breeder farms, feed mills and a contract growing department, Sneha Farms’ fully integrated approach to broiler production has delivered substantial growth for the Company since it was formed in 1995. The new hatchery will be fitted with 18 SmartSet™ 115 Setters and 18 SmartHatch™ Hatchers, to produce 600,000 d.o.c. per week.
Smart boost for Astana Kus in Kazakhstan A comprehensive Government finance program has been launched in Kazakhstan, to support investment in new technology for the country’s poultry businesses. Pas Reform and Crown Central Asia are working together to support this production-boosting initiative, with many hatcheries around the country being refurbished with Smart incubation systems.
The Dutch company’s ability to provide support and feedback through trained Indian engineers locally, was, says Mr. Reddy, an important factor in deciding who to work with on the new hatchery project. Dr. Tan Ee Seng, Pas Reform’s Sales Director in Asia says: ‘We are delighted to have been awarded this contract – and look forward to working with Sneha Farms, to help further their ambitious plans for future growth, in what is for Pas Reform an important strategic growth market’.
Sneha Farms’ director Mr. Reddy is enthusiastic about the new partnership: ‘With a thriving, modern integration in this part of India, the time is right to expand our operations with a state of the art hatchery. ‘Pas Reform has a good reputation here in the Indian market’, he says, ‘and we are impressed by the professionalism and expertise of Pas Reform’s people’.
Pictured during an inspection of Astana Kus GPS Hatchery, near the capital city of Astana, are: (L‑R) Mr. Marat Aldybaev,
President Astana Kus, Michaël
Kampschöer, Sales Director Pas Reform Hatchery Technologies
and Mr. Saulebek Bukharbayev.
Left picture: Mrs. Gulmira Isaeva,
Sales Director Crown Central Asia
A Smart first for Granja Rosanda in Guatemala Guatamala’s Granja Rosanda broiler integration is expanding its current business with the addition of a new Smart hatchery from Pas Reform. Under the leadership of Owner and Founder Lic. Victor Martinez, The Group has selected SmartSet™ setters and SmartHatch™ hatchers from the Dutch hatchery technology company, together with a complete hatchery climate conditioning package.
The construction of Granja Rosanda’s new hatchery represents the largest Smart incubation project in Guatemala to date. ‘The hatchery sector has grown significantly in Central America over the last couple of years,’ comments Ing. Ranulfo Ortiz, Pas reform’s business development manager for the region. ‘We are very pleased to be participating in the region’s growth with this new partnership, and look forward to serving Granja Rosanda’s hatchery needs for many years.’
Altona gets Smart in Western Australia Western Australia’s leading supplier of layer chicks, Altona Hatchery Pty Ltd, has selected Smart incubation technologies from Pas Reform for the refurbishment of its hatchery at Forrestfield, Perth. The commission includes SmartSet™ setters, SmartHatch™ hatchers, a SmartCenter™ Hatchery Information System, egg transfer equipment and Hatchery Climate Control systems. Established in 1942, Altona today supplies customers throughout Western Australia and the Northern Territories, with chicks from Hyline layer stock. The company operates its own breeder farm, hatchery and pullet grower farms under the direction of Mr Peter Bell.
‘Pas Reform’s very professional team have been instrumental in helping us draw up plans for this new project,’ explains Lic. Victor Martinez, ‘with comprehensive engineering drawings and a project management programme that will facilitate rapid, efficient construction. ‘A team of Pas Reform’s ventilation and project management experts will provide complete back up, for the completion of the project later this year.’
Dr. Tan Ee Seng Sales Director Asia Mobile +6012 67 000 87 email@example.com
Pas Reform designs Siberia’s largest poultry complex Russia’s fastest growing poultry integration, ZAO Prioskoljie, has launched a new poultry production complex – Altaiskiy Broiler - in Siberia, adding a further modern feedmill, hatchery, farms and slaughterhouse to its investments. Using Pas Reform’s modular single-stage technologies, the new facility includes SmartSet™ setters, SmartHatch™ hatchers, hatchery automation and climate control systems and advanced hatchery management and information software systems. Pas Reform’s Academy provides on and offsite training and consultancy services, to monitor hatchery results and provide guidance for the finetuning of incubation programmes. With an opening capacity of 36 million eggs per annum, poultry and poultry meat products are being marketed primarily in Biysk, Kemerovo region, under the trademark ‘Altayiskiy Broiler’. Future plans will see Altaiskiy Broiler’s capacity doubled, to extend product marketing more broadly into Siberia, The Urals and for export to the Far East.
The true cost of chilled chicks
A while ago, we visited a day old broiler chick hatchery in Western Europe. The hatchery manager was having serious discussions with one of his clients, who found first week mortality in the chicks delivered from this hatchery to be too high. In the farmers’ opinion, the cause of mortality – often running as high as 3 - 4 per cent – must, he believed, lie with the hatchery as he was providing the best conditions for the broilers, especially during the first week of life. Indeed, registrations of climate in the poultry house seemed fine. Feed and water were supplied via commonly used systems.
However mortality rates at other farms receiving chicks from the same breeder flocks were low to average, usually staying below one per cent. This though was little comfort to the farmer experiencing the losses. And as continuing discussion did not seem to be finding a solution, we offered to help in finding out what was going wrong. Monitoring the process We began on the day of hatch by closely monitoring chick quality and the chick collection process, observing the chicks in the dispatch room and registering the climate. This all appeared to be within acceptable limits. So next, we joined the chicks inside the truck during transportation to the farm. Climate inside the truck was registered as usual during the one hour drive and with temperature maintained at around 25 ºC, appeared satisfactory. On arrival at the farm, we observed the unloading of the chicks, together with the farmer and his wife and a farm employee.
At first sight, the poultry house looked good: the floor was equally covered by a 2 - 3 cm layer of wood shavings; feed and water supply were adjusted to the right height and light intensity and distribution was adequate. The measured temperature in the house was 34 ºC. However, we also noticed that the temperature sensor was positioned at approx.1.3 meters above the floor. Suspecting that a cold floor may be the reason for increased first week mortality, we placed chicks with their feet on the back of our hands – and indeed, their legs did feel cold. The farmer’s wife confirmed our observation by placing the chick’s feet against her cheek. When registrations were taken directly from the floor itself, we recorded a temperature of 25 ºC, which is definitely too low for day old chicks. Low floor temperature After hatching, a chick’s thermoregulatory system is not yet fully matured, which means they have very little ability to regulate their own body temperature during the first 7 - 10 days of their lives. Consequently, environmental temperature has enormous impact on the chick’s own body temperature, which will be reduced accordingly. This costs the chick vital energy – and will impair both the health and growth of the chicks. Mortality then occurs as a result of various health problems, predominantly yolk sac infection, dehydration or starvation.
Poultry specialist joins Pas Reform in Hungary
Founder of poultry health and
After nine years with Shaver,
‘Dr. K˝ orösi is well-established
Hungarian poultry specialist
AgriAL Bt., in 2002, Dr. K˝ orösi began his career as a
role as chief veterinarian and
says Pas Reform Sales Director
Dr. László K˝ orösi (58) has been appointed to represent Pas
Reform, as the Dutch hatchery technology company expands further into Eastern Europe.
veterinarian and technical
consultant for Shaver, with a
MSc from Budapest Veterinary University.
Dr. K˝ orösi left to take up a new technical advisor for a Ross jointventure GP breeding program. Working with PS farms and
hatcheries throughout Eastern Europe, a practical advisory
capacity was central to this role, before László accepted his next
position with Merial’s Hungarian
Distributor, in 1998.
and well respected in Hungary’, Michaël Kampschöer. ‘His skills
and experience complement his role as an advisor to the poultry sector in Hungary, where rapid
growth and sector advancement are important features of EU membership.
(L-R) Mr. Paul Erb, Bell AG and Martin ‘Tiny’ Barten, Senior Hatchery Specialist of Pas
Reform Hatchery Technologies
Pictured are Bouke Hamminga, Director International Sales &
Business Development and José Luis Aviles from Incubadora Mexicana SA
Based on this practical evidence – the farmer agreed to increase floor temperature by preheating the poultry house for 36 - 48 hours before the chicks’ arrival. The chicks feel the cold of the floor through their bodies. And since chicks are in constant contact with the floor, the temperature of the floor is actually more critical to the chick’s body temperature than air temperature. Preheating the broiler house is therefore vitally important, especially in cold weather. It can be useful to preheat the broiler house with the litter, still packed, in the house. This will ensure that the concrete is warm before the litter is d istributed on top of it. Either placing a thermometer on the litter, or using an infrared non-contact thermometer, will accurately determine floor temperature, which should be around 28 ‑ 30 ºC. Observing the chicks’ behaviour, especially during the first week, tells much about their comfort levels. If chicks huddle and stay down on the floor, house temperature must be increased. Simply feeling the temperature of their legs will indicate immediately whether they are chilled. Conversely, if they move away from heat sources and appear listless, they are probably too warm. Happily for this farmer – and for a continuing relationship with the hatchery – after starting to preheat his broiler houses, the problems of first week mortality virtually disappeared, with mortalities decreased to around 0.4 % in the first week. Poor brooding costs The cost of poor brooding temperature to both the grower and the integrator are tremendous: 4 per cent mortality is more than 3 per cent above the acceptable maximum limit for first week mortality. In addition, and probably even more important, is that chicks who survive chilling will deliver inefficient growth. And this eventually will cost a great deal more.
‘Growing demand is creating
many new opportunities. Since 2005, László’s consultancy has
Dr. László K˝ orösi’s contact details are:
also represented Cobb
such well-balanced experience –
2100 Gödöll˝ o
(Germany) in Hungary. With
László’s knowledge will be a
positive asset, as the region’s
hatchery operations expand.’
Let’s assume a drop of 4 points FCR and a slaughter weight of 2.2 kg. If this drop can be avoided by creating proper brooding conditions, 88g of feed is saved per broiler. With 30,000 broilers in a house, this equates to 30,000 birds x 88 g = 2,640 kg of feed. For a farm with seven production rounds, this amounts to 7 x 2,640 = 18,480 kg of feed saved per year. If we then also take into account the adverse effects of poor brooding practice on chick uniformity – and the deductions the processors will levy on growers for birds outside the desired weight range – it is not hard to see how these effects easily justify the additional costs incurred by preheating.
Incubadora Mexicana SA Incubadora Mexicana SA of Mexico have three hatcheries in Sonora and Tehuacan that produce some 30 million day old table egg pullets (90 % white Bovans and 10 % Brown ISA) and 30 million embryos a year for vaccine production. The company have agreed to a new project to expand their Tehuacan facility. 12 SmartSet™ 115 setters and six SmartHatch™ hatchers will be supplied by Pas Reform. This follows on from a previous contract to supply incubators that Pas Reform secured in 2003, as their new machines provided enhanced hatchability, an improved hatch window and better energy utilisation figures.
In-ovo vaccination for ZAO Zagore (Belaya Ptitsa) ZAO Zagore, a member of the agro holding company Belaya Ptitsa in Belgorod, has contracted Pas Reform to fully automate its egg transfer room. With a capacity of 60,000 eggs/ hr, the new, fully automatic candling and transfer system will incorporate Embrex In-ovo vaccination capabilities at the company’s existing hatchery in Shebekina, Belgorod region. Candling will ensure the removal of infertile eggs from the setter trays, before the remaining fertile eggs are vaccinated In-ovo, for automatic transfer into hatcher baskets. ZAO Zagore is a fully integrated company with parent stock farms, a hatchery with a capacity of 67 million eggs per year, broiler farms, a feed mill and slaughter-house. The company produces 73 thousand tons (live weight) of poultry meat.
Dr. Marleen Boerjan Director R&D Telephone +31 314 659 111 firstname.lastname@example.org
Béri Balogh Ádám u. 42 Hungary
Mobile +36 309 820 054
Email email@example.com Fax +36 2 842 0640
L-R: Mr. Hiqmet Driza, founder
and owner of Driza Limited, and Mr. Jan-Peter Eil, Project
Manager Pas Reform Hatchery Technologies
Morocco’s Maroc Dinde diversifies into broiler production with Pas Reform Maroc Dinde, Morocco’s largest turkey producer, is diversifying into broiler production assisted by Pas Reform. The group, headed by owner Mr. Abdelmoulah has signed an agreement for the development of a new green field hatchery, where Pas Reform’s Smart modular, single stage system will be introduced to optimise broiler incubation from day one. The new installation will include SmartSet™ setters, SmartHatch™ hatchers, hatchery automation systems and hatchery climate control systems. Maroc Dinde’s new broiler hatchery will be built in two phases. On completion, the hatchery will have the capacity to produce 600,000 day old broilers per week. Broiler production ‘While we are experienced in rearing turkeys, it is a new challenge for us to expand the business in this way,’ says Mr. Abdelmoulah, ‘We sought a partner that has proven expertise and the technical capability to build such a project. For us, Pas Reform is the best partner to fulfil these requirements – and with such specialised expertise in hatchery climate control, hatchery automation and hatchery project management, we anticipate our new broiler hatchery will deliver in line with these ambitious plans.’
Pas Reform is actively engaged
in the poultry sector worldwide – and as such, we are regularly involved in exhibitions in different countries.
As a Company new to the broiler business, hatchery management training for Maroc Dinde’s personnel is an important part of the new project. ‘Maroc Dinde’s hatchery managers will visit The Netherlands, to work with our team at Pas Reform Academy,’ concludes Mr Bouke Hamminga, Pas Reform’s director of international sales and business development. ‘Here they will learn about the physiology of the chicken embryo – and how to manage their new Smart incubation system for the best performance. ‘Their training will subsequently enable them to train personnel at the hatchery in Morocco – and Pas Reform’s team will also visit regularly, to help monitor progress, finetune the system and ensure that Maroc Dinde achieves the shortest hatch windows for superior chick quality.’
Smart fit for hatchery growth in Albania Albania’s leading poultry producer, Driza Limited, has signed a new Agreement with Pas Reform for a suite of SmartSet™ setters, SmartHatch™ hatchers and Smart Hatchery Automation Systems. Situated in Albania’s most important industrial centre at Fieri, on the Gjanica tributary of the Seman River, Driva has delivered unprecedented growth since first entering the poultry market in 1997. The company’s hatchery will ultimately produce 10 million day old chicks each year. Founder and owner Hiqmet Driza faced massive challenges, when he first launched his poultry production business in 1997. ‘Driza is an incredible success story’, explains Pas Reform Project Manager Jan-Peter Eil. ‘When the business expanded into poultry production, Albania’s poultry processing facilities were severely hampered by technological and managerial inefficiencies, outdated equipment and the want of a skilled workforce.’ ‘Yet in a little over ten years, and with the support of the AAATA (Assistance to Albanian Agricultural Trade Associations) project, Driza has emerged as the region’s leading producer of high quality poultry and poultry meat products.’ With the installation of its Smart products, Pas Reform’s Academy will also deliver full onsite training programmes for Driza’s hatchery personnel. Alongside its broiler operations, Driza also produces 100,000 turkeys each year, with additional revenue streams from ostrich, lamb, pork and wine production. A feedmill, modern broiler slaughterhouse, cooling/freezing operations, distribution and retail networks put the company well on-track in its plans for full integration.
The management team of the Schotman hatchery: Erik, Rob, Diny and Aloys Wolterinck (left to right)
After working with three generations of Pas Reform incubators, The Netherlands’ Schotman Hatcheries is expanding in Europe with Smart modular single-stage incubation technologies from Pas Reform.
The hatchery, owned by father and son Aloys and Erik Wolterinck, produces one million birds a week. Backed up by strong performance over many years with Pas Reform machines, the Wolterincks also selected Smart incubation technology for the benefits of modular single stage incubation in reducing the hatch window. A small hatch window improves day old chick uniformity, which forms the basis for optimising broiler management and achieving the lowest possible feed conversion. ‘We balanced the benefits when making our choice for the latest installation’, explains Aloys. ‘While the older systems demand more attention and skill from the hatchery manager, the new Smart systems run independently and provide much more information to support optimised development for the broiler chicks.’ With 100,000 PS females and its own males, the Schotman operation also incorporates a rearing farm for 100,000 birds, with a further 300,000 PS under contract at farms located strategically in different disease defence compartments of the Netherlands and Germany. This measure secures
SmartTrayTM Enhanced comfort and uniform airflow for improved hatch quality
production in the event of a serious infectious disease breakout, with its inevitable restrictions on the movement of flocks.
Smart growth for Dutch Schotman hatcheries Appreciation and certification
Schotman’s reputation stems from the hatchery’s absolute commitment to chick quality. Appreciation for the quality of Schotman broilers has, says Aloys, been demonstrated not only by a constantly growing customer-base in the Netherlands and Germany, but also by an increasing number of hatcheries further afield, who have contracted the familyrun business to hatch eggs for them, or to deliver broiler chicks to fulfil their own customer’s order requirements. Pas Reform CEO Bart Aangenendt concludes, ’Schotman Hatcheries’ uncompromising dedication to quality has gained recognition and Certification from many national and international quality control bodies throughout Europe, including Food Quality Certification in the UK. ‘This is exactly the kind of environment that Smart was designed for. We are delighted to continue our long association with the Wolterincks – and look forward to supporting their continuing growth and success for many years to come.’
Supports hatching eggs at two levels
Stable, self centring egg positioning
Pas Reform Hatchery Technologies www.pasreform.com Open, spacious grid
Erik Meijer Service Manager Mobile +31 610 491 245 firstname.lastname@example.org
Martine Onnes Office Manager Telephone +31 314 659 111 email@example.com
Mr. Ruben Tan, Owner Marshall Poultry
Smart cost benefits for Marshall Poultry Integration In a year when chicken output in the Philippines was predicted to slow due to reduced consumer demand and the rising cost of feed and production, Marshall Poultry has found enhanced growth in converting to the use of Smart single stage incubation from Pas Reform. After detailed consultation with his production team and a review of the performance of Pas Reform’s Smart technologies in Malaysia, entrepreneur and business owner Mr Ruben Tan is, he says, ‘very optimistic’ of an early return on his investment. Marshall Poultry Farms commissioned a brand new hatchery complex at San Vicente in the Bulacan region in September, opening the new complex with six SmartSet™ setters and six SmartHatch™ hatchers to operate in Single Stage.
Mirza Kochekkhan Iran’s Mirza Kochekkhan Co.
Mr. Lochhead is well known in
Pas Reform has appointed Mr.
and FX (Foreign Exchange
Representative Pas Reform
Enterprises Ltd. to develop
hatchery climate control system. For detailed project information,
hatchery technologies at its
Mr. Kamal Nazari,
family owned and run PS
hatchery in Some Sara, Gilan
State. The installation includes SmartSet™ setters,
Pas Reform expands into New Zealand and the Pacific Islands
egg transfer equipment and a
has commissioned Pas Reform for the installation of Smart
Pas Reform’s project team provided advices to the development of the new hatchery, to include detailed site planning, fine layouts, ventilation specifications and the installation plus commissioning of setters and hatchers. ‘For us, the rising cost of multi-stage incubation was a major concern’, says Mr Ruben Tan. ‘Single Stage incubation has enhanced performance throughout the integration, with improved chick quality and vitality, better feed conversion and ultimately great performance from a higher yielding broiler.’
McGregor Lochhead of Sonoma markets in New Zealand and the Pacific Islands for its modular,
single-stage Smart incubation system.
New Zealand’s poultry sector. Following six years with ANZ
Banking Group in Trade Finance products), he took over the
running of Sonoma Enterprises – a leading local provider of
agricultural equipment and
consultancy - from his father in 2003.
The relevance of Hatchery Climate Control Introduction
While optimising climate inside the incubator best supports the needs of growing embryos, accurate climate control elsewhere in the hatchery also makes an important contribution to overall efficiency. Growing embryos use oxygen and produce carbon dioxide and water vapour during incubation, thus the air within the incubator needs to be refreshed regularly. However to maintain truly efficient climate control, there are other important factors to consider, including temperature and relative humidity in the various rooms of the hatchery, the avoidance of airborne cross-contamination and energy saving. Homogeneous incubation temperature is best achieved when the machines operate in an area where where temperature and humidity are constantly maintained. Maximum room temperature is reduced when the incubator depends partially on air cooling – and in this case, a greater volume of air will be required than when using a water-cooled system, to cater for both the oxygen needs of the embryos and the cooling requirement of the incubators.
Similarly, it is useful to humidify inlet air. This avoids the creation of ‘cold spots’, which arise with the constant operation of a humidifier in the incubator: particularly relevant for hatcheries in dry and/or cold regions. Conversely, hatcheries in hot, humid countries can benefit from dehumidifying inlet air, so avoiding overly high humidity in the setter – which results in insufficient weight loss by the hatching eggs during incubation. Air transport by natural ventilation substantially limits the hatchery’s control of temperature and humidity. An air handling unit (AHU) enables inlet air to be conditioned and regulated, based on the needs of the embryos. This is achieved by controlling the output of the AHU according to the pressure required in various rooms. With pressure differences set such that air flows from ‘clean’ to ‘dirty’ areas, cross-contamination is prevented. By reducing supply air volume to the lowest necessary levels and eliminating unnecessary heating (including humidifying) or cooling (including de-humidifying), energy savings will be realised. Fans operating at variable speeds are more energy efficient for controlling pressure in the hatchery than recirculation – and selecting setter/hatcher room temperature in relation to external, local climate can also have a positive impact on energy consumption.
Sonoma will represent
Sonoma can be contacted at:
products, including Smart
Sonoma Enterprises Ltd.
automation systems and
Pas Reform’s full line of incubators, hatchery
hatchery climate control
systems, with the full support
–– C onsult a specialist when designing the hatchery’s climate control system, as many factors need to be considered and there may be several options available –– Ensure sufficient air supply to the various rooms in the hatchery –– Precondition air in terms of temperature and relative humidity to meet the climate requirements in the room –– Avoid high (>25 ºC) room temperatures in a cold climate –– Use variable air supply with frequency drive instead of recirculation –– Always maintain the highest air pressure in the setter room compared to other areas, to avoid crosscontamination –– Avoid using air ducts to extract used air. These are difficult to clean and encourage an accumulation of pathogens (eg. Aspergillus) –– Maintain the AHU, regularly replacing dust filters and checking the V-belts –– Monitor climatic conditions (temperature, relative humidity, CO2) in relation to the specified requirements for all hatchery rooms every 14 days .
No. 50, Hakanoa Street, Grey Lynn,
Wim Hazekamp Project Manager Mobile +31 651 575 805 firstname.lastname@example.org
of Pas Reform’s Sales, Project
Phone 64 (0) 9 361 1060
Training facilities in Holland.
Mobile 64 (0) 21 341 286
Management and Academy
Fax 64 (0) 9 361 1061
Spain’s Granja Crusvi adopts new SmartPro™ for hatchery expansion
SmartPro™’s modular design
enables the precise control of
temperature, humidity, O2 and CO2 in large incubators.
Complete hatchery remodelling Catalonian integration Granja Crusvi is among the first in the world to adopt Pas Reform’s latest advancement in hatchery technologies. The company is to renovate part of its existing hatchery, replacing its entire hatcher capacity with the new SmartPro™ system, launched this year. The Reus-based integration was also among the first to adopt Pas Reform’s SmartSet™ setters, when they launched in 2005. ‘The technical results we achieved with Smart have been fundamental to our continuing growth over the past four years’, says Evarist Caparo, general manager of Granja Crusvi, ‘and we are once again impressed – this time with the new ‘modular design’ concept of the SmartPro™ hatchers. ‘It is a unique offering in the hatchery sector’, he says, ‘SmartPro™ retains all the strength of modular, single-stage incubation, while further enhancing climate control on a larger scale, to deliver reliably robust day old chicks.’
Smart growth for Pas Reform Russia
over the past four years. ‘Under
Pas Reform Russia will remain in
accommodate that growth
Pas Reform’s Russian subsidiary
director Wim Schaafsma and commercial director Anna
Russian poultry sector, with
customer service, project
is moving into new premises,
just four years since its original formation.
The Russian arm of the Dutch
hatchery technology company
has, says CEO Bart Aangenendt,
delivered outstanding results
the directorship of general
Kolygina, Pas Reform’s market
share now exceeds 50 per cent in the CIS countries, with the production of more than 1
billion eggs per annum from
hatcheries employing our Smart technologies.’
Belgorod, the heart of the
newly built 200 q.m. premises
that include office space, larger storage for service parts, an electronics workshop and a mechanical workshop.
‘With growth continuing
throughout the CIS countries,
the new office will enable us to
without interruption to
management and project
design’, says Wim Schaafsma. Service spare parts can be
delivered out of stock for CIS
customers and later this year,
Pas Reform Russia plans to open a new distribution and storage
centre, to accommodate largerscale deliveries.
Pas Reform’s representative in Spain, Mr. Jaume Sauntaularia, explains, ‘Having worked with Granja Crusvi for the last five years, we are very pleased that our continuing collaboration has culminated in the first phase of a complete hatchery remodelling – and delighted that Granja Crusvi yet again shows its pioneering side – to be the first SmartPro™ adopter in Spain.’
Managing the hatch window: a careful eye for detail pays off During a long, intercontinental flight recently, we found ourselves thinking back on a visit we made to a customer hatchery in Asia, where they had very recently made the change from multi-stage to single-stage incubation. When we arrived, the hatchery had already processed several hatches with their new single-stage equipment – and we received an enthusiastic welcome. One person said hatchability had increased by five per cent, with another citing an increase of as much as seven per cent. Importantly, they were very happy with the quality of the chicks, having previously found substantial variations ranging from dehydrated chicks with long wing feathers, to chicks still being wet at the moment of pulling. After the switch to single-stage incubation, they found the chicks much more uniform in appearance. Today, we would describe their observations as the result of a reduced hatch window. Single-stage vs multi-stage When asked if they knew how many hours before chick take-off the first chicks usually hatched using multi-stage incubation, we were advised that relative humidity in the hatcher spontaneously rose above the fixed set point of fifty-three per cent around 4.00 - 6.00 p.m., two days before chick take-off, which was routinely started at 6.00 a.m. At the point of chick take-off, some chicks were usually still freeing themselves of their shell, while others were still quite wet. However the hatchery could not afford to wait any longer to pull the hatched chicks, as this would cause too much dehydration in those that hatched first.
Pas Reform Russia’s service staff
have undergone comprehensive training at the company’s
Contact details for Pas Reform’s new office are:
Zeddam headquarters in The
Pas Reform Russia
qualified for the delivery of
Netherlands, to become fully onsite inspection and repairs, as well as the test and repair of
parts in Pas Reform’s Belgorod workshops.
Based on these observations, we calculated a hatch window of around 36 hours and over. However with single-stage incubation, relative humidity increased spontaneously at around midnight, 6 - 8 hours later than before. And at chick take-off, virtually all the chicks were dry, with no signs of dehydration. This indicated a hatch window of approximately 24 hours, taking into consideration an allowance of 6 - 8 hours for just hatched chicks to dry. Uniformity a prerequisite A few years later – and based on the hatchery’s earlier experience and results with single-stage incubation – the same integration opened another hatchery with new generation, modular single-stage machines. Here we met a very serious, relatively inexperienced young hatchery manager, who was eager for tips to get good results. We agreed to invest some extra time in training him, giving him detailed, step-by-step instructions against which he made careful notes. Our first advice to him was that he should not focus solely on high hatchability, but also on achieving uniform batches of high quality, day-old-chicks - as uniformity is a prerequisite for optimal management in the broiler farms. To achieve uniform batches, we advised him to set eggs with as similar a background as possible. Combining short stored eggs and long stored eggs, or eggs from both young and old breeder flocks together, will lead to greater variation in the chicks hatching from these eggs. He asked us how much difference in storage time and breeder flock age was acceptable, to which we replied three-to-four days and five weeks respectively, for the period in the setter.
However, during transfer to the hatcher, he should try to keep the batches of eggs separated as much as possible. When the batches of eggs set in one setter differed too much in background, he could, we explained, select different temperature set points per section, to gain back some of the lost uniformity. We also explained that preheating the eggs in the setter prior to incubation, e.g. five hours at 77 ºF (25 ºC), would help to start the incubation process for all embryos more equally, which ultimately would lead to a shorter hatch window. There was no need to explain the importance of uniform temperature distribution, as this had been an important deciding factor in choosing the supplier of equipment for this new hatchery. Bodyweights above target We agreed that the hatchery manager would update our agent regularly with the results he achieved – and through him, we would be informed. In this way, the hatchery manager could also ask questions as they arose. According to the information we received, this hatchery manager regularly achieved a hatch window of 12 - 18 hours. The management of the integration praised their young manager for the good, uniform chick quality he delivered from this hatchery. Their chicks made a very good start in the broiler farms, with 7-day body weights typically way above target. This translated into an improved feed conversion ratio of 4 points – which in a setter of 115,200 egg places (17 cycles/year), with 85 % hatchability, 95 % liveability and a delivery weight of 2.2 kilograms, equals 139,164 kilos of feed saved per year.
Iwan ter Wiel Project Manager Mobile +31 651 618 801 email@example.com
Esenina Street 20V Russia
T +7 4722 58 90 50 F +7 4722 58 90 51
E firstname.lastname@example.org I www.pasreform.ru
Smart sets new standards for hatchery hygiene with Microban®
L-R: Mr. Chuah, Director CAB
Group and Mr. Henk Markhorst, Sales Director Pas Reform Hatchery Technologies
Smart expansion for Malaysia’s CAB Group Having monitored the development of modular single-stage incubation technologies for several years, Malaysia’s CAB Group has collaborated with the Kedah State Economic Development Corporation (KSEDC) to expand its poultry integration in Penang with a new Smart single-stage PS broiler hatchery from Pas Reform. The new hatchery, located at Kedah, is being developed in three phases to produce 1.1 million ParentStock chicks each year by 2013. Mr Chuah, director of CAB Cakaran’s new GP farm project, explained that aside from cost savings of some 20 per cent and the ability to protect the Group’s poultry business from the risks of international embargoes on PS chick imports; PS quality, uniformity and bio-security were also key factors in CAB’s decision. Chick uniformity ‘Pas Reform’s Smart incubators deliver a short spread of hatch, which reduces time to the first intake of feed and water.’ This, said Mr Chuah, promotes excellent uniformity in the day olds, simplifying farm management and producing markedly better performance. ‘As an added bonus, because the chicks are of higher quality and in better condition, they are also better able to withstand the stress of vent sexing, vaccination, transport and so on, which means the PS chick arrives on the farm in very good condition.’
Smart new Logistics Centre
Aangenendt, for excellent access
new 4,500sq.m., purpose-built
Reform has experienced
Pas Reform has commissioned a logistics centre, to serve the company’s expanding
worldwide customer-base. The new facility will be located at Doetinchem, less than eight
kilometres from the Company’s headquarters in Zeddam and
ideally situated, says CEO Bart
to major trunk routes. ‘Pas
CAB employs the most rigorous bio-security measures and this too, said Mr Chuah, had been a deciding factor. ‘Bio security and food safety are central to CAB’s promise to its customers, and Smart incubation fully upholds that promise.’ Bio security and food safety Smart cabinets are constructed of smooth-walled, ‘food-safe’ aluminium, stainless steel and polystyrene: highly durable and resistant to strong disinfectants and corrosion. The absence of closed air ducts improves hygiene and sanitation, as does the incorporation of cooling ducts into the walls of the cabinets – making short work of thorough cleaning between cycles. Dr. Tan Ee Seng, Pas Reform’s Sales Director in Asia, is leading the Dutch hatchery technology company’s delivery for CAB. ‘We never under-estimate the importance of people to the success of any hatchery operation’ says Dr. Tan, ‘and with a tailor-made, onsite training programme in place, CAB’s hatchery professionals will have an excellent grounding in all aspects of single-stage incubation, to help them meet demanding targets on every level of the hatchery’s performance.’
anywhere in the world, both today and in the future.’
unprecedented growth since the
To deliver robust global
hatchery technologies’, he says,
has also upgraded its ICT
launch of our Smart single-stage ‘The new building will
complement existing facilities -
and must also be smart enough to support 24 hour global ordering systems and
communications for customers
communications, Pas Reform platform, migrating to
The company has commissioned Delft-based architects Cepezed, winners of the prestigious BNA
Cube from the Royal Institute of Dutch Architects in 2008, to design the new facility.
Microsoft® Dynamics for
‘Cepezed fuse functionality and
(ERP) and Customer Relationship
process control and
Enterprise Resource Planning Management (CRM) systems that integrate fully with
Microsoft® Office applications.
innovation with outstanding
sustainability: qualities that will further enhance Pas Reform’s
Pas Reform has signed an exclusive Agreement to incorporate Microban®, the world’s leading antimicrobial product protection system, into Smart hatchery technologies. The new Agreement will initially see Microban® technology incorporated into Pas Reform’s patented hatcher baskets, reducing the risk of cross contamination from food poisoning bacteria by up to 99.9 %. Microban® antibacterial technologies have been tailored specifically for incorporation into the polyethylene from which Pas Reform’s hatchery baskets are moulded. The Microban® antimicrobial protection is built-in during the injection moulding manufacturing process, it cannot wash off or wear away and will deliver continuous antibacterial protection throughout the useful lifetime of the product. When bacteria come into contact with the Microban® surface, the patented anti-microbial protection works by penetrating the cell wall of the microbe, to disrupt key cell functions so that the microbe cannot function, grow or reproduce. Pas Reform has always placed great emphasis on the importance of hygiene in the hatchery. The company’s sectorleading Smart incubators already incorporate smoothwalled, ‘food-safe’ aluminium, stainless steel and polystyrene. Cooling circuits are fully integrated into the walls of the SmartHatch™ hatcher to reduce bacterial growth and accelerate highly efficient cleaning. The incorporation of Microban® in Pas Reform’s hatchery products will, says Dr. Marleen Boerjan, Director of Research and Development, deliver enhanced levels of product performance, with added protection from bacteria that can compromise embryo and day old chick development: ‘Heightened awareness of the risks of bacterial transfer and cross contamination in the hatchery means that for us, this was a logical next step in our continual product development strategy.’
L-R: Bouke Hamminga,
Director International Sales
& Business Development of Pas Reform Hatchery Technologies, Mr. Vanderlei Pereira, Grand Parent Stock Manager, and
Thomas Calil, Managing Director of Pas Reform do Brasil.
Cobb Vantress Brasil selects Smart incubation from Pas Reform for GGP facility From multi-stage to single-stage
Pas Reform do Brasil is proud to announce the successful conclusion of negotiations with Cobb-Vantress Brasil, for the complete replacement of incubation technologies at the leading broiler breeding company’s GGP (great grandparent stock) complex near Sao Paulo. The new Smart incubation system will be supplied and installed by Pas Reform do Brasil. Located in the south central region of Brazil, in Guapiacu, Sao Paulo, Cobb-Vantress Brasil – a wholly owned subsidiary of Cobb-Vantress Inc. - is well positioned to supply breeding stock for this, the largest market outside of the United States, with the production of more than 20 million parents a year.
The new, state-of the art Smart hatchery will deliver tight controls through every aspect of great grandparent, grandparent and parent stock production.
‘Pas Reform’s Smart was selected from a number of systems currently available from Brazilian and overseas suppliers, after rigorous evaluation by a select team of technicians from Cobb Vantress Brasil and Cobb Vantress Inc.’s global technical service team’, says Thomas Calil, managing director of Pas Reform do Brasil. ‘This adoption of Pas Reform modular single stage technologies is an important, evolutionary step in Brazil, particularly when there is already a strong move from multi-stage to single-stage incubation in other countries in Latin America.’
The breeding company’s new installation will include 15 SmartSet™ setters and six SmartHatch™ hatchers, with the complete retrofit of pressure and humidity control systems in the hatcher rooms.
ability to deliver increased
high, the new facility will
levelers, to allow access and
customers in more than 60
optimize storage. Flexible
trucks and containers of all sizes.
operating efficiencies for countries’, says Wouter
Heideman, Operations Manager,
employ new ‘reach-trucks’ to loading bays will feature dock
ease of loading/unloading for
Martin Barten Senior Hatchery Specialist Mobile +31 653 763 673 email@example.com
Pas Reform Hatchery Technologies. The Doetinchem Assembly and Logistics Centre has been designed to offer flexible
loading, unloading, storage and workspace. Standing 10 metres
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Published on Apr 9, 2010