26 Rotecna World

ROTECNAWORLD NUMBER TWENTY SIX 2016

SUMMARY TECHNOLOGY

GROW FEEDER ANTI-STRESS, FOR FATTENERS AND FARROWING TECHNOLOGY

HIGHER PROFITABILITY AND VOLUME OF PRODUCTION FOR FATTENERS PIGPRODUCTIONIN...

POLAND, A NICHE MARKET FOR EUROPEAN COUNTRIES

LETTERFROMTHEEDITOR THE R+D+I DEPARTMENT SOMETHINGABOUT Gener Romeu

THE FALLES OF THE PYRENEES

Rotecna's President

ROTECNA WORLD 26

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The early months of 2016 have seen ups and downs. The most developed economies seem to be moving out of the crisis and are growing more strongly.

The exception is China, where industrial production has continued to fall. This situation is leading to the devaluation of its currency and a flight by investors for fear of the economy continuing to slow. Will the world economy’s powerhouse for so many years now become its major weak point and a brake on growth? We shall have to wait and see, but the danger seems very real.

APRIL 2016 EDITION: ROTECNA, S.A.- POL. IND. NAU-3, 25310 AGRAMUNT (LLEIDA) SPAIN DIRECTOR: GENER ROMEU EDITION/PRODUCTION/DESIGN: MONTSE GUERRERO EDITOR: FRANCISCO GARCÍA TRADUCTION: CHRIS BOSWELL PRINT: IMPRENTA BARNOLA L-41-2007

DIGITAL VERSION / issuu.com/rotecnapress

On the other hand, oil prices continue to be of concern. If this fall continues, what will happen to the economies of the main producing countries? What is sure is that its impact will be more than notable on the world economy and could lead to important losses.

In our sector, little has changed. The Russian embargo on European meat producers is still in place, and prices still remain the same however much wishful thinking we apply. In Europe, it seemed that private storage could solve this problem, but this has done little more than hold it for a few days, and the high number of applications received for storage in just two weeks has made it impossible to sustain a situation the solution to which seems to lie in exports to third countries.

Despite this, farmers are selling pigs at below production costs, leading to large losses from the increase in supply and stabilisation of demand. This situation could be attributed to this global context in which the fall in the prices of oil and raw materials has meant that meat has little value and is being sold at below the costs of production.

Gener Romeu

Rotecna's World's editors accept no liability for contributor's opinion.

ROTECNAWE CELEBRATE 25 YEARS WITH...

R+D+I DEPARTMENT FILE: • • • •

Year of creation: 1996 Products patented: 50 Projects developed: 140 Workers: 9

The engineers maintain continuous contact with the farmers and study what they need to increase the productivity of their farms in detail. Later, and bearing in mind possible shortcomings, new products are thought up to simplify the everyday work on the farm.

From left to right: Octavi Saura, Jordi Gasull, Ramon Penella, Antonio Arroyo, Joan Clos, Marcel Folguera, Oriol Vidal and Carme Soldevila. Photo: RotecnaPress

Rotecna’s department of R+D+I (Research, Development and Innovation) is made up of a nine-person team of engineers, draughtsmen, programmers, IT specialists and designers. It was set up in 1996 with a single worker, Ramon Penella.

The department has gradually grown, and over these 20 years, around twenty people have been involved, contributing to the development of important and innovative products, like the hoppers or dispensers patented by Rotecna.

SOMETHINGABOUT...

To reach this point, the organisation of the work has been a key element. In this sense, the members of the team tend to work individually on independent projects.

However, they all take part in a weekly meeting to present their ideas, with the participation of Gener Romeu, president of Rotecna, who sets guidelines and gives advice to make the products adequately. In these meetings, they explain the development of each of the products, so that everyone can contribute suggestions.

Once a project has been defined, the Rotecna team work at workstations equipped with programmes for 3D design. The department also has a large-format plotter to print large-scale plans, and a 3D printer, that enables prototypes of the pieces to be made before making the moulds for the injection, thus facilitating the work and offering multiple options when making the designs.

The beginnings of the department, when there was only one computer to work on to develop new products, are now far off. However, over the years, these professionals have overcome some of the difficulties that the design of products for farms implies and have tackled projects that were true challenges, such as the panels, with their corresponding systems of closing, the double dispenser or the fattening hoppers. On the other hand, circumstances have meant that certain other products

FALLES OF THE PYRENEES, celebration and one of the most traditional festivals of fire, documented since the 11th century, held in a different places along the Pyrenean range. Although the ritual and symbolism are the same everywhere, there are small local variations among the festivals held in 62 villages in the Pyrenees: 34 in France, 17 in Catalonia, 8 in Aragon and 3 in Andorra.

THE BAIXADA DE LES FALLES IN THE PYRENEES, THE TRADITIONAL DESCENT FROM THE MOUNTAIN WITH BURNING TORCHES 2

The falles are held in 62 villages in the Pyrenees: 34 in France, 17 in Catalonia, 8 in Aragon and 3 in Andorra. Photo: Racó Català

The Catalan Pyrenees is a land of customs and traditions that follow the cycle of the seasons in an expression of living culture, full of legends, foods, dances, songs and popular festivals. Coinciding with the solstices and equinoxes, with

religious overtones or ancient pagan links, these celebrations have given the Pyrenean villages their own idiosyncrasies and character.

A example of this are the falles of the Pyrenees, a popular

The falles are habitually held around the summer solstice, coinciding with the festivities of Saint John on the 24th of June. However, there are exceptions, with some places holding it at the end of July to coincide with their summer festivals. Other places, like Bagà and Sant Julià de Cerdanyola, celebrate it on Christmas Eve, coinciding with the winter solstice.

The origins Of ancestral origins, the festival has always been intimately linked to the

GLOBALPIG have never reached production despite the efforts and dedication given to them.

PRIVATE STORAGE

Pushing the skill and imagination to continue innovating, and always attentive to the needs of the market and the evolution of our competitors, the team in Research, Development and Innovation is currently working on the design of new products, notable among which is a new line of slats and dispensers.

Private storage definitively comes to an end throughout the European Union (EU). According to the European Commission, the situation of the pork market and the use of grants for the private storage of meat advised ending it on 27th of January, given the high number of requests received.

From the opening of the storage on the 4th of January, and up to the 20th of the same month, 89,841 Tn was requested in the EU as a whole. At the head of the list were the two giant meat producers, Germany and Spain, with 29.1% and 21.5% of the total respectively, followed by Denmark, Holland and Poland. Regarding the duration, the option of three months was the most popular with 67 % of the total, followed by five months (25 %). De-boned pieces made up 53.6 % of the total.

In contrast, with the private storage that opened in March 2015, it took 15 days to reach a similar amount.

Over the three weeks this measure lasted, 15 member states notified the European Commission that they were granting help to the pig sector within the packet of €420 million from the community approved for sectors in crisis.

Ramon Penella.Photo: RotecnaPress

Ramon Penella. Head of R+D+I Department Ramon Penella started to work in Rotecna in 1996. Over these 20 years, Ramon has designed many Rotecna products, some of them patented.

What was outlined as a solution to increase the price of pork meat, in a market in which the balance between supply and demand was tightly adjusted, has allowed a slight recovery in Holland, Germany, France and Spain.

Private storage enabled prices to be maintained and the sector to live in a bubble during January. Once this measure was cancelled, the harsh reality burst the bubble.

High European meat production, the result of sacrificing excessively heavy animals in recent months, has come up against very weak international demand and a stagnant intracommunity market.

We must now face the underlying problem: the over supply of meat in the main producing and exporting countries. The censuses of pigs in the United States and Spain are still rising, in contrast with Germany and Poland, where they are tending to fall. Meat stocks, the result of forced sacrifice everywhere in recent months, are very high, which is why producers are looking for a solution in exports.

Part of the stored meat will be released on April 17, whereas the rest will be during May and June. The amount of meat that goes on the market represents now 3% of the monthly community output, a percentage important enough to affect prices if demand is insufficient.Thus, if the output of the stored meat worsens the price situation, the European Commission will increase pressure on releasing a new private storage operation.

INTANGIBLE CULTURAL HERITAGE OF THE UNESCO agrarian and solar cycles, and related to the primitive rites of the regeneration of life, fecundity, and giving thanks to the gods for the success of the harvests and the arrival of the good weather. Bringing fire down from the mountain to the village served to purify the fields and forests and to protect the population from evil spirits.

Running the fire The ritual of the falles begins days before the celebration with building them. Torches, about two metres high, are usually made of pine branches wired together with added bunches of ash or hazel. Others are made from a single piece; these are called rantiners and are made of pine trunks split at the thickest part with the help of wood wedges of the same material. As can be seen, there is a wide variety of falles depending on their

appearance, the materials used and the construction process.

On the day of the celebration, the young people gather at a point high on the mountain visible from the village, where they plant a pine (the faro) some days before to mark the point where the falla is lit.

When night falls, the fallaires, young single people, light torches and begin the descent, sometimes running, guided by the fadrí major or head of the group, until they reach the village square, where they are met by music and the ringing of the bells. With the falles half burnt, a large bonfire is built and people perform traditional dances around it.

Intangible cultural heritage of the UNESCO The transversal nature of this celebration, present in three countries

(Spain, Andorra and France) led to it being declared intangible cultural heritage of humanity by the UNESCO on the 1st of December 2015, after the organising entities of the falles presented the candidature “Summer solstice fire festivals in the Pyrenees”.

The declaration of intangible cultural heritage by the UNESCO emphasises both the cultural importance of the tradition and the knowledge and techniques necessary to transmit the tradition to the following generations. At the same time, it is aimed at maintaining cultural diversity against the effects of globalisation and helping to increase their recognition.

With this new declaration, Catalonia adds another element to its list of intangible human cultural heritage, after the human towers and the Patum of Berga.

On arriving in the village square, the fallaires make a bonfire round which they perform traditional dances. Photo: Racó Català

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TECHNOLOGY

GROW FEEDER ANTI-STRESS,

FOR FATTENERS AND FARROWING

ADVANTAGES Reduces the level of stress for the animal and the appearance of stereotypies.

Facilitates the supply of feed rich in fibre.

Avoids quarrelling between animals.

CHARACTERISTICS - It is made with a robust finish without joints or edges, which facilitates cleaning.

- Stackable to optimise space during transport.

Pig production, like any business, seeks to maximise the profitability of the activity, but is also committed to a production that respects the environment and complies with the requirements of animal welfare.

The legislation on animal welfare establishes that pigs must have permanent access to adequate manipulable materials to allow them enough activities of investigation and manipulation, but that do not affect the health of the animals.

Moreover, this normative establishes that young, post weaning and pregnant sows must receive sufficient feed by volume or rich in fibre, as well as feed with a high energy value. With the aim of helping to comply with the legislative requirements and encourage the welfare of the pigs, Rotecna launches the Grow Feeder AntiStress, a hopper to supply straw, to enable the animals to develop their natural instinct to root, 24

satiate pregnant sows and improve welfare in the pens.

The Grow Feeder Anti-Stress hopper has been designed to supply straw as a material the pigs can manipulate, which offers many benefits. Unlike other materials that can be supplied to the pigs to enrich their environment, like chains or plastic objects, straw can be ingested and is totally destructible, factors that help to maintain the interest of the animal in the material. Note that, in contrast with other systems without a lower platform, the hopper design minimise the loss of straw and allows its use in pens with slats, although it is

recommended for installation in areas with compact ground.

With a capacity of up to 60 litres, the Grow Feeder AntiStress hopper is injected in a single piece and has stainless steel protectors on the areas of most wear, which makes the unit more durable.

Under natural conditions, pigs root in the ground as a behaviour of exploration and searching for food. With the intensification of production and the confinement of the animals, the possibility for pigs to root is limited.

Supplying the pigs of manipulable materials helps them to express their natural rooting instinct as a behaviour of curiosity. In consequence,

this encourages the welfare of the animals and reduces stress.

This way, we minimise stereotypies like chewing or biting bars and reduce redirected actions, like tail and ear biting, which can be serious problems in the fattening farms.

Moreover, the supply of straw with the Grow Feeder AntiStress hopper helps to satiate the gestating sows during the stage in which voluntary capacity for ingestion by these animals is greater than the ration offered. This way, the animals are calmer, thus diminishing the incidence of quarrelling between sows and helping the maintenance and growth of the foetuses.

TECHNOLOGY

HIGHER PROFITABILITY AND VOLUME OF PRODUCTION FOR FATTENERS

Figure 1. Proposed distribution for a feeding shed for fattening.

Modular weaning. Photo: Corporation Alimentaria de Guissona.

The high concentration of farms and the little space to build more has led the department of engineering of the Corporation Alimentaria de Guissona to offer the sector a new concept in construction, designed for piglets from 6 to 30 kg, in existing fattening farms.

Evolution of the modular weaning in a feeding shed for existing fattenings The idea of this type of construction arose as a modular weaning pen (from 6 to 25 kg), for piglet production farms. Each shed consists of six modules, each with the capacity for the weekly production of piglets. This way, the sow farm incorporated the transition on the same farm quickly and simply. Nowadays, using this idea of construction has been considered to complement the fattening farms, and thus to remove the piglets from the sow farms to the weaning and continue with a Wean to Finish.

This proposed new model is a removable shed for 1,000 piglets from 6 to 30 kg on an existing farm with 2000 fattening places (two sheds of 1,000 pigs). If we occupy this module for about nine weeks, and then for 15 weeks in fattening sheds, we manage to increase the turnround of the Wean to Finish, entering piglets at 6 kg and removing them at 100 kg.

Description of the model of shed The initial model of the shed proposed is a 11 x 30 m (330 m2) totally removable structure, placed on paved terrain. The pillars, at a maximum distance of 2.75 m, hold up wooden beams and the roof of 3 cm Agropanel.

It can be left open, or a false ceiling of Polipur 3 cm put in. The walls are 5-cm sandwich panels with the first metre above ground level in stainless steel. Part of the ground is plastic slats with polyester plates, and the rest is integral heated concrete slats, which simultaneously configure the

sump and give the structure to place the slats on (Photo 2). The internal distribution can be modified and adapted to the needs of each farmer, but the basic proposal is for 10 10.2 x 3 m pens, with 100 animals per pen and a passage down one side of the shed (Figure 1).

Advantages of the system • Possibility of assembly by the client. This type of construction is completely removable, which enables the client to do their own assembly at a cheaper price ($60/place of material) which becomes a turnkey value of €80/place.

• Very fast installation. Its construction without foundations and necessity for masonry work facilitates fast installation.

• Construction of less than 500 m2. The design of the shed is 11 x 30 m, which is below the minimum built area above which an environmental impact study is required, thus streamlining procedures and minimising costs.

• Without a need for additional land for the livestock wastemanagement plan. If we take advantage of the reductions in nitrogen, which can reach 25%

without an additional external study, this system does not require more land for the application of faeces.

• Improvements in the breeding conditions for recently weaned piglets. The possibility of having installations available specifically designed for piglets from 6 to 30 kg improves the breeding and welfare conditions compared with other Wean to Finish systems that use installations designed initially for fattening.

• Increase in the volume of production of the farm. The greater rotation of the fattening installations with the installation of the feeding shed enables the integrator to increase production by around 30 % and enter piglets at 6 Kg.

Drawbacks of the system The model has some drawbacks, especially regarding health: It does not allow “all in, all out”, as the entry of animals is staggered. This means the piglets must be from one or two origins in all the farm and always from the same farms to maintain the maximum level of health. On the other hand, in the worst of cases, if there were a health problem, a general emptying can be carried out to palliate the health problem. So, the equipment in the shed is also left prepared for fattening, in case the farmer decides one day to use it for all in, all out fattening.

Profitability

• Greater annual profitability of the farm. The change in the type of piglet bred (from 18-100 Kg to 6-100 Kg) plus the increase in the volume of production increases the global profitability of the farm by 50-60% for the integrated livestock farmer.

Table 1 compares the initial profitability of a farm with 2,000 places for fattening with piglet production from 18 to 100 kg (Case 1), with the profitability obtained from the same farm producing piglets from 30 to 100 Kg (Case 2), with higher turnover, thanks to the incorporation on the farm of a shed with 1,000 places for piglets from 6 to 30 kg, always according to preset conditions.

• Rapid return on investment. With the global profitability of the farm, an investment of €80,000 is amortised in three years.

In this specific case, annual production increased by 1,200 pigs (27%) and profitability by €30,000 (62 %).

TABLE 1. COMPARISON OF PRODUCTION AND PROFITABILITY FOR A FARM WITH 2.000 PLACES OF 18-100 KG (CASE 1) AND 1.000 PLACES OF 6-30 KG AND 2.000 PLACES OF 30-100 KG (CASE 2) CASE 2 (1.000 PLACES 6-30 KG + 2.000 PLACES CASE 1 (2.000 PLACES 18-100 KG) 30-100 KG)

Occupation installations (weeks)

23

18

Turns / year

2,2

2,8

4.400

5.600

Price paid (€ / pig)

11

14

Income (€ / year)

48.400

78.400

Pigs produced annually

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PRODUCTIONIN...

Farrowing room with the Rotecna Ni-2. Photo: Darota Janowska.

POLAND, A NICHE MARKET

FOR EUROPEANS COUNTRIES The fall in pig production has led the country to increase its imports up to 606,000 tons.

Poland has a deeply-rooted tradition of production and consumption of pork. However, since joining the European Union, the Polish pig sector has found that its production is insufficient to cover domestic demand because of the European regulations and standards, which in turn this has led to a notable increase in imports, in contrast with the exports.

Production Poland’s entry into the European Union in 2004 brought with it a

series of changes for the Polish pig industry. The health and veterinar y requirements increased alongside the demands from the consumers. The intracommunity regulations were also reinforced, and the opening to the free trade in competitive products led to a fall in the production of the domestic industry.

In 2013, over 15 millions pigs were bred on Polish farms, these being mainly in the north and west of the country. Since 2003,

Source: ICEX (Spanish Institute for Foreign Trade)

when production was above 18 million pigs, this figure has fallen continuously.

Regarding the quantity of pig meat produced (Graph 1), the figures have also been falling. In 2013, 1,606,000 tons of pig meat were produced, a drop of 14% compared with the figures for 2010, when the country produced 1,863,000 tons of pork.

The decrease in the production of the local market has led to over 30% of the pig meat available in Poland being from abroad, principally from European countries.

The figure for imported pork was around 36.000 tons in 2000, but this has increased

GRAPH 2. IMPORTS

2000 production in thousand of tons

Imports and exports

In recent years, Polish pork production has sought new policies to try to increase the

GRAPH 1: PIG PRODUCTION

Sweden 1%

Hungary 1%

Italy 1%

France 2% United Kingdoom 5%

1500

Spain 5% 1000

The Netherlands 11%

500

Denmark 22%

0 6

number of heads in the pig herds through genetic manipulation.

2000

2005

2010

2011

2012

2013

Germany 30%

Belgium 22%

PRODUCTIONIN...

Farrowing pen. Photo: D. J.

steadily over the years to reach 606,000 tons.

These values make it very clear that the productive weakness has been compensated for by the ongoing increase in imports of these products into Poland. So, the future of Polish producers passes through increasing competitiveness compared with the other EU countries.

Among the leading suppliers of pig meat to Poland, we find other European Union states with more highly developed meat industries.

Germany stands out as the country that exports most meat to Poland, with 30% of total imports (Graph 2).

In 2015, Poland exported a total of 132,488 tons of pig meat, 14% less than in 2014 when the figure was around 154,000 tons.

The main importers of Polish pig meat were Italy, Germany and Slovakia.

The fall in production is not the only factor that has influenced this decrease. It has also been affected by the bans imposed by Russia and various Asian markets after the appearance of African Swine Fever in the country during 2014.

Domestic consumption If we look at traditional Polish gastronomy, it can be seen that pork occupies a leading position on the dishes from the country.

According to the Spanish government’s ICEX (Exports and Investments Agency), the annual consumption of pig meat in Poland is estimated at 39.1 kilos per person, over half of all meat consumption, which is calculated at around 73 kilos per head.

Currently, the decisive factor for buying is still price. However, origin and quality acquire an important weight when acquiring the product, especially when this is fresh.

The urban population with higher purchasing power tend towards a greater diversification of the products consumed. On the other hand, the rural population, which is still 38% of the total, remains loyal to the traditional products, whose star ingredient is pork.

African Swine Fever in Poland Since the first outbreak of African Swine Fever (AFS) was detected in the country in February 2014, the disease has been the main threat for pig production in Poland.

Between February and October 2014, the State Reference Laboratory of the Pulawy National Institute of Veterinary Research, the organism that carries out the tasks of vigilance, detection and follow up of AFS, carried out serological tests on samples from

1,683 pigs, Poland being the country that has carried out the largest number of such tests in this period.

Two security zones have been established. The first, the so-called restriction zone, is made up of 20 municipalities where domestic pigs have been infected with the virus. The second, the protection zone, covers 36 municipalities that surround the restriction zone.

Both are in the province of Podlaskie, in the north of the country.

Outside the restriction zone, pigs can only be transferred to other parts of Poland if they are from farms that fulfil a series of strict hygiene and biosecurity conditions, and that are officially certified as free from AFS by the State Reference Laboratory for AFS. No movements of pigs to the EU or third countries are allowed from the restriction zone. Outside the protection zone, only pigs from farms that fulfil a series of strict hygiene and biosecurity conditions can be transported to other EU countries.

POLAND in figures • Capital: Warsaw • Area: 312.679 km2 • Population: 38.483.957 • Density: 123 hab / km2 • GDP: $ 802,1 million • Economy: Service sector (finance, logistics, hostelery, IT, etc.): 65% GDP • Agriculture and livestock: 4 % GDP / 12,6 % of employment

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THE MOST EXTENSIVE RANGE

PANS MAXI PAN MAXI HOPPER PAN MAXITAINER FOR MAXI PAN TECNA PAN INITIATION PAN EASY PAN INITIATION PAN MINI PAN MINI HOPPER PAN MINITAINER

OF PRODUCTS FOR PIG EQUIPMENT

FEEDERS GROW FEEDER MAXI GROW FEEDER MINI SOW FEEDER SWING R3 DUO SWING R3 WET SWING R3 TUBE TR2 FEEDER TR5 FEEDERS SOW BOWL FEEDING BALL

DRINKING BOWLS & VRH-3 VALVE VRH-3 SWING DRINKER EASY DRINKER DUO EASY DRIKER MINI EASY DRIKER MIDI

DISPENSERS CLUTCH DISPENSER DOSIMATIC SIMPLEX D-2 FOUR FIVE ADAPTER LINE DISPENSER OUTLET ADAPTER

COVER NI-2 POR PIGLETS NI-2 CORNER NI-2 MOBILE LAMPHOLDER LID WITH LED LIGHT, 5W

FLOOR DELTA BEAM PROFILE T PROFILE DELTA NET SYSTEM ERGOFIX BASIC POST BEAM CLICK-IN

PVC PVC PROFILES (50,25,10 CM) CLOSE PVC PEN DIVIDERS OPEN PVC PEN DIVIDERS DOORS FAST LOCK BRACKETS U BRACKETS SOLID GRIP

PANELS BLIND PANEL 1200X1000 VENTILATED PANEL 1200X1000 BLIND PANELS MADE TO SIZE VENTILATED PANELS MADE TO SIZE MIXED PANELS MADE TO SIZE FAST DOOR KIT POLIAMID UNION BRAKETS FOR PANELS

CHAIN AND DISK SYSTEM • SHOCK ABSORBING TEETH SYSTEM. • EASY ADJUSTABLE CHAIN TENSIONING SYSTEM WITH GRADUATION SCALE. • CORNERS WITH EASY APERTURE SYSTEM. • SILO EXTRACTION SYSTEM WITH AN AGITATOR.

SLATS WEANER BLIND PARTIAL BLIND SOW TRAP SLAT WEAN TO FINISH ELECTRIC HEATED PLATE WATER HEATED PLATE CAST IRON FERROCAST LEVEL BED / RAISED

AUGER SYSTEM THE SILO OUTLET SYSTEM CONSIST OF A SILO BOOT, A TRANSFER UNIT AND A SLIDE GATE ASSEMBLY THAT ALLOWS HORIZONTAL AND INCLINED INSTALLATION.

SPLAYLEG STOP